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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 08/155,714, filed Nov. 22, 1993, which is a continuation of application Ser. No. 07/906,766, filed Jun. 30, 1992, which is a continuation-in-part of application Ser. No. 07/779,505, filed Oct. 18, 1991, all abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to surgical instruments for applying surgical fasteners or staples to body tissue, and more particularly to an apparatus for applying surgical fasteners having adjustable mechanisms for controlling the spacing between the jaw members through which the tissue passes during the fastening or stapling procedures.
2. Discussion of the Related Art
surgical fastening devices having means for controlling the spacing between the jaw members are well known in the art. These devices typically include indicating means to provide a reading of the spacing between the jaw members. Devices are also known in the art which provide latching mechanisms to actuate the firing mechanism only when the distance between the jaws is within a preset range. These devices typically include a complex lock-out mechanism.
Various closing mechanisms are provided in the prior art for use with surgical fastening devices. The most notable of these devices utilize a complex worm gear-type arrangement or screw bearing member to open and close the spacing between the jaw members of the surgical fastening apparatus. These devices generally provide a rotatable knob or wing-like assembly at the trigger end of the device remote from the jaw mechanism which carries the fastener cartridge, and a screw-like mechanism is provided that passes through the body of the device to translate the rotational movement of the knob into longitudinal movement of the cartridge frame to open and close the spacing between the jaws. As the jaw members are closed around a tissue site to which fasteners are to be applied, the surgeon must grasp the device with one hand while rotating the knob or wing-like assembly with the other hand. As the jaws members close about the tissue to pinch the tissue therebetween, the surgeon then ceases rotation and activates the trigger mechanism to drive the fasteners into the tissue. Several known devices provide a trigger-like mechanism, while others provide a secondary rotatable knob for driving the fasteners by rotational movement. Many devices provide an indicator means near the rotatable knob which gives a visual indication of the spacing between the jaw members prior to firing.
These prior art devices are subject to several disadvantages in both use and construction which render these devices difficult to operate and expensive to manufacture. Many of the devices are cumbersome in use in that the surgeon must operate the device with both hands, holding the body of the instrument in one hand while rotating the knob or wing assembly with the other hand. This may lead to inaccurate stapling or fastening since the surgeon is unable to guide the tissue to be stapled or fastened with his free hand while closing the jaws about the tissue. Furthermore, the number of interacting components provides inaccuracies due to normal break down of tolerances. In addition, the gear arrangement may become worn during extended use, thus rendering an imprecise grasping action at the jaws.
Furthermore, these prior art devices generally involve a complex construction in which a precisely machined or cast worm gear must be constructed and incorporated into the device. This of course increases the cost of manufacturing, and requires a sophisticated assembly procedure to properly locate the worm gear in the instrument to control the spacing between the jaws.
Typical devices having a rotatable knob at the end portion adjacent the handle mechanism of the surgical stapling or fastening device are disclosed in, among others, U.S. Pat. No. 4,930,503 to Pruitt, U.S. Pat. No. 4,788,978 to Strekopytov et al., and U.S. Pat. No. 4,606,344 to DiGiovanni. In each of these devices, an elongated rod member having screw threads machined thereon is provided, which connects a rotatable knob positioned adjacent the handle members to a pusher mechanism which urges a movable jaw in a forward direction toward a stationary jaw to close the spacing between the jaw members. When a desired spacing is reached, a trigger mechanism may be activated to fire the fasteners through the tissue into the anvil member mounted on the stationary jaw. To remove the fastening instrument after application of the fasteners, the knob is rotated in an opposite direction which turns the screw threaded rod member to move the movable jaw member away from the stationary jaw member so that the entire device maybe removed from the tissue.
Surgical fastening instruments having a wing like arrangement positioned adjacent the handle assembly of a device for moving a movable jaw toward a stationary jaws for affixing surgical fasteners to tissue are disclosed in U.S. Pat. No. 4,442,964 to Becht, U.S. Pat. No. 4,354,628 to Green, and U.S. Pat. No. 3,795,034 to Strekopytov et al. These devices are similar to those described above except for the provision of a rotatable wing member in place of the rotatable knob. These devices are also provided with a screw threaded rod member which, when rotated, urges a movable jaw towards a stationary jaw to close the jaw members around tissue to be fastened together. After the application of surgical fasteners, the wing assembly is rotated in an opposite direction to draw the movable jaw away from the stationary jaw so that the instrument maybe removed from the tissue.
Surgical stapling of fastening instruments having a pivotable mechanism external to the device for moving a movable jaw toward a stationary jaw prior to affixing surgical fasteners to tissue are disclosed in, among others, U.S. Pat. No. 3,269,630 to Fleischer, U.S. Pat. No. 4,530,453 to Green, U.S. Pat. No. 4,715,520 to Roehr, Jr. et al., and U.S. Pat. No. 4,978,049 to Green.
Green ('453), Roehr, Jr. et al. and Green ('049) each disclose a pivotable lever member which urges a movable jaw into proximity of a stationary jaw prior to application of the surgical fasteners. Fleischer discloses a surgical stapling instrument in which a pivotable handle urges the movable staple cartridge against the tissue in the direction of the stationary jaw and fires the staples in the same motion. In each of these devices, removal of the instrument after firing of the surgical fasteners is accomplished by pivoting the lever mechanism in the opposite direction to open the jaw members by moving the movable jaw away from the stationary jaw.
U.S. Pat. No. 5,192,203 discloses a spring biased pivotal catch member for approximating the jaws which is held in selected position by a pointed lance member.
It would be desirable for a surgical fastening device to include a locking structure for preventing undesirable firing of fasteners before an appropriate distance between a fasteners cartridge and an anvil has been achieved.
The novel surgical stapling or surgical fastening device of the present invention obviates the disadvantages encountered in the prior art and provides an efficient surgical fastening device having an adjustable closure mechanism for controlling the spacing between the jaw members of the surgical fastening apparatus. The device of the present invention allows a surgeon to operate a surgical fastener with one hand while freeing the other hand to assist in the surgical procedure. Furthermore, the present invention provides a novel means for coupling the fastener driving mechanism to the firing mechanism when the jaws are approximated to a preset distance. The device of the present invention is of lightweight construction and provides ease of handling through the provision of a thumb controlled adjustable closure mechanism which permits a surgeon to set the spacing between the jaw members and fire the device while using only one hand.
SUMMARY OF THE INVENTION
The present invention provides a surgical fastening device having a novel mechanism for adjusting the distance between the movable jaw and the stationary jaw prior to the application of fasteners to the body tissue. The adjustable mechanism controls the closing of the jaw mechanism to approximate the distance between the jaw members prior to activation of the trigger mechanism to fire the fasteners. The device of the present invention may be operated with one hand, which frees the surgeon to accurately locate the tissue to be repaired and to place the fasteners in the proper position during the procedure. The adjustable closure mechanism is operable by using the thumb of the hand which holds the device, and linearly moves the stapling mechanism to properly approximate the distance between the jaw members. The adjustable closure mechanism of the present invention eliminates many moving parts associated with prior devices, and provides a device which is lightweight, and easy to use by allowing the surgeon to set and release the device with one hand.
The adjustable closure mechanism of the present invention may be used with any surgical instrument having jaw members which include a stationary jaw and a movable jaw, or two movable jaws, in which the spacing between the jaw members is adjustable to accommodate various thicknesses of tissue to be secured. The provision of the push button at the handle end of the instrument and the elimination of numerous complex moving parts which are common in prior art devices allows the surgeon to approximate the distance between the jaw members in a fast and efficient manner to position the jaws in the proper alignment for the application of surgical fasteners.
The apparatus of the present invention comprises a first jaw member and a second jaw member in which the first jaw member includes a plurality of fasteners positioned in a cartridge which is movable with the first jaw member towards the stationary second jaw member. The second jaw member may include an anvil surface for clinching the fasteners, or may include means for engaging the fasteners to secured the tissue therebetween. Means for advancing the first jaw member towards the second jaw member to grip the tissue between the jaws are provided, as well as releasable means for retaining the advancing means along a linear path of travel to selectively position the first jaw member in relation to the second jaw member. Means for driving the fasteners into the tissue subsequent to positioning the jaws members in relation to each other by the advancement means is also provided, and the advancement means of the apparatus of the present invention is independent of the driving means.
In a preferred embodiment a push button mechanism is provided at the handle end of the device which may be linearly displaced by the thumb of the surgeon. As the push button and slider bar arrangement is urged forwardly towards the jaws, the releasable retaining means is also urged forwardly within the housing of the apparatus to selectively position the jaws members in relation to each other. As the slider bar and releasable retaining means are continuously moved forward, a linkage arrangement is activated which urges the cartridge frame forward so that the cartridge moves towards the anvil. When the linkage arrangement is fully actuated, the proper distance between the jaw members is set, so that the trigger mechanism may be actuated to drive the fasteners through the tissues.
Preferably, a coupling mechanism is provided which couples the fastener driving means to the trigger mechanism to allow for driving of the staples or fasteners when the proper distance between the jaw members is set. As the slider mechanism is moved forward and the linkage arrangement actuated, the fastener driving means is urged forwardly with the cartridge frame. A coupling arm, which is connected at one end to the trigger mechanism, slides along a bearing surface on the driving means until the slider mechanism is fully deployed. At this point, a camming edge of the coupling arm engages a notch in the bearing surface of the driving means to couple the trigger mechanism to the driving means. At this point, the proper distance between the jaw members is set and the fastener means may be driven into the tissue.
The surgical fastening device may further include a locking structure for retaining a fastener driving structure in a predeterminable position. The locking structure is positioned proximate an actuating handle for selectively preventing the handle from actuating the driving structure. The driving structure cannot engage the fasteners until a first jaw member is positioned a specified distance from a second jaw member.
After the fastening means have been driven into the tissue, the releasable retaining mechanism may be disengaged so that the jaw members may be returned to their original position whereby the fastening device may be removed from the surgical site. In the preferred embodiment, the push button is pivotable to move a second rod member which contacts a release lever which disengages the retaining means. In a second embodiment, a release knob is provided which extends through the housing of the fastening apparatus and which may be pivoted to release the retaining means.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features of the present invention will become more readily apparent and may be understood by referring to the following detailed description of an illustrative embodiment of the surgical fastening instrument and its novel adjustable closure mechanism, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a perspective view of a surgical fastening instrument employing the adjustable closure mechanism of the present invention;
FIG. 2 illustrates a side cross-sectional plan view of a surgical fastening instrument employing the adjustable closure mechanism of the present invention in which the instrument is in an at rest condition;
FIG. 3 illustrates the device of FIG. 2 in which the adjustable closure mechanism is activated and the jaw mechanism is partially closed;
FIG. 4 illustrates the device of FIG. 2 in which the adjustable closure mechanism of the present invention is fully deployed;
FIG. 5 illustrates the device of FIG. 2 in which the adjustable closure mechanism of the present invention is fully deployed and the trigger mechanism of the device has been actuated so that the fastening means have been driven from the cartridge;
FIG. 6 illustrates a partial enlarged view of the handle end of the device of FIG. 2 showing the release mechanism for disengaging the retaining means of the present invention;
FIG. 7 illustrates the retaining means of the present invention at the handle end of the device of FIG. 2 in the at rest condition;
FIG. 7A illustrates a perspective view of the retaining means of the device of FIG. 7;
FIG. 8 illustrates a top plan cutaway view of the instrument of FIG. 1 showing the adjustable closure mechanism of the present invention in the at rest condition;
FIG. 9 shows a top plan cutaway view of the instrument of FIG. 1 showing the adjustable closure mechanism of the present invention in the fully deployed condition;
FIG. 10 illustrates a perspective view of the surgical fastening apparatus employing an alternative embodiment of the adjustable closure mechanism of the present invention;
FIG. 11 illustrates a side cutaway view of the handle end of the instrument of FIG. 10 showing the adjustable closure mechanism of the present invention;
FIG. 12 illustrates a top plan cutaway view of the device of FIG. 10 showing the linkage arrangement of the adjustable closure mechanism of the present invention in an at rest condition;
FIG. 13 illustrates a top plan cutaway view of the device of FIG. 10 showing the linkage arrangement of the adjustable closure mechanism of the present invention in a fully deployed condition;
FIGS. 14A-14C illustrate the coupling mechanism according to the present invention for coupling the trigger mechanism to the fastener driving mechanism used in conjunction with the adjustable closure mechanism of the present invention;
FIGS. 15A and 15B illustrate embodiments of the retaining means of the adjustable closure mechanism of the present invention;
FIG. 16 illustrates a side cutaway view of an instrument showing a locking structure according to the present invention; and
FIGS. 17-19 illustrate side cutaway views of the instrument shown in FIG. 16 showing a sequence of operation of the instrument.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in specific detail to the drawings, in which like reference numerals identify similar or identical elements throughout the several views, FIG. 1 shows a surgical fastening instrument 10 which employs the adjustable closure mechanism of the present invention. Fastening instrument 10 is provided with a stationary handle 12 and an actuating handle 14 which together comprise the trigger mechanism of instrument 10. An elongated body portion 16 is provided which terminates in a distal jaw mechanism 18 which includes an anvil jaw 20 and a cartridge jaw 22. A fastening cartridge (not shown) is positioned within cartridge jaw 22 for driving staples or fasteners through tissue against an anvil surface positioned on anvil jaw 20. Alternatively, the cartridge can contain the fastener portions of two part fasteners which are driven into retainers positioned on the anvil jaw. At the handle end of instrument 10 is provided a push button 26 for operating an advancement mechanism 28, whose function will be described below.
As seen in FIG. 2, push button 26 and advancing mechanism 28 extend outwardly from the handle end of the instrument 10. A releasable retaining mechanism 32 is slidably engaged to the stationary rod member 36 and is coupled to slider mechanism 40 so that as slider mechanism 40 is urged forwardly into housing 30, retaining mechanism 32 is slidably retained along stationary rod member 36.
Advancing mechanism 28 comprises slider mechanism 40 and release rod member 38, such that release rod member 38 and slider mechanism 40 are secured to push button 26. Thrusting push button 26 towards housing 30 slides release rod 38 and slider mechanism 40 into the housing to move the retaining mechanism 32 along rod 36. Slider mechanism 40 extends to linkage structure 42 to activate the linkage structure 42 and urge jaw mechanism 18 distally. Linkage structure 42 moves movable rod 34, as well as fastener driver 56, cartridge frame 44, alignment pin advancement means 24, and cartridge 54 all in a distal direction to selectively position movable cartridge jaw 22 and stationary anvil jaw 20.
For purposes of clarity, the individual mechanisms will be described separately, and then the overall operation of the device will be discussed.
FIG. 7 illustrates a retaining mechanism of the present invention, which slidably engages the stationary rod 36, and which acts in conjunction with the linkage structure 42 to selectively position the jaw mechanism 18 of the surgical fastener apparatus 10. Retaining mechanism 32 is coupled to slider mechanism 40 and is urged rearwardly by biasing spring 80 as shown. The retaining mechanism 32 comprises a clamp member 68, a block member 70, and a spring member 81. The clamp member is provided with a central bore 128 through which stationary rod 36 passes. Clamp member 68 is best seen in FIG. 15A. The clamp member 68 is pivotally secured to the block member 70 and biased into a locking engagement of stationary rod 36 by the spring member 81. Spring member 81 may comprise a coiled spring as shown, or may further comprise any other biasing mechanism such as a leaf spring, rubber block, or the like. Block member 70, which is preferably in the shape of a rectangular polyhedron having a square or rectangular cross-section, may be provided with a central bore (not shown) through which stationary rod 36 passes, or alternatively, block member 70 may have a substantially U-shaped portion to allow stationary rod 36 to pass therethrough. A protrusion 71 is preferably formed on a bottom portion of block member 70 and is secured to biasing spring 80. Alternatively, protrusion 71 may be connected to block member 70 by any suitable means. Block member 70 further comprises shoulder portion 72, preferably extending across at least a portion of the width of block member 70 which abuts the lower portion of clamp member 68 as shown to provide a pivot point for releasing clamp member 68, as will be described below. Block member 70 is positioned on slider mechanism 40 and preferably fits in an opening in slider mechanism 40. As slider mechanism 40 is advanced, it carries block member 70 with it as shown in FIGS. 2-6. Block member 70 is secured to and movable with slider mechanism 40 as seen in the drawings, and slides over rod 36. As slider mechanism 40 is moved, so is block member 70 which carries clamp member 68, and which secures the position of the jaws by securing the position of linkage structure 42 with respect to rod 36. When push button 26 is pivoted to release clamp member 68, block member 70 is returned to its proximalmost position.
As best seen in FIG. 15A, clamp member 68 has an L-shaped portion terminating in a contact face 73 which engages a release mechanism comprising a release lever 74 and a release rod 38. The release lever 74, is pivotably connected to carriage 76 and pivots about pivot point 79. Release lever 74 preferably has a central bore to allow a stationary rod 36 to pass therethrough, but may also be provided with a U-shaped body both to surround stationary rod 36 and engage contact face 73 of clamp member 68. Clamp member 68 is further provided with a guide post 82 which slides within a guide track 83 to fully align clamp member 68 in relation to stationary rod 36.
As shown in FIG. 7, clamp member 68 is biased at an angle to engage stationary rod 36 so that edges of central bore 128 frictionally engage stationary rod member 36. As push button 26 is urged towards housing 30, retaining mechanism 32 slides along stationary rod 36 due to the movement of advancing mechanism 28. Carriage 76 is engaged with movable slider mechanism 40 so that the entire retaining mechanism is urged distally against biasing spring 80. In order to release retaining mechanism 32, as best shown in FIG. 6, push button 26 is rotated in the direction of arrow E until beveled surface 27 contacts housing 30. Pivoting push button 26 in the direction of arrow E moves release rod 38 in the direction of arrow F so that contact surface 78 of release rod 38 pivots release lever 74 to engage contact face 73 of clamp member 68. This pivoting action moves clamp member 68 in the direction of arrow G to release the frictional engagement of the central bore 128 with stationary rod 36. Releasing the frictional engagement causes the entire retaining mechanism 32 to return in the direction of arrow G to the position shown in FIG. 7. This movement is caused by biasing spring 80 (not shown in FIG. 6) which moves the entire mechanism to the position shown in FIG. 7.
Turning now to FIGS. 8 and 9, there is illustrated the linkage structure 42 and its operation in conjunction with slider mechanism 40 and retaining mechanism 32. Structure 42 comprises a pair of linkage arms 84, which are preferably secured by pivot posts to a second pair of linkage arms 84 located below the pair shown in FIG. 8 in mirror arrangement, as clearly shown in FIGS. 2-6. Linkage arms 84 are joined through stationary pivot post 86, and movable pivot posts 88A and 88B. Movable pivot post 88A is secured to rod 34 and cartridge frame 44 to urge these elements distally when push button 26 is activated. Slider mechanism 40 includes a camming surface 90 which engages movable pivot post 88B to collapse linkage structure 42 to move the rod 34 and cartridge frame 44, and consequently move cartridge jaw 22 towards anvil jaw 20.
As best seen in FIG. 9, as push button 26 is fully actuated to contact housing 30, retaining mechanism 32, being coupled to slider mechanism 40 slides along stationary rod 36. Camming surface 90 engages movable post 88B, driving movable post 88A distally to move movable rod 34 and cartridge frame 44 in relation to housing frame 21 as shown. Releasing retaining mechanism 32 as described above returns linkage structure 42 to the configuration shown in FIG. 8.
It can be appreciated from FIGS. 8 and 9 that the linkage structure 42 provides a two-stage approximation of the jaw mechanism 18, whereby initial movement of the slider mechanism 40 caused a large initial approximation, while a smaller, secondary approximation eases the jaws into approximation at the conclusion of movement of the slider mechanism 40. As slider mechanism 40 is initially moved upon actuation of the push button 26, a large portion of the overall distance cartridge jaw member 22 travels towards anvil jaw member 20 is traversed in the initial movement. Typically, as the slider mechanism 40 travels approximately one-half its overall distance, and correspondingly moving movable pivot post 88A a portion of its total distance, cartridge jaw 22 moves approximately 80% of its total distance. As slider mechanism 40 travels its remaining one-half distance, the cartridge jaw moves its final 20% of its total distance. This allows for a fine adjustment of the jaw mechanism to accommodate the various thickness of tissues positioned between the jaw members.
Instrument 10 employing the novel adjustable closure mechanism of the present invention may further include a coupling device for coupling the fastener driving mechanism to the trigger mechanism only when a proper distance between cartridge jaw 22 and anvil jaw 20 has been reached. This mechanism is best illustrated in FIGS. 14A through 14C.
FIGS. 14A through 14C, in conjunction with FIGS. 2-6, illustrate the coupling mechanism of the present invention. Housing frame 21 is provided with a frame track 52 within which a driving pin 50 rides. Driving pin 50 is secured to one leg of an L-shaped driving link 48, where the opposite end of driving link 48 is secured to the alignment pin advancement means 24 and to an end of biasing spring 46. Biasing spring 46 is connected at its other end to stationary rod 36 and biases driving link 48 and pin advancement means 24 proximally. Driving link 48 is further coupled to cartridge frame 22 which is advanced distally by fastener driver 56 via pin 51 when push button 26 is actuated so that as link 48 advances as seen in FIGS. 14A-14C, and in FIGS. 2-4, pin advancement means 24 moves distally as seen in FIGS. 2-4 to move pin 62 into engagement with anvil jaw 20. Pin advancement means 24 comprises an arm member which rides on top of driver 56 and terminates in an upturned portion to engage pin 62. As push button 26 is actuated, linkage structure 42 is deployed and fastener driver 56 is moved distally. Prior to actuation of push button 26, fastener driver 56 is in the position shown in FIG. 14A, and coupling arm 58 is positioned on bearing surface 61 as shown. Coupling arm 58 is connected to actuating handle 14 as best seem in FIG. 2. As is apparent from FIGS. 14A-14C, driver 56 is secured to pin 50 and is advanced with pin 50. Driver 56 terminates in a fastener driver surface (not shown) which is conventional and is moved into the position shown in FIG. 14C by the interaction of pin 50 with track 52. Driver 56 is secured to pin 51 and is advanced with pin 51 along with driving link 48.
As push button 26 is moved, fastener driver 56 is moved forwardly so that coupling arm 58 slides along bearing surface 61 as shown in FIG. 14B. Driving pin 50 travels in frame track 52, while driving link 48 urges alignment pin advancement means 24 as shown. As best seen in FIG. 3, alignment pin advancement means 24 moves forwardly so that alignment pin 62 protrudes from cartridge 54 and aligns with an alignment hole (not shown) in anvil jaw 20. This insures proper alignment of cartridge 54 with anvil jaw 20 so that fastener means 66 are properly driven into position between the jaw members.
As push button 26 is further moved towards housing 30, to the position shown in FIG. 4, cartridge jaw 22 is aligned adjacent anvil jaw 20 so that pin 62 is within the hole in anvil jaw 20. Driving link 48 moves slightly in the proximal direction towards the handle end of instrument 10 to a substantially upright position as shown in FIG. 14C and FIG. 4. This moves alignment pin advancement means 24 slightly proximally to the position shown in FIG. 4 so that alignment pin 62 does not protrude completely through anvil jaw 20.
When push button 26 reaches the position shown in FIG. 4, fastener driver 56 has moved distally to a position where coupling arm 58 slides off bearing surface 61 and into notch 60 as shown in FIG. 14C. At this point, driving link 48 has moved to the position shown in FIG. 14C and driving pin 50 has fully traversed the length of frame track 52. In the position shown in FIG. 14C, coupling arm 58 is engaged with fastener driver 56 so that actuation of handle 14 as shown in FIG. 5 will drive fastener means 66 into the tissue as fastener driver 56 moves in the direction of arrow D. Although not shown, coupling arm 58 may be provided with a leaf spring member to urge coupling arm 58 into engagement with notch 60. As push button 26 is rotated to release retaining mechanism 32, driving pin 50 travels proximally in frame track 52, so that when driving pin 50 reaches the position shown in 14B fastener driver 56 is lifted off coupling arm 58 despite the leaf spring, and coupling arm 58 is no longer engaged in notch 60. As retaining means 32 returns the entire mechanism to the position shown in FIG. 2, driving link 48 and fastener driver 56 return to the position shown in FIG. 14A.
Referring to FIG. 16, another embodiment of a surgical fastening instrument 140 is shown having a locking structure 142. The surgical fastening instrument 140 shown in FIG. 16 is substantially similar to the surgical fastening instrument 10 shown in FIGS. 1-7, however, the locking structure 142 of the surgical fastening instrument 140 provides positive locking of the actuating handle 14 during a specified period of the operation of the instrument 140.
The locking structure 142 includes a cam member 144. The cam member 144 includes an arcuate portion 146 having a recess 148. A proximal end of the cam member 144 is pivotally connected to pivot point 150. The cam member 144 is biased in an upward position by spring 152.
The locking structure further includes a notch portion 154 which is formed in the proximal end of the coupling arm 58. The hook member 154 includes an arcuate portion 155 defining a notch 157. The notch 157 of the notch portion 154 is configured and dimensioned to releasably couple with the arcuate portion 146 of the cam member 144.
Cam member 144 is pivotally mounted within handle 12 in a position below slide mechanism 40. An elongated longitudinal camming groove 158 is formed adjacent the proximal end of the lower portion of slide mechanism 40. The groove 158 has a ramped camming surface 159 at a distal end thereof. Groove 158 is dimensioned to provide a plurality of positions between the anvil jaw 20 and the cartridge jaw 22 in which the instrument can be fired (described below). Camming surface 159 defines the proximalmost position of cartridge jaw 22 where the handle 14 can be squeezed and the fasteners fired.
Returning now to FIGS. 2 through 6, the operation of the surgical fastener apparatus 10 having the adjustable closure mechanism of the present invention will now be described.
After tissue which is to be surgically repaired is positioned between cartridge jaw 22 and anvil jaw 20, push button 26 is pushed in the direction of arrow A as seen in FIG. 3 which moves slider mechanism 40 and release rod 38 into housing 30. As best seen in FIG. 4, slider mechanism 40 extends to linkage structure 42 so that as retaining mechanism 32 is slid distally along stationary rod 36, camming surface 90 of slider mechanism 40 engages stationary post 88b to deploy linkage structure 42. As linkage structure 42 is deployed, movable rod 34 is urged forwardly along with cartridge frame 44, thus urging driving pin 50 along frame track 52. The force of biasing spring 46 is overcome as push button 26 is urged in the direction of arrow A.
As driving pin 50 moves in track 52, driving link 48 is moved to the position shown in FIG. 3, which urges alignment pin advancement means 24 to the position shown at the jaw mechanism 18. In this position, alignment pin 62 protrudes from cartridge 54 and aligns with the alignment hole in anvil jaw 20 as cartridge 54 moves in the direction of arrow A'.
As linkage structure 42 is deployed and movable rod 34 and cartridge frame 44 move distally, fastener driver 56 also moves distally and coupling arm 58 slides along bearing surface 61.
When push button 26 is fully actuated, linkage structure 42 is fully deployed as shown in FIG. 4, and retaining mechanism 32 frictionally engages stationary rod 36 to maintain instrument 10 in the position shown in FIG. 4. At this time, cartridge 54 has moved into position in the direction of arrow A' so that alignment pin 62 is positioned in the alignment hole in anvil jaw 20. Alignment pin advancement means 24 moves slightly proximally so that alignment pin 62 does not protrude beyond anvil jaw 20, and driving link 48 assumes the position shown in FIG. 4. Driving pin 50 has reached the end of track 52. In the position shown in FIG. 4, actuating arm 58 has slid off bearing surface 61 and into notch 60 of fastener driver 56 so that the device as shown in FIG. 4 is ready to be fired.
Once in the position of FIG. 4, actuating handle 14 is moved in the direction of arrow B to fire the fasteners 66. As actuating handle 14 is moved in the direction of arrow B against the force of biasing spring 64, coupling arm 58, having been engaged in notch 60, moves in the direction of arrow C to move fastener driver 56 distally in the direction of arrow D. Fastener driver 56 drives fasteners 66 from cartridge 54 through the tissue (not shown) and into the anvil surface of anvil jaw 20. Upon completion of firing, actuating handle 14 is released and returns to the position shown in FIG. 4.
To remove instrument 10 from the surgical site, it is necessary to release the jaw mechanism 18 to return to the position shown in FIG. 2. This is accomplished by pivoting push button 26 in the direction of arrow E, as best seen in FIG. 6, so that beveled surface 27 contacts the housing 30. As push button 26 is pivoted in the direction of arrow E, release rod 38 travels in the direction of arrow F so that contact surface 78 of release rod 38 pivots release lever 74 as shown, which engages contact face 73 to move clamp member 68 to an upright position and perpendicular in relation to stationary rod 36. This releases the frictional engagement of clamp member 68 with stationary rod 36 and the entire retaining mechanism 32 is moved along stationary rod 36 in the direction of arrow G due to the force of biasing spring 80 (as shown in FIG. 7). The entire mechanism, including the linkage structure 42, jaw mechanism 18, and retaining mechanism 32 is returned to the position shown in FIG. 2.
FIG. 10 illustrates a surgical fastening apparatus 100 employing an alternative adjustable closure mechanism according to the present invention. Apparatus 10 is similar to apparatus 10 of FIG. 1 in that a stationary handle 12 and an actuating handle 14 are provided, along with a body portion 16 and a jaw mechanism 18. Body portion 16 is provided with a flared portion 104 which is symmetrical on both sides of the instrument for accommodating the slider mechanism which will be described below. A push button 102 is provided for actuating the slider mechanism, and a release button 106 is provided to release the retaining mechanism as will be described below.
Turning now to FIG. 11, there is shown the adjustable closure mechanism of the apparatus of FIG. 10. Instrument 100 is substantially identical to instrument 10 except for retaining mechanism 101 and linkage structure 110.
Linkage structure 110 comprise a plurality of linkage arms 112, as best seen in FIG. 12. Linkage arms 112 form a collapsible box structure having a mirror image as shown in FIG. 11. Linkage arms 112 are joined by stationary pivot post 114 and movable pivot posts 115. As seen in FIG. 12, movable pivot post 115A is secured to movable rod 116 whose function will be described below. Push button 102 is connected to slider mechanism 108 which is provided with an essentially Y-shaped configuration. The outer ends of the Y-shaped slider mechanism are accommodated in flared portions 104 of the housing 103 of instrument 100. Movable rod 116 extends from movable pivot point 115A through retaining mechanism 101 to connect to fastener driver 56 and cartridge frame 44 as shown. Movable rod 116 is frictionally engaged by retaining mechanism 101 to selectively position cartridge jaw 22 in relation to anvil jaw 20.
Retaining mechanism 101 comprises clamp member 122 and block member 118 which is provided with shoulder 120. Clamp member 122, as best seem in FIG. 15B, is provided with a central bore 128 whose edges frictionally engage movable rod 116. Movable rod 116, as well as stationary rod 36 of the embodiment of FIGS. 1-9, may be provided with a scored surface to enhance the frictional gripping of clamp members 122 and 68. Clamp member 122 is biased into the engaged position by biasing spring 124.
In use, push button 102 is urged distally towards housing 103 so that camming surfaces 126 engage movable pivot posts 115. As linkage structure 110 collapses to the position shown in FIG. 13, movable pivot point 115A urges movable rod forwardly through retaining mechanism 101 to move fastener driver 56 and cartridge frame 44 distally to selectively position the jaw mechanism. When push button 102 is in the position shown in FIG. 13, linkage structure 110 is fully collapsed as shown and movable rod 116 is frictionally secured by clamp member 122.
As seen in FIG. 11, a handle locking mechanism 130 may also be provided. To fire the device to drive fasteners through tissue positioned in jaw mechanism 118, locking mechanism 130 is pivoted away from actuating handle 114 and the fasteners are driven through the tissue in the manner described above. To return instrument 100 to the position shown in FIG. 11, a release mechanism comprising a release knob 106 is moved in the direction of arrow H so that clamp member 122 is pivoted about shoulder 120. When clamp member 122 reaches a substantially vertical position perpendicular to movable rod 116, the frictional engagement between the central bore 128 and the movable rod 116 is released, and movable rod 116 returns to the position shown in FIG. 11 due to a biasing spring which is not shown. Release knob 106 is then let go of, and biasing spring 124 returns clamp member 122 to the position shown in FIG. 11. Linkage structure 110 returns to the position shown in FIG. 12.
As described above in connection with linkage structure 42, movement of linkage structure 110 provides for a two-stage approximation of the jaw mechanism, providing for a large approximation (about 80% of the total distance) of the jaw distance for movement of the first 50% of the slider mechanism 108. The remaining 50% of the movement of the slider mechanism 108 moves the jaw mechanism 18 its remaining 20% of distance, providing for fine adjustment.
The adjustable closure mechanism of the present invention can also be used in other instruments to close the distance between the movable jaw member and stationary jaw member at the stapling or fastening end of the instrument or between two movable jaw members. That is the jaw mechanism may be of the type, wherein one jaw moves toward and away from the other; however, the present invention is also applicable for use with devices of alternative types, i.e., where both jaws move toward and away from each other. The surgical instrument may be of the type which applies metal staples or two part fasteners of the bioabsorbable type.
The surgical stapling or fastening instrument employing the adjustable closure mechanism of the present invention is a device which may be operated with one hand to effect the closure motion of the jaw members of the instrument followed by activation of the trigger mechanism to fire the staples or fasteners into the tissue. The complex rotational or pivoting arrangement of the prior art devices is eliminated, resulting in a lightweight and easy to handle instrument which is inexpensive to manufacture and easy to assemble.
Referring to FIGS. 16-19, in operation, the surgical fastening instrument 140 operates substantially similarly to the instrument 10 shown in FIGS. 2-6.
However, in the retracted position (FIG. 16), advancing mechanism 28 is in its proximalmost position and cam member 144 is pivoted into engagement with notch portion 154, by surface 161 of slide mechanism 40. As the slide mechanism 40 is moved distally to clamp tissue (FIG. 17), camming surface 159 of groove 158 approaches cam member 144. At this stage, cam member 144 is still positioned in notch 157 so that handle 14 can't be moved, since handle 14 is connected to notch portion 154 at pivot point 156.
As shown in FIG. 18, once the cartridge jaw 22 has been moved a sufficient distance towards anvil jaw 20, cam member 144 is permitted to pivot into groove 158 thus disengaging arcuate portion 146 from notch 157 in coupling arm 58. Thus, there are a plurality of positions, (e.g. FIGS. 18-19), in which the handle 14 of the apparatus can be moved at will by the surgeon.
While the invention has been particularly shown and described with reference to the preferred embodiments, it will be understood by those skilled in the art that various modifications and changes in form and detail may be made therein without departing from the scope and spirit of the invention. Accordingly, modifications such as those suggested above, but not limited thereto, are to be considered within the scope of the invention. | A surgical stapling or fastening instrument for applying surgical fasteners to tissue having an adjustable closure mechanism to linearly approximate the distance between the jaw members of the instrument. The adjustable closure mechanism consists of a retaining mechanism and a linkage structure which is actuable to linearly urge the jaw members towards each other. A coupling arrangement is also provided which permits firing of the staples or fasteners only when the jaw members are approximated a predetermined distance towards each other. | 0 |
BACKGROUND OF THE INVENTION
In both offshore and onshore pipeline construction, the manually welded joint has become the standard by which other forms of pipeline joining are evaluated. Pipe joining, by whatever means, is more costly offshore where weather conditions can severely hinder pipeline construction operations. In recent years considerable improvements have been made in conventional pipelaying systems, and more specifically in pipe joining processes. Semi-automatic and then fully automatic welding systems have been developed, proven in the field, and now accepted offshore. However, the art remains deficient in the provision of mechanical connectors for diverless, subsea tie-ends of large-diameter pipe in deep water. Accordingly, the present invention is directed to overcoming this deficiency of the art.
DISCUSSION OF THE PRIOR ART
The following U.S. patents are relevant to the present invention: U.S. Pat. No. 3,463,518 (Broussard et al.); U.S. Pat. No. 4,169,793 (Lockshaw); U.S. Pat. No. 3,933,378 (Sandford et al.); U.S. Pat. No. 3,912,009 (Davis); U.S. Pat. No. 3,885,851 (Bennett); U.S. Pat. No. 3,339,944 (Poague) and U.S. Pat. No. 3,628,812 (Larralde).
The Broussard et al patent provides a sealing ring 17 (shown in its unstressed condition in FIG. 3) which is generally frustoconical in shape. End portion 15 is provided with an annular seat 18 about its outer periphery to retain the radial seal 17. Part 14 is provided with a seat 19 at the point of contact with the radial seal 17. Accordingly, when parts 13 and 14 are threaded together, radial seal 17 is retained between the members by means of the seats 18 and 19. End portion 15 of Broussard et al is relatively thick, unlike the longer and thinner cantilevered seal lip 21 of the present invention.
Larralde et al. provides a connector utilizing spring fingers for making a connection. Spring fingers 40 are provided with tapered shoulders 46 and 45 which co-act with shoulders 35 and 14 in order to lock the joint into place. A stainless steel sealing ring 25 and crescent shaped member 26 effectively slide together to effect a seal so that the movement of the mechanism is primarily one of translation. By comparison, the present invention utilizes a movement which is primarily rotation as the sealing ring is held under tension and rotated into a sealing connection.
The commercially available Gamma metal seal ring "Gamma Seal Design Handbook" has some similarities to the seal ring used in the present invention. However, there are two major differences. First, good sealing practices, especially for gas applications, require use of less pointed (rounded) sealing edges (page 32 of Industrial Sealing Technology by H. H. Buchter, 1979). Additionally, sharp edges are more susceptible to damage during handling, particularly in offshore operations. Second, the seal must act against at least one elastic seat in order to achieve more reliable sealing. Thus, the seal ring of the present invention has rounded edges and acts against at least one elastic seat.
SUMMARY OF THE INVENTION
The tension spring finger connector of the present invention is composed primarily of joining components for holding pipe ends together and sealing components for preventing leakage. The holding components preferably are colleted spring fingers and a combination drive-lock ring, but other holding components well known in the art can be used, e.g., threaded connectors. Sealing is accomplished with the combination of a seal ring and a cantilevered support. The fingers of the collet spring finger assembly are long enough so that sufficient radial motion of the finger tips exists to allow stabbing of a connector hub without plastic deformation of the fingers. The radial force required to open the fingers is minimized because of the high mechanical advantage achieved, and the fingers will spring closed on their own after stabbing to generate a prelock of the connector hub. The internal taper of the exposed finger tips provides mechanical advantage to spread the fingers with low axial force while the connector pipe end is stabbed.
During locking action, the spring fingers are pretensioned, creating contact forces on the butting connector hubs. The preload contact forces are removed while tensile loads are applied to the connector during service, so the preload holding forces are of sufficient magnitude so that a minimum contact force will remain during loading. The fingers are tensioned by moving their ends radially inward over a tapered backside of the stabbed connector hub. The outside surface of the fingers is tapered so that the fingers are driven inward as a drive ring is pushed over the fingers.
The combination of the tapers at the hub contact point on the inside of the finger ends and at the outside of the fingers gives a significant mechanical advantage without excessive actuation force. The outside taper of the fingers is chosen so that the drive ring will be friction self-locking. For safety, a redundant lock to the drive ring is provided since preload forces will be lost if the ring is allowed to back off significantly.
The seal ring operates by generating high contact loads between the sealing surfaces while developing a backup of stored elastic energy. The seal ring rotates during actuation, causing radial interference between the seal ring and its seat and generating sufficient contact forces for a good seal. Elastic energy is stored in the flexible cantilevered seat or support whose end provides one of the two sealing surfaces. Elastic energy is stored in the seal support which is driven radially inward as the seal ring rotates (twists).
The seal ring is reusable primarily because the sealing surfaces do not slide over one another during makeup and actuation. The seal ring is made of material harder than its seats so that it will deform the seats as required to achieve a seal.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first embodiment of the invention employing a backup ring for the seal support ring.
FIGS. 2 and 3 show second and third embodiments of the invention utilizing alternate backups for the seal support ring.
DESCRIPTION OF PREFERRED EMBODIMENTS
The connector of the present invention meets certain criteria. First, the connector is as strong as the pipe needs to be in carrying bending and axial loads and has sufficient torsional resistance to meet operational loads. Second, the connector provides and maintains sufficient contact pressure and specified geometric relationships to ensure adequate seal actuation. In other words, looseness of the joint is avoided to ensure effective sealing, and an uncomplicated load path is utilized to help reach this goal. Third, the connector is designed to tolerate a small amount of misalignment prior to locking and to be self-aligning during makeup. Fourth, the alignment procedure for the connector is simplified so that torsional alignment of the pipe is not required to mate the connector halves. Fifth, the connector is reversable or remakable. Thus, the alignment and connection process is more reliable since the option of removal and re-insertion after problems are encountered is allowed. Reversability is important since later repair or replacement of components in the connector or adjacent pipeline may be necessary. Sixth, the connector is designed to comply with pipeline operations which require the inner wall of the connector to pass a spherical pig. This is the minimum requirement for cleaning of the completed pipeline. Seventh, the connector is designed for manufacture from corrosion-resistant materials. All connector surfaces exposed to the transported product as well as those exposed to sea water must be compatible and must resist corrosion to help ensure long-term integrity of the joint.
In addition, the seal employed in the connector of the present invention meets the following criteria. First, the seal has high plastic contact stresses to afford maximum sealing in spite of poor surface finishing of the mating surface. Second, the seal is configured such that sliding of sealing surfaces is avoided, making possible the re-use of the seal and seat. Third, the seal has high stored elastic energy in the seal/seat region in order to accommodate potential relative movement of the mating surfaces, and to accommodate potential machining tolerance problems. And fourth, the seal can be seated with low axial preload force, reserving most of the available preload capacity for maintaining connector integrity rather than for sealing.
The basic design of the tension spring finger connector of the present invention is shown in FIG. 1. The colletted spring fingers 10 and the drive-lock ring 11 are the principal holding components of the invention. Outer guard cylinder 12 protects spring fingers 10 from large deformation during stabbing of the connector over an exposed pipe end 13. The exposed pipe end has a locking shoulder or hub 14 having a taper of from 3 to 15 degrees which allows for mechanical tolerances. Spring fingers 10 have an inner shoulder taper angle 15 of 5 to 45 degrees in order to act as a guide cone as the spring fingers are slipped over the locking shoulder 14. For convenience the spring fingers may be manufactured as a solid cylinder and then cut out up to line 16 in order to form the individual fingers. The remaining part of the spring finger piece forms a locking shoulder 17 which secures to the shoulder 18 of a cantilevered hub 19.
Sealing is accomplished with the combination of a seal ring 20 and cantilevered seal lip 21. The seal ring is a section of a truncated cone or, preferably, a flat seal ring. Rotation or twisting of seal ring 20 causes radial interference. Sealing edges on seal ring 20 are slightly rounded for better sealing. Thin-walled seal lip 21 is deflected radially inward at its tip due to rotation of seal ring 20, causing plastic sealing pressures at the seal/seat interface and causing elastic strain energy to be stored so that any subsequent motions of seal ring 20 due to partial separation of connector hubs 14 and 19 during the long-term life of the connector will not cause leaking. In order to avoid excessive seating pressures at the seal/elastic seat interference (locally rupturing the sealing surfaces, and making leaks possible, particularly on re-sealing), seal lip 21 must be longer and thinner than the cylinder shown in U.S. Pat. No. 3,463,518 (see Examples herebelow for calculations).
As above noted with respect to the seal ring 20, a flat rectangular cross section is preferred. This type of ring is easier to fabricate than a frustoconical seal such as shown in U.S. Pat. No. 3,463,518. The twisting action of the frustoconical seal ring and the flat rectangular cross section are similar, but the extra material required for the frustoconical seal ring makes the ring stiffer in torsion than preferred for purposes of the present invention.
The configuration of spring fingers 10 as shown in FIG. 1 is considered critical. An increased axial flexibility, such as caused by a slight bend in the fingers or by inadequate size of ring 17 to which they are attached, decreases the performance of the connector and may lead to premature plastic stretch deformation of the fingers, requiring a shim for further use. The actuation forces required for locking may be adjusted by variation of the extended outer taper, angle 9, on the fingers. For example, an angle of 71/2 degrees is too steep; a preferred taper is from 3 to 4 degrees. The taper is meant to be decreased only near the ends of the fingers, starting around the middle of the fingers.
With respect to FIG. 2, this alternative embodiment provides a backup ring 30 to support cantilevered seal lip 21. As above noted, the function of seal lip 21 is to act as a source of stored elastic strain energy after the seal ring 20 is tipped during seal actuation, driving seal lip 21 radially inward. Design to achieve this goal requires the seal lip to be thin compared to ordinary pipe wall thickness, i.e., ordinarily a thickness of less than one half the pipe wall thickness. In the basic design shown in FIG. 1, seal lip 21 has to resist internal pressure forces which tend to cause expansion of the lip. Design to resist this deformation requires either thickening of the lip (which adversely affects contact loading on the seal surface) or careful control of material properties (e.g., by post manufacture heat treatment of the seal lip to increase yield stress, which is difficult and expensive). Backup ring 30 provides material for resistance to radial expansion of seal lip 20. Since it is not fastened to the seal lip 21, it does not resist the desired flexibility of the lip for inward radial motion. Effectively, the equivalent of a thick seal lip to resist outward motion and a thin seal lip to resist inward motion is provided. Backup ring 30 is a force fit over seal lip 21. The degree of allowable looseness is a function of how far outward seal lip 21 may be allowed to deform radially before the geometry of the lip is changed enough to inhibit the effectiveness of seal 20. Generally, the outside diameter of the backup ring is made large enough to provide sufficient strength to the ring, and for convenience, it is a good fit inside the annulus 31. The backup ring should allow the seal lip to deflect no more than about one percent of the pipe diameter.
An alternative to the use of backup ring 30 is shown in FIG. 3. Thus, an ultra-thin annular space 40 is provided outside the seal lip. This configuration can be made by making the seal lip 21 as a separate piece. In this case, the connector body acts as a backup and support seal ring 21 is welded at location 41. The original design as shown in FIG. 1 is drawn in phantom for comparison purposes. The space 40 should be such that a similar fit between the connector body and seal lip is created as when a back up ring was specified above.
EXAMPLES OF THE INVENTION
The swivel connector of U.S. Pat. No. 3,463,518 uses a cantilevered seal support. But in the highly critical and expensive deep subsea connection operations where the connector of the present invention is suited, a higher degree of radial interference is needed than afforded by solving the equation for "S" in lines 35-40 of U.S. Pat. No. 3,463,518. The deflection "S" for the example would be only 0.002 inches. Machining tolerances for such a connector would normally be greater than this, and the seal fit would be poor. The solution to this problem is to use radial interference "S" of 0.010 to 0.030 inch, then make the cantilever thinner so that the contact pressures between the seal and seat do not become excessive. For the same type of example as in U.S. Pat. No. 3,463,518, the cantilever seal would have a thickness that is less than half the pipe wall thickness.
With respect to seat design procedure, the maximum allowable radial interference based on elastic limit can be approximated by the following hoop stress-strength equation:
δ.sup.R (allow)=(R/E)σ(allow)
where
δ R (allow)=Allowable radial interference in inches
R=Seat mean radius at tip
E=Modulus of elasticity (E=30×10 6 psi for steel)
σ(allow)=Allowable hoop stress, psi
For example, with an allowable stress of 30,000 psi and a means radius of 6 inches a steel seat would permit a radial interference of 0.006 inch. This result is observed to be independent of wall thickness.
This value of 0.006 inch is still not enough to easily accommodate usual machining tolerances, so recommended design procedure calls for allowing the cantilever seat to yield upon seating. If the allowable radial interference is set at 0.030 inch, the hoop strain is 0.6% which is quite low when compared with a 20% typical ultimate elongation of mild steel. The key in this case is that the radial interference is carefully controlled by the seal ring rotation, and later the pressure will act to deform the seat back outward. Consequently, this design is quite safe, provided that the seating material has good ductility. Further, there would be no difficulty with circumferential buckling of the seat under normal conditions since the inward deflection is constrained by the seal ring. Thus, it can be assumed that the seat has been deformed inward by 0.010 to 0.030 inch or more, and the resulting stress will be above yield but less than ultimate stress.
The next step is to determine the seat thickness based on contact pressure limits on the seat/seal interface. Good design practice for sealing is that the contact pressure be at least two times the Yield stress of the softer material (Industrial Sealing Technology by H. H. Buchter, 1979). If the seat material has a yield stress of 30,000 psi (and the seal ring is higher strength), and the effective contact area is ω=3/16 inch, the radial force in lbs/inch is:
V=2σyield ω
V=2(30,000)(0.188)=11,280 lb/inch
The design requirement is to achieve at least this contact loading at the seal seat. The elastic stress limit in this example is 30,000 psi, so the elastic radial deflection (if the connector were taken apart) is about 0.006 inch (as calculated above).
Given the stress and radial deflection, the seat thickness is determined using the following relation (Formulas For Stress and strain, Raymond J. Roark, 1954, page 271).
δ.sup.R =-V/2 Dλ.sup.3 | A tension spring finger connector is provided for offshore pipelines. The connector makes use of a metal seal which is reusable and does not require a diver for subsea connection operations. The holding components of the connector are colleted spring fingers and a combination drivelock ring. Sealing is accomplished with a combination of a seal ring and a flexible cantilevered support. | 8 |
BACKGROUND OF THE INVENTION
This invention relates generally to improvements in surfboards. Generally, an ordinary surfboard is bulky and too lengthy to be transported easily by a vehicle. An ordinary surfboard also has a fixed length, which may only be adequate for a particular weight surfer.
There is need for improvements that will enable a surfboard to be dismantled, for easy transportation, and which will also permit the surfboard to be reassembled quickly and easily. In particular, there is need for a surfboard that can be shortened or elongated for the convenience of a surfer.
SUMMARY OF THE INVENTION
Basically, the apparatus of the invention comprises a sectional surfboard wherein a number of sections can be selectively interconnected.
As will be seen, the sequential sections typically have substantially flush upper surface and substantially flush lower surfaces, and the attachment means is confined between the levels of the upper and lower surfaces.
It is a further object of the invention to provide attachment means that includes
a) connecting structure penetrating longitudinally into the sequential sections and including loops at the split or splits between sections, and
b) a connection pin inserted laterally through the loops at the split, the pin being withdrawable laterally from the loops.
Another object includes provision of connecting structure that includes anchors penetrating longitudinally into the sequential sections, each anchor integral with a loop. The pin typically extends laterally between opposite edges of the board and is releasably connected to the board, whereby the board sections have abutting surfaces at the split. Four such sections may be provided, with pinned interconnections at the junctions of pairs of the sections.
A surfer can adjust the numbers of the middle sections of the surfboard, so that it will provide the most favorable buoyancy for the surfer. When not in use, the surfboard can easily be dismantled back into short, separate sections, for easy transportation.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIGS. 1 and 2 are plan views and elevational views, respectively, of the improved surfboard;
FIGS. 3 and 4 are plan views and elevational views, respectively, of a middle section of the improved surfboard;
FIG. 5 is a schematic plan view of a bolt-nut-washer fastening means;
FIGS. 6 and 7 are plan views and elevational views, respectively, of the nose section of the improved surfboard;
FIGS. 8 and 9 are plan views and elevational views, respectively, of the tail section of the improved surfboard;
FIG. 10 is an elevation view which illustrates the connection details of the apparatus;
FIGS. 11 and 12 are plan views and elevational views, respectively, of a link means; and
FIG. 13 is an enlarged elevation view of a joint end or a joint front.
DETAILED DESCRIPTION
In FIGS. 1 and 2, a surfboard 100 extends longitudinally and has multiple sections, as shown. These include fore and aft sections 6 and 8, and three like intermediate sections 3. Joints or splits are formed at 90, 91, 92, and 93, and extend laterally between opposite edges 80 and 81 of 6; 82 and 83 of each of 3; and 84 and 85 of 8. Pins and anchors, at the splits, releasably interconnect the sections, as will be disclosed.
Referring to FIGS. 11 and 12, a link means includes a short link tube 1101, and a section anchor 1102, providing an anchoring means by which the link means can be anchored to any section of the improved surfboard. The drawings show a nail-type section anchor. The link tube is on one end of the section anchor.
Referring to FIG. 13, at a joint 91 there is a face 1300 at the end of a section 3 of a board. Sunk in the face is a fastening means slot 1301, and there are two surfaces 1303 and two beveled edges 1302. The fastening means slot extends medially along the face 1300. One end of each of the two surfaces 1303 intersects an edge of the fastening means slot. The other ends of the two surfaces 1303 intersect the two edges 1302. Surfaces 1303 on adjacent ends of two sections provide for abutting contact, when the board is assembled to block relative bending of the sections.
Referring to FIGS. 6 and 7, a nose section 6 consists of a nose board 601, a joint end 602, a pair of nut-washer receiving relieved areas 603 adjacent lateral ends of the joint, and three link means 11. The nose board has a relatively sharp front.
Referring to FIG. 13, the edge view of the joint end was described previously. The nut-washer receiving areas are on the side walls of the nose board. As seen in FIG. 6, the section anchors 1102 of the link means are anchored onto the nose board along the fastening means slot of the joint end. The centers of the link tubes 1101 are in lateral alignment and just slightly protruding from the lateral plane of the two surfaces 1303 of the joint end.
Referring to FIGS. 8 and 9, a tail section 8 comprises a tail board 801, a downwardly protruding fin 802, a joint front end 803 of the board 801, a pair of nut-washer, receiving-end areas 804, and a number of (i.e., six) of the link means 11, as shown. The tail board is a board with a relatively sharp or tapering end 8a. The nut-washer depressed areas 804 are located at the laterally spaced side walls 84 and 85 of the tail board.
The link means 11 was described earlier. The section anchor 1102 of the link means is anchored onto the tail board along the fastening means slot (such as slot 1301 at the joint front. The centers of the link tubes are in alignment and just slightly protruding from the two surfaces 1303 of the joint front. The fin 802 extends below the broad, flat, lower face 8c of the tail board.
Referring to FIGS. 3 and 4, a middle section 3 comprises a middle board 301, a joint rear end 302, a joint front end 303, four nut-washer, receiving-relieved areas 304, and a number of the link means 11, as shown. The joint ends were described previously, as in FIG. 13. The areas 304 are located at the laterally spaced side walls of the middle board. The section anchors 1102 of the link means 11 penetrate into and anchor to the middle board along the fastening means slots 1301 of the joint end and the joint rear end. Anchoring may be as by adhesive bonding or by threads, or both. The centers of the link tubes are in lateral alignment and just slightly protruding from the two surfaces 1303 of the joint rear end and the joint front end.
Referring to FIG. 5, a bolt-nut-washer fastening means 5 is typically a long bolt or pin 501 with washers and nut(s) 502.
Referring to FIG. 10, when any two sections (a nose section and a middle section, a middle section and another middle section, or a middle section and an end section, etc.) are connected together, the joint ends are abutted against each other. At at least two places along the abutted joint, the link means of the two sequential board sections are so spaced that tubes 1101 of those links are in lateral endwise engagement, whereby there will be no lateral relative shifting between the two joined sections. See FIG. 1 in this regard.
Due to the existence of the fastening mean slots 1301, the bolt-nut-washer fastening means can penetrate and chain together the concentric link tubes. When two sequential board sections are thus joined together, the two surfaces 1303 of one section end will be very close to those of the other section end. Because of this, the two joined sections can be bent longitudinally by only a very small amount, i.e., a negligible angle. The two registered C-shaped relieved areas of the two joined sections will form an annularly relieved area in which the bolt head, and washer, and/or the washer, can seat. The length of the bolt is selected that no part of it will protrude from the joined sections.
Referring to FIGS. 1 and 2, multiple of the described-like sections 3 can be connected together to form a surfboard. The surfer can select the adequate number of sections desired for any selected buoyancy. The invented surfboard can be quickly disassembled by simply removing the bolt-nut-washer fastening means and separating the board sections.
The foregoing is considered as illustrative only of the principles of the invention. Furthermore, 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 as claimed. | A surfboard, which can be dismantled into sections, for convenient transportation and can be reassembled for use. The surfboard can also be shortened or elongated to provide adequate buoyancy for the convenience of a surfer. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/GB2009/000520 filed on Feb. 25, 2009, which claims the benefit of GB 0804043.8, filed Mar. 4, 2008. The disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a termination tool and corresponding male and female connectors.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] Termination tools exist in many different forms, with the desirable characteristics including portability, ease of assembly, ease of use and reliable termination of the connector to communication wires.
[0005] US Patent Publication No. 2006/0230608 describes a termination tool for use with network jack plugs and sockets such as CAT 5e, CAT 6, etc. The tool is designed to work in two distinct stages. An electrical connector wire arrangement manifold is prepared by inserting wires into the relevant connector slots on said wire arrangement manifold and placing the cap into a cavity on one side of the tool. Adjacent to said cavity are cutting means, mounted such that upon actuation of a trigger mechanism the cutting means are urged astride the prepared wire arrangement manifold, severing any excess wires protruding thereon and driving the wires securely into the connector slots. A second, separate cavity is provided on the other side of the tool into which the trimmed wire arrangement manifold and a jack housing are inserted adjacent each other. Actuation of the trigger mechanism urges a ram against the wire arrangement manifold, pressing it into engagement with the jack housing, whereupon the wires in the wire arrangement manifold make electrical contact with connection terminals in the jack housing, thus securing the wire arrangement manifold within the jack housing, and terminating wire arrangement manifold and housing sections of the electrical connector.
[0006] However, this device suffers from the disadvantage of requiring two distinct operations to be performed; the trimming of wires protruding from the prepared wire arrangement manifold and then the repositioning of said wire arrangement manifold such that a ram may be used to urge the wire arrangement manifold into engagement with a jack housing.
SUMMARY
[0007] According to the present disclosure there is provided a termination tool for terminating multiple wires to a two part electrical connector assembly composed of a wire arrangement manifold and a jack housing, the termination tool comprising a main tool body having a termination housing provided thereon including a first cavity, a second cavity and a passage extending between the first and second cavities, the first cavity having an open side to receive and being shaped to removably retain the wire arrangement manifold, the second cavity having an open side to receive and being shaped to removably retain the jack housing, and the passage being sized to allow, in use, the wire arrangement manifold pass therethrough from the first cavity to the second cavity and having cutting means provided on opposing side of its end proximate to the first cavity, the termination tool further comprising a ram aligned with the passage and actuatable to move between a retracted position in which the ram is withdrawn from the first cavity and a second position in which the ram extends through the passage so as, in use, to press the wire arrangement manifold from the first cavity, through the passage and into engagement with the jack housing located in the second cavity, the cutting means severing any overhanging wire tails from the sides of the wire arrangement manifold as it enters the passage.
[0008] A termination tool is thus provided where corresponding male and female connectors are arranged such that in one motion the tool is used to cut multiple electrical connector wires and then terminate wire arrangement manifold and housing sections of an electrical connector. A termination tool in accordance with the present disclosure has the advantage that the whole termination operation is performed in a single operation, increasing efficiency.
[0009] In one form, the first cavity is of complementary shape to and a close tolerance fit with the wire arrangement manifold such that, in use, the wire arrangement manifold is constrained against lateral movement in the first cavity. Similarly, the second cavity is of complementary shape to and a close tolerance fit with the jack housing such that, in use, the jack housing is constrained against lateral movement in the second cavity. In this way, the wire arrangement manifold and jack housing are accurately aligned with each other so as to ensure reliable termination upon actuation of the tool.
[0010] In one form, the first cavity includes a groove in each side surface thereof adjacent the cutting means at the mouth of the passage in which, in use, tails of wires inserted into the wire arrangement manifold are received so as to align them for trimming by the cutting means upon operation of the tool. This has the further advantage that the longitudinally asymmetric configuration of the grooves prevents insertion of the wire arrangement manifold into the first cavity in the wrong orientation since the wire tails will then not align with the grooves and hence the close tolerance fit of the wire arrangement manifold in the first cavity will prevent entry of the wire arrangement manifold into the first cavity.
[0011] The cutting means, in one form, comprises a pair of blades, one on either side of the mouth of the passage. Further advantageously, the position of the cutting means is related to the thickness and spacing of wires in the wire arrangement manifold, such that, in use, the leading edge of the cutting means engages with, and subsequently severs, the wire tails sequentially, rather than simultaneously. This has the advantage of reducing the force required to operate the tool and therefore, for example, reducing a required actuator pivot length or the like. The sequential severing of the wire tails could be achieved by offsetting the cutting means either side of the mouth of the passage relative to each other, by inclining the cutting edge of the cutting means relative to the direction of movement of the wire arrangement manifold or by a combination of the two. Preferably the wire tails are severed in pairs and further advantageously the cutting means is positioned such that the severance of a pair of wire tails by the cutting means is completed before the next pair of wire tails is subsequently engaged by the leading edge of the cutting means. The width of the passage is also advantageously equal in width to the first cavity.
[0012] The passage may include a longitudinally extending rib on the top of each side, which reduces the width of the passage at the top and thereby prevents the wire arrangement manifold from being removed from the passage during operation of the tool.
[0013] In one form, the second cavity includes one of a projection and a recess in a side thereof, in particular the side opposite the passage, and the jack housing includes a complementary other of a projection and a recess which aligns with the one of the projection and the recess when the jack housing is correctly oriented with respect to the second housing. This has the advantage that it ensures proper alignment of the jack housing upon insertion since it will be prevented from entering the second cavity if wrongly oriented. In a preferred embodiment, the jack housing includes a tab, which engages in a slot, which extends from the open side of the second cavity.
[0014] The open sides of the first and second cavities are on the same side of the tool in one form of the present disclosure.
[0015] The depth of the first cavity is preferably such that when the wire arrangement manifold is fully inserted therein, it aligns with the passage. Similarly, the depth of the second cavity is preferably such that, when the jack housing is fully inserted therein, an opening in the jack housing in which the wire arrangement manifold engages for effecting termination is aligned with and facing the passage.
[0016] In one form, the tool is hand operated, including trigger which is connected to the ram so as to effect longitudinal movement of the ram from its retracted position to its extended position. A ratchet mechanism is advantageously integrated with the trigger mechanism, which operates to prevent retraction of the ram, once operative movement has commenced, until the ram has reached its fully extended position. This has the advantage that it ensures that proper termination occurs between the wire arrangement manifold and the jack housing. Other means may also be provided which prevents operation of the trigger until a wire arrangement manifold has been properly inserted into the first cavity and a jack housing has been properly inserted into the second cavity.
[0017] The trigger may be spring-loaded to effect return of the ram to its retracted position once the termination stroke has been completed.
[0018] The present disclosure further provides a wire arrangement manifold for use with a termination tool according to the disclosure, comprising a body having an end surface with an opening therein through which, in use, a cable formed of a plurality of separate wires is insertable, a front face having a plurality of notches formed therein proximate to at least one side of the wire arrangement manifold, each notch size to retain one of the wires of the cable therein, and a passage extending from the opening in the end surface to the front face for channelling the wires to the notches.
[0019] In one form, the notches in the front face of the wire arrangement manifold are arranged in two rows, one extending along each side of the body, with the notches being equi-spaced along the body. In particular, the end housing has eight notches arranged in two rows of four.
[0020] The body in one form is rectangular in shape, at least when viewed in the direction of the front face. The opening in the end face is preferably open to the back of the end housing, the passage taking the form of a through opening which extends from the back to the front face of the body.
[0021] The present disclosure still further provides a jack housing for matingly engaging with the wire arrangement manifold of the disclosure, the jack housing comprising a body having a socket formed in a front end therein containing a plurality of contacts, an opening in a top side of the body and a plurality of termination jaws upstanding from the bottom of the opening, each termination jaw being electrically connected to an associated one of the contacts, the opening being of complementary size and shape to the wire arrangement manifold such that, in use, the wire arrangement manifold is insertable into the opening from the top thereof such that each wire located in one of the notches in the wire arrangement manifold engages between one of termination jaws, effecting electrical contact therewith.
[0022] In one form, the back wall of the opening in the jack housing has a slot formed therein extending from the top edge, the cable extending from the wire arrangement manifold, in use, being received in the slot as the wire arrangement manifold engages in the opening.
[0023] The bottom of the body advantageously has a guide tab thereon of narrower width than the main body, which, in use, aligns with and engages in a complementary shaped recess formed in the second cavity when the jack housing is correctly oriented with respect to the second cavity and prevents entry of the jack housing into the second cavity in the wrong orientation. The guide tab is advantageously formed as a mounted hook for latching the jack housing in place in a patch panel, wall mounting or the like.
[0024] In one form, the opening includes eight termination jaws arranged in two rows of four to complement the arrangement of the notches in the wire arrangement manifold, each jaw being composed of a pair of metal prongs with a space between them which narrows towards the base of the opening such that as a wire is pressed therebetween, the jaws progressively cut through the insulation on the wire and make electrical contact with the core of the wire.
[0025] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0026] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
[0027] FIG. 1 is a side view of an apparatus according to the invention, showing the insertion of a jack housing and wire arrangement manifold;
[0028] FIG. 2 is an exploded perspective view of the apparatus of FIG. 1 ;
[0029] FIGS. 3( a ), 3 ( b ) and 3 ( c ) are partial perspective views of the apparatus of FIG. 1 , showing extension of the ram;
[0030] FIGS. 4( a ) and ( b ) are overhead views of the first and second cavities at retracted and extended positions of the ram, showing the shape of each cavity;
[0031] FIG. 5 is a perspective view of the apparatus of FIG. 1 , showing the apparatus fully engaged;
[0032] FIG. 6 is a perspective view of the apparatus of FIG. 1 , showing retraction of the ram and subsequent removal of the electrical connection assembly;
[0033] FIG. 7 is a perspective view of the jack housing and wire arrangement manifold;
[0034] FIG. 8 is a perspective view of the wire arrangement manifold cover;
[0035] FIG. 9 is a perspective view of the assembled jack housing, wire arrangement manifold and cover; and
[0036] FIG. 10 is a perspective view of the assembled jack housing, wire arrangement manifold and cover showing the jack socket.
[0037] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
[0038] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0039] Referring first to FIGS. 1 , 2 and 3 , there is shown a hand-held termination tool 100 for effecting automated termination of an wire arrangement manifold 101 into a jack housing 102 for providing electrical connection between wires 103 mounted in the wire arrangement manifold 101 and contact jaws 104 provided in the jack housing 102 . The termination tool 100 has a main tool body 105 with a handle 106 fast with the body 105 and a trigger 107 pivotally attached to the body 105 and operably moveable towards the handle 106 in order to effect movement of a ram 108 as described hereinafter. Biasing means such as a spring (not shown) is connected to the trigger 107 , which urges the trigger 107 away from the handle 106 . Attached to the front portion of the main tool body 105 is a termination housing 109 having a pair of spaced apart cavities 110 and 111 formed therein, each of which extends to the top 109 a of the termination housing 109 , and a passage 112 which extends between the first and second cavities 110 , 111 so as to allow movement of an element from the first cavity 110 to the second cavity 111 as described below.
[0040] As shown in FIG. 3 c , the first cavity 110 is generally rectangular in cross section and is sized to enable the wire arrangement manifold 101 to be engaged end on into the cavity from the top side 109 a of the housing 109 with a close tolerance fit such that the wire arrangement manifold 101 is restrained from lateral movement within the first cavity 110 . The first cavity 110 furthermore includes a pair of side wing slots 113 , one formed in each side wall of the cavity proximate to the end where it meets the passage 112 , each slot 113 extending from the top side 109 a of the housing 109 substantially the full depth of the first cavity 110 .
[0041] The second cavity 111 is similarly generally rectangular in cross section but is of a larger cross section and depth compared with the first cavity 110 to accommodate the larger size of the jack housing 102 . As with the first cavity 110 , the cross section of the second cavity 111 is sized to enable the jack housing 102 to be slid end on into the second cavity 111 from the top side 109 a of the housing 109 , there being a close tolerance fit between the jack housing 102 and the sides of the second cavity 111 so as to prevent lateral movement of the jack housing 102 and hence accurately locate the jack housing 102 laterally therein. The depth of the first and second cavities 110 , 111 are furthermore set so that when the wire arrangement manifold 101 and jack housing 102 are fully inserted into their respective cavities, they are accurately longitudinally located relative to each other as well as relative to the passage 112 .
[0042] The passage 112 which extends between the two cavities 110 , 111 is sized laterally to be a close tolerance fit with the wire arrangement manifold 101 so that the wire arrangement manifold 101 , once fully inserted into the first cavity 110 , can move longitudinally through the passage 112 and into the second cavity 111 and has the same depth as the first cavity 110 . A cutting blade 114 is located on each side of the mouth of the passage 112 at the intersection with the first cavity 110 in alignment with the wing slots 113 , the blades 114 extending substantially the entire depth of the passage 112 and being laterally spaced apart such that the wire arrangement manifold 101 is a close tolerance fit therebetween.
[0043] Although not shown in the illustrated embodiment, the passage 112 may optionally have a rib extending longitudinally along each side proximate to the top, which forms a constriction in the cross section, preventing the wire arrangement manifold 101 from moving vertically as it moves through the passage 112 .
[0044] Ram 108 is mounted in the main body 105 in alignment with the passage 112 and is pivotally connected to the end of the trigger 107 so that when the trigger 107 is operated, the ram 108 is moved forwards into the termination housing 109 from a retracted position (shown in FIG. 2 ) in which it is fully withdrawn into the main body 105 and out of the first cavity 110 , and an extended position in which it is moved longitudinally through the first cavity 110 and into the passage 112 , projecting into the second cavity 111 as shown in FIG. 4 b . Guides 115 channel the path of the ram 108 so as to constrain it to move only in the longitudinal direction. The trigger 107 also includes a ratchet mechanism 120 , which controls the forward movement of the ram 108 and prevents it from being withdrawn back into its retracted position until it has reached its fully extended position. Such mechanisms are within the practical knowledge of the skilled person and will not, therefore, be described here in greater detail.
[0045] The wire arrangement manifold 101 , shown in more detail in FIG. 7 comprises a generally rectangular body 101 a having a through opening 101 b therein which links to an opening 101 c in the rear end of the body. A series of notches 116 are formed in the opposing sidewalls extending from the bottom edge thereof, in the illustrated embodiment four equi-spaced notches 116 in each sidewall, in each of which is engageable a single wire of a cable bundle. As shown in FIG. 2 , the cable 117 is fed through the rear opening 101 c and the wires 103 are fed through the opening 101 b to the bottom of the wire arrangement manifold 101 . Each wire 103 is then located in its allotted notch 116 , identified by colour coding or the like provided on each side of the body 101 a in alignment with the notches 116 , with the free end of the wire 103 extending laterally from the sides of the wire arrangement manifold 101 .
[0046] The jack housing 102 , also shown in FIG. 7 , again comprises a generally rectangular body 102 a having a jack socket 102 b in its front face (shown in FIG. 10 ) with a plurality, in particular eight contacts therein. The top 102 c of the body 102 a has a rectangular opening 102 d formed therein in the bottom 102 e of which are upstanding a plurality, in particular eight, contact jaws 104 , each of which is electrically connected to one of the contacts of the jack socket 102 b. The jaws 104 are of the type known in the art which are self-terminating with an inserted wire, that is they automatically cut through any insulation on an appropriately sized wire pressed between the jaws so as to make electrical contact with the inner core of the wire, and they are arranged in two spaced apart rows of four jaws corresponding to the pattern of the notches 116 in the wire arrangement manifold 101 . The opening 102 d is bound by opposing sidewalls; a front wall and a rear wall, which has a through opening, formed therein which extends to the top of the opening 102 d. The opening 102 d is sized such that the wire arrangement manifold 101 is a press fit therein through the open top of the opening 102 d with the tail of a cable which extends from the wire arrangement manifold 101 locating in the through opening in the rear wall of the opening 102 d, each notch 116 in the wire arrangement manifold 101 aligning the wire 103 located therein with one of the jaws 104 so that as the wire arrangement manifold 101 is pressed fully into the opening 102 d, each wire 103 engages in its associated jaw 104 and makes electrical contact therewith.
[0047] A cover 121 , as shown in FIGS. 8 and 9 , fits over the wire arrangement manifold 101 and secures into the jack housing 102 at the opening 102 d so as to protect the terminated wires 103 and provide an enclosed casing in which the wire arrangement manifold 101 is held. A recess 102 f surrounding the opening 102 d in the jack housing 102 is sized such that the cover 121 is a press fit therein. An opening 121 a in the cover 121 allows the cable 117 to be fed through.
[0048] The tools operates as follows:
[0049] The cable 117 is fed through the opening 121 a of the cover 121 and then through the rear opening 101 c of the wire arrangement manifold 101 . The wires 103 are then inserted through the through opening 101 b and each wire 103 pressed into one of the notches 116 with the excess wire 103 overhanging the sides of the wire arrangement manifold 101 . The jack housing 102 is then inserted into the second cavity 111 with the rectangular opening 102 d in the top thereof facing the first cavity 110 . A mounted hook 118 is provided on the bottom of the jack housing 102 which has a smaller width than the main body 105 and a complementary channel 119 is formed on the side of the second cavity 111 remote from the first cavity 110 such that when the jack housing 102 is inserted into the second cavity 111 in the correct orientation the mounted hook 118 engages in the channel 119 , allowing the jack housing 102 to be fully inserted into the second cavity 111 , whereas if the jack housing 102 is presented to the termination housing 109 in the wrong orientation, the differing width of the second cavity 111 and guide channel 119 prevents the jack housing 102 from being inserted.
[0050] The wire arrangement manifold 101 is then inserted into the first cavity 110 with the bottom 101 d facing the second cavity 111 so that the notches 116 open towards the second cavity 111 . When the wire arrangement manifold 101 is aligned with the first cavity 110 in the correct orientation as shown in FIG. 3 a , the projecting tails of the wires 103 align with the wings slots 113 , providing the extra space to allow the wire arrangement manifold 101 to slide into the first cavity 110 . On the other hand, if the wire arrangement manifold 101 is presented to the first cavity 110 in the wrong orientation, the offset configuration of the notches 116 means that the wire tails 103 do not align with the wing slots 113 , so that the close tolerance fit between the wire arrangement manifold 101 and the first cavity 110 prevents the wire arrangement manifold 101 from entering the first cavity 110 .
[0051] Once both the wire arrangement manifold 101 and the jack housing 102 are fully inserted into their respective cavities 110 , 111 the trigger 107 is pressed towards the handle 106 , moving the ram 108 towards the first cavity 110 , engaging the wire arrangement manifold 101 and pressing it towards the passage 112 . As the wire arrangement manifold 101 is engaged by the ram 108 , the tails of the wires 103 overhanging either side of the wire arrangement manifold 101 are pressed against the cutting blades 114 , severing the wires 103 flush with the sides of the wire arrangement manifold 101 and freeing the wire arrangement manifold 101 to move through the passage 112 and into engagement with the aligned rectangular opening 102 d in the top facing of the jack housing 102 as shown in FIG. 3 b . Although not shown in the illustrated embodiment the cutting surfaces of the cutting blades 114 are angled with respect to the vertically aligned wires 103 such that they engage with, and subsequently cut, the wires sequentially. The wires 103 opposing each other on either side on the wire arrangement manifold 101 are severed in pairs—the cut of each pair of wires 103 is completed before the leading edge of the cutting blade 114 engages with and then cuts the next pair.
[0052] As the ram 108 reaches its fully extended position, the wire arrangement manifold 101 is pressed fully into the jack housing 102 shown in FIG. 3 c , and the wires 103 mounted in the notches 116 are pressed into engagement with the aligned contact jaws 104 upstanding from the base 102 e of the opening 102 d in the jack housing 102 , making electrical contacts therewith. The ratchet mechanism 120 prevents the trigger 107 from being released to withdraw the ram 108 back to its retracted position until it has reached its fully extended position, thereby ensuring that the electrical connections are properly made. Once the fully extended position is reached, release of the trigger 107 causes it to move away from the handle 106 under the action of the biasing means, withdrawing the ram 108 from the cavities 110 , 111 and releasing the jack housing 102 with wire arrangement manifold 101 fastened thereto to be withdrawn from the second cavity 111 . The severed tails of the wires 103 are free to drop out of the wing slots 113 and the tool is ready for the next termination operation. Finally, on removal of the terminated wire arrangement manifold 101 and jack housing 102 from the termination housing 109 , the cover 121 is manually pressed into the recess 102 f in the jack housing 102 so as to enclose the terminated wires 103 .
[0053] Thus, the hand-held tool can be used to achieve a terminated connector assembly by the action of one continuous motion; trimming the connector wires and terminating connector halves, without the need to stop to reposition components.
[0054] It should be noted that the disclosure is not limited to the embodiment described and illustrated as examples. A large variety of modifications have been described and more are part of the knowledge of the person skilled in the art. These and further modifications as well as any replacement by technical equivalents may be added to the description and figures, without leaving the scope of the protection of the disclosure and of the present patent. | A termination tool for terminating multiple wires to a two part electrical connector assembly composed of a wire arrangement manifold and a jack housing is provided by the present disclosure. The termination tool includes a main tool body having a termination housing provided thereon including a first cavity, a second cavity and a passage extending between the first and second cavities. The first cavity has an open side to receive and is shaped to removably retain a wire arrangement manifold, the second cavity having an open side to receive and being shaped to removably retain a jack housing, and the passage being sized to allow, in use, the wire arrangement manifold to pass therethrough from the first cavity to the second cavity and having cutting means provided on opposing sides of its end proximate to the first cavity. | 7 |
This is a division of U.S. patent application Ser. No. 08/699,129, filed Aug. 16, 1996, and now U.S. Pat. No. 5,743,070.
This invention relates to packaging machinery and more particularly to a packaging machine and method of packaging which are especially well suited for loading relatively bulky and liquid products sequentially into bags of a novel, side interconnected, chain of bags.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,969,310 issued Nov. 13, 1990 to Hershey Lerner et al. under the title Packaging Machine and Method and assigned to the assignee of this patent (the SP Patent) discloses and claims a packaging machine which has enjoyed commercial success. One of the major advantages of the machine of the SP Patent resides in a novel conveyor belt mechanism for gripping upstanding lips of bags of a chain as they are transported along a path of travel and registered at a load station. The firmness with which the lips are gripped makes the machine highly suitable for packaging bulky products which are stuffed into the bags. While the machine of the SP Patent was an advance over the prior art, especially in terms of its lip gripping capability, even greater lip gripping capabilities, if achieved, would be useful in enabling packaging of additional products. Expressed another way, the bag gripping forces of the machine of the SP Patent were dependent on clamping pressure applied between pairs of belts. Thus, while the machine was a definite advance over the art, as to any given bag size, it has a finite maximum stuffing pressure it can withstand without slippage.
Since the bag gripping is dependent on the force with which belt pairs are clamped, the length of the path of travel through the load station is limited. Thus the length of a bag along the path of travel is limited, loading of a bag while it moves along the path of travel is not possible and the concurrent loading of two or more bags is not available.
With the machine of the SP Patent there is an intermittent section which includes the loading station and a continuous section which includes a sealing station. Since the section including the loading station is intermittent, obviously the through-put of the machine is inherently less than could be achieved with a continuously operating loading section.
The machine of the SP Patent had further advantages over the prior art, including an adjustable bag opening mechanism which was adapted to accept a wide range of bag sizes and adjustable to provide a range of bag openings. While an advance over the prior art, the bag openings were six sided so that, like most of the prior art, a rectangular bag opening was not achievable.
Although one prior machine provides rectangular openings, the dimensions of the rectangular openings, both longitudinally and transversely, are limited both by the construction of the chain of bags being filled and by guide rods used to transport the bags. Thus, if an operator wished to change from one opening size to another, another and different web of bags was required. Moreover, to the extent, that the packaging machine could be adjusted to vary the configuration of the rectangular opening, such available adjustment was extremely limited because it required substitution of a different set up guide rods. Further, there was excessive packaging material waste in the form of elongate tubes which slid along the guide rails.
While the machine of the SP Patent has been sold under the designation SP-100V for vertical orientation in which products can be gravity loaded into bags and the designation SP-100H for horizontal loading of stuffable products, neither machine was suitable for adjustment from horizontal to vertical and return, nor for orientation at selected angles of product insertion between the horizontal and the vertical.
A problem has been experienced with prior art sealers having pairs of opposed belts to transport bags through a seal station. The problem is that too frequently due to weight of the products there is slippage of bags relative to the belts and sometimes of the bag fronts relative to the backs resulting in poor seal quality. Alternatively or additionally it is too often necessary to provide a conveyor or other support for bags as they are transported through the sealer station.
SUMMARY OF THE INVENTION
With the machine of the present invention, the described problems of the prior art and others are overcome and an enhanced range of available packaging sizes is achieved. In its preferred form the machine has two, independently moveable carriages which are selectively rigidly interconnected. One of these carriages supports a novel and improved bagging section, while the other supports a closure mechanism. The disclosed closure mechanism is a novel and improved sealing section. Because the machine has two separable carriages other closure carriages supporting other closure mechanisms such as bag ties and staples can readily be used.
Each of the sections is rotatably mounted on its carriage, such that once coupled the two sections may be rotated together about a horizontal axis for product loading, by gravity and/or stuffing when in the vertical and by stuffing when in the horizontal. Advantageously the two sections may also be oriented in any one of a set of angular orientations between the horizontal and the vertical.
A major feature of the present machine is that the loading section opens the bags into rectangular configurations. Not only are the bag load openings rectangular configurations, but the transverse and longitudinal dimensions of such openings for any given bag size are relatively and readily adjustable over a wide range.
The machine may be operated in either a continuous or an intermittent mode at the operator's selection. Both sections are operated in the same mode. That is if the loading section is continuous, so too is the sealing section, while both operate in the intermittent mode at the same times.
One of the outstanding advantages of the invention resides in the utilization of a novel and improved mechanism for gripping upstanding lips of bags as they are transported through the load section. This mechanism utilizes conveyor belts of a type more fully described in a concurrently filed application of Hershey Lerner entitled Plastic Transport System, attorney docket 14-160 (the Belt Patent). The Belt Patent is incorporated in its entirety by reference. Gripping is achieved by coaction of the bags upstanding lips and unique belts such that belt clamping mechanisms are neither required or relied on. To this end a pair of main transport belts are provided and positioned on opposite sides of a path of web travel. In the preferred and disclosed embodiment, each main belt has an upstanding lip contacting surface with a centrally located, transversely speaking, lip receiving recess preferably of arcuate cross-sectional configuration. A pair of lip transport belts of circular cross-section are respectively cammed into the main transport belt recesses to force bag lips into the recesses and fix the lips with a holding power far in excess of that achieved with the prior art.
Since the gripping of bag lips for support is accomplished through coaction of the bag lips and the conveyor belts, there is essentially no limit to the length of the loading station. Rather multiple numbers of open bags can be concurrently conveyed through the loading station. With a machine operating on a continuous basis and a synchronized product supply conveyor adjacent the load station, one is able to concurrently transfer a set of products into a like numbered set of bags with the transfer progressing concurrently as the bags and the conveyed products advance through the load station.
Another advantage of an elongated load station is that one may position a series of vibrator feeders along the station. As an example, a first vibratory feeder could deposit a desired number of bolts in a bag at a first location, a second feeder a like number of washers at a second location downstream from the first, and a third feeder a like number of nuts at a third location still further downstream; thus, eliminating the need for a feed conveyor.
With this arrangement extremely high rates of packaging can be achieved. For example, it is possible to load and seal 130 ten inch bags per minute. Rates achieved with the present machine are rates in excess of those that can be achieved with virtually all, if not all, prior art machines including so called "form and fill" machines.
Another feature of the invention resides in a novel and improved mechanism for breaking frangible interconnections between adjacent sides of successive bags. Assuming the machine to be in its gravity fed horizontal mode, this mechanism comprises a belt which is trained about spaced pulleys which are rotatable about respective horizontal axes. The belt has projecting pins. The belt pulleys are rotated to move the belt in synchronism with positioning of a chain of bags being fed through the load section to cause one of the pins to break the frangible bag interconnections each time a set of such interconnections is longitudinally aligned with the belt.
Moving in the downstream direction of the machine to consider other advances, another feature of the invention is in a novel and improved mechanism for adjusting the width of the load station by varying the spacing between the pairs of main and lip transport belts. This adjustment, which is infinite between maximum and minimum limits, coupled with the novel and improved bag web, provides a wide range of available transverse and longitudinal dimensions of rectangular bag openings for any given chain of like sized interconnected bags.
As loaded bags exit the load station it is desirable to advance the lead side edge and retard the trailing side edge of each bag of a chain to bring inside surfaces of the top portions of each bag back into surface to surface touching orientation for sealing. To this end a novel planetary mechanism is provided. This mechanism is driven by the moving bags themselves to effect the stretching action and reestablish inside surface to surface relationship. For larger bags oppositely directed jets of air are employed which are effective to reestablish the surface to surface orientation.
At an exit from the bagging section of the machine, the main transport belts overlie exit belts which in turn overlie the closure section transport belts, such that the closure section picks up the now longitudinally stretched top surfaces of each loaded bag. As the bags are transferred to the closure section belts, a rotary knife cuts the bags near their tops such that the lip portions that have been carried by the main transport belts are cut off and become recyclable scrap. The elevation of the cutter relative to the heat sealer is adjustable so that the extent to which upper portions of the bags are cut away provides loaded bags sized to be neat, and if desired tight, finished packages.
In order to prevent excessive heating of bags passing through the sealing section and the sealing section belts, the heat source for effecting the seals is shifted away from loaded bags and the belts when the machine is stopped and moved to a location adjacent the bags when the bags are moving. Thus, a mechanism is provided for shifting the heat sealer from a seal forming position to a storage position and return in synchronism with cycling of the machine when in the intermittent mode.
As the loaded bags pass through the seal section, a series of longitudinally aligned, juxtaposed and individually biased, pressure members act against one of the seal section conveyor belts. These pressure members bias the one belt against the bags and thence against the other belt to in turn bias the other belt against a backup element to maintain pressure on the bag tops as they are transported through the seal section. Advantageously, unlike a prior machine of similar construction, individual coil springs are used to bias the pressure members.
The belts used in the seal section are novel and improved special belts which are effective substantially to prevent any product weight induced slippage of the bags relative to the belts. The novel belts are also effective to resist longitudinal movement of the face and back of each bag relative to one another and to the belts. One provision to prevent this relative slippage is providing belts which have corrugated belt engaging surfaces with the corrugations of one belt interlocking with the corrugation of the other to produce a serpentine grip of the face and back of each bag. Further, the preferred belts are metal reinforced polyurethane to provide enhanced resistance to belt stretching. A glue and grit mixture may be applied to the surfaces of the sealer belts, further to inhibit bag slippage. A urethane coating is applied over the glue and grit to complete the improvements provided for the prevention of bag slippage.
The belts of the sealer section are driven by a stepper motor through a positive drive, so that the sealer stepper motor in synchronism with bagger stepper motor maintain belt and bag feed rates of travel that are consistent throughout the length of path of bag travel from supply through to finished package.
Lips of the bags which project from the seal section conveyor belts are heated by a contiguous heat tube sealer having an elongate opening adjacent the path of bag lip travel. Heated air and radiation emanating from this sealer effect heat seals of the upstanding lips to complete a series of packages.
Because the machine sections, unlike the machine of the SP Patent, are either both continuous or both intermittent during machine operation, successive bags passing through the closure section are juxtaposed rather than spaced. This juxtaposition provides improved sealing efficiency and sealer belt life.
A web embodying the present invention is an elongate, flattened, thermoplastic tube having face and back sides which delineate the faces and backs of a set of side by side frangibly interconnected bags. The tube includes an elongate top section which is slit to form lips to be laid over and then fixed in the main transport belts. The top section is interconnected to the bags by face and back, longitudinally endless, lines of weakness which are separated from each side edge toward the center of each bag to the extent necessary to achieve the desired rectangular openings. Thus, the present web is far simpler and less costly than the web of the prior system that provided rectangular bag openings.
The invention also encompasses a process of packaging which includes gripping the upstanding front and back lip portions between main and lip transport belts. The belts are then spread as they pass through a load station pulling bag openings into rectangular configurations as portions of bag tops are separated from the upper lip section. After bag loading, top portions of the bag inner surfaces are returned to abutting engagement, a portion of the lip section is trimmed from the bags, and the bags are sealed or otherwise closed to complete packages.
Accordingly, the objects of this invention are to provide novel and improved packaging machine, packaging materials and methods of forming packages.
IN THE DRAWINGS
FIG. 1 is a top plan view of the machine of the present invention;
FIG. 2 is a fragmentary top plan view of the bagger section of the machine of FIG. 1 and on an enlarged scale with respect to FIG. 1;
FIG. 3 is a foreshortened elevational view of the bagger section as seen from the plane indicated by the line 3--3 of FIG. 1;
FIG. 4 is a perspective view of the novel and improved bag web of the present invention showing sections of the transport belts transporting the web through the load station and a novel mechanism for providing spacing of the sides of loaded bags particularly of a small size;
FIG. 5 is a perspective view of a portion of the bag flattening mechanism shown in FIG. 4 and on an enlarged scale;
FIG. 6 is a fragmentary perspective view on the scale of FIG. 5 showing an alternate arrangement to the mechanism of FIG. 5 for flattening bags;
FIGS. 7 and 8 are enlarged sectional views from the planes respectively indicated by the lines 7--7 and 8--8 of FIG. 4 show the main and lip transport belts together with a fragmentary top portion of the bag as bag lips are folded over the main transport belts and then trapped in the grooves of the main belts;
FIG. 9 is a sectional view of the bag flattening or stretching mechanism of FIGS. 4 and 5 as seen from the plane indicated by the line 9--9 of FIG. 2;
FIG. 10 is an enlarged sectional view of the mechanism of FIG. 9 as seen from the plane indicated by the line 10--10 of FIG. 2;
FIG. 11 is an enlarged, fragmentary, sectional view of the transport belt spacing adjustment mechanism as seen from the plane indicated by the lines 11--11 of FIG. 2;
FIG. 12 is an elevational view of a portion of the machine as seen from the plane indicated by the line 12--12 of FIG. 1 showing a bag support conveyor underneath the loading and seal sections;
FIG. 13 is an elevational view of the seal section on an enlarged scale with respect to FIG. 12;
FIG. 14 is an elevational view of the angular orientation maintenance mechanism on an enlarged scale with respect to other of the drawings and as seen from the plane indicated by the line 14--14 of FIG. 12;
FIG. 15 is an enlarged sectional view of the sealer positioning mechanism and a bag support conveyor as seen from the plane indicated by the lines 15--15 of FIG. 13;
FIG. 16 is a sectional view of a web guide as seen from the plane indicated by the line 16--16 of FIG. 3;
FIG. 17 is a sectional view of the lip plow as seen from the plane indicated by the line 17--17 of FIG. 3;
FIG. 18 is an enlarged plan view of a force application element and a fragmentary plan view of the sealer belts;
FIG. 19 is an enlarged fragmentary plan view of a transfer location between the bagger and the closure sections, including a knife for trimming the tops of loaded bags prior to closure;
FIG. 20 is a further enlarged sectional view of the structure of FIG. 19 as seen from the plane indicated by the line 20--20 of FIG. 19;
FIG. 21 is a still further enlarged view of the knife and its height adjustment mechanism as seen from the plane indicated by the line 21--21 of FIG. 20;
FIG. 22 is a plan view of an alternate and preferred sealer for the closure section; and,
FIG. 23 is an elevational view of the sealer of FIG. 22.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
I. The Overall Machine
Referring to FIGS. 1 and 4 a web 15 of side connected bags is provided. The web 15 is fed from a supply shown schematically at 16 to a bagger section 17. The bagger section 17 is separably connected to a sealer section 19. The bagger and sealer sections respectively include wheeled support carriages 20, 21. The support carriages 20, 21 respectively include support frames for supporting bagging and sealing mechanisms.
In the drawings the bagging and sealing mechanisms are shown in their vertical orientations for gravity loading. The machine will be described in such orientation it being recognized that, as described more fully in section IV, the mechanisms may be positioned in a horizontal orientation and at other angular orientations.
II. The Web 15
The web 15 is an elongated flattened plastic tube, typically formed of polyethylene. The tube includes a top section 23 for feeding along a mandrel 24, FIGS. 4 and 16. The top section 23 is connected to the tops of a chain of side connected bags 25 by front and back lines of weakness in the form of perforations 27, 28. Frangible connections 30 connect, adjacent bag side edges, FIGS. 3 and 4. Each bag 25 includes a face 31 and a back 32 interconnected at a bottom 33 by a selected one of a fold or a seal. Side seals adjacent the interconnections 30 delineate the sides of the bags 25. The bag faces and backs 31, 32 are respectively connected to the top section 23 by the lines of weakness 27, 28, such that the top section 23 when the web is flattened itself is essentially a tube.
III. The Bagger Section 17
A. A Bag Feed and Preparation Portion 35
The web 15 is fed from the supply 16 into a bag feed and preparation portion 35 of the bagger section 17. The feed is over the mandrel 24 and past a slitter 36, FIG. 4. The slitter 36 separates the top section 23 into opposed face and back lips 38, 39. The feed through the bag feed and preparation portion 35 is caused by a pair of endless, oppositely rotating, main transport belts 40, 41 supported by oppositely rotating pulley sets 42, 43. The main belts 40, 41 are driven by a stepper motor 44, FIG. 3 through toothed pulleys 42T, 43T of the sets 42, 43. Other of the pulleys 42S, 43S are spring biased by springs S, FIG. 2, to tension the belts.
A plow 45 is provided and shown in FIGS. 3, 4 and 17. For clarity of illustration the slitter and the plow have been omitted from FIG. 1. The plow is positioned a short distance upstream from a roller cam 46. As the lips are drawn along by the main transport belts 41, 42, the lips 38, 39 are respectively folded over the top bag engaging surfaces 41S, 42S, of the main transport belts under the action of the plow 45 as depicted in FIG. 7.
Once the lips are folded over the tops of the main transport belts 41, 42, the roller cam 46 presses endless, lip transport and clamp belts 48, 49 into complemental grooves 51, 52 in the main transport belts 41, 42 respectively. Thus, the grooves 51, 52 function as bag clamping surfaces that are complemental with the clamping belts 48, 49. More specifically, the clamp belts are circular in cross section, while the grooves 51, 52 are segments of circles, slightly more than 180° in extent. The camming of the clamp belts into the grooves traps the lips 38, 39 between the clamp belts and the grooves. The lip clamping firmly secures the lips between the coacting belt pairs such that the lips, due to their coaction with the belts, are capable of resisting substantial stuffing forces as products are forced into the bags at a load station 60. Sections of the clamp belts which are not in the grooves 51, 52 are trained around a set of lip transport belt pulleys 50.
A bag side separator mechanism 53 is provided at a bag connection breaking station. The separator mechanism 53 includes an endless belt 54 which is trained around a pair of spaced pulleys 55 to provide spans which, as shown in FIGS. 3 and 4, are vertical. The pulleys 55 are driven by a motor 57, FIG. 2. As the belt is driven breaking pins 58 projecting from the belt 54 pass between adjacent sides of bags to break the frangible interconnections 30. Thus, as the bags depart the bag feed and preparation portion 35, they are separated from one another but remain connected to the lips 38, 39.
B. The Load Station 60
The load station 60 includes a pair of parallel belt spreaders 61, 62. The belt spreaders are mirror images of one another. As is best seen in FIG. 11, the belt spreaders respectively include channels 63, 64. The channels 63, 64 respectively guide the main transport belts 40,41, on either side of the load station 60. When the transport belts 40,41, are in the channels 63, 64, as is clearly seen in FIGS. 4 and 11, the bags 25 are stretched between the belts in a rectangular top opening configuration.
A schematic showing of a supply funnel 66 is included in FIG. 4. As suggested by that figure, the products to be packaged are deposited through the rectangular bag openings each time a bag is registered with the supply funnel at the load station.
A space adjusting mechanism is provided. This mechanism includes a spaced pair of adjustment screws 68, 69, FIG. 2. The adjustment screw 68, 69 are respectively centrally journaled by bearings 70, 71. The screws have oppositely threaded sections on either side of their bearings 70, 71 which threadably engage the belt spreaders 61, 62. Rotation of a crank 72 causes rotation of the adjustment screw 69. The screw 69 is connected to the screw 70 via belts or chains 73, which function to transmit rotation forces so that when the crank 72 is operated the screws 68, 69 are moved equally to drive the spreaders equally into an adjusted spacial, but still parallel, relationship.
As the spreaders are movably adjusted toward and away from one another, the spring biased pulleys 42S, 43S maintain tension on the main transport belts 40, 41 while permitting relative movement of spans of the belts passing through the spreader channels 63, 64. Similarly, spring biased lip transport belt pulleys 50S maintain tension on the clamp belts 48, 49. The spring biased pulleys of both sets are the pulleys to the right as seen in FIG. 2, i.e. the entrance end pulleys in the bag feed and preparation portion 35.
The main transport pulley sets 42, 43 include two idler pulleys 75, 76 downstream from the load station 60. The idler pulleys 75, 76 are relatively closely spaced to return the main transport belts 40, 41 into substantially juxtaposed relationship following exit from the load station 60.
C. Bag Stretching
As loaded bags exit the load station, it is desirable to return upper portions of the bag faces and backs into juxtaposition. To facilitate this return with smaller bags a novel and improved planetary stretcher 90 is provided. This planetary bag stretcher is best understood by reference to FIGS. 5, 9 and 10. The stretcher 90 includes a support shaft 92 mounted on frame members 94 of the bagger section, FIG. 10.
The planetary stretcher includes a bag trailing edge engaging element 95. The element 95 includes six bag engaging fingers 96. As is best seen in FIGS. 4 and 5, one of those fingers 96 is shown in a lead one of the bags 25 while the next finger is being moved into the next bag in line as the next bag departs the load station 60. As the bags move from right to left as viewed in FIG. 5, an internal ring gear portion 100 drives a planet gear 102. The planet gear orbits a fixed sun pinion 104. The planet gear is journaled on and carried by a lead edge engaging element 105 journaled on the shaft 92. The lead edge engaging element 105 has four fingers 106 which orbit at one and a half times the rate of the fingers 96. Rotation of the lead edge engaging element causes one of the fingers 106 to enter the next bag as it exits the load station and to engage a leading edge 108 of the bag, thereby stretching the bag until top portions of the bag face and back are brought into juxtaposition.
For larger bags this stretching of the now loaded bags as they exit the load station is accomplished with jets of air from nozzles 110, 112 which respectively blow against the lead and trailing edges of the bag, thus stretching the bags from their rectangular orientation into a face to back juxtaposed relationship as the transport belts are returned to juxtaposition.
D. A Transfer Location
After loaded bags have exited the load station 60 and the face and back of each bag have been brought into juxtaposition, the loaded bags are transferred to the closure section 19 at a transfer location 114. Exit conveyors 115, 116 underlie the main transport belts 40, 41 at an exit end of the bagger section 17. Loaded bags are transferred from the main transport belts to the exit conveyors. The exit conveyors in turn transfer the loaded bags to closure section conveyor belts 118, 119.
Referring to FIGS. 19-21, a rotary knife 120 is positioned a short distance downstream from the exit conveyors. The knife is rotatively mounted in an externally threaded support tube 121. The tube in turn is threadedly connected to a knife support frame section K. An adjustment lock 123 is slidably carried by the frame section K. When the lock 123 is in the position shown in solid lines in FIG. 21, it engages a selected one of a plurality of recesses R in the perimeter of the support tube 121 to fix the knife in an adjusted height position. When the lock 123 is slid to the phantom line position of FIG. 21, the tube 121 may be rotated to adjust the vertical location of the knife 120.
The knife 120 is driven by a motor 122 to sever the bag lip portions 38, 39, leaving only closure parts of the lip portions for closure, in the disclosed arrangement, by heat sealing. The trimmed plastic scrap 124, FIG. 12, from the severed lip portions is drawn from the machine with a conventional mechanism, not shown, and thereafter recycled.
IV. The Closure Section 19
As is best seen in FIG. 1, the novel and improved sealer includes a plurality of independently movable force application elements 125. One of the force elements is shown on an enlarged scale in FIG. 18. The force elements 125 slidably engage the outer surface of a bag engaging run 126 of the belt of the conveyor 119. Springs 128 bias the elements 125 to clamp the bag faces and backs together against a coacting run 130 of the conveyor belt 118. A backup 132 slidably engages the coacting run 130 to resist the spring biased force of the application elements 125.
A stepper motor 134, FIG. 1, is drivingly connected to the closure section conveyor belts 118, 119 to operate in synchronism with the stepper motor 44 of the bagger section, either intermittently or continuously.
As is best seen in FIGS. 13 and 15, a heater tube 135 is provided. A heat element 136, FIG. 15, is positioned within the tube to provide heat to fuse upstanding bag lips when the heater tube 135 is in the position shown in solid lines in FIG. 13. The heat transfer to the lips is effected by both radiation and convection through an elongate slot 135S in the bottom of the tube.
The heater tube 135 is connected to a pair of supports 137, 138. When the bags 25 are vertical the heater tube 135 is suspended by the supports 137, 138. The supports in turn are pivotally connected to and supported by a pair of cranks 140, 142. The cranks 140, 142 are pivotally supported by a section of the frame of the sealer carriage 21. The cranks 140, 142 are interconnected by a rod 144 which in turn is driven by an air cylinder 145. The air cylinder 145 is interposed between the carriage frame and the rod 144. Reciprocation of the air cylinder is effective to move the heat tube between its seal position shown in solid lines and a storage position shown in phantom, FIG. 13. When the conveyor belts 118, 119 are operating to transport bags through the closure section the sealer is down, while whenever the machine is stopped the sealer is shifted to its storage or phantom position of FIG. 13.
As is best seen in FIG. 18, the adjacent runs 126, 130 of the sealer conveyor belts 118, 119 have surfaces that are corrugated and interfitting. These interfittings corrugations provide both enhanced bag gripping and holding power and resistance to relative longitudinal movement of the runs as well as the faces and backs of the bag. The gripping and holding power of the belts is further enhanced by coating the belts with a glue and sand slurry and applying a polyurethane coating over the slurry to further enhance the frictional grip of the belts on bags being transported. The combined effects of the belt corrugations and coating substantially prevent slippage of the bags due to weight in the bags.
V. Section Interconnection and Adjustments
A. Section Interconnection
The bagger and closure sections 17,19 are physically interconnected when in use. In the disclosed arrangement this interconnection includes a pair of lock bars 150. The lock bars which are removably positioned in apertures 151,152 formed in bosses 154,155 respectively projecting from frames of the bagger and closure stations 17,19.
B. Angular Positioning
As has been indicated, the bagger and closure sections are adjustable to horizontal or vertical orientations as well as angular orientations between the horizontal and the vertical.
The bagger section 17 is rotatably supported on a pair of trunions one of which is shown at 157 in FIG. 3. As can best be seen in FIGS. 12 and 13, the sealer section 19 is rotatably supported on the carriage 21 by spaced trunions 170, 172. The trunions 157,170 & 172 are axially aligned. The end trunion 170, to the left as viewed in FIGS. 12 and 13, is associated with an angular position holder. The holder includes an apertured plate 174 secured to and forming part of the frame of the carriage 21, FIG. 14. The plate 174 includes a set of apertures 175 spaced at 15° intervals to provide incremental angular adjustments of 15° each between the horizontal and vertical orientations of the machine. Each of the apertures 175 may be selectively aligned with an aperture in a sealing section plate 176. A pin in the form of a bolt 178 projects through aligned apertures to fix the sealer section and the interconnected bagger section in a selected angular orientation.
VI. A Support Conveyor
While there normally is no need for bottom support of the bags 25 as they pass through the bagger section 17, nonetheless a conventional support conveyor 160 may be provided, see FIG. 3. More frequently a conveyor 162 will be provided under the closure section 19. In either event, suitable height adjustment and locking mechanisms 164 are provided to locate the conveyors 160,162 in appropriate position to support the weight of loaded bags being processed into packages.
VII. The Preferred Sealer
Referring to FIGS. 22 and 23, the preferred sealer for the closure mechanism is disclosed. The sealer includes an air manifold 180 for receiving air from a blower 182. In an experimental prototype a 300 cubic foot per minute variable pressure blower was used to determine optimized air flows and pressures.
The manifold 180 has three pairs of oppositely disposed outlets 184,185,186. Each outlet is connected to an associated one of six flexible tubes 188. The tubes in turn are connected to pairs of oppositely disposed, T-shaped sealer units 190,191,192 to respectively connect them to the outlets 184,185,186. The T-shaped sealer units respectively include tubular legs 190L,191L,192L extending vertically downward from their respective connections to the flexible tubes 188 to horizontal air outlet sections 190H,191H,192H. The outlet sections are closely spaced, axially aligned, cylindrical tubes which collectively define a pair of elongate heater mechanisms disposed on opposite sides of an imaginary vertical plane through the loaded bag path of travel.
Each horizontal outlet section includes an elongate slot for directing air flow originating with the blower 182 onto upstanding bag lips being sealed. Each of the sealer unit legs 191,192 houses an associated heater element of a type normally used in a toaster. Thus air flowing through the T--shaped units 191,192 is heated and the escaping hot air effects seals of the upstanding bag lips. Air flowing through the units 190 is not heated, but rather provides cooling air to accelerate solidification of the seals being formed.
The T-shaped sealer units 190,191,192 are respectively connected to the rod 144 for raising and lowering upon actuation of the air cylinder 145 in the same manner and for the same purpose as described in connection with the embodiment of FIGS. 12 and 13.
A further unique feature of the embodiment of FIGS. 22 and 23 is a vertical adjustment mechanism indicated generally at 194. The vertical adjustment 194 permits adjustment of the slope of the horizontal sections of the t-shaped units 190-192 such that the outlet from 191H is lower than that of 192H. This downward sloping of the heater mechanism in the direction of bag travel assures optimized location of the hot air being blown on the plastic. The location is optimized because as the plastic melts it sags lowering the optimum location for the direction of the hot air. Further the cooling air from the unit 190 is directed onto a now formed bead.
VIII. Operation
The carriages 20, 21 are independently wheeled to a desired location. The two are then physically interconnected by inserting the lock bars 150 into the apertures 151,152.
Assuming the bagger and sealer are in a vertical orientation, the relative heights of the bagger and closure section conveyors are adjusted as is the height of the knife 120. If the angular orientation of the machines is to be adjusted, the bolt(s) 178 is(are) removed and the bagger and sealer section are rotated about the axis of the trunions 157,170, 172 to a desired orientation. Following this rotation the bolt(s) is(are) reinserted to fix the mechanism in its desired angular orientation.
Next a web 15 of bags 25 is fed through the bagger and sealer by jogging the two. The transverse spacing of the main conveyor belts 40, 41 is adjusted by rotating the crank 72 until the load station 60 has the desired transverse dimension. A control, not shown, is set to provide a desired feed rate and a selected one of continuous or intermittent operation. Assuming continuous operation, the feed rate may be as high as 130 ten inch bags per minute.
Once the machine is in operation, the top section 21 of the web 15 is fed along the mandrel 24 and slit by the slitter 36. This forms the lips 38, 39 which are folded over the main transport belts 41, 42 by the action of the plow 45. The lip clamp belts 48, 49 descend from the elevated and spring biased pulleys 50S, as shown in FIG. 3. The roller cam 46 cams the clamp belts 48, 49 respectively into the transport belt recesses 51, 52 to provide very positive and firm support for the bags as they are further processed. As successive side connections 30 of the bags are registered with the bag side separator 53, the motor 55 is operated to drive the belt 54 and cause the breaker pins 58 to rupture the side connections 30.
As adjacent runs of the transport belts 41, 42 progress downstream from the bag feed and preparation portion 35, the belts are spread under the action of the belt spreaders 61, 62. As the belts are spread, the lips 38, 39 cause the front and back faces 31, 32 adjacent the lead edge of each bag to separate from the lips 38, 39 by tearing a sufficient length of the perforations between them to allow the lead edge to become the mid point in a bag span between the belts as the bag passes longitudinally through the load station 60. Similarly, the perforations adjacent the trailing edge are torn as the trailing part of the bag is spread until the bag achieves a full rectangular opening as shown in FIG. 4 in particular.
Next a product is inserted into the rectangular bag as indicated schematically in FIGS. 3 and 4. While the schematic showing is of discrete fasteners, it should be recognized that this machine and system are well suited to packaging liquids and bulky products which must be stuffed into a bag, such as pantyhose and rectangular items, such as household sponges.
After the product has been inserted, the adjacent runs of the main transport belts are brought back together and the loaded bag tops are spread longitudinally of the path of travel either by the planetary stretcher 90 or opposed air streams from nozzles 110, 112.
As is best seen in FIG. 3, exit ones 50E of the lip belt pulley set are spaced from the main transport belt and rotatable about angular axes. Expressed more accurately, when the machine is in a vertical loading orientation, the pulleys 50E are above the main transport belt such that the lip transport belts are pulled from the grooves 51, 52.
The now loaded bags pass through the transfer location onto the exit conveyors 115, 116 and thence to the seal station conveyors 118, 119. At this juncture the scrap 124 is severed from the loaded bags by the action of the knife 120. As the bags are advanced through the sealer section, the heater tube 135 is maintained in its lowered and solid line position of FIGS. 12, 13 and 15. If the machine is operated in its intermittent mode, the cylinder 145 is cycled in coordination with the starts and stops of the intermittently operated machine to shift the heater tube 135 between its solid line seal position and its storage position shown in phantom in the FIG. 13.
Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction, operation and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed. | A packaging machine and process for loading bags of a novel web of side connected bags are disclosed. The web is fed through a bagger section by a pair of grooved main transport belts and a pair of lip transport belts each disposed in the groove of the associated main belt to trap bag lips in the grooves. Adjustable belt spreaders space reaches of the transport belts as they move through a load station whereby to sequentially open the bags into rectangular configurations. A closure section in the form of a novel and improved heat sealer is releasably connectable to the bagger section. The sections are adjustable together between horizontal and vertical orientations. Processes of opening, closing and sealing side connected bags are also disclosed. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to exhaust systems for vehicles having internal combustion engines and, more particularly, to exhaust systems for such engines which reduce and eliminate pollution from the exhaust of such engines.
Recent governmental pollution control requirements in the United States and other countries have spawned many anti-pollution exhaust systems and pollutioncontrol systems for internal combustion engines. Such control standards generally limit the emissions of hydrocarbons, carbon monoxide, oxides of nitrogen, and smoke (minute solid particles) from the exhausts of vehicles. Many of the prior known systems have utilized filtering devices such as activated charcoal filters, liquid filters, various filtering screens, and the like. Some require the use of particular chemicals making them expensive to use and operate. In certain of the prior systems, water or another liquid is sprayed into the exhaust from an internal combustion engine, allowed to pass through the normal muffling devices of the exhaust system and thereafter is separated into liquid and gas portions. Sudh systems have tended to be complicated and therefore expensive and difficult to maintain.
It has recently been discovered that a simplified, compact anti-pollution, exhaust-purifying, exhaust system for vehicles having internal combustion engines is possible based on the principle of liquid scrubbing. Such system utilizes water or commonly available antifreeze solutions of the type normally used in the cooling systems of automobiles or other vehicles and eliminates the need for complex apparatus, uncommon, expensive chemicals, and other inconveniences which have made prior known systems impractical.
In addition, certain exhaust systems for reducing air pollution require the use of non-leaded or unleaded gasoline for proper operation. The present system allows the use of any type of fuel including all grades of gasoline, diesel fuels, and the like.
SUMMARY OF THE INVENTION
Accordingly, it is the purpose of the present invention to provide an anti-pollution, exhaust-purifying exhaust system for vehicles having internal combustion engines. The system is compact, may be incorporated in present day automobiles or other vehicles, is simple to operate and maintain and is reliable in operation. The exhaust system is based on the principle of liquid scrubbing wherein the exhaust gases are mixed with a liquid which dissolves certain soluble gases and retains certain solid particles present in the gases after which the liquid gas mixture is separated into liquid and gas portions with pollutants from the exhaust gases remaining in the liquid portion. The gas portion is vented to the atmosphere in a cleansed state.
The present system is self-contained, is separate from the normal internal combustion engine cooling system, but works in conjunction with and cooperates with that cooling system. The system is compact with the majority of its elements being fitted in the engine compartment adjacent the internal combustion engine and its cooling system. Further, the system relies on the engine as a source of power and therefore requires no other power source for operation.
In one aspect of the invention, an anti-pollution exhaust system is defined in combination with an internal combustion system mounted in a vehicle including receiving tank means for receiving a quantity of liquid including means for mixing exhaust gases from the internal combustion engine with the liquid to form an exhaust liquid mixture in the receiving tank. Separating tank means are included for receiving the mixture from the receiving tank means including separating means for separating the liquid from the gases while leaving pollutants from the gases in the said liquid and vent means for venting the separated, cleansed gases to the atmosphere. Exhaust gas conduit means are provided for conveying exhaust gases from the engine to the receiving tank. First and second fluid conduit means are provided for conveying fluid from the receiving tank to the separator tank and also for conveying fluid from the separating tank back to the receiving tank. Pump means are included for pumping fluid through the conduit means. Means for driving the pump with the internal combustion engine are also provided such that the entire system cleanses the exhaust gases via the liquid before those gases escape to the atmosphere.
In other aspects of the invention, an anti-pollution exhaust system is defined for incorporation with an internal combustion engine mounted in a vehicle, the system including elements similar to those mentioned above in addition to cooling means provided in the exhaust gas conduit means for cooling the exhaust gases prior to their mixture with the cleansing liquid in the receiving tank means. In the preferred embodiment, either water or an antifreeze solution based on ethylene glycol is used as the scrubbing liquid.
These and other objects, advantages, purposes, and features of the invention will become more apparent from a study of the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the antipollution exhaust system of the present invention incorporated with a typical internal combustion engine having its own separate liquid cooling system;
FIG. 2 is a fragmentary view of a portion of another embodiment of the exhaust system illustrating an alternative, sinuous path forming the cooling means for the exhaust gas conduit;
FIG. 3 is a perspective view illustrating the separating tank and a portion of the internal combustion engine and its liquid cooling system;
FIG. 4 is a perspective view of the receiving tank illustrated with the exhaust system in FIG. 1; and
FIG. 5 is a sectional view of the separating tank taken along plane V-V of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in greater detail, FIG. 1 illustrates the anti-pollution exhaust system 10 of the present invention as incorporated with typical internal combustion engine 12 on an automobile or other vehicle. The engine 12 includes a conventionally known, liquid-type cooling system including a radiator 14 and a fan 16 powered by the engine via a rotating shaft 18. The fan draws a flow of cooling air through the radiator core to transfer heat from the water or other liquid coolants contained in the radiator. The coolant is in turn circulated through the engine to cool the same. The exhaust gases resulting from operation of the engine 12 are conducted from the engine in the conventionally known manner via tubular pipes 20 and 22 leading to an exhaust pipe 24 in which a conventionally known muffler 26 is included to muffle the exhaust noise. The exhaust system 10 of the present invention is adapted to connect with the exhaust pipe 24 after the position of the muffler at the rear of the vehicle and to convey the exhaust gases forwardly to the primary portions of the exhaust system 10 located in the engine compartment of the vehicle.
As illustrated in FIG. 1, an exhaust gas conduit or pipe 28 leads from a suitable pipe connection or joint 27 behind the muffler to an exhaust cooling apparatus 30 forming a portion of the pipe 28. The exhaust cooling apparatus 30 includes portions of pipe 28 formed into elongated loops or lengths 32 providing the pipe with an overall sinuous path in the cooling portion. The cooling portion of the pipe is preferably mounted below the rear of the vehicle such that it is exposed to the flow of air under the vehicle when the vehicle is in motion causing the air to contact all portions of the loops 32 to transfer heat therefrom and to cool the exhaust gases within the pipe. In the form illustrated in FIG. 1, the lengths of pipe 32 in the cooling portion 30 extend lengthwise of the vehicle generally parallel to its direction of motion.
As an alternative to the cooling portion 30 shown in FIG. 1, a cooling portion 30a as illustrated in FIG. 2 may be used. With embodiment 30a, pipe 28 leads to a portion of the pipe bent into a sinuous path and including lengths or loops 32a extending transverse of the vehicle on which the system 10 is mounted. As with embodiment 30, embodiment 30a of the cooling portion of the exhaust pipe is located beneath the rear of the vehicle and exposed to the atmosphere and air flow thereunder to cause heat transfer from the pipe. The transverse loops or lengths 32a may be used in vehicles where there is less space or other structure preventing pipes from being located lengthwise under the vehicle.
With either cooling portion 30 or 30a, exhaust pipe portion 34 extends from the end of the cooling portion and is connected to receiving tank 40. Within receiving tank 40, the exhaust gases are mixed with a scrubbing liquid after which the pressure of the exhaust entering the tank plus the suction provided by a pump 64 conducts the mixture through outlet conduits 60 leading to fluid conduit 62. Conduit 62 is in turn connected to fluid pump 64 which helps draw the mixture from the receiving tank through conduit 66 into the separating tank 70.
When the exhaust liquid mixture enters separating tank 70, it is forced against an internal wall of the tank to separate the pollutant-containing liquid portion from the cleansed gas portion. The cleansed gas portions rise to the top of the tank and exit through vent conduits 72. The liquid portion drops to the bottom of the tank from which position it is withdrawn via outlet conduit 74 leading to a second pump 76.
Fluid pump 76 facilitates the withdrawal of the pollutant-containing liquid from the tank 70 and forces it through the return conduit 78 into the bottom of receiving tank 40. Accordingly, the scrubbing liquid contained in the exhaust system 10 circulates in a closed path between receiving tank 40 and separating tank 70. Although a portion of the liquid is continually lost through vent conduits 72 in the form of vapor not completely separated from the exhaust gases, water vapor formed as a portion of the products of combustion from the internal combustion engine 12 is continuously being added to the system in receiving tank 40 via condensation in the various exhaust pipes. Thus, the liquid level in the system stays at a fairly constant level and requires replenishment only infrequently or after long periods of operation when the liquid becomes saturated with pollutants.
Preferably, the liquid used in the system is water or an antifreeze solution although other types can be used. Antifreeze solutions which have been found suitable are of the ethylene glycol based type although other types may be used. Depending on climatic conditions, one or the other type of liquid may be used to allow year-around operation.
Referring to FIG. 4, receiving tank 40 comprises a rectangular metallic tank having top and bottom walls 42 and 43, opposing side walls 44 and 45 and opposing end walls 46 and 47. A quantity of the scrubbing liquid L is maintained at a predetermined level within the tank, the liquid being originally inserted through a suitable filling aperture 48 closed by a suitable, removable closure cap 50. Conventional manually operated valve means 51 are provided from the bottom 43 of tank 40 to drain the liquid from the tank when desired.
Insertion of the exhaust gases into the tank 40 is accomplished via a rigid insertion tube or conduit 52 extending generally horizontally into the tank through end wall 46 for connection to exhaust pipe 34 via a suitable pipe connector or joint 53. Insertion tube 52 includes a downwardly extending portion 54 which extends below the liquid level of liquid L in the tank and includes an outlet opening 55 below that level. Accordingly, the pressure of the exhaust passing through the exhaust system from the engine forces the exhaust gases out of opening 55 in a turbulent manner such that they strike against the bottom 43 inside the tank and completely mix with the liquid L.
Pipes 60, which lead to conduit 62 and pump 64, are connected to the tank 40 by suitable pipe connectors or joints 61. These outlet pipes are positioned close to the top of the receiving tank (see FIG. 4) so that not all of the liquid will be drawn out of the tank. Thus, placement of outlets 60 above the liquid level causes a portion of the liquid to remain in the tank for mixture with the incoming exhaust gases while a portion of the exhaust gasliquid mixture exits through the outlets.
Return of the separated, pollutant-containing scrubbing liquid L from the separating tank 70 via conduit 78 to receiving tank 40 is accomplished via a return tubular conduit 56 extending through end wall 47. Conduit 56 includes a right angle bend and a portion 57 ending in an outlet opening 58 located below the level of liquid L. The returning liquid L is forced against the inside of wall 44 providing additional turbulence which helps mix exhaust gases with the liquid in the tank. Outlet 58 is positioned below the liquid level in tank 40 to prevent the pressure of the exhaust gases entering and within tank 40 from obstructing the return of the liquid from tank 70 through line 78. Thus, the effect of any back pressure is minimized. Generally, the receiving tank is small enough to be included within the engine compartment of the vehicle on which the system is mounted (see FIG. 1). The liquid L is normally maintained at a level approximating one-third the height of the tank.
Although the preferred embodiment includes two pumps 64 and 76, it is possible to remove pump 64 and operate the system without it. In that case, the pressure of the incoming exhaust gases from outlet 34 forces the exhaust-liquid mixture out through outlet conduits 60. Also, pump 76, provides some drawing effect through tank 70 and conduits 66, 62, and 60.
Referring to FIGS. 3 and 5, separating tank 70 comprises a generally vertically upstanding, liquid-tight tank having a width less than its height. Tank 70 includes top and bottom walls 80 and 82, front and back walls 84 and 86, and end walls 88 and 90. A plurality of tubular air passageways 92 extend completely through tank 70, through front and rear walls 84 and 86 to provide air flow passages through the tank. Tubes 92 are located over the entire walls 84, 86 except along the bottom below the level of liquid L in the tank. The liquid level is normally maintained between the bottom row of tubes 92 and the bottom of the tank. This flow of air does not communicate with the contents of the tank. When the tank 70 is mounted in its preferred position immediately ahead of the normal cooling radiator within the engine compartment of the typical vehicle, movement of the vehicle causes an air flow which passes through the passageways 92 acting both to cool the exhaust gases and liquid L within tank 70 and to allow an air flow through the core of radiator 14 to allow normal operation of the cooling system of the engine.
Insertion of the exhaust-liquid mixture from fluid conduit 66 leading from the pump 64 and receiving tank 40 is accomplished via a rigid insertion conduit or tube 94 extending through end wall 88 generally horizontally and inwardly of the tank. Insertion conduit 94 includes a right angle portion 96 ending in an outlet 98 immediately adjacent the rear wall 86 of tank 70 as is best seen in FIG. 5. The violent splashing of the mixture forced against the wall 86 from outlet 98 causes a separation of the exhaust gases from the liquid L. The separated pollutant-containing liquid falls to the bottom of the tank while the cleansed gases rise to the top of the tank and are vented to the atmosphere via conduits 72 via the pressure of the gases within tank 70. Conduits 72 are positioned adjacent the top of the tank to provide a maximum distance to separate the cleansed gases from liquid L. Outlet 98 is accordingly located immediately above the liquid level to obtain this maximum separation distance.
The pollutant-containing liquid L is removed from tank 70 via an outlet conduit 100 extending through end wall 90 at a position below the level of the liquid L in tank 70. Normally, the liquid L maintains a level above the position of conduit 100. This level varies with the engine speed because the volume of fluid pumped by pumps 64, 76 varies with that engine speed. Conduit 100 is connected to conduit 74 via suitable connection means. In order to properly fit the tank 70 in certain vehicular models, it may be necessary to provide various cut-out portions such as cut-out area 101 in the top of the tank as shown in FIG. 3. Cut-out 101 provides the space for locating the hood latch assembly of the normal vehicle. Conduits 66, 72, and 74 are all suitably connected to the tank 70 via hose con-nectors, pipe joints, or the like.
Fluid pumps 64 and 76 are of a high-head, selfpriming centrifugal type which transfer a high volume of liquid and are especially designed to transfer liquid with entrained air or gases therein. A suitable pump of this type is the Teel pump, Model No. IP746A, manufactured by Datton Electric Manufacturing Company of Chicago, Ill. Pumps 64 and 76 are normally mounted adjacent the fan and fan shaft 16 and 18 of the engine 12 and are rotatably powered thereby via bolts 102, shaft pulley 104, and pump pulleys 106 and 108 (see FIG. 1). Fluid conduits 62, 66, 74, and 78 are connected to pumps 64 and 66 as shown in FIG. 1 via suitable pipe or hose connections. These conduits, as well as conduits 60 and 72 may be either flexible rubberized or synthetic hose or rigid tubular conduits depending on the space available for installation of the system.
It has been found that the present anti-pollution exhaust system greatly reduces the hydrocarbons and carbon monoxide present in the exhaust. With a system of the type described herein installed on a 1971 Ford V-8 engine, the exhaust emissions have been reduced to about 0.1 to 0.2 percent carbon monoxide (CO) and about 60 parts per million (ppm) hydrocarbons (HC) at idle speed (600-800 rpm). At approximately 2,000 rpm, the emission levels were about 0.1-0.2 percent CO and about 35-40 ppm HC.
Accordingly, the present system provides a compact, simplified, easily maintained anti-pollution exhaust system for use with generally all types of vehicles having internal combustion engines. The system may be added to existing vehicles, or built into the vehicle when new. When mixed with the scrubbing liquid L in receiving tank 40, the exhaust gases are cleansed of pollutants including soluble gases and certain solid particles which are dissolved and retained in the liquid. The gases are thereafter separated from the pollutant-containing liquid in the separating tank and released to the atmosphere in a cooled, cleansed state.
While several forms of the invention have been shown and described, other forms will now be apparent to those skilled in the art. Therefore, it will be understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and are not intended to limit the scope of the invention which is defined by the claims which follow. | An anti-pollution exhaust system for vehicular-mounted internal combustion engines. The exhaust system is separate from but cooperates with the normal engine cooling system and supplements the normal engine exhaust system. Engine exhaust gases are conveyed to and mixed with a liquid such as water or an antifreeze solution in a receiving tank. The liquid dissolves and retains therein both soluble and solid pollutants from the gases. The cleansed gases are separated from the pollutant-retaining liquid and vented to the atmosphere by a separating tank. Pumps driven by the engine are included to recirculate the pollutant-adsorbing liquid in the exhaust system. Means for cooling the exhaust gases prior to mixing with the liquid are included. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 13/216,847, filed Aug. 24, 2011, which claims the benefit of U.S. Provisional Application No. 61/376,293, filed Aug. 24, 2010, the disclosures of which are incorporated herein in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is in the field of feminine cooling pads.
2. Relevant Technology
A common problem experienced by women is discomfort of the vulva, perineum, and surrounding regions. Such discomfort can have a variety of causes, including but not limited to, vaginal itching and burning as a result of infection (e.g., yeast infection), urethral pain or inflammation as a result of infection (e.g., urinary tract infection), vaginal varicosity (e.g., during pregnancy), damage to the perineum following child birth, and chronic inflammation (e.g., atopic dermatitis).
While various ways of cooling the perineum have been proposed, none have gained acceptance in the market place. Perhaps this is due to inconvenience in the mode of application and/or poor design, causing additional discomfort. If a product is inconvenient and hard to use and/or causes discomfort it will fail in the market place.
U.S. Pat. No. 4,397,315 to Patel and U.S. Patent Publication No. 2007/0142807 to Lee et al. are examples of cooling devices for the perineum that have been proposed. U.S. Pat. No. 3,871,376 to Kozak discloses a flexible adhesive bandage designed to adhere to tissue immediately surrounding a wound, absorb fluid, and provide cooling. These devices have certain design aspects that limit their usefulness and effectiveness.
Accordingly, there remains a need to provide a feminine cooling pad that is designed to more comfortably and conveniently cool and provide relief to the vulva and/or adjacent regions of a woman's body.
SUMMARY
Disclosed are embodiments of feminine cooling pads that provide relief and comfort for women experiencing pain or discomfort of the vulva and/or adjacent regions (i.e., “pubic area”). According to one embodiment, a self-contained feminine cooling pad that requires no special manipulation or loading of a cooling element prior to use is provided. The feminine cooling pad of this embodiment includes a cooling gel that can be placed in a cooling environment prior to use, such as a refrigerator or freezer, and then removed from the cooling environment and immediately placed over the vulva and/or adjacent region to provide relief and comfort without manipulation or loading of a cooling element.
According to one embodiment, the cooling gel is advantageously smooth, flexible and/or moldable in order to maximize comfort and minimize or eliminate lumps or protruding regions of rigid material. As compared to cooling products that utilize ice chunks, a cooling gel that is smooth, flexible, and/or moldable is far more comfortable to wear and can more evenly distribute the cooling action to the vulva and/or adjacent region. And as compared to chemical cooling media (e.g., that are cooled by a chemical interaction between water and a salt such as a thiosulfate having a positive enthalpy of dissolution), a cooling gel that is cooled in a cooling environment prior to use can provide greater cooling and/or cooling for longer periods of time.
According to another embodiment, a feminine cooling pad is provided that includes an absorbent layer designed to be placed against the vulva, a cooling layer adjacent to the absorbent layer, and an adhesive layer adjacent to the cooling layer designed to adhere the feminine cooling pad to an undergarment of the user. This keeps the feminine cooling pad in the desired position while eliminating the need for cumbersome attachment mechanisms, such as belts or harnesses, thereby enhancing comfort and promoting compliance. The adhesive layer may include a removable backing layer that protects the adhesive prior to use and which can be conveniently removed by the user just prior to use. Eliminating cumbersome belts or harnesses also yields a feminine cooling product that is less visually noticeable when worn beneath ordinary clothing. This can provide enhanced assurance and emotional well being so that the product can be worn in public with minimal embarrassment compared to products that produce unsightly undergarment bulges and lines.
According to one embodiment, the feminine cooling pad is elongated so as to provide cooling to the entire vulva and/or adjacent region. The feminine cooling pad can also have a length so as to extend against the woman's perineum to provide cooling and relieve to the perineum following child birth. The feminine cooling pad may also extend beyond the perineum and over the anal region to provide cooling and relief to that region if desired.
In the case where the feminine cooling pad is sufficiently flexible or moldable when in a cooled condition just prior to use, the feminine cooling pad can be flat. This permits several cooling pads to be stacked in a container that can be placed directly into a refrigerator or freezer after purchase and an individual cooling pad withdrawn from the container as needed just prior to use. This maximizes convenience to the user by providing multiple cooling pads that can be used one after the other as needed and then discarded after use. The feminine cooling pads are advantageously disposable in order to maximize cleanliness to the user and eliminate the need to clean and reuse the product.
In the case where the feminine cooling pad is substantially rigid when in a cooled condition just prior to use, the feminine cooling pad may assume a pre-curved orientation that approximates the curvature of the region of a woman's body to which the product is designed to cover. For example, an elongated product can have an approximate U-shaped configuration in order to conform to the front and back of a woman's crotch region and thereby minimize the amount of flexing that is required to conform the cooling pad to the woman's body prior to use.
The vulvar and perineal regions (pubic area) can be particularly sensitive and painful following childbirth and/or it can be extremely painful to remove bandages that become adhered to pubic hair. Therefore, according to one embodiment, the surface of the feminine cooling pad that faces the body can be free of adhesives or adhesive layers that might irritate sensitive skin and/or tug on pubic hair when removing the feminine cooling pad following use. This can be accomplished by simply refraining from applying an adhesive layer or region on the side of the absorbent layer or enclosure that contacts the body during use. The aforementioned adhesive layer designed to adhere the feminine cooling pad to an undergarment (or other clothing) should not cause irritation when simply adhered to an undergarment or clothing instead of pubic hair and surrounding skin.
The invention can be embodied as a kit of single-use absorbent pads (e.g., 10-25) and one or more reusable cooling gel packs that can be inserted and removed from a compartment within each pad. This permits a cooling gel pack to be removed from a used pad and inserted into a fresh pad (e.g., through a slit down the side of the absorbent pad). Closure means can be used to retain the cooling gel pack within the compartment of the pad during use. In the case where the kit includes multiple single-use absorbent pads and two cooling gel packs, one gel pack can be placed in the freezer while the other one is in use. When the user decides to use a fresh cooling pad, the cooling gel pack is removed from the used pad and placed into the freezer, and the cold gel pack is removed and placed into a fresh pad. This process can be repeated indefinitely for any number of fresh absorbent pads.
These and other advantages and features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
FIGS. 1A and 1B are top (or body facing) views of embodiments of feminine cooling pads;
FIGS. 2A, 2B, and 2C are side (or cross-sectional) views of embodiments of feminine cooling pads; and
FIGS. 3A and 3B are bottom (or undergarment facing) views of embodiments of feminine cooling pads.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-3 illustrate embodiments of feminine cooling pads according to the disclosure. The smaller cooling pad shown in FIGS. 1A, 2A and 3A may be characterized as a “light” product, while the larger cooling pad shown in FIGS. 1B, 2B and 3B may be characterized as an “ultra” product. It will be appreciated that the feminine cooling pads can assume a variety of different sizes, thicknesses and/or configurations depending on the particular needs and requirements of the user and/or the intended use of the product.
FIGS. 1A and 1B show top (or body facing) views of differently sized feminine cooling pads 100 showing an enclosure 110 , a portion of which forms an outer surface or layer 102 that is designed to be oriented toward the user's body. The outer surface or layer 102 may comprise a layer of a soft woven or cloth material that is soft and comfortable to the touch in order to minimize discomfort when placed against the user's skin. In the case where a liquid absorbent pad or layer is positioned beneath outer surface or layer 102 (see, e.g., FIGS. 2A and 2B ), outer surface or layer 102 is advantageously permeable to liquids so as to permit free passage of liquids (e.g., bodily fluids or discharges) through outer surface or layer 102 and into the absorbent pad or layer.
The vulvar and perineal regions can be particularly sensitive and painful following childbirth and/or it can be extremely painful to remove bandages that become adhered to pubic hair. Therefore, according to some embodiments, outer surface or layer 102 can be free of adhesives or adhesive layers that might irritate sensitive skin and/or tug on pubic hair when removing feminine cooling pad 100 following use. This can be accomplished by simply refraining from applying an adhesive layer or region on the outer surface or layer 102 that contacts the body during use. Fabrics, plastic, and other common and well-known materials contemplated for use in making outer surface or layer 102 will typically not have an adhesive layer or region unless one is applied thereto and thus are inherently disclosed in U.S. patent application Ser. No. 13/216,847, filed Aug. 24, 2011, and U.S. Provisional Application No. 61/376,293, filed Aug. 24, 2010, incorporated herein by reference.
FIGS. 2A, 2B, and 2C show side (or cross sectional) views of differently sized feminine cooling pads 100 . The cooling pads 100 include the outer surface or layer 102 described above, which forms a portion of enclosure 110 , an absorbent pad or layer 104 adjacent to or near the outer surface or layer 102 , a cooling gel layer 106 adjacent to or near the absorbent pad or layer 104 , and an adhesive strip 108 with removable backing layer 109 designed to adhere the cooling pad 100 to an undergarment or other clothing near the region to be cooled. The absorbent pad or layer 104 and cooling gel layer 106 may be held together by means of the enclosure 110 . According to one embodiment, a portion of the enclosure 110 may form a plastic type enclosure to prevent leakage of bodily fluids from the absorbent pad or layer 104 from between the interface of the absorbent pad or layer 104 and the cooling gel layer 106 during use. According to one embodiment, the adhesive strip 108 may be attached to an outer surface of the enclosure 110 . Alternatively, the adhesive strip 108 may be attached directly to an exposed surface of a casing surrounding the cooling gel layer 106 .
The absorbent pad or layer 104 is positioned beneath the outer surface or layer 102 in order to absorb fluids that may be secreted by the user's body during use. The absorbent pad or layer 104 can also prevent direct contact of the cooling gel layer 106 with the user's skin, thus avoiding injury and providing an initial level of insulation and providing a gradual cooling sensation. The absorbent pad or layer 104 may be constructed from a variety of different materials and may comprise one or more layers of material. According to one embodiment, the absorbent pad or layer 104 is comprised of cotton or other natural fiber having a high degree of liquid absorbance. Alternatively, or in addition, the absorbent pad or layer 104 may include synthetic absorbent materials such as liquid absorbing polymer particles. Particles may be encased within a liquid absorbent and/or liquid permeable casing. As liquids absorbed by the absorbent pad or layer 104 tend to be more conductive of heat and cold than the absorbent pad or layer 104 , the absorption of bodily fluid may increase the flow of heat through the absorbent pad or layer 104 and thereby enhance the cooling effect of the cooling gel layer 106 .
The cooling gel layer 106 may include any cooling gel capable of being placed in a cooling environment and then provide a cooling effect over an extended period of time (e.g., at least about 15 minutes, or at least about 30 minutes, or at least about 45 minutes, or at least about 1 hour). An appropriate cooling gel may be enclosed within a liquid impermeable casing, such as a plastic pouch.
An example of a cooling gel is a composition that includes water, salt, and a gelling agent, such as cellosize (hydroxyethyl cellulose). The gel may also include colorants (e.g., green or blue) and preservatives. An anti-freeze material, such as ethylene glycol, propylene glycol, or isopropyl alcohol, may be added in order to soften the cooled gel and render it more flexible or moldable after being cooled in a freezer. The amount of anti-freeze material can be varied to provide a desired level of flexibility and/or moldability of the product when cooled to freezing (e.g., below 32° F. or 0° C.). Some amount of congealing of the water may be desirable as allowing water to undergo a phase change may increase the overall ability of the cooling gel to provide a desired cooling effect.
In some embodiments, as illustrated in FIG. 2C , it may be desirable to include freezable cooling particles or beads 106 a within a flexible casing 106 b . Freezable cooling particles or beads 106 a may be comprised of hollow plastic or glass spheres that contain water or salt water without an anti-freeze material (or a relatively small amount of anti-freeze material). This permits the water in the particles or pellets to freeze and/or be cooled to below 0° C. without self-adhering. This, in turn, permits the overall cooling pack to remain flexible and conformable to the user's body after being cooled in a freezer.
The cooling layer 106 may alternatively include a two part chemical cooling media that can supplement and/or replace cooling by a freezable cooling gel. Two part chemical cooling media known in the art can be used.
The adhesive layer 108 may comprise a variety of different adhesive materials known in the art. According to one embodiment, the adhesive material is able to maintain adequate adhesion to a user's undergarment or other clothing even at cool or cold temperatures. Cool temperatures within a refrigerator are typically between 33-45° F. (0.5-10° C.). Cold temperatures within a freezer are typically between 0-32° F. (−20-0° C.). To protect the adhesive and/or prevent self-adhesion of adjacent cooling pads, the adhesive layer 108 may include a removable backing layer, such as a strip of polymer coated paper or a polymer sheet. The removable backing layer may include a laterally extending tab (not shown) that assists the user in removing the backing layer prior to use. The adhesive layer 108 should not cause irritation when simply adhered to an undergarment or clothing instead of pubic hair and surrounding skin.
FIGS. 3A and 3B show bottom (or undergarment facing) views of differently sized feminine cooling pads 100 showing the adhesive strip 108 that is designed to be oriented toward the user's undergarment. The adhesive strip 108 advantageously covers a majority of the undergarment facing surface of the cooling pad in order to maximize the area of interface between the adhesive strip 108 and the undergarment. This enhances the ability of the adhesive strip 108 to adhere and maintain the cooling pad 100 in a desired orientation relative to the user's undergarment and body during use. According to one embodiment, a portion of absorbent pad 104 and/or enclosure 110 may extend beyond the adhesive strip 108 in order to capture additional body fluids that may be excreted by the user's body.
According to one embodiment, the corners of the cooling pad may be rounded in order to prevent the corners of a relatively rigid cooling pad from poking or otherwise irritating the user's body during placement and use. Rounding the corners of the feminine cooling pad may be particularly useful in the case where the cooling layer becomes rigid when frozen.
The cooling pad may assume other configurations in order to maximize comfort to the user. As discussed above, in the case where the feminine cooling pad is desired to wrap around a user's crotch, it may be desirable for the cooling pad to have a curved (e.g., U-shaped) configuration prior to use. This reduces or eliminates the amount of bending that must be performed during placement of the relatively rigid device over a woman's body. This, in turn, maximizes comfort of the product and compliance by the user.
The feminine cooling pads can have a variety of different sizes and/or thicknesses to provide a desired level of comfort, cooling ability and/or coverage. According to one embodiment, a “light” cooling pad may have a length of about 6 inches and a width of about 2 inches. According to another embodiment, an “ultra” cooling pad may have a length of about 9 inches and a width of about 3 inches.
Nevertheless, it will be appreciated that the cross sectional area and dimensions can be selected depending on the intended use. According to one embodiment, the length can be in a range of about 4 inches to about 12 inches, or about 5 inches to about 10 inches, or about 6 inches to about 9 inches. According to another embodiment, the width can be in a range of about 1 inch to about 4 inches, or about 1.5 inch to about 3.5 inches, or about 2 inches to about 3 inches.
According to one embodiment, the cross sectional thickness of the absorbent layer in a “light” cooling pad may be about ⅛ inch and the cross sectional thickness of the cooling gel layer may be about ¼ inch. According to another embodiment, the cross sectional thickness of the absorbent layer in an “ultra” cooling pad may be about ¼ inch and the cross sectional thickness of the cooling gel layer may be about ½ inch.
Nevertheless, it will be appreciated that the cross sectional thicknesses of the absorbent layer and cooling gel layer can be selected depending on the intended use. According to one embodiment, the cross sectional thickness of the absorbent layer can be in a range of about 1/16 inch to about ½ inch, or about 3/32 inch to about ⅜ inch, or about ⅛ inch to about ¼ inch. According to another embodiment, the cross sectional thickness of the cooling gel layer can be in a range of about ⅛ inch to about ¾ inch, or about 3/16 inch to about ⅝ inch, or about ¼ inch to about ½ inch.
In addition to the foregoing, it is possible to provide a microwaveable material as a separate layer or as part of the cooling layer. The microwaveable material permits the cooling pad to also function as a heating pad when it is desired to provide heat instead of and/or prior to and/or subsequent to cooling. According to one embodiment, the microwaveable material includes an organic product such as rice or other grain that can become hot when placed into a microwave. It is generally desireable to cool the perineum for the first 24-48 hours post partum, and apply heat 48 hours post partum.
Alternatively, the heating pad may include a two part chemical heating media that can supplement and/or replace heating by a microwaveable material. Two part chemical heating media known in the art can be used.
The feminine cooling pads disclosed herein can be used to alleviate pain and discomfort caused by a wide variety of feminine ailments, such as pain and discomfort of the vulva, perineum, and surrounding regions. Such discomfort can have a variety of causes, including but not limited to, vaginal itching and burning as a result of infection (e.g., yeast infection), urethral pain or inflammation as a result of infection (e.g., urinary tract infection), vaginal varicosity, which may involve formation of varicose veins in the vulva or vagina during pregnancy due to increased pressure by the fetus that prevents adequate blood drainage, damage to the perineum following child birth, or chronic inflammation (e.g., atopic dermatitis).
The invention can be embodied as a kit of single-use absorbent pads (e.g., 10-25) and one or more reusable cooling gel packs that can be inserted and removed from a compartment within each pad. This permits a cooling gel pack to be removed from a used pad and inserted into a fresh pad (e.g., through a slit down the side of the absorbent pad). Closure means can be used to retain the cooling gel pack within the compartment of the pad during use. In the case where the kit includes multiple single-use absorbent pads and two cooling gel packs, one gel pack can be placed in the freezer while the other one is in use. When the user decides to use a fresh cooling pad, the cooling gel pack is removed from the used pad and placed into the freezer, and the cold gel pack is removed and placed into a fresh pad. This process can be repeated indefinitely for any number of fresh absorbent pads. A similar process of use and replacement can be used to serially refresh warming pads as disclosed herein.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A feminine cooling pad configured for cooling a vulva and/or adjacent region. The cooling pad may include a non-adhesive outer liquid permeable layer configured to be oriented toward the pubic area during use. A liquid absorbent layer forming or adjacent to the outer layer absorbs bodily fluids or discharges during use. A cooling layer adjacent to the liquid absorbent layer provides cooling for at least about 15 minutes when the cooling pad is placed adjacent to the pubic area of a woman. An optional adhesive layer adjacent to the cooling layer can adhere the feminine cooling pad to an undergarment or clothing during use and maintain the cooling pad in a desired orientation. A feminine heating pad may include a microwavable material that becomes warm or hot when placed in a microwave oven. A feminine cooling pad can operate as a heating pad when heated instead of cooled. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to stable injectable solutions containing diphosphonates.
BACKGROUND
[0002] Various diphosphonic acids can be used as therapeutic active agents for the treatment of hypercalcaemia and in medication for the treatment of diseases such as osteoporosis and tumor osteolysis. In a prepared solution, the active agent will be present as anions and is generally called diphosphonate, bisphosphonate or biphosphonate. An injection solution of diphosphonate can be prepared from the diphosphonic acid or one of its salts. A convenient method for administering these active agents is by intravenous infusion of prepared solutions into the bloodstream of a patient to be treated.
[0003] One diphosphonic acid, pamidronic acid is currently available in the form of a lyophilised product to be reconstituted prior to use. This reconstitution step involves not only both time and effort, but also introduces the possibility of adverse consequences through, for example improper reconstitution and mixing of the powder and contamination prior to administration. Previous efforts to formulate pamidronate solutions have suffered from stability problems with the solutions showing turbidity and loss of active product over time.
[0004] Glass has long been the material of choice for containers for pharmaceutical products. However, it has been found that diphosphonate solutions left in glass for extended periods display unacceptable levels of turbidity despite the good solubility and chemical stability of diphosphonates generally.
[0005] It is known that the level of turbidity of diphosphonate solutions in glass is affected by the pH of the solution, and that the level of turbidity decreases with increased acidity.
[0006] An approach to minimise the problem of reaction between the active substances and glass leachates is the use of excipients such as polyethylene glycols or acid buffers such as organic acids. Whilst the use of such excipients may assist, it is generally preferable to minimise the number of additional constituents of any injectable product solution.
SUMMARY OF THE INVENTION
[0007] Surprisingly, the inventors have found that it is possible to formulate stable diphosphonate solutions such as, in particular, pamidronate, which are neither highly acidic nor which involve the use of buffer systems. The inventors have found that solutions of diphosphonates of relatively neutral pH values do exhibit satisfactory stability provided appropriate containers are used.
[0008] This invention provides a stable and preprepared injectable solution of diphosphonate ready to be diluted by a practitioner administering the product to the patient. This enables the product to be provided in a consistent quality and avoids the need for the practitioner to reconstitute the active agent at the time of administration.
[0009] According to one aspect the present invention provides a pharmaceutical product comprising a container containing a diphosphonate in solution, wherein the solution:
[0010] (a) has a pH of between 5 and 8;
[0011] (b) is free of organic acid buffer and polyethylene glycol; and wherein the container consists of at least one component manufactured from glass having at least a surface in contact with the solution, at least one said surface having been pre-treated to protect against the leaching of impurities from the glass by the solution.
[0012] According to a further aspect, the present invention provides a pharmaceutical product comprising a container containing a diphosphonate in solution, wherein the solution:
[0013] (a) has a pH of approximately 6.5; and
[0014] (b) is free of organic acid buffer and polyethylene glycol and wherein the container consists of at least one component manufactured from glass having at least a surface in contact with the solution, at least one said surface having been pre-treated so as to protect against the leaching of impurities from the glass by the solution.
[0015] According to a further aspect, the present invention provides a pharmaceutical product comprising a container containing a diphosphonate in solution, wherein the solution:
[0016] (a) has a pH of between 5 and 8;
[0017] (b) is free of organic acid buffer and polyethylene glycol; and
[0018] wherein the container consists of at least one component manufactured from a non-glass material.
[0019] According to a further aspect the present invention provides a method of preparing a pharmaceutical product, said method comprising the steps of:
[0020] (a) preparing a suspension of pamodronic acid in water;
[0021] (b) adding sodium hydroxide solution to the suspension to obtain a second solution;
[0022] (c) adjusting the pH of the second solution to between 5 and 8; and
[0023] (d) transferring the second solution to a container.
DESCRIPTION
[0024] In order to obtain adequate long-term stability, appropriate containers must be used for the solution of diphosphonate. Appropriate containers for this product include ampoules, vials, bottles, ready to use syringes and Shell Glass Vials.
[0025] It is believed that the principal cause of turbidity where glass containers have been used in the past is the leaching out from the glass of aluminium and/or other cations such as magnesium or calcium, depending upon the glass composition.
[0026] Where glass containers are used it is necessary to pre-treat the contact surface of the glass with an appropriate method to protect against the leaching of impurities from the glass by the solution. Preferably all potential contact surfaces will be appropriately treated. In this way, the extent to which impurities leach from the glass over time is reduced. A preferred method of pre-treatment is a siliconization process using a one percent silicone solution to wash the vials, followed by double draining and heating at 310° C. for thirty minutes. Vials pretreated in this manner are available from the French vial manufacturer Saint-Gobain Desjonqueres (SGD).
[0027] Other vial pretreatment techniques include the use of a high purity SiO 2 barrier formed on the inside vial surface by a plasma-deposition process. The process involves microwave energy being applied to a silicon containing precursor in the presence of oxygen. A plasma forms and a SiO 2 layer is formed on the glass surface from the gas phase. Vials pretreated in this manner are available from Schoft.
[0028] In addition to treating the surface of the glass, it is also recommended to use containers which are made from glass having a low aluminium content. Glass typically used for pharmaceutical vials has in the order of 5 percent aluminium oxide. In order to reduce the problem of aluminium ion leaching, glass with lower aluminium content is recommended.
[0029] Where the solution is stored in a stoppered vial, the stopper provides a potential source of contamination. Typical elastomeric stoppers are potentially a source of metal ions eg calcium, zinc and magnesium ions which can react with the diphosphonate to form insoluble matter. In order to reduce the possibility of contamination, stoppers with low levels of these ions and other potential contaminants are to be used, preferably coated to form an inert barrier. An example of an appropriate stopper is the Daikyo D777-1 stopper. Daikyo D777-3 stoppers may also be used. Preferably the stopper has a low calcium, magnesium and ash content and is at least coated on the contact surface (being the surface of the stopper which when placed in a vial is exposed to the contents of the vial) with a fluorinated resin such as tetrafluoroethylene polymer, trifluorochloroethylene polymer, tetrafluoroethylene-hexafluoropropylene copolymer, fluorovinylidene polymer, vinylidene fluoride polymer, vinyl fluoride polymer, tetrafluoroethylene-ethylene copolymer, ethylene-tetrafluoroethylene copolymer, or perfluoroalkoxy polymer. It is more preferred that the stopper is coated with a fluorinated resin selected from a group consisting of tetrafluoroethylene polymer, trifluorochloroethylene polymer, tetrafluoroethylene-hexafluoropropylene copolymer, vinylidene fluoride polymer, vinyl fluoride polymer, and tetrafluoroethylene-ethylene copolymer. For example, the stopper can be a FluroTec® stopper manufactured by Daikyo and distributed by West Pharmaceuticals Services.
[0030] Containers, such as vials, may be constructed from any suitable other materials in addition to glass, such as polyethylene, polypropylene and polymethylpentene. For example, the vial could be constructed from Crystal Zenith® resin as manufactured by West Pharmaceuticals Services.
[0031] This invention is generally applicable to all diphosphonates. Specifically, this includes solutions of pamidronate, zolindronate, chlodronate, etidronate, alendronate and tiludronate. These can be prepared from their respective diphosphonic acid form or from a therapeutically acceptable salt form. The acids of the above diphosphonates are:—pamidronic acid [(3-amino-1-hydroxypropylidene)diphosphonic acid], zoledronic acid [(1)-hydroxy-2-(1H-imidazol-1-yl)ethylidene)diphosphonic acid]; chlodronic acid [dichloromethylene disphosphonic acid]; etidronic acid [(1-hydroxyethylidene)diphosphonic acid]; alendronic acid [(4-amino-1-hydroxy-butylidene diphosphonic acid]; and tiludronic acid [[((p-chloro-phenyl)thio)methylene]diphosphonic acid]respectively. This invention is particularly applicable to pamidronate and zolendronate.
[0032] It is preferred to have a product within the biological pH range i.e. of between about 5 and 8, to reduce the incidence of potential adverse reactions relating to acidic or alkaline solutions. Surprisingly it has been found that a stable solution can be produced having a pH of 5-8. A pH level of approximately 6.5 is preferred. At pH levels below about 5 there is a risk of producing venous type irritations and other unwanted side effects. pH levels above about 8 give rise to generally unacceptable levels of turbidity.
[0033] Solutions of diphosphonates will generally have a pH above that desired. For example, a solution of one percent pamidronate disodium salt in distilled water has a pH of approximately 8.3. The pH is adjusted with a suitable acid or alkali. Suitable acids include any acid such as hydrochloric or phosphoric acid. Phosphoric acid is preferred. Suitable alkalis include sodium hydroxide.
[0034] As the person skilled in the art will appreciate, other standard components, such as sugar alcohols and sodium chloride and water may be included in the solution, as required. Mannitol is the preferred sugar alcohol.
[0035] Pamidronate solutions are preferably prepared by slowly adding sodium hydroxide solution to a suspension of pamidronic acid in water in a 2:1 molar ratio of sodium hydroxide to pamidronic acid, adding mannitol if desired, mixing by stirring until both pamidronic acid and mannitol (if appropriate) are completely dissolved and adjusting the pH with phosphoric acid and if necessary sodium hydroxide solution. Preferably the preparation of the solutions is carried out under nitrogen. Other diphosphonate solutions can be prepared in analogous fashion.
EXAMPLE 1
Preparation of Pamidronate Solution
[0036] To a mixing vessel approximately 10% of the required amount of Water for Injection is added and then bubbled with nitrogen gas for at least 15 minutes. The sodium hydroxide, in an amount to give a 2:1 molar ratio to pamidronic acid is then added with stirring to dissolve and the solution cooled to less than 30° C.
[0037] A different closed mixing vessel is flushed with nitrogen gas for at least 15 minutes. Approximately 70% of the Water for Injection is added to the closed mixing vessel through a port and the mixing bubbled with nitrogen gas for at least 15 minutes. Pamidronic acid is then added to the mixing vessel with stirring and mixed for 5 minutes giving a suspension. The sodium hydroxide solution is then added over a 5 minute period with stirring to give a clear solution. Mannitol is then added to the solution with stirring for at least 5 minutes until dissolved. The pH is then checked and adjusted to a range of between 5 and 8 preferably, between 6.3 and 6.7 by addition of 1.0N phosphoric acid at the rate of approximately 12.1 g/L (calculated on total batch size) and if necessary 1.0N sodium hydroxide, whilst keeping the temperature between 35° C. and 45° C. The volume is adjusted to the required level with Water for Injection and the solution cooled to below 30° C. The pH is then rechecked and adjusted if necessary to between 6.3 and 6.7, with 1.0N phosphoric acid or 1.0N sodium hydroxide if and as necessary.
EXAMPLE 2
[0038] In this example the product solution was composed of the following:
pamidronic acid 2.53 mg mannitol 47.0 mg sodium hydroxide 0.43 mg pH qs to 6.3-6.7 using 1.0 N sodium hydroxide or 1.0 N phosphoric acid Water for Injection qs to 1.0 mL
[0039] The formulated solution was filled into 10 mL siliconised, low aluminium, Type I glass vials, supplied by SGD. Each vial was enclosed by a 20 mm, S10-F451, D777-1, B2-40, FluroTec® stopper supplied by West Pharmaceuticals Services.
[0040] Table 1 shows the test results measured over a 24 month period while being stored inverted at 25° C., relative humidity (RH) 60%.
TABLE 1 Initial (0 6 12 18 24 months) months months months months Appearance N N N N N Potency 98.7% 99.9% 99.8% 100.1% 99.1 pH 6.4 6.2 6.3 6.4 6.5 Metal ions silicon ppm 0.6 2.9 2.9 calcium ppm 0.09 0.05 0.07 aluminium ppm 0.05 0.12 0.11
EXAMPLE 3
[0041] In this example the product solution was composed of the following:
pamidronic acid 7.58 mg mannitol 37.5 mg sodium hydroxide 1.29 mg pH qs to 6.3-6.7 using 1.0 N sodium hydroxide or 1.0 N phosphoric acid Water For Injection qs to 1.0 mL
[0042] The formulated solution was filled into 10 mL siliconised, low aluminium, Type I glass vials, supplied by SGD. Each vial was enclosed by a 20 mm, S10-F451, D777-1, B2-40, FluroTec® stopper supplied by West Pharmaceuticals Services.
[0043] Table 2 shows the test results measured over a 24 month period while being stored inverted at 25° C., relative humidity (RH) 60%.
TABLE 2 Initial (0 6 12 18 24 months) months months months months Appearance N N N N N Potency 100.2% 101.9% 100.4% 102.3% 101.1 pH 6.4 6.3 6.4 6.3 6.5 Metal ions silicon ppm 0.6 6.2 12.9 calcium ppm <0.04 0.1 0.24 aluminium ppm 0.06 0.25 0.56
EXAMPLE 4
[0044] In this example the product solution was composed of the following:
pamidronic acid 2.53 mg mannitol 47.0 mg sodium hydroxide 0.86 mg pH qs to 6.3-6.7 using 1.0 N sodium hydroxide or 1.0 N phosphoric acid. Water For Injection qs to 1.0 mL
[0045] The formulated solution was filled into 10 mL siliconised, low aluminium, Type I glass vials, supplied by SGD. Each vial was enclosed by a 20 mm, S10-F451, D777-1, B2-40, FluroTec® stopper supplied by West Pharmaceuticals Services.
[0046] Table 3 shows the test results measured over a 21 month period while being stored inverted at 25° C., relative humidity (RH) 60%.
TABLE 3 Initial (0 6 12 18 21 months) months months months months Appearance N N N N N Potency 103.6% 103.5% 104.0% 104.0 104.5 pH 6.5 6.4 6.5 6.6 6.5 Metal ions silicon ppm 0.31 0.2 0.47 — — calcium ppm 0.06 <0.04 <0.04 — — aluminium 0.17 <0.04 <0.04 — — ppm
EXAMPLE 5
[0047] In this example the product solution was composed of the following:
pamidronic acid 7.58 mg mannitol 37.5 mg sodium hydroxide 2.58 mg pH qs to 6.3-6.7 using 1.0 N sodium hydroxide or 1.0 N phosphoric acid. Water For Injection qs to 1.0 mL
[0048] The formulated solution was filled, into 10 mL siliconised, low aluminium, Type I glass vials, supplied by SGD. Each vial was enclosed by a 20 mm, S10-F451, D777-1, B240, FluroTec® stopper supplied by West Pharmaceuticals Services.
[0049] Table 4 shows the test results measured over a 21 month period while being stored inverted at 25° C., relative humidity (RH) 60%.
TABLE 4 Initial (0 6 12 18 21 months) months months months months Appearance N N N N N Potency 98.9% 99.2% 100.0% 99.1 99.4 pH 6.5 6.4 6.5 6.6 6.5 Metal ions silicon ppm 0.29 0.3 0.65 — — calcium ppm 0.18 0.10 0.13 — — aluminium ppm 0.12 <0.04 0.07 — —
[0050] In each of the examples 2 to 5 above, the solution was prepared by the process set out in Example 1.
[0051] It is understood that various modifications, alternatives and/or additions may be made to the product specifically described herein without departing from the spirit and ambit of the invention.
[0052] Throughout the description and claims of this specification the word “comprise” and variations of that word such as “comprises” and “comprising” are not intended to exclude other additives, components, integers or steps. | A pharmaceutical product containing pamidronate and other diphosphonate solutions in an appropriate container, a pH of between 5 and 8 and without organic acid buffer or polyethylen glycol. The container may be treated glass or made of other appropriate material. Coated elastomeric stoppers are also included. A method of producing a pharmaceutical product comprising steps of making a suspension of pamadronic acid, adding sodium hydroxide, to form a solution adjusting the pH to between 5 and 8 and transferring the solution to a container. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to phosphorus-containing polyarylene ethers and sulfides modified by reaction with mono-, di- or polyamine functionality.
2. Description of the Prior Art
Polyarylene ether materials which can contain a variety of divalent activating groups, including the phosphine oxide group, are shown or suggested and described in U.S. Pat. Nos. 4,108,837 and 4,175,175, for example. These polymeric materials are said to be characterized by excellent high temperature resistance, toughness and stability and each of these patents is incorporated herein by reference for their teachings. German Offen. No. 3,521,125 contains a disclosure of the following phosphorus polyoxyarylene repeating units (where Ar stands for phenyl): ##STR1##
The repeating unit ##STR2## is shown in a literature reference abstracted in Chemical Abstracts, Vol. 108, 95027z (1988). Each of the above are incorporated herein to illustrate the phosphorus-containing polyoxyarylene materials which are to be reacted with the amine functionality in accordance with the present invention. As known in the art, these polymers are soluble in a number of solvents including tetrahydrofuran, chloroform, methylene chloride, dimethylsulfoxide, N-methylpyrrolidone, and dimethyl acetamide. Soluble polyarylene ether phosphine oxide materials, for example, can be prepared by reacting a bisphenol with a halogen-substituted tertiary arylphosphine oxide of the type shown in German Offen. No. 3,532,359, namely ##STR3## as shown in Example 1 hereinafter.
DESCRIPTION OF THE DRAWING
The Figure illustrates a representative reaction scheme where an amine functional prepolymer is used as a curing agent for a polyarylene ether phosphine oxide.
SUMMARY OF THE INVENTION
The present invention relates to such above-mentioned phosphine oxide-containing polyarylene ethers and sulfides which have been modified by reaction with amine functionality. In one embodiment, thermally crosslinkable materials are provided which have improved chemical resistance, flame retardancy and thermo-mechanical stability. In another embodiment, the reaction between amine and phosphine oxide-containing polyarylene ether or polyarylene sulfide, can be used to graft the amine-containing material onto the phosphine oxide-containing polymer.
DETAILED DESCRIPTION OF THE INVENTION
Prepolymers or engineering thermoplastics containing the phosphine oxide group (I) have been found, in one embodiment of the present invention, to be thermally crosslinkable with an amine to provide high performance materials. The phosphine oxide moiety is situated in the backbone of the polymer: ##STR4## where R is substituted or unsubstituted aryl. The crosslinking reaction has been demonstrated, for example, by preparing high molecular weight soluble polyarylene ether phosphine oxides, isolating them, curing them (e.g., at 300° C.) with an alkylene diamine to yield insoluble, tough, film-forming materials which have improved chemical resistance, flame retardancy, and thermo-mechanical stability. In its broadest embodiment, the polymers can be cured in the solid state by being subjected to a temperature above the glass transition temperature of the polymeric material, e.g., from about 200° C. to about 325° C., preferably about 200° C. to about 300° C. If the curing is performed in solution, the curing temperature range could be significantly lower.
As an illustration, a soluble polyarylene ether phosphine oxide of the formula I: ##STR5## can be formed by reacting II and III, as depicted below: ##STR6## under the conditions described in Example 1 hereinbelow. The polymer which is formed is soluble in a number of organic solvents including tetrahydrofuran, chloroform, methylene chloride, dimethylsulfoxide, N-methylpyrrolidone and dimethylacetamide. Further details in regard to these phosphine oxide-containing materials are given in the references mentioned above in the discussion of the prior art. Also included within the scope of the present invention as suitable precursor materials are the analogous phosphine oxide-containing polyarylene sulfides which contain a sulfur atom in place of the oxygen atom depicted in the polymer backbone.
The number of network repeat units per polymer comprised of phosphine oxide can be varied in such precursor polymers depending upon the type of polymeric material ultimately desired. If a lightly crosslinked material is desired, the number of phosphine oxide moieties can be as low as one phosphine oxide moiety per polymer. If a much more tightly crosslinked network is desired, the number of phosphine oxide moieties can be much greater. They can be present in substantially all of the repeat units in the polymer. It is within the contemplation of the instant invention for the polymer to contain from about 1 to about 300 phosphine oxide moieties, preferably from about 5 to about 200°. In situations in which it is desired to have less than all of the repeat units contain a phosphine oxide moiety, the phosphine oxide monomer used in forming the polymers can be copolymerized with other activated aryl halide monomers typically used for synthesis of polyarylene ethers or polyarylene sulfides. Representative activated aryl halide monomers include 4,4-dichlorodiphenylsulfone, 4,4'-difluorodiphenylsulfone, and the like.
The amines which can be used to modify the phosphine oxide-containing polyarylene ethers or sulfides include monofunctional or multifunctional amines and they can be either aliphatic or aromatic. The crosslinking reaction is illustrated by Example 2, below, and changes the phosphine oxide-containing precursor polymers, which are soluble in a variety of organic solvents, into crosslinked materials which are more insoluble. For example, crosslinked materials which are insoluble in refluxing chloroform can be synthesized. The reaction between the phosphine oxide group in the precursor polymer and the amine, which can be a difunctional amine-of the formula
H.sub.2 N--Ar--R--Ar--NH.sub.2
where Ar is a phenyl ring and R is alkylene (e.g., methylene) takes place between the amino hydrogen and the oxygen of the phosphine oxide group. The following structure is formed between two polymeric chains: ##STR7##
It is also within the scope of the instant invention to use amines of the general formula
H.sub.2 NArOROArNH.sub.2
where Ar is a phenyl ring and R is a polyarylene ether, a polyarylene sulfide, a polyarylene ether sulfone, or a polyarylene ether sulfide. In the Figure, the first depicted reagent containing the repeating unit depicted by "x" is an example of one type of molecule of this type.
It is believed that the crosslinking reaction of the present invention yields materials superior to conventional epoxy cured systems since a potentially reactive hydroxyl group is not formed during the reaction. The resulting materials should also be less hygroscopic than cured epoxy systems due to the absence of tertiary amine and hydroxy groups. It is believed that these characteristics will decrease the level of moisture uptake and, hence, contribute to improved environmental stability as compared to the epoxy analogues referred to earlier, particularly at elevated temperatures.
The Figure provides an example of using an amine functional prepolymer (a polyarylene ether sulfone oligomer with aromatic amine termination) as a curing agent with a polyarylene ether phosphine oxide. The first step, in such a scenario, would involve the preparation of the depicted aromatic amine-terminated polyarylene ether sulfone oligomer followed by using it to cure the also preformed polyarylene ether phosphine oxide. Such a crosslinked product should have long shelf life.
Another embodiment of the present invention utilizes the reactivity between the phosphine oxide moiety of the aforementioned polymers and an amine moiety to achieve grafting rather than crosslinking. For example, a monoamine functional polyether, such as polypropylene oxide or polyethylene oxide or a polydimethylsiloxane prepared anionically, could be grafted onto the polyarylene ether or sulfide phosphine oxide. The resulting novel material could be useful as a perm selective membrane material or as a toughened glass.
Another embodiment of the present invention can utilize mixtures of monoamine terminated prepolymers and multifunctional amines to produce novel crosslinked membrane materials.
It is also within the contemplation to have the polyarylene ether and polyarylene sulfide materials containing the phosphine oxide group(s) in admixture with other engineering plastics (e.g., ether sulfones) and/or elastomers in a range of from about 1 mole % to about 99 mole % to yield crosslinked compositions containing such blended polymeric components. When the engineering plastic or elastomer which is selected as the other additive is not crosslinked by the action of the organoamine, the degree of crosslinking of the composite structure will be dictated by the proportion of the composition which is constituted by the novel, crosslinkable embodiment of the present invention.
The Examples which follow provide certain additional information on certain embodiments of the instant invention.
EXAMPLE 1
This Example illustrates the preparation of a poly(arylene ether) phosphine oxide.
A 250 ml 4-neck, round bottom flask, equipped with an overhead stirrer, a nitrogen inlet, a Dean-Stark trap with condenser and a thermometer, was charged with 5.7 grams (0.025 mole) bisphenol-A and 7.85 grams (0.025 mole) bis-parafluorophenyl phenyl phosphine oxide. The polytetrafluoroethylene-coated aluminum pans used to transfer the monomers were rinsed into the flask with NMP, for a total volume of 85 ml. An excess of potassium carbonate (10 grams, 0.07 mole) and 45 ml of toluene were added to the reaction mixture. A constant purge of nitrogen was maintained and the temperature was controlled by a silicone oil bath. The toluene and water azeotroped at 140° C. and the system was allowed to dehydrate about four hours. Next, the temperature was raised to 160° C. and held for eight hours. The solution was dark brown with a white heterogeneous inorganic salt suspension. Finally, the mixture was allowed to cool, diluted with an equal volume of tetrahydrofuran and filtered. Glacial acetic acid was added to the filtrate to neutralize the solution, which was then precipitated in 75/25 methanol-water in a high speed blender. The polymer was dried at 80° C. in a vacuum oven for sixteen hours, redissolved in chloroform, filtered, reprecipitated, and dried again under the same conditions. The resulting polymer had an intrinsic viscosity of 0.40 dl/gm when measured in tetrahydrofuran at 25° C. Its glass transition temperature by DSC was about l90° C.
EXAMPLE 2
This illustrates the crosslinking of the poly(arylene ether) phosphine oxide of Example 1.
Five grams of the poly(arylene ether) phosphine oxide and 0.055 gram of methylene dianiline were solution blended in chloroform and a film of the blended material was dried at 80° C. in a vacuum oven to constant weight. The dried film of the blend was cured in a press at 300° C. for up to a one hour time period. The initial sample from Example 1, which was soluble in many solvents, including chloroform, was thereby transformed into a network or cured-type specimen which was greater than 90% insoluble in boiling chloroform.
The foregoing Examples should not be construed in a limiting sense since they are intended to merely illustrate certain embodiments of the present invention. The claims which follow define the subject matter for which protection is sought. | Phosphine oxide-containing polyarylene ethers and sulfides can be reacted with organoamines to form novel graft copolymers (with monofunctional amines) or novel crosslinked thermosetting network compositions (with multifunctional amines). The network materials show desirable resistance to a variety of organic solvents including chloroform. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/507,950 filed Jul. 14, 2011, the entirety of which is hereby incorporated by reference.
FIELD OF INVENTION
[0002] This invention relates to the treatment of patients with cancer, particularly cancer in advanced stages through combination therapies comprising the use of hyperbaric oxygen with histone deacetylase inhibitors with and without glycolytic therapies.
BACKGROUND OF THE INVENTION
[0003] In 2007, the ten most commonly diagnosed cancers among men in the United States included cancers of the prostate, lung, colon, rectum, and bladder; melanomas of the skin; non-Hodgkins lymphoma; kidney cancer, mouth and throat cancer, leukemia, and pancreatic cancer. In women, the most common cancers were reported as breast, lung and colon cancer. Overall, 758,587 men were told they had cancer and 292,853 men died from cancer in the U.S. in 2007. In women there has been a prevalence of 6,451,737 advanced cases reported by SEER at CDC. In general there were 11,957,599 advanced cancer cases in the US reported in 2010 by CDC and the incidence has been almost unchanged over the previous 8 years (482,000 cases in 2000 versus 456,000 cases in 2008). There has been an annual percentage change of only (−0.6) between years 1999 to 2008 in cancer incidence. Statistics show that deaths caused by advanced cancers from all types have not significantly changed since a decade ago, and in some cases, such as lung cancer with increased incidence since 1930, the death rate has remained rising, especially among women. As more and more chemotherapy agents are introduced to the market for advanced stages of disease, the patient survival rates have remained essentially unchanged. Moreover, the potential toxicity of many chemotherapeutic agents can be a devastating factor both for the clinician and the patient. Therefore the need for non-toxic therapies, used either alone or in combination with traditional chemotherapy, is evident.
[0004] Besides chemotherapy agents, many natural and several synthetic medications have been separately assessed to target cancer in different trials. Dichloroacetic acid (DCA), 3 Bromopyruvate (3BP), Sodium phenyl butyrate, and some natural antioxidants such as quercetin as a strong epigenetic modifier and an antioxidant have been used separately in research, and several clinical trials have shown promise in treating patients with advanced cancer either to achieve a response or increase the quality of life. Many of such treatments have been examined and combined with traditional chemotherapies and prove to function as chemosensitizing and radiosensitizing agents increasing their potential effect (1), (2), (3), (13), (46).
SUMMARY OF THE INVENTION
[0005] Very generally, the method of the invention comprises administering a predetermined dose of one or more HDACI substances to a patient. The patient is then subjected to a hyperbaric environment of substantially pure oxygen. Dosages, pressures, and durations are selected so as to have a therapeutic effect on the patient.
[0006] According to one embodiment of the invention, a predetermined dose of a histone deacetylase inhibitor (HDACI) substance or substances is administered to a patient either intravenously or orally. In particular, sodium phenyl butyrate and quercetin have been found to be useful substances. Within substantially one hour of administering the predetermined substance or substances, the patient is subjected to a hyperbaric environment of substantially pure oxygen at a pressure of substantially one and one half to two atmospheres for a duration of substantially one hour. Preferably, a standard high pressure hyperbaric chamber is used for this step of the method. The predetermined dose is selected as described with more particularity below to have a therapeutic effect upon the patient when used in combination with the hyperbaric environment.
DETAILED DESCRIPTION OF THE INVENTION
Histone Deacetylase Inhibitors
Sodium PhenylButyrate (SPB)
[0007] Sodium phenylbutyrate(SPB) is classified by the FDA as an orphan drug for the treatment of urea cycle disorders. Phenylbutyrate (PB) is a prodrug. In the human body, it is metabolized by beta-oxidation to phenylacetate. Phenylacetate conjugates with glutamine to phenylacetylglutamine, that is eliminated with the urine. Phenylbutyric acid (PBA) has growth inhibitory and differentiation-inducing activity in vitro and in vivo in model systems. It stops the cell cycle in its G1-G0 phase. PB is an efficient HDACiand induces apoptosis—probably via c-jun N-terminal kinase (JNK). In lung carcinoma cells,56 p21 wafl -mediated growth arrest in MCF-7 cells, tumor necrosis factor (TNF)-α58 or peroxisome proliferator-activated receptor (PPAR)λ-mediated cell differentiation, and is more potent than phenylacetate in prostate cancer cells, while increasing MHC class I expression (4), (5), (6), (7), (8). PB is converted in vivo into the active metabolite phenylacetate (PA) by β-oxidation in the liver and kidney mitochondria. Most dose-limiting toxicities (DLTs) are fatigue, nausea, and somnolence. Preliminary studies have been conducted in patients with recurrent glioblastoma multiform (GBM) (9). Phase I studies have been conducted in patients with hormone refractory prostate cancers, refractory solid tumor malignancies like colon carcinoma, non-small cell lung cancer (NSCLC), anaplastic astrocytoma, GBM, bladder carcinoma, sarcoma, ovarian carcinoma, rectal hemangiopericytoma, and pancreatic carcinoma, mainly as intravenous infusions but also in AML and myelodysplastic syndrome (MDS)(10). It works by affecting the NF Kappa-B pathway and lowering the inflammatory response and down regulating more than a hundred genes. The optimal dose and place in therapy is yet to be defined, but oral doses up to 36 grams per day have been used with minimal toxicity. In one study (11), 25 percent of patients had stable disease for more than 6 months while on the drug. SPB in oral form is well tolerated and achieves the concentration in vivo that has been shown to have biological activity in vitro. It has been suggested that SPB has a role as a cytostatic agent and should be additionally explored in combination with cytotoxics and other novel drugs. SPB intravenously has been used in advanced solid tumors with a good safety profile (12), (13). However in most studies SPB has been used orally and not intravenously, and certainly has not been combined with other therapies described here including hyperbaric oxygen.
Quercetin
[0008] Quercetin is a polyphenyl extracted from apples. Although there is still uncertainty about quercetin's effects against cancer, several mechanisms have been suggested. It has been suggested that quercetin may interact with a variety of cellular receptors, although little evidence is currently available. Mechanisms of cancer treatment suggested by Lamson et al. include inhibition of cellular growth phase at G1 and G2, inhibition of tyrosine kinase to prevent uncontrolled proliferation, influencing estrogen receptors, and interacting with heat shock proteins to prevent proliferation. Regarding cancer prevention, Li et al. have shown that quercetin may interact with receptors like Raf and MEK that are involved in tumor proliferation. Interactions with other receptors are also suspected, mainly affecting expression of surface receptors and growth of cancerous cells. A second theoretical mechanism of cancer prevention is modification of signal transduction. Quercetin is reported to affect cell cycle regulation, cell death, inflammatory reactions and derivation of new blood supply. There is limited in vivo research demonstrating quercetin's ability to treat cancer. One phase 1 clinical trial discussed below has used quercetin to treat a range of advanced cancers in humans. This trial determined an effective dosage for a phase 2 trial, but did not focus on cancer outcome or survival time.
[0009] Ferry et al. conducted an open label, uncontrolled dose-finding clinical trial of quercetin as a cancer treatment in 1996. The purpose of this phase 1 trial was to establish a safe dosage for further studies, and thus it was not designed to track cancer progression. In this trial, increasing values of up to 1700 mg/m2 intravenous quercetin were administered for 3 weeks to 50 patients who had cancer deemed no longer treatable by conventional methods. Patients with a variety of cancers were treated including large bowel, stomach, pancreas, ovarian and melanoma. None of the patients achieved suppression as defined by the radiological criteria of WHO, but two showed sustained decreases in unique cancer markers following quercetin therapy (one with metastatic hepatocellular carcinoma, and the other with stage 4 metastatic ovarian cancer that had been previously unresponsive to chemotherapy). In addition, tyrosine kinase levels were measured in 11 subjects, and a decrease in 9 was reported. (Tyrosine kinase may lead to the uncontrolled proliferation of cancer by overriding signals that control cell growth). The authors concluded that this study provides preliminary evidence suggesting quercetin's ability to inhibit tyrosine kinase, and phase 2 studies should be undertaken at doses no higher than 1400 mg/m2 (14). The results of this study have been supported by several in vitro trials in which quercetin caused suppression of tyrosine kinase expression in malignant and non-malignant cells (15).
[0010] Two animal studies have been conducted to assess quercetin's ability to treat cancer. One study reported a 20% increase in lifespan after quercetin was injected peritoneally in mice inoculated with acites tumor cells (16). Another study involving mice inoculated with a human squamous cell carcinoma line showed selective inhibition of cancer growth when quercetin was injected interperitoneally, with minimal effects on surrounding normal cells (17). Additional clinical studies are needed to confirm these findings and determine if they are applicable to humans.
[0011] It is hypothesized that quercitin can show promising results in treating almost every cancer cell due to its genetic regulatory effects (lowering RAS and bcl-2) and epigenetic effect along with chemo sensitizing effects and estrogen receptor modulation in hormonal dependent tumors. It is also suggested that it has a preventive role in cancer incidence. In one study by Nothlings, U., Murphy, S. P., Wilkens, L. R., Henderson, B. E., Kolonel, L. N. published at American Journal of Epidemiology. 2007; 166(8): 924-31, a total of 529 cases of exocrine pancreatic cancer that arose during the previous 8 years, was tracked through state cancer registries. Quercetin intake was negatively correlated with pancreatic cancer among current smokers, showing a significantly decreased (0.55) relative risk between the highest and lowest quintiles of intake.
[0012] There do not, however, appear to be human studies that have looked at quercetin's effects when used intravenously in conjunction with other epigenetic therapies (such as sodium phenyl butyrate).
Lipoic Acid
[0013] Lipoic acid(LA) is a cofactor of pyrovate dehydrogenase in Mitochondria. It is not synthetized in human being and is not available in enough quantities in diet or food. Naturally occurring lipoic acid is always covalently bound and not immediately available from dietary sources. Low levels of lipoic acid have been correlated to a variety of disease states (18), (19), (20), (21). A study of LA demonstrated the maximum concentration in plasma and bioavailability are significantly greater than the free acid form, and rivals plasma levels achieved by intravenous administration of the free acid form. Lipoic acid is today considered to be a “conditionally essential nutrient”. LA is generally considered safe and non-toxic. RLA is being used in a federally funded clinical trial for multiple sclerosis at Oregon Health and Science University. R-lipoic acid (RLA) is currently being used in two federally funded clinical trials at Oregon State University to test its effects in preventing heart disease and atherosclerosis. Alpha-lipoic acid is approved in Germany as a drug for the treatment of polyneuropathies, such as diabetic and alcoholic polyneuropathies, and liver disease.
[0014] More recently the primary effect of lipoic acid is revealed to be not as an in vivo free radical scavenger, but rather an inducer of the oxidative stress response as described below used with hyperbaric oxygen potentiating the oxidation in combination therapy against cancer. It has been shown that Alpha-Lipoic acid induces apoptosis in human colon cancer cells by increasing mitochondrial respiration with a concomitant free oxygen radical generation. Several studies provide evidence that Alpha Lipoic acid can effectively induce apoptosis in human colon cancer cells by a prooxidant mechanism that is initiated by an increased uptake of oxidizable substrates into mitochondria (22).
[0015] In 2010, studies have shown great promise in using lipoic acid to treat a variety of cancer cells in mouse syngenic cancer models: MBT-2 bladder transitional cell carcinoma, B16-F10 melanoma and LL/2 Lewis lung carcinoma. Lipoic acid reduced the cell number by 10-50% depending on concentrations. The efficacy of a combination treatment mainly using lipoic acid appeared similar to conventional chemotherapy (cisplatin or 5-fluorouracil) as it resulted in significant tumor growth retardation and enhanced survival. Such preliminary studies suggest a clinical trial is warranted (23).
[0016] Lipoic acid decreases cancer cell viability and increases DNA fragmentation of the cells. In general, Lipoic acid's anticancer effect is mediated by induceing apoptosis through caspase-independent and caspase-dependent pathways, which is mediated by intracellular Ca (2+) (24).
[0017] Recently there has been a great effort by the pharmaceutical industry to manufacture expensive drugs that have histone deacetylase inhibitory effect. New chemotherapy agents, Hydroxamic derivatives such as LBH 589, and Vorinostat have been suggested to be effective against variety of cancers. It is shown that histone deacetylase inhibitors (HDACI), also inhibit angiogenesis (25). Using lipoic acid and Butyrate in combination can enhance such effect which, independent from their anti apoptotic effect, is considered a new cutting edge method to inhibit metastasis of cancer.
Effects of Hypoxia
[0018] Free radicals and Hypoxia can increase the damage to mitochondrial DNA and produce undesirable changes in epigenetics related to risk of cancer growth and metastasis through Hypoxia induced factor one and VEGF. Hypoxia is a common characteristic of locally advanced solid tumors that has been associated with diminished therapeutic response and, more recently, with malignant progression, that is, an increasing probability of recurrence, locoregional spread, and distant metastasis. Emerging evidence indicates that the effect of hypoxia on malignant progression is mediated by a series of hypoxia-induced proteomic and genomic changes activating angiogenesis, anaerobic metabolism, and other processes that enable tumor cells to survive or escape their oxygen deficient environment. The transcription factor hypoxia-inducible factor 1 (HIF-1) is a major regulator of tumor cell adaptation to hypoxic stress. Tumor cells with proteomic and genomic changes favoring survival under hypoxic conditions will proliferate, thereby further aggravating the hypoxia. The selection and expansion of new (and more aggressive) clones, which eventually become the dominant tumor cell type, lead to the establishment of a vicious circle of hypoxia and malignant progression (26). Hypoxia increases tissue factor expression by malignant cells which enhances tumor cell-platelet binding and hematogenous metastasis (27). Hypoxia, whatever its duration, rapidly increases the nuclear content of HIF-1 as well as the mRNA levels of erythropoietin and VEGF. The transcriptional factor hypoxia-inducible factor-1 (HIF-1) plays an important role in solid tumor cell growth and survival. Overexpression of HIF-lalpha has been demonstrated in many human tumors and predicts a poor response to chemoradiotherapy (28).
Hyperbaric Oxygen Therapy
[0019] There are studies that suggest that Hyperbaric oxygen therapy (HBOT) can play a positive role in certain malignancies and significantly increase quality of life in patient when used along with chemotherapy(29), inhibit the certain cancer genes and tumor growth in vitro (30),(31), and reduce the tumor burden and restrict the growth of large tumor cell colonies (32). It is possible that this effect is through lowering the hypoxia induced factor one which can change the expression in the VEGF gene subsequently involved in tumor metastasis. VEGF is a major initiator of tumor angiogenesis (33), (34). Furthermore, it is found that VEGF expression is potentiated by hypoxia and that the potentiation of VEGF production in hypoxic areas of solid tumors contributes significantly to VEGF-driven tumor angiogenesis (35), (36).
[0020] However hyperoxia as a result of hyperbaric oxygen also produces reactive oxygen species which can damage tumors by inducing excessive oxidative stress (37). On the other hand, free radical related lesions that do not cause cell death can stimulate the development of cancer and can promote cancer growth and metastasis (38) and VEGF exocytosis requires free radicals formation (39). Reactive oxygen species generate mitochondrial DNA mutation and up regulate hypoxia inducible factor-1 alpha gene transcription (40). Therefore reducing oxidative damage is beneficial.
[0021] There are available treatments that effectively reduce free radical production and cellular damage. These treatments can potentially modify the epigenetics and increase the effectiveness of other treatments such as DCA and 3 BP. As a result combining HBOT with such modality would offer an advantage to each modality.
[0022] In accordance with the invention, the use of HDACI's, administered either orally or intravenously, in combination with HBOT and, optionally, in combination with other modalities described herein, has achieved surprising results in treating various forms of cancer. The results are particularly surprising in connection with advanced cancers as evidenced by the cases described below. Because each patient is different, the specific patient protocol is adjusted to achieve optimal results. However, common to all protocols is the underlying method of the invention as claimed herein.
Optional Strategies
[0023] One strategy to destroy or prevent cancers is by targeting their cellular energy production factories. All nucleated animal/human cells have two types of energy production units, i.e., systems that make the “high energy” compound ATP from ADP and P (i). One type is “glycolysis,” the other the “mitochondria.” In contrast to most normal cells where the mitochondria are the major ATP producers (>90%) in fueling growth, human cancers detected via Positron Emission Tomography (PET) rely on both types of power plants. In such cancers, glycolysis may contribute nearly half the ATP even in the presence of oxygen (“Warburg effect”). Based solely on cell energetics, this presents a challenge to identify curative agents that destroy only cancer cells, as they must destroy both of their power plants causing “necrotic cell death” and leave normal cells alone (41).
Dichloroacetic Acid (DCA)
[0024] DCA is a byproduct of chlorinization of water. By stimulating the activity of pyruvate dehydrogenase, DCA facilitates oxidation of lactate and decreases morbidity in acquired and congenital forms of lactic acidosis. The dichloroacetate ion stimulates the activity of the enzyme pyruvate dehydrogenase by inhibiting the enzyme pyruvate dehydrogenase kinase. Thus, it decreases lactate production by shifting the metabolism of pyruvate from glycolysis towards oxidation in the mitochondria.
[0025] Cancer cells change the way they metabolize oxygen in a way that promotes their survival. Solid tumors, including the aggressive primary brain cancer glioblastomamultiforme, develop resistance to cell death, in part as a result of a switch from mitochondrial oxidative phosphorylation to cytoplasmic glycolysis. DCA depolarizes mitochondria, increases mitochondrial reactive oxygen species, and induces apoptosis in glycolytic cancer cells, both in vitro and in vivo. DCA therapy also inhibits the hypoxia-inducible factor-1alpha, promoted p53 activation, and suppressed angiogenesis both in vivo and in vitro (42). There is substantial evidence in preclinical in vitro and in vivo models that DCA might be beneficial in human cancer (43), (44), (45). Furthermore, as predicted, activating mitochondria by DCA increases oxygen consumption in the tumor and dramatically enhances the effectiveness of hypoxia-specific chemotherapies in animal models (46). In laboratory studies of isolated cancer cells grown in tissue culture, DCA restores the original metabolism, and promotes their self-destruction. This has led to the use of DCA for treating cancer, by individuals experimenting with it themselves, by doctors administering it to patients, by scientists testing it in cancer tissue cultures in cell culture and in mice, and in human Phase II studies. A phase one study published in January 2007 by researchers at the University of Alberta, who had tested DCA on cancer cells grown in mice, found that DCA restored mitochondrial function, thus restoring apoptosis, allowing cancer cells to self-destruct and shrink the tumor. Akbar and Humaira Khan have, since 2007, treated cancer patients using DCA off-label at their private clinic, Medicor Cancer Centres, in Toronto. They have treated several types of cancer and revealed that some patients “are showing varied positive responses to DCA including tumor shrinkage, reduction in tumor markers, symptom control, and improvement in lab tests.” DCA has improved certain biochemical parameters, but it has not demonstrated improved survival. The mitochondria-NFAT-Kv axis and PDK are important therapeutic targets in cancer; the orally available DCA is a promising selective anticancer agent (47). However there are no studies in literature in regards to using DCA intravenously to maximize its effect when combined with other treatments such as 3 BP or SPB intravenously.
3 Bromopyruvate (3BP)
[0026] 3-bromopyruvate (3BP), a hexokinase inhibitor, lowers the ATP production in cancer cell and has shown great promise in animal studies either used as intra arterial or intratumoral injection. 3-bromopyruvate (3-BrPA), a lactic acid analog, has been shown to inhibit both glycolytic and mitochondrial ATP production in rapidly growing cancers (48), leave normal cells alone, and eradicate advanced cancers (19 of 19) in a rodent model (49). Recent research in tumor metabolism has uncovered cancer-cell-specific pathways that cancer cells depend on for energy production. 3-bromopyruvate (3-BrPA), a specific alkylating agent and potent ATP inhibitor, has been shown both in vitro and in vivo to disrupt some of these cancer-specific metabolic pathways, thereby leading to the demise of the cancer cells through apoptosis. As an alkylating agent and a potent inhibitor of glycolysis, it has recently been exploited to target cancer cells, as most tumors depend on glycolysis for their energy requirements. The anticancer effect of 3-bromopyruvate is achieved by depleting intracellular energy (ATP) resulting in tumor cell death. The principal mechanism of action and primary targets of 3-bromopyruvate, and the impressive antitumor effects of 3-bromopyruvate in multiple animal tumor models, have been discussed recently. The primary mechanism of 3-bromopyruvate is via preferential alkylation of GAPDH. 3-bromopyruvate mediates cell death linked to generation of free radicals. Research also has revealed that 3-bromopyruvate induces endoplasmic reticulum stress and inhibits global protein synthesis, further contributing to cancer cell death. Therefore, studies reveal the tremendous potential of 3-bromopyruvate as an anticancer agent (50).
[0027] Also there is interest in researching transport ATPase that has seen tremendous progress. These ATPases driven in reverse by a proton gradient have the capacity to interconvert electrochemical energy into mechanical energy and finally into chemical energy conserved in the terminal bond of ATP (51). It is suggested that 3BP inactivates H+-vacuolar ATPase, the enzyme that makes certain compartments in the cell acidic. Inactivation probably involves alkylation of the enzyme on a thiol group, essential for H+-ATPase activity for dithiothreitol secured complete protection from 3-Br PA inactivation. The findings are discussed with regards to a possible involvement of lysosome destabilization in 3-Br PA induced cell death (52). Studies at Johns Hopkins University (53) and (54) recently have shown efficacy and dose related response when 3 BP is used as even a single therapy, when used intraarterially. However, its role in more aggressive cancers as a solo treatment is not supported. Also its intravenous application has not caused tumor regression due to lower concentration at the target site. However, if used intravenously, combined with other therapies described here, a different scenario results. This may theoretically be due to an additive or synergistic effect on Mitochondria.
Octreotide
[0028] Octreotide (brand name Sandostatin,) is an octapeptide that mimics natural somatostatin pharmacologically, though it is a more potent inhibitor of growth hormone, glucagon, and insulin than the natural hormone. Octreotide is absorbed quickly and completely after subcutaneous application. Maximal plasma concentration is reached after 30 minutes.
[0029] Oncogenes express proteins of “Tyrosine kinase receptor pathways”, a receptor family including insulin or IGF-Growth Hormone receptors. Other oncogenes alter the PP2A phosphatase brake over these kinases. Octreotide has been used in variety of medical conditions since 1979. Since it inhibits secretion of insulin and also acts as a suppressing agent for Insulin growth factor one (IgFl), its use has been suggested in a variety of Glycolytic cancers. Octreotide is found to have therapeutic application beneficial to patients as shown by experiments on animals (55).
[0030] GH hormone induces in the liver, the synthesis and release of insulin like growth factor (IGF). The latter activates, like insulin, the IGF-tyrosine kinase receptors (IGFR), triggering the MAP kinase-ERK mitogenic signal. In normal physiology GH stimulates a triglyceride lipase in adipocytes, increasing the release of fatty acids and their β oxidation. In parallel, OH would close the glycolytic source of acetyl CoA, perhaps inhibiting the hexokinase interaction with the mitochondria. This effect, which renders apoptosis possible, does not occur in tumor cells.
[0031] GH mobilizes the fatty acid source of acetyl CoA from adipocytes, which should help the formation of ketone bodies. But since citrate synthase activity is elevated in tumors, ketone bodies do not form. Hence, butyrate cannot inhibit histone deacetylase (HDAC), the enzyme cuts acetylated histone tails, this will silence several genes like PETEN, P53, or methylase inhibitory genes. Therefore combining the histone deacetylase inhibitors with Octreotide can have a significant additive effect on glycolytic tumors.
[0032] There appears to be a correlation between IgF1 receptors and the behavior of the cancer cell. The surface distribution of IGF-IGFR may determine if a cell is sterile or endowed with a mitotic potential (55). Therefore, using octreotide along with other combination therapies can potentially change the cancer cellular motivation to differentiate. Finally, the recent discovery of a population of Dwarfs with no GH receptors, which does not develop cancers, illustrates the GH/IGF prediction, establishing a link between ancient and recent biochemical observations on tumors (56).
[0033] Finally there are studies that have suggested a correlation between both the cancer risk as well as the cancer prognosis with the serum IgF-1 level in human (57). For example observations implicate IGF-I as an important factor during the initiation and progression of primary prostate cancer and provide evidence that there is a strong selection against expression of IGF1R and IGF2R in metastatic and androgen-independent disease (58), (59). Growing links between insulin and the etiology as well as prognosis in colon, prostate, pancreatic, and, particularly, breast cancer are reviewed. Of particular concern is the evidence that elevated IGF-1 may interfere with cancer therapy, adversely affecting prognosis (60).
[0034] Octreotide used in protocols described below demonstrates the effectiveness of such treatment in lowering the IgF-1 significantly.
EXAMPLES
[0035] Based on above facts, such substances have been employed using Intravenous and oral targeted therapies to reduce anabolic glycolysis in patients with cancer along with epigenetic treatments with HDACI and hyperbaric oxygen. These treatments can increase quality of life and can improve the patient survival. More particularly, an integrative cancer care/approach was undertaken to treat patients who referred for such intervention voluntarily. As of October 2011, 40 patient charts were selected randomly and reviewed. The inclusion criteria were diagnosis of cancer. No patients were excluded. Patients were aged 27 to 83 years. All were diagnosed by their oncologist/physician and were offered standard conventional treatment of surgery, traditional chemotherapy or radiation. Out of 40 patients 20 of them refused standard care or there was no conventional option available for them due to severity of the disease. Out of 40 patients, 23 of them had advanced stage disease with micro or macro multiple metastasis at the time of referral, before starting the treatment. 19 of these patients (47 percent) had already been treated with multiple chemotherapy agents unsuccessfully and had progression or recurrence of disease manifested by their tumor markers or scans.
[0036] The patients were managed based on unique developed protocols that were designed in correlation with available research studies and clinical trials that implicate using specific natural and synthetic IV therapies. IV therapies are targeted at epigenetic level and consist of antioxidants, quercetin, DCA, sodium phenyl butyrate, and lipoic acid separately or in combination. All patients received one or more of such treatments. The most effective synergistic combination was found to be intravenous sodium phenyl butyrate and quercetin. Doses of each treatment remained the same or close on each treatment, Quercetin was given intravenously at the dose 0.5 to 1.0 gram (50 mg/ml). When administered, SPB was dosed at 5 to 10 gram (25 to 50 ml of 200 mg/ml, When administered, DCA was dosed at 500 mg to 6 gram (maximum 100/kg) When administered, lipoic acid was given at 600-1000 mg, Hyperbaric oxygen treatment was applied, with standard 1.5 to 2.0 atmosphere pressure for 45-90 minutes (average 60 minutes) on each session. When administered octreotide was given subcutaneously at 50-400 mcgs.
[0037] All patients started the program after educating them about their possible options of conventional and non conventional treatments and consents obtained. The progression of disease was measures during the course of treatment through tumor markers, Imaging studies and markers for cancer growth, necrosis, LDH, and inflammation, CRP, as well as the Natural killer cell activity or lymphocyte count and Circulatory tumor cells.
[0038] The following results were obtained during or after completing the course of therapy:
1) Subjective Increase in QOL (increase energy level, less pain scores and elevation in mood: 100 percent 2) Immunological response: Increase in Natural Killer cell activity or WBC count: 35% of patients had initial low NK/WBC, all these patients have increased NK activity after therapy 3) Potential decrease in tumor activity by measuring LDH: 40 percent of patients had high LDH, ALL these patients have shown decreased LDH after the therapy 4) Response in Tumor markers, enough to qualify for clinical response: 50 percent 5) Shrinkage of tumor in radiographic studies: 35 percent 6) Decrease in CRP (correlation with improved survival): 23 percent 7) Decrease in IgF-1: 12 percent of these patients had increased IgF-1, suggested to correlate with prognosis in literature. All these patients had improved IgF-1 after the treatment
[0046] Since patients with cancer may have significant stratifying confounders in selecting their control group, we used each patient's pre interventional status as the control arm. Patients other stratifying confounders did not change during the study.
Results:
[0000]
1) These data reveals superior response in the group of patients compared to the controls. In 47 percent of patients treated there was no conventional option available at the time of referral. In this group results are far better compared to conventional modalities of treatment. (no treatment option available)
2) Patients who received both HBOT and IV therapies did better as far as their imaging, their quality of life and tumor shrinkage as well as controlling their tumor markers than the ones who did the IV therapies only.
3) Patients with stage four terminal disease receiving the above program, exceeded response beyond the standard of care expectations, and the patients who did receive chemotherapy concurrently with above targeted therapies had significant improvement in quality of life and chemotherapy response.
CONCLUSION
[0050] In an integrative cancer care program that combines hyperbaric oxygen therapy with specific Intravenous antioxidants and epigenetic modifications, along with intravenous and/or oral DCA and 3BP, patient survival as well as quality of life improved significantly. The above described modality of care was found to be superior to conventional standards of care. The exact reasons for this are still uncertain, but could possibly be due to the conjunctive effect on the cancer cell mitochondria.
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48) Glucose catabolism in the rabbit VX2 tumor model for liver cancer: characterization and targeting hexokinase
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49) Advanced cancers: eradication in all cases using 3-bromopyruvate therapy to deplete ATP. BiochemBiophys Res Commun. 2004 Nov 5;324(1):269-75.
Ko Y H, Smith B L, Wang Y, Pomper M G, Rini D A, Torbenson M S, Hullihen J, Pedersen P L.
[0109] The Russell H. Morgan Department of Radiology, Johns Hopkins University School of Medicine, Baltimore, Md. 21205-2185, USA. yko@jhmi.edu
50) 3-bromopyruvate: a new targeted antiglycolytic agent and a promise for cancer therapy.
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52) Inactivation of H+-vacuolar ATPase by the energy blocker 3-bromopyruvate, a new antitumour agent
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53) 3-Bromopyruvate induces endoplasmic reticulum stress, overcomes autophagy and causes apoptosis in human HCC cell lines.
Ganapathy-Kanniappan S, Geschwind J F, Kunjithapatham R, Buijs M, Syed L H, Rao P P, Ota S, Kwak B K, Loffroy R, Vali M.
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56) Growth hormone receptor deficiency is associated with a major reduction in pro-aging signalling, cancer, and diabetes in humans. Guevara-Aguirre J, Balasubramanian P, Guevara-Aguirre M, Wei M, Madia F, Cheng C W, Hwang D, Martin-Montavalvo A, Ingles S, de Cabo R, Cohen P, Longo V D: 57) Insulin, insulin-like growth factors, insulin resistance, and neoplasia
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[0124] Source: 239 Glenville Road, Greenwich, Conn. 06831, USA. dbb@integrativeoncology.org | A method for treating cancer is described using combination therapies comprising the use of hyperbaric oxygen with histone deacetylase inhibitors, with and without glycolytic therapies. The patient is subjected to a hyperbaric environment of substantially pure oxygen. A predetermined dose of one or more HDACI substances is administered to the patient. In addition, glycolitic inhibitors may also be administered. Dosages, pressures, and durations are selected as described herein to have a therapeutic effect on the patient. | 0 |
This is a division of application Ser. No. 426,054, filed Dec. 19, 1973, now U.S. Pat. No. 3,890,721, issued June 24, 1975.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a developing liquid recovery device for use in a copying machine. More particularly, it relates to a carrier liquid recovery device for use in an electrophotographic copying machine of the wet development type.
2. Description of the Prior Art
In an electrophotographic copying machine of the wet development type, it has usually been the practice to form an electrostatic latent image on a photosensitive sheet or medium as by applying of electrostatic charge and image light, directing the image-bearing sheet or medium into a pool of developing liquid composed of carrier liquid such as Isopar or like petroleum with toner dispersed therein to develop the latent image into a visible image. Where a photosensitive sheet is used, most of the developing liquid remaining thereon is then squeezed by a pair of squeeze rollers, whereafter any residual carrier liquid on the photosensitive sheet is vaporized by a fixing-drying device to fix the toner on the sheet. In case of an image transfer type copier, the toner image on the photosensitive medium is transferred to transfer medium through the agency of carrier liquid, and such transfer medium is further passed to a fixing-drying device, where the residual carrier liquid is vaporized to fix the toner image.
The carrier vapor produced in the above case is usually exhausted from the machine directly into the atomospher such as office room or the like, but even a slight amount of carrier liquid should not be neglected because it is a hygienically deleterious petroleum solvent. Especially, if a copying machine were installed in a shut-up room, the carrier vapor exhausted from the machine at a high rate per unit time would harm the health of the workers in the room inasmuch as the rate of exhaust in newer machines has a tendency toward further increase with the increasing copying speed.
Also, the amount of the carrier liquid carried away with the photosensitive sheet or the transfer sheet from the developing device is inappreciable when taken with respect to an individual sheet (0.3 to 1 cc per sheet of format A), whereas mass production of copies would involve a considerable waste of carrier liquid which should never be neglected from an economical point of view.
Recovery of carrier vapor by utilizing the adsorbing property of active carbon or by condensing the vapor has heretofore been proposed, but it is nearly impossible to attain sufficient recovery of carrier vapor by these means.
Recovery of carrier vapor by cooling and condensing the vapor has also been proposed. However, the recovered carrier liquid is heated to a high temperature in the fixing station to dry and fix the copy medium. As a result, part of the carrier liquid is thermally cracked and activated, thus producing a considerably unpleasant odor. If such odorous carrier liquid were returned to the developing liquid for repeated use, the odor would remain on copy mediums even after they have passed through the fixing-drying device, and such residual odor would finally be exhausted with copy mediums to cause unpleasant conditions for the workers in the room, although the odor might be slight in extent.
SUMMARY OF THE INVENTION
It is an object of the present invention to prevent exhaust air contaminated by the vapor of developing liquid, especially carrier liquid in an electrophotographic copying machine of the wet development type, from being discharged outwardly of the machine, and to recover the developing liquid efficiently.
It is another object of the present invention to enable the carrier vapor to be cyclically used without being discharged outwardly of the machine and to cause the carrier vapor to be condensed to a high density in a circulating system and recovered from the air to thereby eliminate the hygienic problem while, at the same time, permitting the recovered carrier liquid to be reused for development, thereby providing an economical advantage as well.
It is still another object of the present invention to provide a device which can separate the recovered carrier liquid from the water contained in the air and copy mediums and recirculate the carrier liquid alone into the developing tank for reuse.
It is yet another object of the present invention to provide a device in an electrophotographic copying machine having a carrier liquid recovery device, which device can deodor and decolor the recovered carrier liquid to make such liquid effective for reuse.
It is a further object of the present invention to enable the carrier vapor to be cyclically used without being discharged outwardly of the machine and to cause the carrier vapor to be condensed to a high density in the circulating system for recovery from the air, thereafter to pass the recovered carrier through an adsorbent such as active carbon, silica gel, active alumina, active magnesium, acid clay, bentonite, diatomite, calcium carbonate, titanium oxide or the like to thereby deodor and purify the recovered carrier liquid, thus making it ready for reuse for development.
The developing liquid recovery device of the present invention comprises a fixing-drying chamber hermetically sealed as far as possible except for the inlet and outlet ports for copy paper so that the air in the chamber may be recirculated by a blower so as to be repeatedly used for fixing and drying, while the interior of the chamber is being maintained at a pressure level below the atmospheric pressure to thereby prevent exhaust of the air containing carrier vapor. In the air circulating system, a carrier vapor recovery device is provided so that an amount of air corresponding to the amount of air admitted through the gaps of the chamber may be made hygienically harmless and exhausted outwardly of the machine. More specifically, the carrier vapor once used for fixing-drying is directed into a condenser and a mist collector for recovery of the carrier, whereafter most of the air is directed into the fixing-drying chamber by a blower for cyclical use, while the rest of the air is directed into a cooler to remove most carrier vapor therefrom before it is exhausted from the machine. The condenser comprises a flat, orthogonal flow type heat-exchanger as a first stage in which the low-temperature air subjected to carrier recovery is made into a low-temperature fluid; and a flat, orthogonal flow type heat-exchanger for making ambient air into a low-temperature fluid. The mist collector is designed to collect the mist in an electric field, the mist being charged with corona discharge.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a copying machine which adopts an embodiment of the pesent invention.
FIG. 2 is a perspective view showing a form of the heat-exchange condenser means.
FIGS. 3 and 4 are fragmentary perspective views showing two forms of the mist collector means.
FIG. 5 shows a tank for recovered carrier liquid and a developing device.
FIG. 6 schematically shows liquid level detector means provided in the tank and developing device of FIG. 5.
FIG. 7 is a diagram of the electric circuit in the device of the present invention.
FIG. 8 is a circuit diagram of the liquid level detector means.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is a shown an embodiment of the present invention. A transfer paper sheet S, which bears a visual image transferred from a photosensitive sheet or medium having an electrostatic latent image developed by means of developing liquid, may be admitted into a fixing-drying chamber 1 through an inlet port 2 and discharged therefrom through an outlet port 3 into a tray 4. The fixing-drying chamber is hermetically sealed as far as possible with its inlet and outlet ports 2 and 3 being sealingly closed by sealing rollers 5 1 , 5 2 and 6 1 , 6 2 , respectively. When admitted into the fixing-drying chamber 1 through its inlet port 2, the transfer paper sheet S may be moved forward with its back side in intimate contact with a heated plate 7 having a heater contained therein and with its image-bearing surface exposed to the blast from a duct 8 for preparatory drying. Subsequently, the sheet S may pass between a heat roller 9 having a heater contained therein and press roller 10 so as to be dried and fixed with the carrier liquid completely vaporized.
A suction port 11 is provided in the latter half portion of the fixing-drying chamber 1 to direct the hot air with the carrier vapor into a recovery device 13 provided in a portion of a stand 12 for the copying machine. The air so directed into the recovery device 13 may then be passed through a heat-exchange condenser 14 and a mist collector 15 and sucked into a blower 16. The air is blown off from the blower 16 and passed through a duct 17 and a heat-exchanger 14 1 into a duct 8, through which the air may again be blown off into the fixing-drying chamber 1. Thus, there is provided a circulation path. Part of the air may be divisionally directed by a duct 17 into a cooling chamber 18 such as a refrigerator, and then exhausted through an exhaust port 19.
In the above-described arrangement, air with carrier liquid in the fixing-drying chamber 1 is circulated by the blower 16, except for that part of the air which is exhausted through the exhaust port 19, so that the interior of the fixing-drying chamber 1 is below the atmospheric pressure. This prevents the air containing a high density of carrier vapor in the chamber 1 from leaking therefrom through some gaps the presence of which is actually unavoidable to such chamber. Rather, the chamber sucks a small amount of air thereinto through those gaps. It is an amount of air corresponding to or more than such a small amount of air that is exhausted through the exhaust port 19.
The recovery of carrier liquid will now be described. The heat-exchange condenser 14, as is shown in FIG. 2, is an orthogonal flow type heat-exchanger comprising a plurality of sheets 20 of good heat-conductivity laminated with spacers 21 interposed therebetween. The cooling side of the condenser 14 is formed into three stages. The first stage 14 1 is meant to cool the air down to the room temperature to recover the carrier liquid contained therein, and the air used as coolant therein is the air flow A3 which is to be returned to the fixing-drying chamber 1. In the second and third stages 14 2 and 14 3 , ambient air flows C1, C2 and C3 sucked thereinto by a fan 22 (FIG. 1) are used as coolant. The hot air flow A1 containing a high density of carrier vapor directed from the fixing-drying chamber 1 is cooled down to a temperature near the room temperature as it is passed through the above-described heat-exchange condenser 14. As the cooling progresses, the carrier vapor in the air A1 is over-saturated so that part of such vapor is deposited on the walls of the condenser and progressively grown up into large drops of liquid, which finally fall from gravity. Most of the rest of the carrier vapor changes into minute particles which remain suspended as mist in the air. The air A2 containing the carrier mist and so cooled down to a temperature near the room temperature is then directed to the mist collector 15.
The mist collector 15, as is shown in FIG. 3, comprises electrode plates 23 with a high DC voltage applied thereto and grounded electrode plates or meshes 24, the plates 23 and meshes 24 being alternately arranged and suitable spaced apart for insulation from each other. Each electrode plate 23 has a needle discharge electrode 25 provided adjacent the entrance of the collector.
The mist suspended in the air A2 is passed through the corona discharge between each needle electrode and adjacent grounded electrode, whereby the mist is electrically charged. When passing through the subsequent field between the electrodes, the charged mist is attracted to the grounded electrode by Coulomb force and deposited thereon, so that the charged mist is neutralized for dripping. If the grounded electrode were in the form of a wall (FIG. 3), the entire wall surface of the grounded electrode would be covered with carrier liquid too rapidly for the charged mist to be well neutralized.
More particularly, the charged mist loses its charge after it has been deposited on the grounded electrode, and the speed at which the charged mist loses its charge is variable depending on the magnitude of the electrical resistance of the mist itself. If the entire wall surface of the grounded electrode is covered up with carrier liquid, the apparent electrical resistance of the charged mist will become higher even though the mist reaches the wall surface due to Coulomb force, thus reducing the speed at which the mist loses its charge (i.e. the speed at which the mist is neutralized). Moreover, as a large amount of charged mist gathers with the process of continuous copying, the quantity of charged mist overcomes the speed at which the charge is lost, and thus more and more of charged mist gathers there until it results in spark discharge. For this reason, the neutralization of charged mist must proceed at an appropriate speed.
On the other hand, a grounded electrode in the form of mesh would never be thickly covered with carrier liquid. Further, the electrode in such form would ensure electrical neutralizatin of charged mist to proceed at an appropriate speed, thereby eliminating the above-described danger. FIG. 4 shows an example of the grounded electrode in the form of mesh.
By making the grounded electrodes in such mesh form, exhaust of the hygienically deleterious carrier vapor can be prevented substantially completely and the recovered carrier liquid can be reused, and this leads to the provision of a recovery device which is highly economical and highly safe. Substantially all (90% or more) of the mist in the air A2 is removed by the mist collector described above, while the slight amount of remaining mist is completely removed by a simple filter 26 such as wire netting or the like, and thus the air A3 now containing only a slight amount of carrier vapor (saturated vapor at room temperature) is returned to the fixing-drying chamber by the blower 16 for reuse.
The carrier liquefied by the heat-exchange condenser 14 and mist collector 15 may be collected through a discharge port 27 into a tank 28, from which the carrier liquid is returned to a developing device for reuse.
On the other hand, an air flow A3' divided from the air flow A3 at the duct 17 is further cooled down in the cooling chamber 18 to an extreme extent so that substantially all of the carrier vapor in such air flow is liquefied, and then exhausted into the atmosphere. This exhaust air, indicated by A5, is of small amount and substantially clean, thus being never deleterious hygienically. The amount of carrier liquid resulting from the condensation in the cooling chamber 18 is collected in a tank 29, but the carrier liquid so collected in this tank 29 carries with it some water content of the air resulting from the condensation effected in the cooling chamber and cannot directly be reused. It must be regenerated before being reused.
The carrier liquid used with the electrophotographic copying machine of the liquid development type is a petroleum solvent generally known by the tradename of Isopar whose main component is isoparafine which is initially low in unsaturation degree and odorless. However, when the carrier liquid has been heated and vaporized in the fixing station after development or after image transfer and thereafter the carrier liquid has been recovered with the isoparafine vapor cooled and condensed, the polymerization chain of hydrocarbon is cut off under the influence of thermal cracking or the like to increase the unsaturation degree of isoparafine, as is well known. Moreover, the carrier liquid so recovered might further contain other ingredients resulting from the thermal cracking of the constituents forming the copy medium and thermal cracking of the constituents forming the developing liquid, and it is believed that the odor emitted from the recovered carrier liquid is attributable to the combination of those various ingredients, although the true cause has not yet been discovered definitely.
Nevertheless, the investigations into the method of deodorizing and purifying the recovered carrier liquid have shown that the unpleasant odor noted above can be almost completely removed by passing the carrier liquid through an absorbent such as active carbon, silica gel, active alumina, active magnesium, acid clay, bentonite, diatomite, calcium carbonate, titanium oxide or the like.
The present invention enables the repeated use of the recovered carrier liquid by employing one of the above-enumerated adsorbents as the adsorbent indicated at A in FIG. 1 so that the carrier liquid resulting from the active of the heat-exchange condenser and mist collector may pass through the adsorbent A.
Thus, the carrier liquid recovered in the abovedescribed manner is deodorized and safely available for reuse.
FIG. 5 shows the details of the tank 28. The tank 28 for recovering the carrier vapor produced from the developing liquid and storing the thus recovered liquid includes a first partition wall 28 1 and a second partition wall 28 2 which serves to separate the recovered liquid until it reaches a predetermined liquid level. In the first chamber (right-hand side), the carrier liquid recovered by the recovery device is mixed with water and other impurities and the mixture drips into the tank 28 through the inlet 27. The first partition wall 28 1 serves to prevent the mixture of carrier liquid and water from running directly over the surface of the recovered liquid to go beyond the second partition wall, and for this purpose the lower end 28 1a of the partition wall is at a lower level than at least the upper end 28 2a of the second partition wall. The mixture of carrier liquid and water is first stored in the first chamber, where with lapse of time the mixture is completely separated into an upper layer of carrier liquid 41 and a lower layer of water 42 due to the difference in specific gravity (for example, if the carrier liquid is Isopar H, the ratio of specific gravity between the Isopar H and water is 0.75 : 1). As is already apparent, the carrier liquid forming the developer must be insulative and should not be mixed with water. It is for this reason that the carrier liquid and water are completely separated from each other in the first chamber, and thereafter when the liquid level exceeds a predetermined level, only the Isopar H liquid forming the upper layer is caused to overflow the top 28 2a of the second partition wall 28 2 for collection in the second chamber (left-hand side). The carrier liquid so collected in the second chamber is delivered by a pump 31 driven from a motor 29 through the rotary shaft 30 thereof so as to be returned through a pipe 32 into a developer tank D which is the developer storage container of the developing means, thus becoming ready for reuse. In this case, however, the carrier liquid contains no developer and therefore, it is necessary to add a suitably concentrated developer to the stored liquid and control the density of the developing liquid by means of a toner density regulator or the like.
Within the recovered liquid tank 28 of the described construction, liquid level detector means is further provided in each of the first and second chambers. Especially, the water recovered and stored in the first chamber must not overflow the second partition wall 28 2 and for this reason, it is necessary to detect the liquid level of the lower layer when it exceeds a predetermined level and to remove the excess liquid. In FIG. 5, such detector means is designed to detect the level with the aid of the difference between the dielectric constant of carrier liquid and that of water, and comprises two conductive plates closely spaced and opposed to each other to detect the variation in induction coefficient therebetween. This circuit is shown in FIG. 7. When the water of the lower layer exceeds a predetermined level, an electrical signal is produced to open an electromagnetic valve V1 for a predetermined time to permit the water to fall into a tank 36 located below the tank 28. The electromagnetic valve V1 remains open until the water 42 sufficiently flows down, whereafter the valve is again closed to store the recovered liquid in the tank 28. In the second chamber, there is provided level detector means for controlling the liquid level within a predetermined range, and this level detector means includes a float 33, an actuator 34 actuated by the float 33, and microswitches MS1 and MS2 actuated by the actuator 34. Microswitch MS1 detects the upper limit of the liquid level and microswitch MS2 detects the lower limit of the liquid level. The operating circuit is shown in FIG. 8. As shown there, MS2 is a normally closed switch. When the float 33 rises to actuate the actuator 34 out of engagement from the microswitch MS2, the microswitch MS2 is closed. When the liquid level further rises to close the microswitch MS1, a relay RL-A is energized whose contact a-1 is thus closed to energize the motor 29, while in turn drives the pump 31 to pump the carrier liquid into the developing tank D. If this condition remains unchanged, the microswitch MS1 would immediately be opened to substantially prevent the carrier liquid 41 from being pumped up. To avoid this, the relay RL-A is held by its contact a-2 to maintain the motor energized irrespective of the opening of the switch MS1, and the motor M is not deenergized until the lower limit detector microswitch MS2 is opened, whereupon the pumping operation is stopped.
FIg. 6 shows liquid level detector means for detecting the liquid level of the lower layer within the first chamber by using a float 40 and a microswitch MS3. This utilizes the difference in specific gravity between the two liquid layers (0.75 : 1) and the float 40 is disposed in the interface between the two layers. When the float 40 exceeds a predetermined level, it actuates the switch MS3 to open the electromagnetic valve V1, thus permitting the liquid of the lower layer to fall into the underlying tank 36.
Further, in this embodiment, the developing tank D is provided with a liquid level detector microswitch MS4, a float 37 and an actuator 38. A great deal of carrier liquid (Isopar H) is prestored in the second chamber 28, and the carrier liquid (Isopar H) recovered by the recovery device is caused to overflow the first chamber to mix with the pre-stored carrier liquid in the second chamber. By the operation of the liquid level detector means of the developing tank D, the pump 31 is operated to supply the carrier liquid from the second chamber to the developing tank. The liquid pre-stored in the second chamber is not limited to carrier liquid but it may be developer with which the recovered carrier liquid may be mixed, and such mixture may be circulated to the developing device.
The electric circuit of FIG. 7 will now be explained. It More specifically a base tuning type oscillator circuit 1, a voltage doubling detector circuit 2, and a detection output amplifier circuit and thyristor trigger circuit 3 which varies the tuning frequency of the detector circuit in accordance with the variation in the capacitance of a capacitor Cx. The capacitance of the capacitor Cx is greater when the space between electrodes of the capacitor is filled with water than when such space is filled with air or Isopar, thus reducing the tuning frequency. The output voltage of the detector circuit can be higher as the turning frequency f 1 is closer to the frequency f 2 of the oscillator circuit, and this may be utilized to detect the level. More especially, if the oscillation frequency in the dotted frame 1 is f O , the tuning frequency f 1 of T 2 is in the relation that f 1 ≃f O with the capacitor Cx filled with water and the output voltages Ei and Er are regulated by a variable resistor VR to satisfy the relation Ei> Er, and the output voltage Eo is produced in the amplifier A. This is regulated so as to assume a sufficient value to trigger the thyristor SCR. When the thyristor SCR is triggered, the element K is energized to close the contacts K1 and K2 and thereby energize the motor M while the microswitch MS2 is a closed and the valve operating solenoid SL also energized to open the valve. As the motor M is rotated to cause the cam-1 to actuate and open the microswitch MS1, the thyristor SCR is turned off to deenergize the element K and open the contacts K1 and K2, thus deenergizing the solenoid SL and closing the valve. Irrespective of the opening of the contact K1, the motor M continues its rotation because the microswitch MS2 is closed, but when the cam-2 actuates the switch MS2, this switch is opened to deenergize the motor M in preparation for a subsequent operation.
The above-described construction of the present invention results in the advantages described below.
Exhaust of the hygienically deleterious carrier vapor into the atmosphere is substantially completely avoided and this ensures safety during a mass production of copies.
The recovered carrier liquid is available for reuse, which is a great economical advantage.
Since most of the air used for the fixing-drying process is cyclically used, the rate of recovery of the carrier is higher than when such cyclical use of the air is not adopted, and the heat-exchange condenser 14 need not be of so great a capacity. Also, the air A5 exhausted into the atmosphere is so small in amount that the cooler 18 may be of small capacity.
Since the heat-exchange condenser 14 is of the flat type and the mist collector 15 is of the corona discharge type, the flow path resistance is much less than in a filter type collector using steel wool or like material, and thus the blower in the flow path may be of small size.
The air A3 once used to recover the carrier is heated in the heat-exchanger 14 1 and then used for the fixing-drying process to expedite such process, which means a thermal economy.
Further, the liquid containing carrier vapor from the developing station and from the fixing station can be recovered in the tank having the first and second partition walls and can be separated into carrier liquid and water due to their difference in specific gravity, whereafter the carrier liquid so separated can be returned to the developing tank for reuse. This leads to the provision of a highly economical device which permits reuse of the developing liquid. | In a copying machine, especially of the liquid development type, a developing liquid recovery device includes heating means for heating wet-developed copy mediums to dry and fix them, wherein developing liquid vapor is produced from the copy mediums. Condenser means is provided for cooling the developing liquid vapor by means of a heat exchanger to thereby form the vapor into mist. Mist collector means for electrically charging the mist-like developing liquid vapor collects the vapor in an electric field. Circulating means is provided for circulating an air flow through the heating means, the condenser means and the mist collector means in succession. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to British Patent Application Serial No. 1113963.1 filed Aug. 15, 2011, which is incorporated herein by reference in its entirety.
FIELD AND BACKGROUND OF THE INVENTION
[0002] This invention relates to electrochemical sensors for determining an analyte in a fluid. There are numerous circumstances in which it is desirable to detect, measure or monitor a constituent of a fluid. Electrochemical sensors may be used for this purpose and the electrochemistry may incorporate a redox-active species whose oxidation and/or reduction is monitored as a part of the analysis.
[0003] For instance to measure pH, WO 2005/066618 disclosed an electrochemical sensor in which the electrochemical cell contains two organic compounds which are pH-sensitive redox systems and a ferrocene compound as an internal reference which is not sensitive to pH. To measure sulfide, WO2001/063094 and WO2004/011929 described an approach in which electrochemistry is coupled through a mediator compound to sulfide which is the intended analyte. This mediator compound is present in an electrochemical cell which is exposed to the sulfide. Both in the presence and absence of the sulfide analyte, an electrochemical oxidation and reduction of the mediator compound can take place when appropriate electrical potential is applied to the electrodes. However, one of the redox reactions of the mediator compound can also be brought about through a chemical reaction with the sulfide, and when this takes place there is a measurable change to the electrochemistry. Ferrocene carboxylate and sulfonate were suggested as mediator compounds in Electroanalysis Vol. 18, pages 1658-63 (2006) and in Electrochimica Acta Vol. 52, pages 499-50 (2006). A number of ferrocene sulfonates for possible use in this way have been described in Journal of Organometallic Chemistry Vol. 692, pages 5173-82 (2007). Experimental work in this area has, however, generally been confined to laboratory experiments at ambient temperature.
[0004] An issue which can arise in connection with electrochemical analytical systems is the stability of the redox active species employed, in particular stability when exposed to elevated temperatures during use. Exposure to elevated temperature may, however, be unavoidable when using an electrochemical sensor to monitor an industrial process.
[0005] One circumstance where there is exposure to temperature arises when carrying out analysis of fluids encountered downhole in a wellbore. Analysis of downhole fluids can be an important aspect of determining the quality and economic value of a hydrocarbon formation and can be applied to save costs and increase production at many stages of oil and gas exploration and production. Some chemical species dissolved in water (for example, Cl − and Na + ) do not change their concentration when moved to the surface and information about their quantities may be obtained at the surface by analysis of downhole samples and in some cases surface samples of a flow. However, the state of chemical species, such as H + (pH=−log [concentration of H + ]), CO 2 , or H 2 S may change significantly while tripping to the surface. The change occurs mainly due to a difference in temperature and pressure between downhole and surface environment. In case of samples taken downhole, this change may also happen due to degassing of a sample (seal failure), mineral precipitation in a sampling bottle, and (especially in case of H 2 S)—a chemical reaction with the sampling chamber. It should be stressed that pH, H 2 S and CO 2 are among the most critical parameters for corrosion and scale assessment. Consequently it is of considerable importance to determine their downhole values and there have been proposals for analytical sensors to be used downhole even though this is a difficult environment for an analytical system.
[0006] Redox reactions of organic compounds solubilised in surfactant micelles have been examined, in particular for biochemical analyses carried out close to ambient temperature. One instance is Ryabov et al., J. Phys. Chem., Vol. 99, 14072 (1995) which reports voltammetry studies of ferrocene and alkyl-substituted ferrocenes in surfactants, in a biochemical context where the ferrocene redox system is coupled to glucose and glucose oxidase.
SUMMARY OF THE INVENTION
[0007] Broadly, we have now found that solubilisation with surfactant is a route to providing redox active species with better thermal stability so that they can be used for analytical procedures at temperatures which are elevated above ambient.
[0008] In a first aspect this invention provides an electrochemical sensor for an analyte, capable of use at a working temperature of at least 50° C., comprising a plurality of electrodes in contact with an electrolyte solution containing a redox-active species electrochemically convertible between reduced and oxidised forms wherein the electrolyte solution contains surfactant and at least one of these forms of the redox active species is present within surfactant micelles. This form of the redox active species may be solubilised by the surfactant micelles.
[0009] Embodiments of sensor may be used to measure pH generally as disclosed in WO 2005/066618 although with a redox active species entering surfactant micelles. In such a sensor the redox active species which is present within surfactant micelles may be a ferrocene compound as an internal reference which is not sensitive to pH. Embodiments of sensor may be used to measure sulfide using the approach described in WO2001/063094 and WO2004/011929 in which electrochemistry of a redox active species is coupled to sulfide which is the intended analyte. Here too, the redox active species which is present within surfactant micelles may be a ferrocene compound.
[0010] The redox active species may be a compound having a low water-solubility so that it could not be dissolved in water at a concentration giving an adequate electrochemical signal. Solubilization by surfactant then increases the concentration in solution and allows the compound to be used. We have observed good stability of such compounds when solubilised in surfactant micelles, outperforming stabilities shown by more soluble redox active compounds without surfactant present.
[0011] In a second aspect this invention provides a method of measuring concentration of an analyte, comprising: providing a plurality of electrodes in contact with an electrolyte solution containing the analyte and a redox-active species electrochemically convertible between reduced and oxidised forms wherein the electrolyte solution contains surfactant and at least one of these forms of the redox active species is present within surfactant micelles, and may be solubilised thereby; applying potential to the electrodes and observing current flow as voltage is varied, while the electrolyte solution is at a temperature of at least 50° C.
[0012] Electrochemical observation of the redox reaction is preferably carried out by voltammetry, although the stabilisation of a redox active species in accordance with this invention could also be used with other electrochemical techniques.
[0013] In some embodiments of this invention, the method may be used to measure analyte in a test fluid which is not itself the electrolyte in contact with the electrodes. This can be done by allowing analyte to migrate from the test fluid into the electrolyte. This may be done by bringing the electrolyte and a test fluid containing the analyte into contact with opposite sides of a barrier, which may be a membrane, which is permeable to the analyte so that analyte can migrate through the barrier. The method can then be used to measure the concentration of analyte in the electrolyte, which will also be an indirect measure of the analyte concentration in the test fluid.
[0014] We have observed that surfactant micelles enhance stability of a redox active species when exposed to elevated temperatures. In some embodiments of this invention a sensor and/or method are used at a working temperature which is at least 75° C. and possibly at least 100° C. or 125° C.
[0015] This invention may be employed in a diverse range of applications, including equipment for testing fluids at above-ambient temperatures the Earth's surface. However, an area of application which is of particular interest is in devices to be used downhole in a well for testing subterranean fluids. It is normal that temperatures prevailing downhole are higher than ambient temperature at the surface.
[0016] Thus, some embodiments of sensor may be incorporated in a downhole tool for measuring an analyte below ground. So in a third aspect this invention provides a downhole tool incorporating an electrochemical sensor for an analyte in a subterranean fluid, capable of use at a downhole temperature of at least 50° C., comprising an enclosure for an electrolyte solution, a plurality of electrodes in contact with an electrolyte solution in the enclosure and a barrier, permeable to the analyte, to separate the electrolyte solution from the subterranean fluid but allow analyte to migrate through the barrier into the electrolyte in the enclosure, wherein the electrolyte contains a redox-active species electrochemically convertible between reduced and oxidised forms and also contains surfactant and at least one of these forms of the redox active species is present within surfactant micelles (and may be solubilised thereby). A sensor or downhole tool embodying this invention may comprise, or be used together with, control means to apply varying potential to the electrodes and measure current flow through the electrolyte. This control means may record applied potential and current at each applied potential, and/or it may record the potential(s) at which current flow is at a maximum.
[0017] Downhole measurement tools for oilfield applications are known as such. An electro-chemical technique using a sensor in accordance with the present invention can be applied for example as part of a production logging tool or an open hole formation tester tool for use in a well drilled for oil or gas. In such a case, the invention may be used in providing a downhole real-time water sample validation or downhole pH or sulfide measurement which in turn can be used for predicting mineral scale and for corrosion assessment. Such tools may be devices lowered into a well by means of a cable, such as wireline or slickline, or may be tools carried into a well by coiled tubing, or even tools which are positioned downhole for a longer period.
[0018] Downhole measurement tools are also used in wells drilled to monitor groundwater or to access subterranean aquifers. A sensor in accordance with the invention can be utilised in such tools, notably in providing real time measurement of pH and/or oxygen content.
BRIEF SUMMARY OF THE DRAWINGS
[0019] FIG. 1 shows the results of cyclic voltammetry applied to a heat treated sample and a control, in Example 2;
[0020] FIG. 2 shows a plot of oxidative peak current against square root of scan rate;
[0021] FIGS. 3A and 3B illustrate electrochemical reaction coupled to reduction of bisulfide ion;
[0022] FIG. 4 shows a plot of peak current in cyclic voltammetry applied to a solutions containing increasing sulfide concentration;
[0023] FIG. 5 is a schematic representation of a wellbore tool which is positioned in a wellbore;
[0024] FIG. 6 is a schematic cross sectional view of the electrochemical sensor within the tool of FIG. 5 ; and
[0025] FIG. 7 shows the electrodes on one face of an electrode assembly within the sensor of FIG. 6 .
DETAILED DESCRIPTION
[0026] As set forth above, this invention utilises a redox active species and surfactant. These are used in an electrochemical sensor. The redox active species may, in some forms of this invention be a compound with a water solubility of not more than 0.5 mmole/liter at 25° C., possibly not more than 0.2 or 0.1 mmole/liter. In some forms of this invention the redox-active species comprises a metallocene, which may bear substituent groups on its organic rings. The redox-active species may comprise ferrocene which may bear substituent groups. More specifically, ferrocene may be substituted with at least one substituent group which reduces its water solubility relative to the water solubility of ferrocene itself (which has been reported as 4.25×10 −2 mmole/liter). Such a substituent group may possibly be an alkyl or alkenyl group and may be an alkyl group of 1 to 6 carbon atoms or an alkenyl group of 2 to 6 carbon atoms. Groups containing 3 to 6 carbon atoms may be straight chain or branched.
[0027] The redox-active species may be a molecule which undergoes a single oxidation and reduction. However, it is possible, within the scope of this invention to employ a molecule which undergoes more than one redox reaction or to employ a polymer or oligomer with a number of redox active sites in the same molecule.
[0028] The surfactant may be anionic, non-ionic, cationic or amphoteric or may comprise a mixture of surfactant types. Desirably the surfactant is chosen to solubilise the redox-active species within micelles. For ferrocene and water-insoluble substituted ferrocene compounds we have found that cationic surfactant is suitable.
[0029] The surfactant may comprise one or more cationic surfactants of general formula
[0000]
[0000] where R 1 is a saturated or unsaturated, linear or branched aliphatic chain of at least 10 carbon atoms; R 2 , R 3 and R 4 are each independently a linear or branched saturated aliphatic chain of 1 to 3 carbon atoms, preferably a CH 3 or a CH 2 CH 3 group, or a linear or branched saturated aliphatic chain of at least 1 to 3 carbon atoms with one or more of the hydrogen atoms replaced by a hydroxyl group, e.g. —CH 2 CH 2 OH (hydroxyethyl); or R 2 and R 3 may together be an alkylene chain of 4 to 6 carbon atoms so that N, R 2 and R 3 form an aliphatic ring; and X − is an anion such as a halide. R 1 may have up to 24 carbon atoms, such as from 12 to 18 carbon atoms and may be interrupted by an ether oxygen atom. Examples of such surfactants are dodecyltrimethylammonium bromide (DTAB) and cetyltrimethylammonium bromide (CTAB).
[0030] The surfactant may comprise one or more anionic surfactants. An anionic surfactant may incorporate an alkyl chain of at least 9 carbon atoms, possibly 12 to 18 carbon atoms and an ionic headgroup. Neutral and zwitterionic surfactants may also incorporate a hydrophobic alkyl chain of such length, with a polar or zwitterionic headgroup.
[0031] We have observed that surfactant micelles can usefully enhance thermal stability of ferrocene and derivatives, even up to 125° C. or 150° C., indicating that micelles containing ferrocene are intact up to such temperatures.
[0032] The redox reaction may be observed electrochemically by applying potential to the electrodes and observing current flow with sufficient time for reaction between the mediator compound and the analyte, for thereby enabling observation of the concentration of the analyte species present. More specifically, the application of potential may be carried out as cyclic voltammetry in which the potential applied to a working electrode is cycled over a sufficient range to bring about the oxidation and reduction reactions while recording the current flow as the potential is varied. Such cyclic voltammetry has been described and exemplified in Electroanalysis Vol. 12, page 1453 (2000), and in later documents, including WO2004/063743. The recorded current shows peaks at the potentials associated with the reduction and oxidation reactions.
[0033] Cyclic voltammetry is normally carried out using an electrochemical cell with three electrodes: a working electrode, a counter electrode and a reference electrode. A varying potential relative to the reference electrode is applied to the working electrode. Cyclic voltammetry is customarily performed with a potential which is varied linearly from a lower limit value to an upper limit value and then back again after which the cycle may be repeated. The potential changes sufficiently slowly that electrochemically oxidised mediator compound is able to come into contact with analyte within the electrolyte. Potential which changes in steps rather than continuously can possibly be employed as an alternative, provided the steps are long enough for steady-state conditions to be established before a subsequent step in potential. It is also possible that this variation in potential whilst recording current flow could be carried out over only a portion of the reduction and oxidation cycle. This would be classed as linear scan voltammetry.
[0034] The direct measurement from the procedure is the current flow as potential is applied. The values of particular interest are peak values of current flow together with the applied potentials at which these peaks of current occur. However, it is also possible for the data obtained throughout a cyclic voltammetry experiment to be used as input to a computer program for modelling the chemical processes which occur.
EXAMPLE 1
[0035] A number of experimental tests were carried out. Three substituted ferrocene derivatives were used: these were 1,1′-diethylferrocene and vinylferrocene, which are both solids, and t-butylferrocene which is a liquid. Saturated micelle solutions of each ferrocene derivative were prepared by adding the ferrocene derivative to a solution of 2 wt % DTAB in de-ionised water until the solution became saturated and a small undissolved excess of the ferrocene derivative could be seen. With the two solid compounds, the solution was then filtered through a 0.2 μm filter syringe device in order to remove the excess of solid material. In the case of t-butylferrocene which is a liquid, the aqueous surfactant solution was decanted off, leaving the excess of material at the bottom of the flask.
[0036] Saturated micelle solutions were each split into multiple samples which were then purged for 5 min with nitrogen in order to remove air. Some of these samples were placed in closed, pressure tight bottles and heated in an oven to 125° C. or 150 ° C. for 24 or 48 hours. Control samples were not heated but were kept in the dark for the same amounts of time.
[0037] After subjecting the samples to heat treatments in this way, voltammetry measurements were made using an electrochemical cell with three electrodes which were a working electrode (Boron Doped Diamond or Edged Plane Pyrolitic Graphite), a reference electrode (silver electrode) and a counter electrode (Platinum). Electrochemical measurements were recorded using an PGSTAT30 potentiostat (Ecochemie, Netherlands) using a scanning rate of 0.1V/second. The Boron Doped Diamond (BDD) working electrode was used for the samples treated for 24 hours. The Edged Plane Pyrolitic Graphite (EPPG) working electrode was used for the samples treated for 48 hours.
[0038] The oxidative peak current was recorded for each sample. The extent of destruction of the ferrocene compounds was calculated as
[0000]
%
degradation
=
Iref
-
Isol
Iref
*
100
%
[0000] where, Iref corresponds to the oxidative peak current obtained using a control sample and Isol corresponds to the oxidative peak current obtained using a heat treated sample.
[0039] All measurements were made in duplicate. The following results were obtained.
[0000]
1,1′-diethyl ferrocene
t-butyl ferrocene
vinyl ferrocene
current
degradation
current
degradation
current
degradation
Treatment
(μA)
(%)
(μA)
(%)
(μA)
(%)
24 hours at
21.72
27.13
10.52
room temp.
24 hours at 125° C.
22.93
0%
26.86
1%
10.29
2.2%
24 hours at 150° C.
21.73
0%
26.36
2%
9.29
11.7%
48 hours at
23.95
29.30
10.65
room temp.
48 hours at 125° C.
24.19
0%
29.21
0%
9.98
6.3%
48 hours at 150° C.
24.16
0%
27.6
5.8%
8.31
22%
EXAMPLE 2
[0040] The procedure of Example 1 was repeated using a solution of t-butylferrocene in 2 wt % DTAB in a pH7 phosphate buffer. FIG. 1 shows (as a solid line) the voltammogram obtained with a sample heated to 150° C. for 24 hours superimposed on the voltammogram obtained with a control sample (broken line). It will be seen that the curve obtained with the heat treated sample is almost indistinguishable from the control. The conclusion is that there was no observable degradation over 24 hours even at 150° C.
[0041] Voltammetry was carried out at a number of scan rates. FIG. 2 shows a plot of oxidative peak current against square root of scan rate. The plot is a straight line which is evidence that the oxidative and reductive processes are both diffusion controlled.
EXAMPLE 3
[0042] This example demonstrates the coupling of concentration to the voltammetric response of vinyl ferrocene in micellar solution.
[0043] A micellar solution of vinyl ferrocene in a solution of 2 wt % DTAB in deionised water was made as in Example 1 and subjected to 150° C. for 43 hours. A 0.05 molar solution of sodium sulphide in water was prepared. This solution was added by 20 μL or 40 μL increments to 10 mL of the micellar solution of vinyl ferrocene. After each addition, the voltammetric response was recorded as in Example 1 using a BDD electrode.
[0044] The observed voltammetric response is similar in form to voltammetry observed with ferrocene compounds in the presence of sulfide when surfactant is absent. It is consistent with the vinylferrocene undergoing an electrochemical oxidative process and the oxidized form being reduced back to vinylferrocene by reaction with bisulfide ion. A proposed mechanism for this is illustrated by FIGS. 3A and 3B . As shown at the left of FIG. 3A , vinylferrocene (vFc) is contained within surfactant micelles which have the cationic headgroups of surfactant molecules at their exterior. The vinylferrocene is oxidized electrochemically to the vinylferrocinium cation. It is energetically favorable for this cation to migrate out of the micelles into the aqueous solution as illustrated at the right of FIG. 3A . In solution, the vinylferrocinium cation is reduced back to vinylferrocene by reaction with HS − ion in the aqueous solution, as shown by FIG. 3B and the vinylferrocene then returns to the interior of a surfactant micelle.
[0045] FIG. 4 is a plot of oxidative peak current against hydrogen sulfide concentration. It can be seen that peak current increases linearly with sulfide concentration.
EXAMPLE 4
[0046] An experimental test, similar to that in Example 1 above, was carried out using the anionic surfactant sodium dodecyl sulfate and using t-butylferrocene as the ferrocene derivative. A saturated micelle solution of t-butylferrocene was prepared by adding the ferrocene derivative to a solution of 2 wt % DTAB in de-ionised water until the solution became saturated and a small undissolved excess of the t-butylferrocene could be seen. The solution was then filtered through a 0.2 μm filter syringe device.
[0047] The saturated micelle solution was split into several samples which were then purged for 5 min with nitrogen in order to remove air. Some of these samples were placed in closed, pressure tight bottles and heated in an oven to 125° C. or 150° C. for 30 hours. Control samples were not heated but were kept in the dark for the same amounts of time.
[0048] After subjecting the samples to heat treatments in this way, voltammetry measurements were made as in Example 1 using a BDD working electrode. The following results (mean of duplicate experiments) were obtained.
[0000]
Treatment
current (μA)
degradation (%)
30 hours at room temp.
52.7
30 hours at 125° C.
50.66
3.8%
30 hours at 150° C.
39.73
24.5%
Downhole Tools
[0049] FIGS. 5 to 7 illustrate equipment used to perform the method of the invention below ground, within a wellbore. The tool 10 comprises an elongate substantially cylindrical body which is suspended on a wireline 14 in the wellbore 16 , adjacent an earth formation 18 believed to contain recoverable hydrocarbons. The tool is provided with a radially projecting sampling probe 20 . The sampling probe 20 is placed into firm contact with the formation 18 by hydraulically operated rams 22 projecting radially from the tool on the opposite side from the sampling probe 20 and is connected to a conduit 26 within the tool. A pump 28 within the tool 10 can be used to draw a sample of the hydrocarbons into the conduit 26 . The pump 28 is controlled from the surface at the top of the wellbore via the wireline 14 and control circuitry (not shown) within the tool. The conduit 26 leads through an electrochemical sensor 30 located close to the sampling probe 20 .
[0050] The sensor 30 is shown rather schematically in cross section in FIGS. 6 and 7 . It may be constructed as described in greater detail in WO2004/063743 and/or WO2005/066618. The sensor 30 is generally cylindrical. A flowpath for the fluid whose sulfide content is to be determined extends through the sensor 30 and forms part of the conduit 26 . A gas permeable membrane 36 separates this flow path from an axial bore through the sensor, within which an electrode assembly 38 is located. This assembly 38 comprises an insulating body, having three electrodes on its face 40 shown in FIG. 7 , namely a working electrode 42 made from boron-doped diamond, a reference electrode 44 in the form of a silver dot coated with silver chloride or silver iodide, and a counter electrode 46 comprising a printed platinum track. The electrodes 42 , 44 , 46 are connected via respective electrical conductors molded into and extending axially through the body of the electrode assembly 38 to respective electrical leads 48 , which connect the sensor 30 to control circuitry 32 within the tool. The enclosed space 50 between the face 40 of the electrode assembly and the membrane 36 is filled with a polar electrolyte which may be an aqueous solution in which a ferrocene compound, which may be t-butylferrocene, vinylferrocene or diethylferrocene as discussed above, are present in micellar surfactant solution.
[0051] Once the tool is in place, fluid is drawn through the conduit 26 by the pump 28 . Hydrogen sulfide in the fluid can pass through the membrane 36 into the electrolyte in the space 50 . After a time for equilibrium to be reached, the control unit 32 (possibly on command received via the wireline 14 ) applies varying potential to the electrodes and meters the current flowing. This is done as cyclic voltammetry with a scan rate which is slow enough to allow time for reaction between the mediator compound and the sulfide which has entered the electrolyte. The current flowing and the applied potential may be communicated to the surface in real time via the wireline 14 or may be recorded until the tool is retrieved to the surface. | An electrochemical sensor measuring concentration of an analyte in a test fluid at 50° C. or above by voltammetry uses electrodes in contact with an electrolyte containing the analyte and a redox-active species electrochemically convertible between reduced and oxidised forms. At least one form of the redox active species is present within surfactant micelles. The surfactant micelles enhance thermal stability of the redox active species and may also solubilise a species with poor water solubility, such as t-butylferrocene. A downhole tool incorporating such a sensor comprises a barrier, permeable to the analyte, to separate the electrolyte from subterranean reservoir fluid, so that the sensor directly measures analyte which has passed through the barrier and thereby indirectly measures analyte in the test fluid. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for metallizing submicron contact holes in semiconductor bodies, in which metal is deposited in the submicron contact hole.
Such methods are increasingly necessary in semiconductor technology, since often a plurality of conductive layers, which are disposed with an increasing scale of integration in various planes, are used. Suitably structured, they serve as conductor tracks for electric currents. These tracks are insulated from one another by suitable nonconductive layers. If conductor tracks that are disposed in different planes are to be conductively connected to one another or to the Si substrate, then an opening (contact hole) must be structured in the intervening insulation layer. Sometimes, however, a direct connection is precluded for physical reasons. For instance, an n + -doped silicon substrate cannot be contacted directly with an AlSi (1%) conductor track. That would create a diode instead of an ohmic contact, since the silicon that precipitates out is p + - doped by aluminum. In such cases, an indirect connection must be made via an intermediate layer. Typically, these intermediate layers, which are intended to make an ohmic contact with the silicon, comprise titanium (Ti), titanium silicide (TiS x , where x≦2) or titanium/tungsten (TiW). A barrier layer is also necessary, which preferably comprises titanium nitride (TiN) or TiW. Both of these materials exhibit relatively high impedance, with a specific resistance of 70 to 150 μΩcm.
With increasing miniaturization of microelectronic components ("submicron technology"), the diameters of the connecting holes are becoming ever smaller, yet because at the same time better planarization of the insulation layers is necessary, they are also becoming ever deeper. For reasons of reliability and because of the trend to faster switching times and greater current densities, it is necessary that the connecting holes be metallized without shrink holes with a highly conductive material, while at the same time replicably low-impedance contacts to all the layer materials in question must also be assured.
As the hole aspect ratios continue to increase (i.e., the ratio between depth and diameter), this contact metallizing can no longer be done by deposition of the usual layer construction (such as Ti/TiN/W), since current sputtering methods do not allow conformal deposition for Ti/TiN and thus always leave behind a negative blank angle, which even with conformal tungsten CVD leads to shrink hole formation. If one considers that for a contact hole diameter of 0.3 μm, for instance, at least 50 nm of Ti and 80 nm of TiN must be deposited in order to achieve an adequate, cohesive layer even at the bottom of the contact holes, then all that remains for the low-impedance, current-carrying tungsten is a minimum residual diameter of contact hole of less than 0.1 μm. Shrink-hole-free filling of the hole is thus precluded. Moreover, this described process sequence is expensive and time-consuming.
In the known, conventional metallizing process (sputtering), one or more metal layers (such as AlSi or Ti/TiN/AlSiCu) are deposited by physical processes (such as sputtering or vapor deposition) and structures are created from them by suitable photographic and etching steps. Because of the poor edge coverage of these methods, this contact metallizing, even at aspect ratios of approximately 1, is feasible only with additional process steps (such as flaring or beveling of the upper half of the contact hole) and makes subsequent processes (such as planarization) more difficult. For metallizing in contact holes with aspect ratios >1 and at elevated current densities, it can no longer be used reliably. Further developments in sputtering technology, such as collimated sputtering (i.e., oriented deposition by means of suitable, for instance mechanical, apertures)--as described, for instance, in P. Burggraaf, Semiconductor International, Dec. 1990, p. 28--do produce thicker layers at the bottom of the contact hole than conventional processes, but also cause the resultant aspect ratios to increase still more. This is so because the thickness of the layer deposited on the horizontal insulator surface always exceeds the thickness of the layer at the bottom of the contact hole. Hence the demands for conformity and planarization in the ensuing processes only become more stringent.
Metallizing of contacts by full-surface CVD tungsten deposition (using WF 6 /H 2 ) and back-etching--described, for instance, in P. E. Riley and T. E. Clark, J. Electrochem. Soc. Vol. 138, No. 10 (1991), p. 3008--has progressed relatively far in industrial testing and application. However, it is a complicated and therefore expensive method, because is entails the following individual steps:
b1) sputtering of a contact layer (such as Ti) to produce a low-impedance contact zone at the boundary faces with silicon or aluminum.
b2) sputtering of a barrier layer (such TiN or TiW), to prevent the reactive WF 6 molecules from attacking the Ti, Al or Si layers.
b3) full-surface, conformal deposition of the CVD tungsten layer, followed by an etching step, with which the metal is removed from the horizontal insulator layers.
Because of the poor edge coverage of the two sputtering processes (b1 and b2) required, these layers have to be deposited ever thicker as the aspect ratio increases, to obtain a just barely adequate layer thickness in the relative zones of the contact holes and thus to assure the barrier function.
The geometric situation at the outset for the (actually conformal) tungsten deposition becomes appreciably less favorable; shrink-hole-free filling of the holes is no longer possible, and moreover as the hole diameter decreases further, the resultant volumetric proportion of the low-impedance tungsten metal in the contact metallization drops. Even if conformally deposited CVD contact and barrier layers are available, as described for instance in U.S. Pat. No. 5,478,780 to Koerner et al. (corresp. European Patent Application EP 90 106 139), a complicated and expensive method remains, which appears practicable, if at all, in various chambers of a multichamber high-vacuum system.
If some other metal (such as aluminum) or a metalloid (such as TiN) is used instead of tungsten for the contact metallization, which substances can in principle also be conformally deposited using CVD methods (see for instance in U.S. Pat. No. 5,478,780), then the above statement again applies, since a multilayer metallizing must again be employed for similar reasons. This statement is especially significant when CVD-TiN is used. While, in principle, the feasibility of filling with a CVD-TiN plug is described in I. J. Raaijmakers and A. Sherman, Proceedings of 7 th Int'l IEEE VLSI Multilevel Interconnection Conference, Santa Clara, Calif. 1990, nevertheless this method can be used solely for contacts in which beforehand, as in salicide (an abbreviation for self-aligned silicide) technology, the actual contact and transition zone was formed in a previous multistage process. The method described by Raaijmakers and Sherman cannot be used for contacts with polycrystalline and monocrystalline silicon (because of overly high transition resistances), nor can it be used to metallize via-holes (for the same reason and because of overly high process temperatures).
In the selective CVD of metals and silicides, the goal is that a certain highly conductive material grow selectively (that is, exclusively) on certain substrates to be contacted (such as Si, silicide or metal surfaces). If a suitable substrate for this purpose is present on the bottom of the connecting holes, then direct, shrink-hole-free filling of the holes is possible. In none of the methods named here explicitly or any other imaginable methods has it been possible until now to perform them in a permanently replicable way under production conditions, which is why these methods have not been used industrially.
Their major disadvantages are the following:
the necessity of replicable, efficient cleaning of the contact zones prior to the actual deposition, which becomes increasingly difficult as the aspect ratio of the connecting holes increases;
the massive boundary face reactions, in particular upon contact with silicon, that occur when certain aggressive chemicals such as WF 6 are used, and that lead to unacceptably high leakage currents in diodes and transistors;
the resultant narrow process window, caused for instance by ready, frequent "nonselective" deposition on insulator surfaces because of the nucleation seeds that are located there;
the variously deep connecting holes cannot be filled to the same extent (ideally as far as the upper edge of the insulator), or can be still filled only by means of other complicated provisions, since the filler material grows uniformly in the vertical direction from the contact bottom.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method for metallizing submicron contact holes in semi-conductor bodies, which overcomes the above-mentioned disadvantages of the heretofore-known methods of this general type and which is a reliable method that can be used without limitation in future technologies and that in particular can replace the methods described and named above but does not have their disadvantages.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method for metallizing submicron contact holes in semiconductor bodies, which comprises:
placing a semiconductor body in a CVD chamber; and
depositing metal in a submicron contact hole formed in the semiconductor body in a single CVD process inside the CVD chamber, the CVD process including a first step of depositing a titanium-rich layer (e.g. Ti, TiSi) and a second step of depositing a low-impedance TiSi 2 layer.
In accordance with a preferred mode of the invention, the step of depositing the TiSi 2 layer follows immediately after the step of depositing the titanium-rich layer, without interrupting a vacuum in the CVD chamber.
In other words, the objects of the invention are satisfied with a process in which the contact metallization is generated by means of a single highly conformal CVD process, with which both the contact layer and the low-impedance contact filler material can be deposited in a single CVD chamber. In particular, it is a method in which deposition takes place first from an organometallic titanium-rich layer (ideally Ti or TiSi, hereinafter called CVD-Ti). This is followed immediately thereupon in the same chamber, by joining together further reaction partners or by varying the deposition parameters, with the deposition of a conformal, low-impedance (i.e., 20-40 μΩcm) CVD titanium disilicide layer (CVD-TiSi 2 ). Its thickness depends on the remaining residual diameter of the connecting holes. To complete the metallization, a back-etching process can follow, with which the Ti/TiSi 2 "plugs" deposited on the horizontal insulator surfaces remain in the connecting hole. The subsequent wiring is effected as usual by applying and structuring known low-impedance materials, such as AlSi or TiN/AlSiCu, for instance by sputtering. In contact holes with diameters ≦0.4 μm, the back-etching is unnecessary, since the deposited Ti/TiSi x layer thickness is approximately 0.2. TiN/AlSiCu is sputtered onto it, for instance, and the Ti/TiSi x /TiN/AlSiCu lamination package is structured as before in a single operation. As an alternative, instead of the back-etching process, in planes where only short metal connections have to be made, the CVD-Ti/TiSi 2 layer can be structured at the same time with suitable lithographic/etching methods, so that the contact metallization and the conductor track are formed in a single operation.
Optionally, the method of the invention can be
preceded by: cleaning the contact zones (either wet chemically or dry, as needed and depending on the substrate with a preferred chemical or physical component, if possible preferably in situ in multichamber systems, as described in U.S. Pat. No. 5,478,780 or German Patent Application DE-A 41 32 561);
followed by: an annealing step between 450° C. and 800° C., preferably by means of RTP or in a vertical furnace, in order to assure a homogeneous, complete siliciding reaction at the boundary face between Si and CVD-Ti, as described in further detail for instance in U.S. Pat. No. 5,478,780.
The above objects are attained with a process according to the invention in which, inter alia, the excitation of coreactants by coupled-in microwave energy is performed, which occurs spatially separately from the deposition reaction and creates reactive, neutral particles, and these particles are then delivered to the actual reactor (CVD system; this method is called "remote-plasma" CVD). The basic principle of microwave excitation and the method thereof are described in German patent application DE-A 41 32 560.
The method of the invention offers the following advantages in particular:
Because of the complete lack of nonconformal sputtered layers and the use of a single conformal CVD process, no technological limit to its utility--from a geometric standpoint--is now apparent. This effect is promoted by what--in comparison with CVD tungsten, for instance--is a substantially smoother layer surface (roughness of the CVD-TiSi 2 <50 nm). In particular, the contact metallizing can readily be combined with modern methods for global planarization, such as CMP (chemical mechanical polishing), which necessarily lead to connecting holes with a high aspect ratio.
Since only CVD-Ti and CVD-TiSi 2 are generated quasi-continuously in one operation and in one CVD chamber, fewer contact zones result, and consequently lower transition resistances, which overall leads to lower contact resistances.
In particular, the introductory partial step of highly conformal deposition of CVD-Ti assures a low-impedance contact resistance, since unlike the situation with physical deposition, enough Ti metal can be brought to the contact zone even in contacts with a high aspect ratio. Because of its high affinity with oxygen, this metal bonds with deposit oxide that might be present at the surface of the silicon or aluminum and thus assures low-impedance contacting.
Since the contact metallizing is generated virtually in a single step and in a single chamber, the method proves, especially in comparison with known methods, to be especially economical and production-friendly. Another decisive reason for its being production-friendly is that the risks inimical to production that are associated with the selective CVD methods, for instance (such as excessive boundary face reactions, loss of selectivity, uneven filling of unequally deep connecting holes) do not occur, because of the selected chemistry and the selected method.
The contact metallizing according to the invention enables more-homogeneous distribution of the current over the entire contact volume and hence over the contact surface area as well, since only one material is used (contrast with Ti/TiN/Al or /W, for instance). Hence the current-carrying capacity and the reliability of the contact metallizing is increased substantially in comparison with the prior art methods, especially when the hole diameters are small and the current densities are high.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method for metallizing submicron contact holes in semiconductor bodies, it is nevertheless not intended to be limited to the details shown, since various modifications and procedural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific exemplary embodiments.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The method of the invention can be largely performed with commercially available CVD reactors. Especially suitable reactors are the CVD reactors described in in the aforementioned DE-A 41 32 560 and U.S. Pat. No. 5,478,780.
The process parameters in each case are chosen such that the depositions occur within the boundaries of surface-controlled kinetics, so that ideal conformal layers are obtained.
I. CVD-Titanium Deposition:
Optionally, the deposition of CVD-titanium can be preceded by a so-called sputtering etching step (low-energy Ar ions; 100 eV) or a so-called in-situ precleaning step, as described in further detail in U.S. Pat. No. 5,478,780, for instance.
The following classes of substances can be used, either directly or in combination with microwave-activated coreactants, for titanium CVD depositions as an example, but not exclusively:
1. Titanium tetrachloride=TiCl 4
2. Tetrakisdialkylamino titanium=Ti[NR 2 ] 4 where R=methyl, ethyl . . .
3. η 7 -Cycloheptatrienyl-η 5 -cyclopentadienyl titanium (0) (C 7 H 7 )Ti(C 5 H 5 ) ##STR1## 4. η 8 -Cyclooctatestraenyl-η 5 -cyclopentadienyl titanium (III) (C 8 H 8 )Ti(C 5 H 5 ) ##STR2## 5. Dimeric compounds, such as [(R,R') 2 Ti (SiH 2 )] 2 e.g. with R, R'=alkyl, aryl, C 5 H 5 , NR 2 where R=H, CH 3 , C 2 H 5 , . . . ##STR3## 6. Compounds of type Ti[(CH 2 ) 2 (NR) 2 ] 2 with R=H, CH 3 , C 2 H 5 , Si (CH 3 ) 3 , . . . such as ##STR4## SiH 4 , Si 2 H 6 and/or H 2 can thereby be used (if necessary) as reducing agents.
All the gases involved may be activated selectively by means of the external microwave excitation and delivered separately to the reactor. The agents SiH 4 or Si 2 H 6 and/or the titanium compound may, however, also be admixed in an unexcited state prior to the so-called shower head electrode.
Reaction equation: ##STR5## where * indicates "excited". II. CVD-Titanium Silicide Deposition:
Optionally, the deposition of CVD-titanium can be preceded by a so-called sputtering etching step (low-energy Ar ions; 100 eV) or a so-called in-situ precleaning step.
In principle the same classes of substances as listed in I above can be used, either directly or in combination with microwave--activated coreactants, for the titanium disilicide CVD deposition:
Reaction equation: ##STR6## where * indicates "excited". Process parameters:
______________________________________Excitation: Microwave power 300-850 W H.sub.2 flow rate 0-500 sccm Ar or He flow 20-150 sccm Pressure 10.sup.-2 -10.sup.-1 PaDeposition: Process temperature 200 -550° C. Evaporator temperature 20-140° C. Carrier gas Ar, He, H.sub.2 Carrier gas flow 0-100 sccm (SiH.sub.4 or Si.sub.2 H.sub.6 flow 0-200 sccm) (RF power 200-800 W) (Electrode spacing 0.3 to 2.5 cm)______________________________________
III. Etching Process:
The CVD Ti/TiSi 2 layer can be either back-etched by the process described below far enough that Ti/T 2 plugs remain only in the connecting holes or can be structured with the usual photographic etching steps:
Alternatively, instead of the back-etching step, the TiSi 2 located on the horizontal surface can also be removed ("ground back") by a CMP (chemical mechanical polishing) step.
III.1. Back-Etching Process:
The back-etching process preferably comprises a "bulk etching step", with which about 90% of the layer deposited on the horizontal insulator surface is etched isotropically. The corresponding plug is then produced in a second, more strongly anisotropic "overetching step", which exhibits strong selectivity to the insulator layer and a minimal loading effect.
______________________________________ Anisotropic Process Parameters: Bulk Etching Overetch Structuring______________________________________Cl.sub.2 (sccm) 30-200 10-150 30-200 Hbr (sccm) 5-100 5-50 5-100 Ar (sccm) 10-100 10-100 10-100 N.sub.2 (sccm) -- -- 0-50 Pressure (mTORR) 100-300 5-260 100-300 Power (watts) 200-500 50-400 200-500 Cathode temperature (° C.) 10-50 10-50 10-50 Magnetic field (Gauss) 0-150 0-150 0-150______________________________________
The following publications provide additional information with regard to the above-described process, and they are herewith incorporated by reference:
1. P. E. Riley, T. E. Clark J. Electrochem. Soc. Vol. 138, No. 10 (1991), p. 3008
2. U.S. Pat. No. 5,478,780
3. I. J. Raaijmakers and A. Sherman Proceedings 7 th Int'l IEEE VLSI Multilevel Interconnection Conference, Santa Clara, Calif. 1990
4. E. K. Broadbent J. Vac. Sci. Technol. B5 (6), 1987, p. 1661
5. T. Amazawa, H. Nakamura and Y. Aita Technical Digest IEEE International Electron Device Meeting, 1987, p. 217
6. C. Bernard, R. Madar and Y. Paulea Solid State Technology, February 1989, p. 79
7. G. N. Parson, Appl. Phys. Lett. 59 (20), 1991, p. 2546
8. J. F. Mission Brodaz et al. Proc. 6 th European Conference on CVD, R. Porat, Ed. 1987, p. 280
9. A. Bouteville, A. Royer and J. C. Remy J. Electrochem. Soc., Vol. 134, No. 8, 1987, p. 2080
10. DE-A-4132560
11. B. Aylett Mat. Res. Soc. Symp. Proc., Vol. 131, 1989
12. B. Aylett Transformation of organometallics into common and exotic material: design and activation, R. M. Laine ed., M. Nijhoff publ., 1988, pp. 165-177
13. M. J. Aylett J. Organometallic Chem. Lib., 9, 327, 1978
14. DE-A-4132561 H. Steinhardt, Fa. SECON, Wien, K, Hieber, E. Buβmann, SIEMENS AG, Munchen
15. P. Burggraaf Semiconductor International, December 1990, p. 28. | Submicron contact holes in semiconductor bodies are metalized in a single operation. A titanium-rich layer is first deposited, which is followed by a low-resistance TiSi 2 layer. The two layers are thus deposited in one contiguous CVD process inside a single CVD chamber. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to techniques for automatic execution of operations of multiplication, i.e., to techniques for generating, starting from at least one first binary digital signal and one second binary digital signal representing respective factors to be multiplied together, an output signal representing the product of these factors.
The invention has been developed with particular attention paid to its possible application to the multiplication of floating-point real numbers, with a view to its use in devices such as, for example, low-power-consumption electronic devices, in particular portable wireless devices.
2. Description of the Related Art
The arithmetic logic units (ALUs) of electronic devices traditionally comprise multiplication units for floating-point numbers. These are typically circuits which, starting from a first binary digital signal and a second binary digital signal representing respective factors to be multiplied, expressed in floating-point format, generate an output signal, which is also expressed in floating-point format and represents the product of the factors multiplied together.
For reasons of clarity and simplicity of illustration, in the remainder of the present description, both in discussing the solutions of the known art and in presenting possible embodiments of the invention, exclusive reference will be made to the multiplication of two factors. What has been said with reference to the multiplication of two factors extends, however, also to multiplications involving more factors.
In the framework of units for floating-point multiplication, by far the most widely used representation is the one envisaged by the standard IEEE754. According to this standard, real numbers are expressed via a binary representation of the fractional part or mantissa and of the exponent in powers of a base 2, according to the general formula:
f = ∑ i = - K K a i · 2 i a i ∈ { 0 , 1 } ( 1 )
where f is the real number to be represented, and K is the number of bits available for the representation.
A number represented in the floating-point form comprises three basic components: sign SGN, exponent E, and mantissa M.
According to the IEEE754 standard, it is possible to adopt a representation in single precision of the real number f, using: a number NS, equal to one, of sign bits SGN; a number NE, equal to 8, of exponent bits E; and a number NM equal to 23, of mantissa bits M.
Alternatively, it is possible to adopt a double-precision representation, where NS has the value 1, NE has the value 11, and NM has the value 52.
In this way, the mantissa M and the exponent E are represented by means of two respective integer values.
The sign bit SGN is always just one and assumes the value “0” to indicate a positive number, and the value “1” to indicate a negative number.
For the exponent E there is adopted a representation that envisages adding a fixed value, referred to as “bias”, to a base exponent exp. For example, if the base exponent has the value 73 and the bias value is 127, the encoded exponent E has the value 200.
The bias value is fixed and assumes the value 127 in single precision and the value 1023 in double precision. The adoption of the fixed bias value means that the lowest number will be represented in the exponent by a series of zeroes in binary form, whilst the highest one will be represented by a series of ones.
According to the IEEE754 standard, there is moreover adopted a so-called normalized representation of the real number f according to the formula:
f=(− 1) SGN *(1.0+M)*2 (E-bias) (2)
The convention on normalized numbers envisages, that is, that the first bit upstream of the point will always have the value one, and all the bits downstream of the point will be used for representing the mantissa M and will increase the precision.
Summing up, the rules for encoding a real number according to the IEEE754 standard are the following:
the sign bit SGN has the value “0,” for indicating a positive number and “1” for indicating a negative number; the base of the exponent E is 2; the field of the exponent E is obtained by adding the value of the exponent exp to a fixed bias value; and the first bit of the mantissa M is always one and hence is not represented explicitly.
The IEEE754 standard moreover adopts a representation, termed “denormalized representation”, when the real number f has exponent zero and mantissa other than zero. This notation is used for representing the real numbers very close to zero.
f =(−1) SGN *0.M*2 (-bias- 1) (3)
In this case, that is, there is not, hence, a one set before the mantissa M.
In brief, the IEEE754 standard envisages the use of two encodings:
a denormalized encoding for numbers very close to zero; and a normalized encoding in all the other cases.
This double representation calls for adding the bias in the exponent in order to distinguish the two cases (denormalized if EXP=0)
1. xxxxx . . . x normalized form; and 0. xxxxx . . . x denormalized form, which, under due analysis, represents the weak point in the perspective of a low power-consumption multiplier device.
The reason for this is that, in the denormalized case, there does not exist the guarantee that the product of the mantissas is made between two “big” numbers.
It will moreover be appreciated that the term “normalized” is applied because the real number with the most significant bit is normalized to one.
With the above rules, by encoding the real number f using a sign bit NS, a number NM of bits for the mantissa and a number NE of bits for the field of the exponent, we obtain, for example, as regards the range of variation, a maximum positive value Nmax:
N
Max
=
∑
i
=
0
NM
2
-
i
·
2
bias
(
4
)
Other characteristics of the encoding according to the IEEE754 standard regard the zeroes, which is not represented in normalized form, on account of the presence of the one as first mantissa bit. The zero is expressed with a special value with a field of the exponent zero and mantissa zero.
The IEEE754 standard moreover envisages specific encodings to indicate infinite values, indeterminate values and errors (NaN codes).
In order to make a multiplication between floating-point numbers defined in mantissa M and exponent E according to the encoding envisaged by the IEEE754 standard, there is hence necessary an operation of addition on the exponents of the operands, whilst there is required an operation of product for their mantissas.
The multiplication between real numbers expressed according to the IEEE754 standard, in particular with reference to the number of bits necessary for the exponent and mantissa, hence requires—for a “canonical” embodiment—the use of arithmetic logic units with characteristics of complexity and power absorption that are far from compatible with the conditions of use typical of portable electronic devices, such as mobile phones and PDAs.
In order to deal with the problem, a possible solution could be a reduction of the number of bits used for representing the exponent and, in particular, for representing the mantissa. This approach would lead, however, to an undesirable loss of precision in obtaining the result.
It is moreover necessary to consider the fact that, for the calculation of floating-point products, there are normally used integer multiplier circuits, such as partial-sum multiplier circuits. These multiplier circuits are based upon the calculation of the partial sums of partial products calculated by a logic circuit based upon a matrix, such as the one represented in FIG. 1 .
In the specific case of 4-bit integers, such a matrix logic circuit consists of a matrix of AND logic gates, which receives on the rows the bits A 0 . . . A 3 of the mantissa of an operand and on the columns the bits B 0 . . . B 3 of the mantissa of the other operand, supplying addenda of partial products P 1 . . . P 16 , corresponding to the product of bits A 3 B 0 . . . A 0 B 3 , ordered according to rows and columns. Subsequently, there are performed partial sums of the partial sums on the rows of the matrix, on the columns or else on the diagonal.
In this case, the area occupied by the circuit and its power consumption depend basically upon the number of the rows or of the columns that it requires.
Alternatively, in multiplication units there is also used the so-called Booth algorithm for multiplication.
An integer Y can be expressed as a sum of powers of a base 2 with coefficients y i :
Y=y 0 2 m +y 1 2 m−1 +y 2 2 m−2 + . . . +y m−1 2+y m (5)
It hence follows that a product U between a multiplicand number X and the integer Y can be expressed as:
U
=
XY
=
∑
i
=
0
m
(
y
i
+
1
-
y
i
)
·
X
·
2
m
-
1
(
6
)
A multiplication can hence be made by getting the arithmetic logic unit to perform repeated operations of addition and shift on the multiplicand X, as indicated in Table 1 appearing below, which represents the rules of the so-called Booth algorithm 1:
TABLE 1
Arithmetic
Y i+1
y i
operation
0
0
0
0
1
−X
1
0
X
1
1
0
The adoption of the Booth algorithm, albeit advantageous in so far as it leads to a sensible increase in the processing speed, does not lead to an economy in terms of power absorbed by the circuits and in terms of area occupied thereby.
BRIEF SUMMARY OF THE INVENTION
An embodiment of the present invention provides a technique for the multiplication of floating-point real numbers that will enable a reduction in the power-consumption levels and overall dimensions of the circuit without thereby degrading appreciably the performance in terms of error rate and processing speed.
Embodiments of the invention are directed to a method and a corresponding device, as well as to the corresponding computer-program product which can be directly loaded into the memory of a digital processor and comprises software code portions for implerhenting the method according to the invention when the product is run on a computer.
Basically, one solution according to the invention envisages the real number being normalized to 0.5, by resorting to a “completely normalized” representation because there are no other encodings in the representation (for example denormalized numbers in the case of the IEEE754 standard).
An embodiment of the invention, which can be implemented, for example, in arithmetic logic units of processors for portable wireless electronic devices, envisages adopting a representation of the mantissa and of the exponent that uses a smaller number of bits, as well as adopting a non-exact multiplication method that makes use of the particular representation of mantissa and exponent for rounding the results, at the same time maintaining an error rate (understood as margin of imprecision in the determination of the result of the multiplication) sufficient for ensuring good operation of the devices in which the corresponding solution is applied. These devices may be, for example, decoders, such as decoders for Viterbi decoding (SOV) of convolutional codes and/or filters of various nature, such as, for example, filters of an autoregressive type for noise filtering.
The solution described herein may be applied also to the Booth algorithm (or, rather, algorithms) provided that:
the mantissa and sign are encoded in twos complement in a single field; the Booth algorithm works, in fact, with integers with sign in twos complement, whilst the IEEE754 standard and the solution described herein encode in modulus and sign on two distinct fields; a variant of the Booth algorithm is used in the case of integers without sign.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, purely by way of non-limiting example, with reference to the annexed drawings, in which:
FIG. 1 , corresponding to the known art, has already been described previously;
FIG. 2 represents an operation of multiplication according to a possible embodiment of the invention;
FIG. 3 represents a first method of rounding that can be applied in the context of the invention;
FIG. 4 represents a second method of rounding that can be applied in the context of the invention;
FIG. 5 represents the block diagram of a device that implements the method according to the invention;
FIG. 6 represents a detail of the device of FIG. 5 ;
FIG. 7 represents the block diagram of a circuit that can be associated to the device of FIG. 5 ;
FIGS. 8 to 12 represent in greater detail the device of FIG. 5 ;
FIGS. 13 to 15 and 19 represent in greater detail a device that implements the method exemplified in FIG. 3 ;
FIGS. 16 to 18 represent in greater detail a device that implements the method exemplified in FIG. 4 ;
FIGS. 20 to 25 represent conversion encoding circuits that can be associated to the devices illustrated in FIGS. 5 to 19 ; and
FIGS. 26 and 27 represent diagrams corresponding to operation of devices that implement the method according to the invention.
FIG. 28 represents an operation of multiplication according to a further possible embodiment of the invention;
FIG. 29 represents a rounding method that can be applied in the embodiment of FIG. 28 ;
FIG. 30 represents a schematic diagram of a circuit implementation of the embodiment of FIG. 28 ;
FIG. 31 represents a diagram of the error introduced by the embodiments of FIGS. 2 and 28 .
DETAILED DESCRIPTION OF THE INVENTION
Basically, the technique described herein envisages use of a binary encoding of real numbers different from the one envisaged by the standard IEEE754.
Said different binary encoding of real numbers envisages representing a real number, its encoded form being in what follows designated by the reference FN, using a number MA of bits for a mantissa or fractional part MN and a number EA of bits for an exponent EN, in a form that, as has been seen, is “completely normalized”, since it envisages that the real number will be normalized to 0.5.
In the solution described herein:
the exponent EN is encoded in twos complement expressed in base two; the first bit of the mantissa MN, i.e., the bit with weight 2 −1 , has the always value one; in this way, the encoded real number FN has always a mantissa MN that assumes values comprised between 0.5 and 1, whilst the residual value is transferred onto the exponent EN.
The mantissa MN defined herein can be expressed as:
MN
=
∑
i
=
1
MA
b
i
·
2
-
i
where
b
1
=
1
(
7
)
Hence, according to this formalism, we will have, for example:
2 is converted into
0.5 and 2 2
3.1 is converted into
0.775 and 2 2
0.7 is converted into
0.7 and 2 0
4.9 is converted into
0.6125 and 2 3
The coefficient b 1 —set to the value one in the mantissa MN—is used, even though it is redundant, for representing the value zero.
Other particular values in the method according to the invention are the following:
Zero: mantissa MN and exponent EN zero;
Infinite: the bits of mantissa MN and of exponent EN are equal to one; NaN: mantissa equal to zero and exponent other than zero.
The technique described herein is based upon the observation that multiplication according to the IEEE754 standard entails multiplying the mantissa via exact integer product, subsequently using rounding techniques to correct the result represented by the most significant bits of the integer product.
The technique described herein defines, instead, the mantissa MN in such a way that it will always assume “high” values, in particular comprised between 0.5 and 1 so that the product of mantissas can be calculated via an operation of multiplication based upon a non-exact algorithm, which uses for the calculation the partial products such as to determine the most significant part of the resulting mantissa or product mantissa. This brings about an operation of truncation with respect to the use of an exact algorithm. Since the value of the mantissa is always high as compared to the truncated least significant part of the product, it is possible to obtain low error rates.
To process the addenda of the partial products thus selected there can then be used traditional partial-sum architectures, such as the one described with reference to FIG. 1 or architectures implementing the Booth algorithm. In fact, both types of architectures require performing a sum on the partial products.
If the number MA of bits of the mantissa MN is eight, the worst case is the multiplication of 128 by 128: in fact the mantissa MN has the value 0.5. The multiplication of integers produces a number of bits equal to 2×MA, but, according to the technique illustrated herein, just the top part or most significant part of the quantity that said bits represent is of interest.
A further aspect of the solution illustrated herein therefore consists in considering for the operation of multiplication only the bits of the partial products contained in a window W of pre-set amplitude.
FIG. 2 represents an operation of multiplication of a first 8-bit mantissa MN 1 (the multiplicand) with a second 8-bit mantissa MN 2 (multiplier), which will be assumed as being received in corresponding registers.
The operation of binary multiplication entails multiplying the mantissa MN 1 separately for each of the bits of the mantissa MN 2 , so determining eight multiples of the mantissa MN 1 , referred to as partial products, which are then appropriately arranged in columns and summed up to obtain a resulting mantissa MN, which is the product of the mantissas MN 1 and MN 2 . Each partial product consists of addenda, each of which is the product of just two bits. There are eight addenda per partial product in the case represented. The addenda constitute a set of addenda P.
The resulting mantissa MN is made up of fifteen bits.
The technique described herein requires only eight bits, according to the representation chosen. The eight bits of the resulting mantissa MN are calculated via the partial sums of the addenda of the set P contained in the window W alone, the said window W having a predetermined amplitude. This amplitude is evaluated in terms of the number of bits of the significant part that it is desired to preserve, in'the case of FIG. 2 , the amplitude of the window W is seven bits and the eighth bit is the one furthest to the left, obtained as the carry of the previous sums: see, in this connection, also the unit 22 that produces said bit operating only on the carries of the previous sums—illustrated in FIG. 9 , which will be described in what follows.
The above procedure is irrespective of the criterion according to which the partial products are summed. Hence, the method can be applied to methods based upon the partial sums of the partial products, as well as to the calculation of the coefficients according to the Booth algorithm.
A further aspect of the solution described herein is linked to the adoption of specific measures for rounding the truncation error of the integer product referred to the mantissa.
In particular, illustrated herein are a method of rounding by columns and a method of rounding by rows.
FIG. 3 represents the method of rounding by columns of the truncation error on an operation of multiplication, illustrated in a similar way as for FIG. 2 , i.e., showing the set of partial products.
According to the method of rounding by columns, there is performed a bit-by-bit OR operation referred to each of the columns in a window C outside the window W used for selecting the addenda of the set P to be used for the partial sums. If the result of said bit-by-bit OR operation on the addenda of each column belonging to the window C is one, one is added to the final sum.
As may be seen, in FIG. 3 , the window C comprises only the two columns corresponding to the most significant bits of the part that is truncated, i.e., the two columns immediately adjacent to the ones contained in the window W.
FIG. 4 represents the method of rounding by rows of the truncation error.
According to the method of rounding by rows, there is performed a bit-by-bit AND operation referred to each row included in the window RW outside the window W used for selecting the addenda P to be used for the partial sums. If the generic row has all values one, one is added to the adder pertaining to that row.
It will therefore be appreciated that rounding by rows is irrespective of how the partial products are summed up (i.e., whether by rows—unit 86 —or by columns—unit 87 ). Again, not necessarily must the window where rounding is carried out, RW, which is external to the window W, be complementary to W, i.e., such that (W)U(RW) is equal to the totality of the partial products.
The technique described herein can hence assume at least four forms:
multiplication method with partial sums of the partial products without rounding; multiplication method with partial sums of the partial products associated to the method of rounding by columns; multiplication method with partial sums of the partial products associated to the method of rounding by rows; and multiplication method with treatment of the partial products according to a Booth algorithm.
The multiplication method that uses partial sums of the partial products can in turn perform said operation of partial sum by rows or by columns, the partial sum by rows being the fastest.
Appearing below in Table 2 are values corresponding to the encumbrance, power consumption, error rate and speed evaluated in terms of WNS (Worst Negative Slack) of the various possible architectures of the multiplication units according to the invention considered previously.
TABLE 2
Area
Consumption
Max
WNS
(μm 3 )
(nW)
Err %
(ns)
Sum by columns without
1448
17.51
5.03
1.11
rounding
Sum by columns with rounding by
1662
33.75
4.2
1.02
columns
Sum by columns with rounding by
2073
40.7
4.01
1.17
rows
Sum by rows without rounding
1682
28.29
5.03
0.39
Sum by rows with rounding by
1984
40.81
4.2
0.38
columns
Sum by rows with rounding by
2134
31.18
4.01
0.39
rows
Booth 2 (comparison example)
6182
169.35
2.75
0.05
As may be seen, the technique proposed herein is not the best in terms of speed. The possible use in an architecture of a pipeline type, which enables calculation of more than one product for each cycle, enables an improvement of performance in terms of speed for the applications in which this factor is particularly significant.
FIG. 5 illustrates a first example of a multiplication device implementing one embodiment of the method for multiplication of floating-point numbers according to the invention.
If FN 1 is a first real floating-point number with sign SN 1 , mantissa MN 1 and exponent EN 1 encoded according to the technique described herein, and FN 2 is a second floating-point number with sign SN 2 , mantissa MN 2 and exponent EN 2 encoded according to the technique described herein, the reference number 1000 designates a multiplication unit, which receives at its inputs the numbers FN 1 and FN 2 .
The multiplication unit 1000 is made up of a number of modules, namely:
designated by the reference number 1001 is a module that receives at its inputs the sign bits SN 1 and SN 2 and supplies at output the resulting sign bit SN; designated by the reference number 1002 is a module that receives at its inputs the exponents EN 1 and EN 2 and supplies at output the resulting exponent EN; designated by the reference 100 is a multiplication module that receives at its inputs the mantissas MN 1 and MN 2 and supplies at output the resulting mantissa MN, i.e., the product, by applying the method described herein; the resulting mantissa MN is constituted by corrected partial sums R 7 . . . R 0 , the meaning of which will be described in greater detail in what follows, in particular with reference to FIG. 10 .
The module 1001 simply performs a XOR operation on the sign bits SN 1 and SN 2 .
The module 1002 comprises a simple adder that performs the following operations:
EN1+EN2 if S7=1
EN1+EN2− 1 if S7=0
where S 7 , as will be specified in greater detail in what follows, is the value of the most significant bit of a set of partial sums S 1 . . . S 7 and is supplied by the module 100 to the module 1002 .
FIG. 6 represents in detail the diagram of operation of the adder that implements the module 1002 . Indicated by EN 10 . . . EN 15 are the bits of the exponent EN 1 and by EN 20 . . . EN 25 are the bits of the exponent EN 2 . As may be noted, the bit S 7 is sent negated to the module 1002 so as to be used for subtracting one from the sum of EN 1 and EN 2 .
A further exception module 1100 can be associated to the multiplication unit 1000 represented in FIG. 5 in order to solve the cases in which the operand is an infinite value or a NaN value.
The exception module 1100 is connected in parallel to the unit 1000 , as shown in FIG. 7 , and their outputs are sent to a multiplexer MUX 1 , which selects the output according to the value of an exception signal EXC supplies by the exception module 1100 itself.
The exception module 1100 is obtained via a combinatorial network, which verifies whether the numbers FN 1 and FN 2 are infinite values or NaN.
FIG. 12 represents the block diagram of a multiplication module 100 , in which designated by 10 is a block representing a matrix logic circuit for generating partial products, which receives at input bits A 7 . . . A 1 of the mantissa MN 1 and bits B 1 . . . B 7 of the mantissa MN 2 and supplies at output, to a block 30 , addenda of the partial products P 1 . . . P 28 .
The block 30 is designed to perform operations of partial sum on the addenda of the partial products P 1 . . . P 28 and supplies at output partial sums S 0 . . . S 7 to a block 40 , which is designed to perform a correction step of the partial sums S 7 . . . S 0 and supplies corrected partial sums R 0 . . . R 7 .
FIG. 8 represents the matrix logic circuit 10 , which is designed to generate the addenda of the partial products P 1 . . . P 28 .
The circuit 10 receives at input the bits A 7 . . . A 1 of the mantissa MN 1 on the columns and the bits B 7 . . . B 1 of the mantissa MN 2 on the rows. Columns and rows of the circuit 10 form the inputs of AND gates that supply the products P 1 . . . P 28 .
Since the technique described herein envisages using for calculation a subset of the set P of addenda of the partial products contained in a window W of predetermined amplitude and corresponding to the most significant part of the product, the circuit 10 conceived with an already conveniently reduced structure, i.e., provided just with the gates necessary for calculating the addenda of the partial products comprised in the subset identified by said window W.
It may be readily verified that the diagonals of the a matrix of the circuit 10 correspond to the columns comprised in the window W in the representation of the operation of multiplication of FIGS. 2 , 3 and 4 .
FIG. 9 represents the block 30 , which is basically formed by a parallel adder structure comprising a plurality of adders designated by the references 22 to 27 for performing the sum by columns of the addenda of the partial products P 1 . . . P 28 supplied by the circuit 10 .
The adder 22 is a modulo-2 adder which sums two bits at input and supplies two bits at output. The adder 23 is a modulo-3 adder, which sums three bits at input and supplies two bits at output. The adder 24 is a modulo-4 adder, which sums four bits at input and supplies three bits at output. The adder 25 is a modulo-5 adder, which sums five bits at input and supplies three bits at output. The adder 26 is a modulo-6 adder, which sums six bits at input and supplies three bits at output. The adder 27 is a modulo-7 adder, which sums seven bits at input and supplies three bits at output.
Each adder sends its own output bits, i.e., the result of the operation of addition on the addenda of the partial products, at input to the adjacent adders, except for the output least significant bit or LSB, which is supplied as the result of the operation of partial addition. For example, the modulo-4 adder 24 , which has three output bits, supplies the first two significant bits respectively to the adder 23 and to the adder 22 , whilst the least significant bit constitutes the partial sum S 5 .
As already mentioned previously, each adder 22 to 27 operates on the addenda of the partial products lying on a diagonal of the matrix of the circuit 10 .
Thus, for example, the modulo-7 adder 27 operates on the addenda P 1 , P 3 , P 6 , P 10 , P 15 , P 21 , P 28 for supplying the partial sum S 0 , whilst S 6 is supplied by the modulo-3 adder 23 which operates just on the product P 22 , and the modulo-2 adder 22 does not have at its input addenda of partial products, but only the bits at output from the adders 23 and 24 .
The partial sum S 7 , as already seen with reference to FIG. 5 , has also the function of driving the calculation of the exponent in the module 1001 .
The partial sums S 7 . . . S 0 are sent to one-bit multiplexers 41 belonging to a block 40 , represented in FIG. 10 , which carries out a correction on the partial sums S 7 . . . S 0 to supply the corrected result R 7 . . . R 0 according to the value of the sum S 7 . Said block 40 , as has been said, is hence a simple one-bit multiplexer controlled by the bit of the partial sum S 7 . If the partial sum: S 7 is equal to zero, certainly the partial sum S 6 has the value one; hence, the block 40 performs a shift to the left of the bits S 7 . . . S 0 . If the partial sum S 7 has the value one, then the result is left unchanged.
FIG. 11 represents, by means of a schematic representation of its adder network, a module 50 , alternative to the circuit 30 used in the module 100 , which performs the sum of the partial products by rows.
In FIG. 13 designated by 110 is a module that, with respect to the module 100 of FIG. 12 , implements the method of rounding by columns.
Said module 110 comprises the block 10 , which receives the bits A 7 . . . A 0 and B 7 . . . B 0 'and supplies the addenda of the partial products P 1 . . . P 28 to a block 60 , which, like the block 30 , carries out the partial sums.
The bits A 7 . . . A 0 and B 7 . . . B 0 are however sent in parallel also to a block 70 , illustrated in detail in FIG. 19 . The block 70 performs the operation of rounding on the columns, as mentioned with reference to FIG. 2 , i.e., performs a bit-by-bit OR operation on the columns and supplies a carry signal CR to the module 60 that performs the partial sums.
As may be seen from the diagram of FIG. 19 , the block 70 comprises a first array of AND gates for calculating the addenda that form the two columns selected in the subset identified by the window C in FIG. 3 .
Next, two OR gates execute the one-bit OR operation on the addenda of the two columns, and from the outputs of said OR gates, which are sent to an AND gate, the carry signal CR is obtained to perform the rounding.
The module 60 , represented in FIG. 14 , comprises, set in cascaded fashion, a modulo-8 adder 28 , with eight inputs and three outputs, three modulo-7 adders 27 and the adders 25 , 24 , 23 and 22 . Supplied to the modulo-8 adder are the addenda P 1 , P 3 , P 6 , P 10 , P 15 , P 21 , P 28 originated on the longest diagonal of the matrix of the circuit 10 , and the carry signal CR coming from block 70 is moreover supplied to the remaining input.
In FIG. 15 , designated by the reference 80 is the detailed diagram of a circuit, alternative to the block 60 , which carries out the partial sums on the partial products proceeding by rows.
Designated by 120 in FIG. 16 is a module that adopts the method of rounding by rows.
The module 120 hence comprises the circuit 10 for generation of the addenda of the partial products P 1 . . . P 28 , which are supplied to a block 87 , which performs the partial sums by columns.
The block 87 receives also a bus C 6 . . . C 0 of carry signals supplied by an appropriate block 85 , which is used to calculate the partial sums S 7 . . . S 0 rounding them by rows.
The block 87 is described in FIG. 17 and comprises, connected in cascaded fashion, one after another, an adder 27 , three adders 28 , a further adder 27 , and then the adders 26 , 25 , 23 , 22 .
To the inputs of the first modulo-7 adder 27 there is sent the bus C 6 . . . C 0 of carry signals, which represent the sums on the rows contained in the window RW of FIG. 4 .
The unit 85 , not represented in detail, produces the bus C 6 . . . C 0 of carry signals according to the following relations:
C 6 =A 0 &B 7 C 5 =(A 0 &B 6 )&(A 1 &B 6 ) C 4 =(A 0 &B 5 )&(A 1 &B 5 ))&(A 2 &B 5 ) C 3 =(A 0 &B 4 )&(A 1 &B 4 ))&(A 2 &B 4 ))&(A 3 &B 4 ) C 2 =(A 0 &B 3 )&(A 1 &B 3 ))&(A 2 &B 3 ))&(A 3 &B 3 ))&(A 4 &B 3 ). C 1 =(A 0 &B 2 )&(A 1 &B 2 ))&(A 2 &B 2 ))&(A 3 &B 2 ))&(A 4 &B 2 )&(A 5 &B 2 ) C 5 =(A 0 &B 1 )&(A 1 &B 1 ))&(A 2 &B 1 )&(A 3 &B 1 )&(A 4 &B 1 ))&(A 5 &B 1 ) &(A 0 &B 1 )
where the symbol & represents the one-bit AND operator.
In other words, the unit 85 implements the bit-by-bit AND operation on the rows belonging to the subset of addenda in the window RW, as defined for the method of rounding by rows illustrated with reference to FIG. 4 , and supplies the values for each row in the form of the bus of carry signals C 6 . . . C 0 .
Represented in FIG. 18 is then a block 86 , which performs the partial sums by rows, alternative to the block 87 .
Described in what follows are conversion circuits for conversion from the floating-point binary encoding according to the IEEE754 standard to the binary encoding envisaged by the method according to the invention.
The signals M 0 . . . M 22 represent the 23 bits of the mantissa according to the IEEE754 representation in single precision.
The signals E 0 . . . E 7 represent the 8 bits of the exponent according to the IEEE754 representation in single precision.
FIG. 20 represents a conversion circuit 3000 from the IEEE754 format to the representation according to the invention.
In the above circuit 3000 there is envisaged a multiplexer MUX 2 , which, in the case of a normalized value, receives at input the mantissa bits M 0 . . . M 6 appropriately associated with the value one in a block 3001 . The bits M 7 . . . M 22 in said block 3001 are ignored in so far as, in the implementation of the method according to the invention described herein, for the mantissa MN only eight bits are used.
If the real number f at input is denormalized, the mantissa to be converted is sent to a search unit 2004 , which searches for the first one present in the string of bits that constitutes the mantissa and supplies a position I thereof in the string to a group shifter 2005 , which extracts the first 8 bits starting from said position I and sends them to the multiplexer MUX 2 .
The output of the multiplexer MUX 2 is driven by the output of a block 2001 represented in detail in FIG. 21 , which receives at input the bits of mantissa M 0 . . . M 22 and exponent E 0 . . . E 7 and is designed to establish whether the floating-point number f is normalized or denormalized. The logic value 0 at output from the circuit 2001 means that the number is denormalized, whilst the logic value 1 at output from the circuit 2001 means that the number is normalized.
The index I which indicates the position in the bit string that constitutes the mantissa is moreover sent to a circuit 2000 for conversion of the exponent.
The conversion circuit 2000 is represented in FIG. 22 and comprises a module 2003 for the conversion of the exponent, the output of which is sent to a multiplexer MUX 3 together with the output of a block 2010 , which subtracts from the value of the exponent the index I found by the search unit 2004 .
The unit 2003 for the conversion of the exponent is represented in FIG. 23 and consists basically of an adder that receives at input the exponent and the bias value.
In fact, the IEEE754 representation uses the following rules for encoding the exponent in the normalized and denormalized forms:
E=Bias+exp if normalized E=0 if denormalized.
Then, in the converter for conversion from IEEE754 to completely normalized encoding, if the number at input is normalized there is added a bias value in twos complement, represented with 8 bits. Correction of the first one present in the mantissa requires correction of the exponent with a value +1. If E=0, the exponent is calculated by adding the contribution due to positioning of the mantissa and coming from the circuit 3000 .
Hence, the unit 2003 supplies at output exp=E-Bias, whilst the unit 2010 supplies exp in the case of a denormalized number.
In a way similar to that of the circuit 3000 , the multiplexer MUX 3 is driven, for selecting between a normalized and a denormalized number, by a block 2001 that establishes whether the number to be converted is normalized or denormalized.
FIG. 24 represents a circuit 3003 for conversion of the exponent of completely normalized numbers into the IEEE754 standard.
The circuit 3003 comprises a block 2003 , basically an adder, which receives at input the value of the base exponent exp and of bias, in this case positive. A multiplexer MUX 4 , which operates under the control of the circuit 2002 , which likewise receives the exponent, chooses the output of the block 2003 or else a value zero in the case of a denormalized number.
FIG. 25 represents a circuit 3004 for conversion of the mantissa of completely normalized numbers FN into the IEEE754 standard.
The above circuit 3004 comprises a unit 2003 , which receives at input the exponent exp and a bias value equal to −126. A completely normalized number with exponent smaller than or equal to −126 is converted into the IEEE754 denormalized form: i.e., the exponent has the value −126, and the mantissa MN is scaled via a shift to the right by a number of positions equal to the difference between the exponent value and 126, by means of a shift-to-the-right unit 2006 .
If the completely normalized number has a value such as to require an IEEE754 normalized encoding, the bit in the position MN 7 is omitted, in so far as it is implicit.
The 23 bits of the IEEE754 mantissa are formed with the MN−1 bits of the completely normalized number FN, leaving the remaining 23−MN+1 bits at zero and decrementing the exponent by one.
A multiplexer MUX 5 driven by a unit 2002 then selects the normalized or denormalized value.
Provided in what follows are the results of tests carried out on a multiplication unit that executes ten million random products, calculating the maximum error.
FIG. 26 represents the percentage error according to the width of the window W. The line NR indicates the line obtained using the method according to the invention without rounding, the line RI corresponds to the method with rounding by columns, and the line RII corresponds to the method with rounding by rows.
FIG. 27 represents the maximum percentage error according to the number MA of bits used for representing the mantissa MN in a multiplication unit for floating-point numbers according to the technique described herein.
As may be noted, for a value of MA from 8 bits onwards the percentage of maximum error remains below 2%, a value that is considered acceptable. In this condition, the bit-error rate of the system remains in any case within the threshold of −3 dB.
Simulations of this sort point towards a number NE of bits equal to 6 for the exponent EN.
In the following a technique for further reducing, with respect to the embodiment already described with reference to FIGS. 2 , 3 and 4 , the set of significant partial products in the floating-point mantissa multiplication will be detailed. Such a technique provides for eliminating the rows of partial products corresponding to the first bits of the multiplier. A new type of truncated multiplier is thus introduced, in a “stand-alone” solution. Such techniques can be introduced jointly with the truncated multiplier architecture. A “vertical-cut”, i.e. the truncation of columns to the left corresponding to least significant bits, introduced by the truncated multipliers in order to determine the amplitude of set of addenda in terms of number of bits of the significant part that it is desired to preserve, is integrated with a “horizontal-cut”, i.e. the truncation of first rows, corresponding to multiplication of the multiplicand for the least significant bits of the multiplier, in the set of partial products. In this case is determined also a height of the set of addenda, in terms of most significant bits of the multiplier that it is desired to preserve. In this way, a bi-dimensional truncated multiplier architecture is originated. In FIG. 28 is shown an example of such bi-dimensional truncated multiplier architecture applied to partial products.
FIG. 28 represents the method of reducing partial products in a way similar to that adopted in FIGS. 2 , 3 , and 4 , i.e., showing the set of partial products P generated by the multiplication of the mantissa MN 1 by the mantissa MN 2 .
On the partial products P, FIG. 28 shows a window 2 D encompassing a subset of addenda on which the sum of partial products is to be performed. Such a window 2 D is the result of a bidimensional truncation, that includes a vertical truncation step, by truncating, or discarding, the columns in a vertical window V, in a way similar to the truncation originating window W in FIG. 2 . The bidimensional truncation furthermore includes a horizontal truncation step, by truncating or discarding, the rows in a horizontal window H. As a consequence, the multiplier architecture does not take in account some horizontal and vertical set of partial products P. It must be underlined that, in order to operate on a different partial products set, the multiplicand MN 1 and the multiplier MN 2 can be exchanged in role.
The bi-dimensional truncated multiplier architecture operating according to the procedure just described with reference to FIG. 28 , implements suitable rounding procedures for precision recovery.
As can be appreciated from FIG. 29 , the first rows of partial products P in the horizontal window H, generated by the first bits of the multiplier MN 2 , are excluded, resulting in a “horizontal-cut” of the set of addenda. If those bits in the horizontal window H bear a logical zero value, the horizontal-cut has no influence in the computed result. In general, however, the exclusion of the first rows of partial products P in the horizontal window H introduces a computation error. The most external bits, or partial products, in the excluded rows, indicated by circles E in FIG. 29 , that are the most significant bits of such rows, assume a value in accordance with the corresponding bit in the multiplier MN 2 , when operating with normalized numbers. If, for instance, the second bit of the multiplier MN 2 is a logical one, the most external bit in the second row surely will be a logical one as well.
Here is proposed a horizontal rounding procedure exploiting the most external partial products E, in the excluded rows in the horizontal window H, adding such most external partial products E as horizontal carries HR in a Wallace tree multiplier in'the way as shown with reference to: FIG. 30 , where also vertical carries VR resulting from a vertical rounding procedure that will be now detailed, are added.
The vertical rounding procedure, similarly to the vertical rounding already described with reference to FIG. 3 , provides rounded results P that come from the sum of a truncated result P Truncated and a rounding constant C Round .
P=P Truncated +C Round
Ex indicates a horizontal-cut depth, i.e. the number of rows contained in the horizontal window H, while Ey indicates a vertical-cut depth, i.e. the number of truncated columns contained in the vertical window V, the vertical rounding constant C Round : is:
C
Round
=
∑
i
=
1
Ey
&
j
=
1
i
P
i
,
j
p i,j indicates the partial product placed in column i at row j, so that, as can be seen in FIG. 29 the vertical rounding mode, for each row of the vertical window V provides for performing a bit wise AND (& operator) among the partial products (p i,j ) there contained.
This new set of partial products, i.e. the products in window 2 D joint with the results of the horizontal and vertical rounding procedures above detailed, can use a Wallace tree for partial products multiplication, as shown in FIG. 30 , but can also use an array multiplier. The array multiplier introduces less capacitive load in the interconnections, by virtue of its regular layout.
More in detail, the gain in terms of hardware is remarkable if a Wallace tree is used when a sufficient number of rows is erased so that the number of matrixes need to implement the circuit is reduced.
On the other hand, the gain in terms of hardware is ensured if an array of adders is used. This is slow circuit if the precision is high.
In summary, the preferred implementations are:
Wallace tree, for a fast circuit and high precision, where it is possible to erase a remarkable number of rows (MA value is high) Array Multiplier for a slow circuit and low precision, where, by erasing even a single row there is an appreciable cost in terms of area and power (MA value is low).)
An error analysis of the bi-dimensional truncated multipliers according to the invention has been performed.
The bi-dimensional truncated multiplier was simulated, operating with a single precision normalized mantissa (MA=22). The result of such a simulation are shown in FIG. 31 , where the maximum error Max Err % is shown as a function of the erased lines, or rows, by applying the ‘horizontal cut’. The truncated multiplier operated according to procedures disclosed in FIGS. 3 and 4 , introduces an error at 0.08%, operating with a mantissa of 22 bit. Such an error is shown, as a horizontal dotted line in FIG. 31 .
The bi-dimensional truncated multiplier was also simulated, progressively erasing lines, i.e. first rows, from 1 to 10. The maximum error regression curve for the bi-dimensional truncated multiplier (continuous line) is shown in FIG. 31 , while diamonds indicate the corresponding data.
It must be noted that the precision error that is introduced is very limited, if a few lines are erased. This issue has a large impact in the realization process, since the reduced partial products matrix wastes less area, the entire circuit dissipates less power. As far as the timing closure point of view is concerned, the bi-dimensional truncated multiplier will be less critical, allowing higher frequencies of operation.
Considering now the implementation and VLSI design of the bi-dimensional truncated multiplier, as far as the architectural point of view is concerned, the Mantissa multiplication problem, as already detailed, requires two different circuits' devoted to the partial products generation and addition. A matrix generates the partial products, executing a crossed AND between the single bit of multiplicand and multiplier, while a procedure like the Booth algorithm generates a reduced set of partial products, achieving a fast multiplication. The high-speed multipliers widely use this solution. Partial products from either the set of addenda or Booth encoder will be added using adders by rows or by columns. This architecture has regular layout.
Fast multiplier use of the Wallace tree does not have a regular layout. The carry-ripple adders (CRA) might be used in partial products addition by rows. The high-speed parallel multiplier is a solution that has been widely used in the past and in literature a variety of solution are shown in order to perform fast multiplication with arrays. At system level, the carry-ripple adders could be changed with the faster carry look-ahead (CLA) circuit.
The preferred implementation of the bi-dimensional truncated multiplier, as already mentioned, provides for using a Wallace tree, using a configuration of input signals as shown in FIG. 30 . The Wallace tree thus considers partial products P included in the window 2 D with a further column of vertical carries VR in place of the truncated subset of columns in vertical window V. The vertical carries VR are originated from the vertical rounding, i.e. originated by the bit wise AND (& operator) among the partial products (p i,j ). The Wallace tree also considers a further row of horizontal carries HR coming from the horizontal rounding procedure, i.e. the three most external partial products E in the horizontal window H of FIG. 29 .
The partial products generation can use a matrix or Booth encoder. The Wallace tree circuit, although very fast, can be replaced, as mentioned, with arrays (rows, columns, diagonals) and Dadda's multipliers. The Table 3 below reports the area, power, WNS (timing violation) and mean percentage error of the proposed solution, using a 8 bit mantissa and of the other circuits. These circuits were realized by the use of a high-speed technology library 0.13 micron at 400 MHz from ST Microelectronics.
TABLE 3
Area
Avg. Power
Avg.
WNS
Architecture
μm 2
μW
Error %
(sec)
Wallace 1
2557
91.58
5.00%
0.00
Array NR
2214
128.74
5.00%
0.00
Array RR
2573
148.52
4.00%
0.00
Array RC
2458
151.85
4.20%
0.00
Wallace proposed
2912
74.43
7.57%
0.00
Booth2 reference
5248
301.16
2.75%
0.00
In Table 3:
‘Wallace 1 ’ indicates the truncated multiplier realized by the Wallace tree without rounding circuits;
‘Array’ is the array multipliers with matrix for partial products generation. NR=no rounding, RR=rounding by rows, RC=rounding by columns.
‘Booth 2 ’ indicates an unsigned 8×8 bit mantissa multiplier. The partial products were generated by Booth 2 encoder and added by a matrix by rows which employs CRA adders. ‘Wallace proposed’ refers to the proposed architecture. The circuit employs a reduced matrix for partial products generation. The Wallace tree adds the partial products and rounding carries.
Thus from Table 3 it can be observed that the bi-dimensional truncated multiplier introduces an additional computation error compared to the prior art. This error is very limited; the related architecture dissipates less power and the circuit delay is reduced.
In a possible further embodiment, the least significant rows of partial products might be excluded without applying the vertical-cut. In this case a new kind of truncated multiplier is obtained, which is convenient for timing, using the Wallace tree as strategy for partial product addition.
It has to be underlined that the Wallace tree introduces equal stages compressors, to the number of rows, which have a key role in the speed of circuitry. The field of application of bi-dimensional truncated mantissa multiplier concerns thus the design of critical circuits (in timing) with low-power target. These constraints have a key role compared to the loss in precision.
The solution described above enables considerable advantages to be obtained as compared to known solutions. It will be appreciated that the main advantage of the solution described above derives, in terms of area occupied on the chip and of power consumption, from the reduction in the number of circuits dedicated to the calculation of the partial products, obtained by means of an appropriate floating-point representation that enables just the most significant part of the partial products to be considered, hence with an acceptable truncation error.
All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet are incorporated herein by reference, in their entireties.
Of course, without prejudice to the principle of the invention, the details of implementation and the embodiments may vary widely with respect to what is described and illustrated herein, without thereby departing from the scope of the present invention. | In a method for multiplication of floating-point real numbers, encoded in a binary way in sign, exponent and mantissa, the multiplication of the mantissa envisages a step of calculation of partial products, which are constituted by a set of addenda corresponding to the mantissa. In order to reduce the size and power consumption of the circuits designed for calculation, there is adopted a method of binary encoding which envisages setting the first bit of the mantissa to a value 1, in order to obtain a mantissa having a value comprised between 0.5 and 1. Also proposed are methods for rounding of the product and circuits for the implementation of the multiplication method. Also illustrated are circuits for conversion from and to encoding of floating-point teal numbers according to the IEEE754 standard. Preferential application is in portable and/or wireless electronic devices, such as mobile telephones and PDAs, with low power-consumption requirements. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to an improved data processing system, and in particular to a computer implemented method, an apparatus and a computer program product for graphically navigating tree structures.
[0003] 2. Description of the Related Art
[0004] In conventional systems, data is usually represented by using a tree structure. A tree is a hierarchical structure that shows the relationship of one object with another. Each object is represented as a part in the tree. A user can access an object that is contained by another object by drilling down to that object in the tree structure. Drilling down means to move to or view lower levels in the hierarchical structure. For example, in a file directory using the tree analogy, the directory structure may be displayed as a tree indicating the various levels from the main or root directory through sub-directories or branches down to the individual files or leaves. In a similar manner, a network and related resources may be viewed.
[0005] However, in conventional systems, data displayed by a tree view can be overwhelming. Some objects in a tree that are frequently used by some users are contained under a complex tree structure. To select a desired object, the user has to scroll to the corresponding parent object and then expand this object until the desired object is made visible. For large tree structures this operation can be extremely slow.
[0006] For large trees, it is also hard to understand the tree's complete structure since the tree is too large to be viewed on the current display. The entire content of the tree cannot be seen in the tree view window. A known solution uses display scrolling with scroll bars to scroll the tree and expand the selected item. This known solution is not ideal as it does not scale for large trees where the operation of the known solution becomes slow and awkward. The user is unable to see the entire tree content at once and typically becomes lost. Further, frustration is added because multiple mouse selections are required when using the scroll bar and expand mechanism to locate an object in the tree. There is a need to more efficiently view a large tree structure and navigate to a desired object.
SUMMARY OF THE INVENTION
[0007] Illustrative embodiments provide a computer implemented method, an apparatus in the form of a data processing system, and a computer program product for graphically navigating tree structures. In one illustrative embodiment, the computer implemented method comprises creating an outliner view of a tree view comprising the entire tree structure and determining whether an object has been selected from the tree view to create a selected object. The computer implemented method further responsive to a determination that the object was selected, displays the entire tree view and further displays the selected object only in a legible form in the outliner view.
[0008] In another illustrative embodiment, a data processing system comprises a bus, a memory connected to the bus, a display connected to the bus, a communications unit connected to the bus, a persistent storage connected to the bus, wherein the persistent storage has computer usable instructions tangibly embodied thereon, a processor unit connected to the bus, wherein the processor unit executes the computer program instructions to create an outliner view of a tree view comprising the entire tree structure, and determine whether an object has been selected from the tree view to create a selected object. The processor unit further executes the computer program instructions to respond to a determination that the object was selected and display the entire tree view and further display the selected object only in a legible form in the outliner view, otherwise, display a current portion of the entire tree view in the outliner view.
[0009] In another illustrative embodiment, a computer program product comprising a computer usable recordable medium having computer usable program code tangibly embodied thereon, the computer usable program code comprises computer usable program code for creating an outliner view of a tree view comprising the entire tree structure and computer usable program code for determining whether an object has been selected from the tree view to create a selected object. The computer usable program code further comprises computer usable program code, responsive to an object being selected, for displaying the entire tree view and further displaying the selected object only, in a legible form, in the outliner view; otherwise, displaying a current portion of the entire tree view in the outliner view.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0011] FIG. 1 depicts a pictorial representation of a network of data processing systems in which illustrative embodiments may be implemented;
[0012] FIG. 2 is a block diagram of a data processing system in which illustrative embodiments may be implemented;
[0013] FIG. 3 is a block diagram of a portion of an outliner in accordance with illustrative embodiments;
[0014] FIG. 4 is a textual representation of conventional tree view of a file structure, in accordance with illustrative embodiments;
[0015] FIG. 5 is a textual representation of an outliner view of the tree view of FIG. 4 in accordance with illustrative embodiments;
[0016] FIG. 6 is a textual representation of an outliner view of FIG. 5 , with a cursor over an object, in accordance with illustrative embodiments;
[0017] FIG. 7 is a textual representation of an outliner view of FIG. 5 , with an object selected, in accordance with illustrative embodiments;
[0018] FIG. 8 is a flowchart of the outliner process in accordance with illustrative embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] With reference now to the figures and in particular with reference to FIGS. 1-2 , exemplary diagrams of data processing environments are provided in which illustrative embodiments may be implemented. It should be appreciated that FIGS. 1-2 are only exemplary and are not intended to assert or imply any limitation with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environments may be made.
[0020] FIG. 1 depicts a pictorial representation of a network of data processing systems in which illustrative embodiments may be implemented. Network data processing system 100 is a network of computers in which the illustrative embodiments may be implemented. Network data processing system 100 contains network 102 , which is the medium used to provide communications links between various devices and computers connected together within network data processing system 100 . Network 102 may include connections, such as wire, wireless communication links, or fiber optic cables.
[0021] In the depicted example, server 104 and server 106 connect to network 102 along with storage unit 108 . In addition, clients 110 , 112 , and 114 connect to network 102 . Clients 110 , 112 , and 114 may be, for example, personal computers or network computers. In the depicted example, server 104 provides data, such as boot files, operating system images, and applications to clients 110 , 112 , and 114 . Clients 110 , 112 , and 114 are clients to server 104 in this example. Network data processing system 100 may include additional servers, clients, and other devices not shown.
[0022] In the depicted example, network data processing system 100 is the Internet with network 102 representing a worldwide collection of networks and gateways that use the Transmission Control Protocol/Internet Protocol (TCP/IP) suite of protocols to communicate with one another. At the heart of the Internet is a backbone of high-speed data communication lines between major nodes or host computers, consisting of thousands of commercial, governmental, educational and other computer systems that route data and messages. Of course, network data processing system 100 also may be implemented as a number of different types of networks, such as for example, an intranet, a local area network (LAN), or a wide area network (WAN). FIG. 1 is intended as an example, and not as an architectural limitation for the different illustrative embodiments.
[0023] In illustrative embodiments, an outliner provides a capability to graphically navigate the entire tree structure efficiently. In an illustrative embodiment an outliner may be implemented as a browser extension on a client, while in another the outliner may be implemented as a web service or applet, accessed and used from a server when needed. In another illustrative embodiment an outliner may be implemented as part of a file system manager and viewer. For example, a user on client 110 may wish to process a set of files contained on server 106 through network 102 of FIG. 1 . The outliner allows the user, on client 110 , to quickly navigate the tree structure representation of the file system on server 106 , with only one mouse selection. The user has only to move the mouse over a portion of the view and that portion of the tree is automatically expanded and made legible.
[0024] The outliner provides a graphical view that represents an overview of the tree structure. The graphical view allows the user to visualize the entire tree structure, see where the selection is made within the tree and navigate the tree structure by using a mouse selection.
[0025] With reference now to FIG. 2 , a block diagram of a data processing system is shown in which illustrative embodiments may be implemented. Data processing system 200 is an example of a computer, such as server 104 or client 110 in FIG. 1 , in which computer usable program code or instructions implementing the processes may be located for the illustrative embodiments. In this illustrative example, data processing system 200 includes communications fabric 202 , which provides communications between processor unit 204 , memory 206 , persistent storage 208 , communications unit 210 , input/output (I/O) unit 212 , and display 214 .
[0026] Processor unit 204 serves to execute instructions for software that may be loaded into memory 206 . Processor unit 204 may be a set of one or more processors or may be a multi-processor core, depending on the particular implementation. Further, processor unit 204 may be implemented using one or more heterogeneous processor systems in which a main processor is present with secondary processors on a single chip. As another illustrative example, processor unit 204 may be a symmetric multi-processor system containing multiple processors of the same type.
[0027] Memory 206 , in these examples, may be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 208 may take various forms depending on the particular implementation. For example, persistent storage 208 may contain one or more components or devices. For example, persistent storage 208 may be a hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by persistent storage 208 also may be removable. For example, a removable hard drive may be used for persistent storage 208 .
[0028] Communications unit 210 , in these examples, provides for communications with other data processing systems or devices. In these examples, communications unit 210 is a network interface card. Communications unit 210 may provide communications through the use of either or both physical and wireless communications links.
[0029] Input/output unit 212 allows for input and output of data with other devices that may be connected to data processing system 200 . For example, input/output unit 212 may provide a connection for user input through a keyboard and mouse. Further, input/output unit 212 may send output to a printer. Display 214 provides a mechanism to display information to a user.
[0030] Instructions for the operating system and applications or programs are located on persistent storage 208 . These instructions may be loaded into memory 206 for execution by processor unit 204 . The processes of the different embodiments may be performed by processor unit 204 using computer implemented instructions, which may be located in a memory, such as memory 206 . These instructions are referred to as program code, computer usable program code, or computer readable program code that may be read and executed by a processor in processor unit 204 . The program code in the different embodiments may be embodied on different physical or tangible computer readable media, such as memory 206 or persistent storage 208 .
[0031] Program code 216 is located in a functional form on computer readable media 218 that is selectively removable and may be loaded onto or transferred to data processing system 200 for execution by processor unit 204 . Program code 216 and computer readable media 218 form computer program product 220 in these examples. In one example, computer readable media 218 may be in a tangible form, such as, for example, an optical or magnetic disc that is inserted or placed into a drive or other device that is part of persistent storage 208 for transfer onto a storage device, such as a hard drive that is part of persistent storage 208 . In a tangible form, computer readable media 218 also may take the form of a persistent storage, such as a hard drive, a thumb drive, or a flash memory that is connected to data processing system 200 . The tangible form of computer readable media 218 is also referred to as computer recordable storage media. In some instances, computer recordable media 218 may not be removable.
[0032] Alternatively, program code 216 may be transferred to data processing system 200 from computer readable media 218 through a communications link to communications unit 210 and/or through a connection to input/output unit 212 . The communications link and/or the connection may be physical or wireless in the illustrative examples. The computer readable media also may take the form of non-tangible media, such as communications links or wireless transmissions containing the program code.
[0033] The different components illustrated for data processing system 200 are not meant to provide architectural limitations to the manner in which different embodiments may be implemented. The different illustrative embodiments may be implemented in a data processing system including components in addition to or in place of those illustrated for data processing system 200 . Other components shown in FIG. 2 can be varied from the illustrative examples shown.
[0034] As one example, a storage device in data processing system 200 is any hardware apparatus that may store data. Memory 206 , persistent storage 208 , and computer readable media 218 are examples of storage devices in a tangible form.
[0035] In another example, a bus system may be used to implement communications fabric 202 and may be comprised of one or more buses, such as a system bus or an input/output bus. Of course, the bus system may be implemented using any suitable type of architecture that provides for a transfer of data between different components or devices attached to the bus system. Additionally, a communications unit may include one or more devices used to transmit and receive data, such as a modem or a network adapter. Further, a memory may be, for example, memory 206 or a cache, such as found in an interface and memory controller hub that may be present in communications fabric 202 .
[0036] With reference to FIG. 3 , a block diagram of a portion of an outliner, in accordance with illustrative embodiments is shown. An outliner is a graphical view which represents an overview of the tree and allows the user to visualize the entire tree structure. As seen in FIG. 2 , components of a file browser 300 are in memory 206 as previously shown in system 200 of FIG. 2 .
[0037] File browser 300 provides the capability to access and view elements of the file system as may be found on persistent storage 208 of FIG. 2 . Typically, file browser 300 uses tree view 302 to visualize the content of the file system. For example tree viewer 302 , when requested, would cause the content of the file system to be displayed in a tree structure format. Tree viewer 302 renders the file system content in a convention manner typically seen in the form of a hierarchy of directory entries. The hierarchy of directory entries flows from the root or main directory to list various subdirectories and files of the main directory.
[0038] Outliner viewer 304 works with tree view 302 in the viewing of the file system entries. Outliner viewer 304 makes the entire tree view of the directory structure visible, while focusing on a small relevant portion within the structure to make that portion legible or readable to a user. The area of focus allows objects within the structure to be zoomed by a mouse over operation or to be selectively expanded to show a sub-tree structure within the structure. These examples of functional elements are illustrative and not intended to be limiting on the manner or the location in which an implementation of viewer components is made. For example, as stated previously outliner view 304 may be implemented in a variety of ways including as a portion of tree view 302 .
[0039] With reference to FIG. 4 , a textual representation of a conventional tree view of a file structure is shown. The exemplary view represents a hierarchical file directory structure as may typically be generated by tree view 302 and rendered in a view showing the file directory. This typical view is commonly used to show the relationships between the various levels of a directory. Tree view 400 is shown as a typical view of a file system structure listing contents in the form of a hierarchy of subdirectories. Each element of the view is legible, which means, in this case, able to be read by the user, as a line of text with associated graphic figures. For example, element 402 is a subdirectory that has been expanded to expose the content within, while element 404 is an object that has been highlighted within the tree view.
[0040] In the example of FIG. 4 , a portion of the tree is shown, while most of the tree structure cannot be displayed due to the number of entries and therefore the size of the structure. The scroll bar 406 , on the right side of the display, is visible to allow the user to move within the file structure.
[0041] With reference to FIG. 5 , a textual representation of an outliner view of tree view 400 of FIG. 4 , in accordance with illustrative embodiments is shown. Outliner view 500 , as may be generated by an illustrative embodiment of outliner view 304 of FIG. 3 , is an enhanced representation of tree view 400 of FIG. 4 , in which the whole tree structure may be seen at once. Outliner view 500 displays the entire tree structure in contrast to the partial tree structure of tree view 400 . While the entire tree structure is portrayed in outliner view 500 , the entire content is not legible. In this case while the content is visible it is not entirely legible to the user. Outliner view 500 presents the entire tree structure in a visible manner allowing the user to recognize content and major areas of the structure but does not present the entire structure in detail. A view port 502 is defined by a rectangular area in which the text entries for the file system elements are made visible and legible, now being able to be read by the user. View port 502 defines a current focus area within the complete tree structure. The focus area was determined by the selection of an object from within the tree view of FIG. 4 .
[0042] For example, within view port 502 is shown element 402 of FIG. 4 . Element 402 is the root or parent of the selected object that is element 404 of FIG. 4 . The object, element 404 , was selected in tree view 400 . While the entire tree is shown in the outliner view 500 , only the selected object and the path to the object's root parent is made visible and legible or readable for the user within view port 502 .
[0043] With reference to FIG. 6 , a textual representation of the outliner view of FIG. 5 , with a cursor over an object, in accordance with illustrative embodiments is shown. When a cursor, or mouse pointer, is moved over a specific portion of a tree within the outliner view, the rendering of that portion is changed. The specific portion of the tree is expanded to show increased detail one level down. The portion of the tree is highlighted and zoomed or enlarged to be legible allowing the user to read the text or visualize the image of the tree for the object under the mouse pointer.
[0044] For example, within view port 502 of outliner view 500 is shown the parent, element 402 and highlighted entry, element 404 from FIG. 4 . Moving the mouse pointer over element 402 causes the element to expand revealing further detail in element 600 comprising text entries. The expanded entries, while present, are not legible. Moving the mouse pointer over element 602 , for example, renders that object visible, or legible, in the outliner view.
[0045] With reference to FIG. 7 , a textual representation of an outliner view of FIG. 6 , with an object selected, in accordance with illustrative embodiments is shown. Within the tree structure of outliner view 500 , element 506 is further selected. Selecting or clicking the element of the tree structure in the outliner view results in the expansion of the element's sub-tree structure. The expanded element 700 now becomes the only tree structure portion visible within the outliner view, having all text entries legible. When compared with FIG. 6 in which only the mouse over of element 602 causes element 602 to be legible, and all similar entries under parent element 404 of FIG. 4 comprising expanded element 700 are now visible.
[0046] With reference to FIG. 8 , a flowchart of the outliner process in accordance with illustrative embodiments is shown. Process 800 is an example of an outliner view process, such as that used in an illustrative embodiment of outliner viewer 304 of file browser 300 of FIG. 3 .
[0047] Process 800 starts, assuming existence of a tree view is present (step 802 ), and opens an outliner view (step 804 ). A determination is made as to whether an object has been selected in the entire tree view (step 806 ). If an abject is selected, a “yes” is returned in step 806 otherwise a “no” results.
[0048] If a “yes” was obtained in step 806 , position the outliner view to highlight the selected object and make the text entries for the object visible (step 808 ). If a “no” was obtained in step 806 , or step 808 completed, place the view port rectangle in the outliner view to highlight a visible portion of the respective entire tree view (step 810 ). In the absence of a specific selection of an object in the tree view, the outliner view would default to a portion of the currently displayed entire tree view.
[0049] A determination is then made whether the cursor, or mouse pointer, is over an object within the outliner view port space (step 812 ). If a “yes” results, then the outliner view is positioned to highlight the object currently under the cursor, or mouse pointer, and makes the text entry for the object visible (step 814 ). Further, expansion is performed to reveal any children of the highlighted object.
[0050] If a “no” was obtained in step 812 , or step 814 completed, process 800 determines whether an object selection has been made (step 816 ). If a “yes” was obtained in step 816 , the selected object is completely expanded in the outliner view to reveal the contents (step 818 ). In addition, the selected object is made the only object visible in the outliner view. If a “no” was obtained in step 816 , or step 818 completed, process 800 determines whether the cursor, or mouse pointer, has moved over the tree view (step 820 ). If a “yes” is obtained in step 820 , process 800 loops back to step 806 to determine whether an object in the entire tree view has been selected, and process 800 continues as previously described. If a “no” was obtained in step 820 , the outliner view is closed (step 822 ), and process 800 terminates thereafter (step 824 ).
[0051] Thus, the illustrative embodiments provide a capability enabling a user to navigate the hierarchical structure of the entire tree view, while seeing the entire tree content at once, further allowing the user to quickly navigate the tree with only a mouse selection. The user has only to move the mouse pointer over a portion of the entire tree view and the hidden tree structure is automatically expanded and made visible based on the cursor, or mouse pointer, position. Further selection of an object makes that object and its child elements the only point of focus in the outliner view.
[0052] The invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the invention is implemented in software, which includes, but is not limited to, firmware, resident software, microcode, etc.
[0053] Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer readable medium can be any tangible apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
[0054] The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable recordable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W) and DVD.
[0055] A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution.
[0056] Input/output or I/O devices (including, but not limited to, keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers.
[0057] Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modems, and Ethernet cards are just a few of the currently available types of network adapters.
[0058] The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | Illustrative embodiments provide a computer implemented method, an apparatus and a computer program product for graphically navigating tree structures. In one illustrative embodiment, the computer implemented method comprises creating an outliner view of a tree view comprising the entire tree structure and determining whether an object has been selected from the tree view to create a selected object. The computer implemented method further, responsive to a determination that the object was selected, displays the entire tree view and further displays the selected object only, in a legible form, in the outliner view. | 6 |
FIELD OF THE INVENTION
[0001] The present disclosure relates to the field of plows and plow assemblies and more particularly to a moveable snow plow.
BACKGROUND OF THE INVENTION
[0002] Traditional snow plow blades when attached to a plowing vehicle are capable of being raised and lowered and can be rotated about a vertical axis to direct snow to the left or right of the plowing vehicle. A controller inside the vehicle allows the operator to position the blade in a desired orientation. These plow assemblies, however, do no have the ability to move the entire snow plow blade left or right of the center of the vehicle. A problem with these types of plow systems is that snow rolling off the end of the plow blade often curls behind the plow blade and deposits in front of the wheels of the plowing vehicle. This is undesirable because the vehicle wheel compacts the snow on the surface being plowed and reduces vehicle traction.
[0003] The size of a snow plow blade is typically chosen based on the weight carrying capacity of the plowing vehicles and the type of the anticipated plowing. A narrow plow blade allows an operator to carefully clear driveways and other narrow spaces, whereas a wider plow can be used to clear wider areas such as parking lots. A draw back to a narrow plow is that the edge of the plow blade may not extend past the vehicles side mirrors, which can present a problem when trying to remove snow along a garage or other structure. A draw back to a wider plow blade is that it can make navigating narrow spaces and driving in traffic more difficult.
[0004] Some plow assemblies provide a forward extending gate to catch snow rolling off the snow blade. However, these types of assemblies do not allow the operator to move the edge of the plow blade to enable the operator to remove snow along a garage or other structure.
[0005] Some plow assemblies have a support member extending from and attached to the front of the vehicle. The support member is pivotable with respect to the central longitudinal axis of the vehicle and has a snow plow blade attached to it at its remote end. These assemblies typically employ four pistons for offsetting the plow from the central longitudinal axis of the vehicle so that the plow is positioned in front of the tire path of and ahead of the direction of travel of the vehicle. A first set of the pistons is coupled between the vehicle and the structural member and a second set of pistons is coupled between the structural member and the plow blade. The first set of pistons is used to adjust the angle of the support member to the vehicle and the second set of pistons is used to adjust the angle of the plow blade to the support member. The centerline of the plow can be moved relative to the centerline of the plowing vehicle, but the centerline must move in an arcuate path and requires four pistons.
[0006] A prior art snow plow blade 100 is shown in FIG. 1. The plow blade may be an “M” series plow available from Fisher Engineering of Rockland, Me. The plow blade 100 may be made of a curved piece of steel 102 having a front surface 102 A for contacting snow to be plowed and a rear surface 102 B. A plurality of stiffening ribs 108 A-H may be secured, preferably welded, to the back surface 102 B and a horizontal stiffening rib 108 J may extend along the top edge of the plow blade.
[0007] A trip-edge 104 may be provided along the bottom edge of the plow blade. When the trip edge strikes an obstacle, the lower edge trips back, compressing one or more of the springs 112 A-D on the black side of the plow. When the obstacle is cleared, the springs 112 A-D return the trip-edge to its normal position. The springs 112 A-D extend between the trip edge 104 and gussets 114 A-D secured, preferably welded, to the back surface of the plow blade. A pair of anti-wear shoes 106 A and 106 B may extend beyond the lower surface of the trip-edge 104 . The height of the anti-wears shoes may be adjustable. Edge markers 110 A and 110 B may be coupled to the horizontal stiffening rib 108 J to mark the ends of the plow blade 100 . A pair of horizontal ribs 116 and 118 may extend along a length of the rear surface of the plow blade 100 . The upper rib 116 may have a plurality of holes 116 A, 116 B, and 116 C and the lower rib 118 may have vertically aligned holes 118 A, 118 B, and 118 C respectively. Holes 116 A and 118 A and holes 116 B and 118 B may be used to couple the plow blade 100 to a pair of controllable actuators 250 A and 250 B (see FIG. 3).
[0008] The controllable actuator 250 A and 250 B are preferably hydraulic pistons having a body portion 254 and an extendable rod 256 . A pin 236 may be inserted through the hole 116 A, a hole 258 A in the controllable actuator 250 A, and then through the hole 118 A to couple the controllable actuator 250 A to the plow blade 100 . Likewise, a pin 236 may be inserted through the hole 116 B, a hole 258 B in the controllable actuator 250 B, and then through the hole 118 B to couple the controllable actuator 250 B to the plow blade 100 . A retainer 238 may prevent removal of the pins 236 . A hollow cylinder 120 may be aligned with the holes 116 C and 118 C and extend between the upper rib 116 and the lower rib 118 . A first horizontal plate 122 with a hole 122 A having a vertical axis may be aligned with hollow cylinder 120 . A second horizontal plate 124 with a hole 124 A having a vertical axis may also be aligned with hollow cylinder 120 . A pivot pin 214 (see FIG. 2) may be inserted through the vertically aligned holes 124 A, 116 C, 118 C, and 122 A and hollow cylinder 120 to rotatably couple the plow blade 100 to a cooperating A-frame 200 (see FIG. 2).
[0009] A prior art A-frame 200 is shown in FIG. 2. The A-frame 200 may be available from Fisher Engineering of Rockland, Me. as part number 26090 RD or 26410 HD. The A-frame may be made up of structural member 202 A, 202 B, and 202 C. A pair of tabs 204 A and 204 B may extend from the structural member 202 C for rotatably coupling the A-frame to a frame assembly (not shown) that may be fixedly secured to the frame of the plowing vehicle. The shape and configuration of the tabs 204 A and 204 B may depend on the A-frame manufacture and model number. A lift arm 206 may also be rotatably coupled to an upper portion of the frame assembly. A first end of a controllable actuator 270 (see FIG. 4), preferably a hydraulic piston, may be coupled to a tab 234 on the lift arm 206 and the second end of the controllable actuator may be coupled to the structural member 202 C. As the lift arm 206 is moved upward by the controllable actuator 270 , a chain 208 urges the A-frame to rotate upward. Likewise the A-frame lowers as the lift arm 206 is lowered. A first end of the chain 208 may be coupled to a loop (not shown) secured to the A-frame 200 . The chain 208 may then be threaded through a loop 220 coupled to the lift arm 206 , through a loop 210 coupled to the A-frame 200 and the loose end of the chain 208 may be secured in a slot in a tab 212 coupled to the frame assembly.
[0010] A first pair of horizontal plates 230 A may be secured, preferably welded, to the A-frame 200 along a rear portion of the A-frame on a first side and a second pair of horizontal plates 230 B may be secured, preferably welded, to the A-frame 200 along a rear portion of the A-frame on a second side. The plates 230 A and 230 B may have a pair of vertically aligned holes 232 for coupling the controllable actuators 250 A and 250 B to the A-frame 200 . Pin 236 inserted through the vertically aligned holes 232 and a hole 252 A in the controllable actuator 250 A may couple the controllable actuator 250 A to the A-frame 200 . Likewise a pin 236 inserted through the vertically aligned holes 232 and a hole 252 B in the controllable actuator 250 B may couple the controllable actuator 250 B to the A-frame 200 .
[0011] A hollow cylinder 216 may be vertically aligned and coupled, preferably welded, to a front portion of the A-frame 200 along an upper surface. The first hollow cylinder 216 may be supported by a pair of gussets 218 . A second hollow cylinder 224 may be vertically aligned with the first hollow cylinder 216 and coupled, preferably welded, to a front portion of the A-frame 200 along a lower surface. To couple the plow blade 100 to the A-frame 200 , the hollow cylinders 216 and 224 on the A-frame 100 are first vertically aligned with the holes 124 A, 116 C and 122 A on the plow blade 100 and then the pivot pin 214 is insert therein. A retainer pin 226 may prevent removal of the pivot pin 214 .
[0012] [0012]FIG. 3 shows a hydraulic pump 264 coupled to the controllable actuators 250 A through a hose 262 A and a coupling 260 A, to controllable actuator 250 B through a hose 262 B and a coupling 260 B, and to controllable actuator 270 (see FIG. 4) through a hose 262 C and a coupling 260 C. The hydraulic pump 264 may be secured to the frame assembly and receive signals from a controller located in the plowing vehicle. The controller may signal the hydraulic pump 264 to either pump fluid into or out of a controllable actuator. The hydraulic pump 264 may be coupled to a pair of opposing controllable actuator, for example 250 A and 250 B. As fluid is pumped out of controllable actuator 250 A it may be pumped into controllable actuator 250 B. The hydraulic pump 264 may allow fluid to flow from controllable actuator 250 A to controllable actuator 250 B and vice versa in the event the plow blade 100 strikes a non-moveable object such as a telephone pole or a curb.
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to provide a snow plow assembly having an A-frame securable to a vehicle, a plow, and a coupling assembly. The coupling assembly being located between the A-frame and the plow. The coupling assembly having a first member, a second member, and a first controllable actuator. The first member being couplable to the A-frame and slidably coupled to the second member. The second member further coupleable to the plow. The first controllable actuator being coupled to the first member and the second member and configured to urge the second member to move relative to the first member.
[0014] It is another object of the present invention to provide a coupling assembly, having a first member, a second member and a controllable actuator. The first member is linearly slidably relative to the second member along a first axis. The controllable actuator is coupled to the first member and the second member to urge the second member to move relative to the first member along a linear path. The first member further having a hole for pivotably coupling the first member to an A-frame about a second axis, the second axis generally perpendicular to the first axis. The second member having at least one hole for coupling the second member to a plow.
[0015] It is a further object of the present invention to provide a snow plow controller having a first actuator for raising the snow plow off the ground, a second actuator for causing the snow plow to rotate about a vertical axis, and a third actuator for causing the snow plow to move in a plane parallel with the vertical axis.
[0016] It is still another object of the present invention to provide a fluid steering assembly, comprising a first port coupleable to a hydraulic pump, a second port coupleable to a first piston, a third port coupleable to a second piston, and a switch coupling the first port to the second port as long as a first signal is received and coupling the first port of the third port in the absence of the first signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Other objects, features, and advantages of the present invention will be apparent in the following detailed description thereof when read in conjunction with the appended drawings wherein the same reference numerals denote the same or similar parts throughout the several views, and wherein:
[0018] [0018]FIG. 1 is a perspective view of a prior art snow plow blade;
[0019] [0019]FIG. 2 is a perspective view of a prior art “A” frame;
[0020] [0020]FIG. 3 is a plan view of the plow blade and “A” frame of FIGS. 1 and 2;
[0021] [0021]FIG. 4 is a side view of the plow blade and “A” frame of FIGS. 1 and 2;
[0022] [0022]FIG. 5 is an exploded plan view of a snow-plow assembly consistent with the present invention;
[0023] [0023]FIG. 6 is a side view of the assembly of FIG. 5;
[0024] [0024]FIG. 7 is a side view of a first component of the assembly taken through line 7 - 7 in FIG. 5;
[0025] [0025]FIG. 8 is a side view of a second component of the assembly taken through line 8 - 8 in FIG. 5;
[0026] [0026]FIG. 9 is a simplified hydraulic schematic useable with the plow assembly of FIG. 3;
[0027] [0027]FIG. 10 is a simplified hydraulic schematic consistent with the present invention
[0028] [0028]FIG. 11 is a simplified schematic of a fluid steering assembly consistent with the present invention; and
[0029] [0029]FIG. 12 is a controller consistent with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] The general arrangement of the elements is shown most clearly in FIGS. 5 and 6. A snow plow assembly includes an A-frame 200 pivotable securable to a vehicle, a plow 100 and a coupling assembly disposed between the A-frame 200 and the plow 100 . The A-frame is preferably removeable securable to the vehicle. The A-frame 200 is preferably pivotable about the vehicle about a horizontal. The coupling assembly may include a first member 300 , a second member 370 , and a controllable actuator 350 . The first member 300 may be coupleable to the A-frame and slidably coupled to the second member 370 . The second member 370 may be coupleable to the plow 100 . The first controllable actuator 350 , preferably a hydraulic piston, may be coupled to the first member 300 and the second member 370 . The controllable actuator 350 may be configure to urge the second member 370 to move relative to the first member 300 . In an alternative embodiment, the second member may be urged to move relative to the first member by a rotatable screw, a cable, a rack and pinion moved by a motor or other suitable means of urging a second member to move relative to a first member.
[0031] The first member 300 (see FIG. 7) may include a first plate 330 having a first pair of horizontally aligned hollow cylinders 334 A and 334 B (located on a first side 330 A) spaced from a second pair of horizontally aligned hollow cylinders 336 A and 336 B by a distance D. The interior dimension of the hollow cylinders 334 A, 334 B, 336 A and 336 B are sized to allow rods 376 and 374 respectively slide therein. A second plate 332 may extend outward from the first side 330 A. The plate may have a hole 332 A. A third plate 316 and a fourth plate 318 may extend outwardly from a second side 330 B of plate 330 . The plates 316 and 318 may be made from a section of U-shaped channel stock. The vertical distance between the plates 316 and 318 allows for the controllable actuators 250 A and 250 B to extend therein. Plate 316 may have a pair of spaced holes 316 A and 316 B and plate 318 may have a pair of spaced holes 318 A and 318 B that are vertically aligned with the holes 316 A and 316 B. Holes 316 A, 316 B, 318 A and 318 B are preferably spaced to align with controllable actuators 250 A and 250 B. Pivot pins 236 may be used to couple the plates 316 and 318 to the controllable actuators 250 A and 250 B. Retainer 238 may prevent removal of the pins 236 . A fourth plate 322 and a fifth plate 324 may also extend outwardly from the second side 330 B of plate 330 . Plate 322 may have a hole 322 A vertical aligned with a corresponding hole 324 A in plate 324 . The holes may be sized to allow passage of pivot pin 214 to pass therethrough. The vertical distance between the plates 322 and 324 corresponds generally to the distance from the top of cylinder 216 to the bottom of cylinder 224 . When the plate 330 is coupled to the A-frame and the controllable actuators 250 A and 250 B, the plate can be raised and lowered and rotated left and right about a vertical axis.
[0032] The second member 370 (see FIG. 8) may include a first plate 372 having a first horizontally aligned rod 374 spaced from a second horizontally aligned rod 376 . The rods may be vertically spaced by a distance D. The ends of rod 374 may be secured in brackets 384 and 386 . The brackets may be secured along the bottom edge of the plate 372 . The first end of rod 376 may be secured in bracket 378 and the second end in bracket 420 . Bracket 378 may be made up of a first element 382 and a second element 378 . The first element 382 may have a hole 382 extending therethrough. The brackets 420 and 378 may be secured along the top edge of the plate 372 , preferably welded. A second plate 388 and a third plate 3902 may extend outwardly from the plate 372 . Plate 390 and may have a pair of spaced holes 390 A and 390 B that are vertical aligned with corresponding holes 388 A and 388 B in plate 388 . The holes may be sized to allow pins 412 to pass therethrough. A retainer 416 may prevent removal of the pins 412 . The holes 390 A and 390 B may be spaced to align with holes 116 A and 116 B on plate 116 on plow blade 100 . The vertical distance between the plates 388 and 390 corresponds generally to the distance from the top of plate 116 to the bottom of plate 118 on the plow blade 100 . Plates 388 and 390 may have cut outs 398 and 400 aligned with ribs 108 C and 108 D. The plate 390 may have a vertically aligned hollow cylinder 392 extending upwardly. The cylinder 392 may be supported by gussets. The opening in the hollow cylinder 392 may be sized to allow a pin 410 to extend therethrough. A retainer 414 may prevent removal of the pins 410 . The pins 410 and 412 fixedly secure the second plate 370 to the plow blade 100 . Rods 374 and 376 extend through brackets 334 A and 334 b and 336 A and 336 B respectively to slidably couple the first member to the second member.
[0033] In an alternative embodiment, the second member may be welded to the backside of the plow blade 100 .
[0034] The controllable actuator 350 may have a body portion 352 having a bracket 356 secured at a first end and a moveable cylinder 354 extending from a second end. The cylinder may have a bracket 358 at a distal end. The bracket 358 may have a pair of horizontally aligned holes for securing the bracket 358 to bracket 378 on the second member 370 of the coupling assembly. The bracket 356 may have a vertically aligned hole for securing the bracket 356 to bracket 332 on the first member 300 of the coupling assembly. The controllable actuator is preferably a hydraulic piston manufactured by Chief of Romania under part number 214945 and has a 24″ stroke. Other pistons may be used with out departing from the present invention. The controllable actuator 350 may be bi-directional, capable of moving the cylinder 354 in and out. Alternatively, two separate uni-directional pistons may be used without departing from the present invention. The controllable actuator body portion 352 may have a first coupling 360 coupled to a hose 364 and a second coupling 362 coupled to a hose 366 . Operation of the controllable actuator 350 will be discussed below.
[0035] [0035]FIG. 9 is a simplified hydraulic system schematic of the plow assembly of FIG. 3. The hydraulic system includes a hydraulic pump 264 , hydraulic hoses 262 A-C, and controllable actuators 250 A, 250 B, and 270 . The hydraulic pump 264 is powered by a powered supply (not shown) and pumps hydraulic fluid from a reservoir to a controllable actuator. The hydraulic pump 264 receives control signals from a controller 500 typically located inside the plowing vehicle. The controller 500 is capable of raising and lowering a coupled plow blade by pumping hydraulic fluid into or out of controllable actuator 270 . The hydraulic fluid is transported to the controllable actuator 270 through a coupling 264 C located on the hydraulic pump 264 , a hose 262 C and a coupling 260 C located on the controllable actuator 270 . Hydraulic fluid can be transferred from the left controllable actuator 250 A to right controllable actuator 250 B to cause a coupled plow blade to rotate counterclockwise about a vertical axis. Hydraulic fluid may be pumped from the controllable actuator 250 A, through a coupling 260 A, a hose 262 A, and a coupling 264 A located on the hydraulic pump 264 and into the hydraulic pump 264 . Fluid may then be pumped from the hydraulic pump 264 , through a coupling 264 B located on the hydraulic pump 264 , a hose 262 B, a coupling 260 B located on the controllable actuator 250 B and into the controllable actuator 250 B. Likewise a coupled plow may be caused to rotate clockwise by transferring fluid from the right controllable actuator 250 B to the left controllable actuator 250 A.
[0036] The controller 500 may have an “up” actuator 502 for causing a coupled plow to rise, a down actuator 504 for causing a coupled plow to lower, a “right” actuator 506 for causing a coupled plow to rotate clockwise, and a “left” actuator 508 for causing a coupled plow to rotate counterclockwise. The controller 500 may be coupled to the hydraulic pump 264 by a cable 510 . Alternatively, the signals may be sent by radio frequency.
[0037] [0037]FIG. 10 is a simplified hydraulic system schematic consistent with the present invention. The system adds a fourth controllable actuator 350 , a fluid steering assembly 700 , and hoses 264 A′, 264 B′, 364 and 366 to the system schematic shown in FIG. 9 and replaces controller 500 with a controller 600 . Hydraulic hoses 264 A and 264 B are now coupled to the fluid steering assembly 700 at couplings 702 A and 702 B (see FIG. 11) respectively. Controllable actuators 250 A and 250 B are now coupled to the fluid steering assembly 700 at couplings 702 A″ and 702 B″ respectively. Hoses 364 and 366 are coupled at a first end to the fluid steering assembly 700 at couplings 702 A′ and 702 B′ respectively through hoses 264 A′ and 264 B′ respectively. The other end of hoses 364 and 366 are coupled to couplings 360 and 362 on the fourth controllable actuator 350 .
[0038] When fluid is pumped from the hydraulic pump 264 to the controllable actuator 350 , the second member 370 is urged to move relative to the first member 300 . Fluid pumped through coupling 360 causes the plow blade to move perpendicular to the longitudinal axis of the plowing vehicle towards the right and fluid pumped through coupling 362 causes the plow blade to move perpendicular to the longitudinal axis of the plowing vehicle towards the left. Bushings and/or bearings may be added to allow the moving parts to slide more freely and parts may be coated with a lubricant to reduce friction and help prevent rust or corrosion.
[0039] A cable 604 couples the controller 600 to the hydraulic pump 264 and the fluid steering assembly 700 . A portion 604 A of cable 604 couples the controller 600 to the fluid steering assembly 700 and a portion 604 B couples the controller 600 to the hydraulic pump 264 .
[0040] The controller 600 includes a handle portion 602 and an actuator portion 606 . The actuator portion may have an “up” actuator 610 , a “down” actuator 612 , a “right” actuator 614 and a “left” actuator 616 . The actuators send signals to the hydraulic pump 264 . The controller 600 may also include an actuator 618 . The function of the “right” actuator 614 and the “left” actuator 616 may be changed based on the status of the actuator 616 . The actuator 616 is preferably a momentary actuator, however maintained actuator may be used. When the momentary actuator 618 is not being actuated, a pair of controllable switches 704 A and 704 B in the fluid steering assembly 700 fluidly couple coupling 702 A to coupling 702 ″ and coupling 702 B to coupling 702 B″. The controllable switches preferably work in unison. When the momentary actuator is actuated, a signal may be sent to the fluid steering assembly 700 to toggle the position of controllable switches 704 A and 704 B. During this time, the pair of controllable switches 704 A and 704 B fluidly couple coupling 702 A to coupling 702 ′ and coupling 702 B to coupling 702 B′. The “right” actuator 614 now causes a coupled plow blade to travel linearly to the right and the “left” actuator 616 causes a coupled plow blade to travel linearly to the left. When the actuator 618 is released, the controllable switches 704 A and 704 B in the fluid steering assembly 700 may return to their original position. Using a momentary actuator is preferred over a maintained actuator because if the fluid steering assembly is left in the second position and the coupled plow blade strikes a non-moveable object the first controllable actuator 250 A and the second controllable actuator 250 B may be damaged. Alternatively, the controller 600 may have a dedicated actuator 620 for controlling the side-to-side position of a coupled plow blade.
[0041] Alternatively, actuator 618 may send a signal to the fluid steering assembly 700 to change the state of the switches 704 A and 704 B. In an alternative embodiment, the fluid steering assembly 700 may be separated into two separate enclosures.
[0042] In another alternative embodiment, a hydraulic pump with five or more couplings may be used. This embodiment is less preferred to the hydraulic pump 264 due to cost.
[0043] It should be understood that, while the present invention has been described in detail herein, the invention can be embodied otherwise without departing from the principles thereof, and such other embodiments are meant to come within the scope of the present invention as defined in the following claim(s) | A plow blade assembly is disclosed that allows the centerline of the plow blade to be moved transversely about the centerline of a plowing vehicle. The operator can extend the end of the plow blade past the side of the plowing vehicle and in front of the vehicle tires. By positioning the blade to one side of the vehicle, the operator can prevent snow from rolling off the end of the plow blade and coming into contact with the vehicle tires and provide a greater distance between the outside edge of the plow blade and the side of the vehicle, including any extending mirrors. The assembly can control the angle of the blade relative to the longitudinal axis of the plowing vehicle and control the position of the blade relative to the centerline of the vehicle. A controller in the vehicle allows the operator to independently position the blade. | 4 |
CROSS-REFERENCED TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to buckets used with work vehicles. More specifically, this invention relates to multi-purpose buckets used with work vehicles.
II. Related Art
Various work vehicles exist in the art. Such work vehicles include, without limitation, skid-steer loaders, back hoes, excavators, power shovels, front end loaders, tractors and the like. A variety of bucket attachments have been developed for use with such vehicles. However, such buckets typically are designed for a single purpose.
For example, some buckets are designed for excavating. See U.S. Pat. No. 6,546,650 to Meurer. Others are designed for grading. See U.S. Pat. No. 6,662,478 to Virnig. Still others are designed for digging. See U.S. Pat. No. 4,028,823 to Edwards et al; U.S. Pat. No. 5,018,283 to Fellner and U.S. Pat. No. 3,478,449 to Baker. Some are designed for dislodging (or moving) rocks, stumps and other large and bulky debris. See U.S. Pat. No. 6,098,320 to Wass and U.S. Pat. No. 4,607,441 to Norton. Others are designed for scooping and lifting. See U.S. Pat. No. 3,807,587 to Maurer. Still other are adapted for sue in hard materials such as rock strata, caliche, soapstone and plastic soils such as clay. See U.S. Pat. No. 4,476,641 to Ballinger. Some buckets are designed for ripping and trenching applications. See U.S. Pat. No. 4,616,433 to Knell et al. Still other buckets are designed for scraping or leveling the ground. See U.S. Pat. No. 7,562,473 to Westendorf et al; U.S. Pat. No. 6,434,863 to Meurer and U.S. Pat. No. 6,910,290 to Meurer.
The specialized nature of bucket attachments forces owners and operators of work vehicles to make a choice. They have to decide whether the work vehicle will be used for a single purpose or whether the work vehicle will be used for multiple purposes at various job sites. If the work vehicle is equipped with a single specialized bucket, several work vehicles may need to be transported and operated at the job site to complete the job. This can greatly increase the cost of the job and needlessly tie up expensive equipment. If the work vehicle will be used for multiple purposes, various specialty buckets will need to be transported to the job site to complete the job. The task of changing buckets, however, can lead to inefficiency and also increase the risk of job related injuries. This choice and the problems associated with each of the two options could be eliminated by providing a multi-purpose bucket suitable for performing multiple tasks such as excavating; grading; lifting; digging; dislodging rock, stumps and other debris; scooping and lifting; working with hard materials such as rock strata, caliche, soapstone and clay; ripping and trenching; and scraping and leveling. While other have developed multi-purpose attachments for work vehicles (see U.S. Pat. No. 6,820,357 to Menard et al and U.S. Pat. No. 5,564,885 to Staben, Jr.), these attachments have been limited in terms of the number of applications they can perform effectively and efficiently.
SUMMARY OF THE INVENTION
The present invention relates to work vehicle attachments adept at performing a variety of work related functions. These functions can all be performed by an open bucket having a suitable configuration comprising an open front, a bottom wall, a top wall, a back wall and a pair of side walls. The bottom wall of the bucket has a back edge, a front edge shorter than the back edge, and a pair of side edges. Each of the side edges have a first portion extending from the back edge in a direction normal to the back edge and a second portion extending at an angle from the first portion to an end of the front edge. The top wall of the bucket has a substantially rectangular shape. The front and back edges of the top wall are of substantially the same length as the back edge of the bottom wall. The side edges of the top wall are substantially shorter than the side edges of the bottom wall. A back wall and two side walls join the top wall and the bottom wall. The back wall extends between the back edges of the top wall and bottom wall. Each of the side walls have a top edge substantially co-extensive and joined to a side edge of the top wall, a back edge substantially co-extensive with and joined to a side edge of the back wall, and a bottom edge substantially co-extensive with and joined to the first portion of a side edge of the bottom wall. The front edge of each of the side walls has a first section extending substantially normal to the top wall. This first section extends from the top wall to a point more than two-thirds the distance from the top wall to the bottom wall. The front edge of each side wall also includes a second section extending substantially normal to the bottom wall from the bottom wall. A third section of the front edge of the side wall joints the first and second sections.
The attachment also includes a plurality of tines. The tines are joined to the bottom wall and each extends past and over portion of the front edge of the bottom wall. Each tine is spaced from the first portions of the side edges and the center of the front edge of the bottom wall.
In some embodiments of the invention, the attachment is joined to a pair of loader arms of a work vehicle. The loader arms each have a longitudinal axis and the tines are positioned so each tine resides between the longitudinal axes of the loader arms.
In some embodiments there is an even number of tines. In such embodiments, half the tines reside between the center of the bottom wall and one of the side walls and the other half of the tines reside between the center of the bottom wall and the other of the side walls. Likewise, in some embodiments the tines extend above the bottom wall. Some embodiments also include a length of angle iron along the back edge of the bottom wall.
The attachment can also include a thumb. Such a thumb comprises a movable member joined by a hinge connector to one of the walls of the bucket so the movable member is movable between a first position in which the movable member extends across the open front of the bucket and a second, retracted position. A ram such as a hydraulic or pneumatic ram can be used to pivot the movable member about the hinge connector between the first and second positions.
In some embodiments, the movable member of the thumb comprises first second and third arm segments. The second arm is connected at one of its ends by a hinge connector to an end of the first arm and at the other of its ends by a hinge connector to an end of the third arm. Hinge connectors are also provided to attach a midpoint of the first arm to a wall of the bucket and to attach the first arm to a ram. The hinge connectors joining the three arms permit the movable member of the thumb to be folded and unfolded with respect to each other. Locking pins may be used to secure the arms in the folded or unfolded positions.
The invention briefly described above is suitable for a number of tasks. The attachment is adept at digging and transplanting small trees and shrubs. The shape allows for carrying long objects. The construction allows for a smooth back dragging function. The arrangement of the tines allows them to be used for scarifying, captivating, prying, lifting, separating, moving and positioning of items. The arrangement of the tines also permits the apparatus to be used for setting poles (such as telephone poles) in holes. The arrangement of the tines and the bottom wall of the attachment also impedes movement and rolling of items (such as rocks) within the bucket as such items are being transported. The positioning of the tines also limits certain damaging forces that would otherwise be encountered by the loader arms.
These and other advantages of the present invention will be better appreciated from a reading of the detailed description of the invention in conjunction with the drawings provided as part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a first embodiment of the attachment of the present invention attached to the loader arms of a work vehicle;
FIG. 2 is another perspective view showing generally the front of the embodiment of FIG. 1 ;
FIG. 3 is still another perspective view showing generally the back of the embodiment of FIG. 1 ;
FIG. 4 is another perspective view showing generally the bottom of the embodiment of FIG. 1 ;
FIG. 5 is a front view of the attachment of FIG. 1 ;
FIG. 6 is a side view of the attachment of FIG. 1 ;
FIG. 7 is a top view of the attachment of FIG. 1 ;
FIG. 8 is a perspective view of another embodiment of the attachment of the present invention;
FIG. 9 is another perspective view of the embodiment of FIG. 8 ;
FIG. 10 is another perspective view of the attachment of FIG. 8 showing the thumb in a folded position for storage.
DETAILED DESCRIPTION
FIG. 1 shows a pair of loader arms 2 , 3 of a work vehicle (not shown). Associated with each loader arm is a hydraulic ram 4 , 5 . FIG. 1 also shows an attachment 10 secured to each of the loader arms 2 , 3 . More specifically, a pivot pin 6 is used to pivotally secure the distal end of each of the loader arms 2 , 3 to the attachment 10 . A pivot pin 7 is likewise used to pivotally secure the distal end of hydraulic rams 4 , 5 to the attachment 10 . This arrangement permits the attachment 10 to be not only raised and lowered by the loader arms 2 , 3 , but also be tilted with respect to the loader arms in a conventional fashion. Those skilled in the art should recognize the attachment 10 may be attached to a loader arm is any conventional manner without deviating from the invention. For this reason and to assist in better illustrating the invention, the loader arms 2 , 3 and rams 4 , 5 are not shown in the drawings other than in FIG. 1 .
As will be explained with reference to FIGS. 2-7 , the attachment 10 includes a bucket 12 having a unique shape and construction. Generally, the bucket 12 includes an open front 14 , a bottom wall 16 , a top wall 18 , a back wall 20 and first and second side walls 22 and 24 .
The shape of bottom wall 16 is best shown in FIG. 4 . The bottom wall 16 is essentially a plate having a back edge 30 , a front edge 32 , and side edges 34 and 36 . Each side edge has a first portion 38 and a second portion 40 . As shown, the front edge 32 is generally parallel to the back edge 30 . The front edge 32 , however, is substantially shorter than the back edge. For example, the back edge 30 could be four feet long and the front edge 32 could be three feet long. Typically, the front edge 32 will be about the same length or shorter than the distance between the loader arms 2 , 3 of the work vehicle. The back edge 30 can either be secured to or comprise an L-shaped piece of angle iron 42 .
The first portion 38 of each of the side edges 34 , 36 extends in a substantially normal direction (i.e., substantially at a 90° angle) from an end of the back edge 30 . The second portion 40 of each side edge 34 , 36 connects the first portion 38 with the front edge 32 . The angle 44 between the front edge and the second portion 40 of each side edge 34 , 36 can vary. As shown, this angle is about 135°. This angle ideally (but not necessarily) is between 130° and 140°.
As shown in the drawings, the attachment also includes six tines 50 . Each of the tines 50 is fastened to the top of the bottom wall 16 , for example by welds. Each of the tines 50 extend from the back edge 30 of the bottom wall 16 past the front edge 32 of the bottom wall 16 . The tines 50 each extend in a direction normal to, past and over a portion of the front edge 32 of the bottom wall 16 . Further, the tines 50 are all located between the longitudinal axes of the loader arms 2 , 3 . Each of the tines 50 is spaced from the first portion 38 of the side edges 34 , 36 of the bottom wall 16 . Each of the tines 50 is also spaced from an imaginary line 51 parallel to the first portions 38 running through the center of the bottom wall 16 . When an even number of tines are used, they are uniformly spaced and no tine resides along this imaginary center line. Each of the tines 50 extends well past the front edge 32 of the bottom wall 16 and terminates at an angled tip 52 .
The top wall 18 of the bucket 12 has a substantially rectangular shape having a front edge 54 and a back edge 56 and a pair of side edges 58 , 60 . The front and back edges 54 , 56 of the top wall 18 are approximately the same length as the back edge 30 of the bottom wall 16 . The side edges 58 , 60 of the top wall 16 are substantially shorter in length than the first portions 38 of the side edges 34 , 36 of the bottom wall 16 . As shown in the drawings, the side edges of the top wall 16 are about one-third the length to the first portion 38 of the side edges 34 , 36 of the bottom wall 16 . This can vary, but generally the side edges 58 , 60 of the top wall 18 should be between one-quarter and one-half the length of the first portion 38 of the side edges 34 , 36 of the bottom wall 16 .
The back wall 20 extends between the bottom wall 16 and the back edge 56 of the top wall 18 . The back wall 20 has a center section 62 . As shown in the drawings, center section 62 is substantially shorter in length than the distance between the top wall 18 and bottom wall 16 . The center section 62 also extends along a plane substantially normal to the planes of the top wall 18 and bottom wall 16 . The back wall 20 also has a top section 64 extending between the center section 62 and the back edge 56 of the top wall 18 . A bottom section 66 of the back wall 120 extends between the center section 62 and the bottom wall 16 . The top section 64 and bottom section 66 can either be curved or angled with respect to the center section 62 to provide a bucket shape.
The side walls 22 , 24 each have a top edge 67 substantially co-extensive with and joined to a side edge 58 or 60 of the top wall 18 . The side walls 22 , 24 also have a back edge 68 substantially co-extensive with and joined to a side edge of the back wall 20 . The bottom edge 70 of each of side walls 58 and 60 is co-extensive with and joined to the first portion 38 of a side edge 34 of 36 of the bottom wall 16 . The front edge 72 of each of side walls 22 , 24 has a first section 74 extending down from the corner at which the front edge 54 and one of the side edges of the top wall intersect. The first section 74 of front edge 72 extends along a line substantially normal to the top wall 18 to a point 75 . Point 75 is generally along a line parallel to the top wall and extending through the intersection between the center section 62 and bottom section 66 of the back wall 20 . As shown in the drawings, the first section 74 extends more than three-fourths of the length between the top wall 18 and bottom wall 16 , but this is not necessarily the case.
The front edge 72 of each side wall 22 , 24 also has a second section 76 . Section 76 extends upwardly from the intersection of the first portion 38 and second portion 40 of a side edge 34 or 36 of the bottom wall 16 in a direction substantially normal to the bottom wall 16 .
Completing the front edge 72 of each side wall 22 , 24 is a third section 78 extending between the bottom of the first section 74 and the top of the second section 76 . While the angles between the third section and the first and second sections could be a right angle, as shown in the drawings, they are not. The lengths of first section 74 and second section 76 are such that the third section 78 is not at a right angle with respect to the first section 74 or the second section. Instead, the third section 78 slopes toward the bottom wall 16 as it extends away from the first section 74 toward the second section 76 .
The construction of the bucket 12 and tines 50 described above offers numerous advantages. The tines can be used to loosen soil and the bucket used to remove the soil when trenching. The tine and bucket arrangement also makes the attachment 10 well suited when transplanting small trees and shrubs. The shape defined by the side walls 22 , 24 and tines 50 make the attachment well suited for carrying long objects such as tree trunks, poles and lumber. The incorporation of an angle iron at the back edge of the bottom wall is highly beneficial when smoothing excavated ground. The spacing of the tines 50 allow the attachment 10 to be used effectively when scarifying, captivating, prying, lifting separating, moving or positioning items. The spacing of tines 50 also allows the attachment 10 to be used effectively for setting and orienting poles, posts, small trees or the like in holes. When carrying rocks or other objects the arrangement of the tines and walls of the bucket inhibits rolling of such items leading to greater stability and safety.
Safety and stability of objects carried by the attachment 10 can be even further enhanced if the thumb assembly 100 shown in FIGS. 8-10 is also provided as part of the attachment. The thumb 100 has a first position in which it crosses the open front 14 of the bucket 12 as shown in FIG. 9 . The thumb 100 also has a second, retracted position above the open front 14 . A third folded position is shown in FIG. 10 .
The thumb 100 comprises a movable member 102 having a first arm 104 , a second arm 106 and a third arm 108 . One end of arm 106 is coupled by a hinge connector 110 to an end of the arm 104 . The other end of arm 106 is coupled by a hinge connector 112 to arm 108 . Further, the first arm 104 is connected at a midpoint by a hinge connector 114 to a wall of the bucket 12 . The first arm 104 is also connected to a ram 120 used to pivot the movable member 102 between the first position across the open front 14 of the bucket 12 and the second, retracted position. The thumb 100 also includes one or more locking pins 122 used to lock the position of the arms 104 , 105 and 108 either in the unfolded position shown in FIGS. 8 and 9 or the folded position shown in FIG. 10 .
As best shown in FIGS. 8 and 9 , the arms 104 and 106 each comprise a pair of parallel members 105 and 105 a secured together by cross members. For example, one or more cross members join the parallel members of arm 104 . One cross member 150 is located at the point where arm 104 is pivotally attached to the ram 120 . Another cross member 152 can be used to pivotally attach arm 104 to hinge connector 114 . A third cross member may be provided where the arm 104 is pivotally attached to arm 106 and serve as hinge connector 110 . The parallel members 107 and 107 a of arm 106 may be secured together by a cross member (such as 156 ) at hinge connectors 110 and 112 .
As also shown in FIGS. 8 and 9 , the arm 108 comprises four parallel members. These are joined by the cross member 156 at the location of hinge connector 112 and by a second cross member 158 at approximately the midpoint between the hinge connector 112 and the free end 160 of arm 108 .
To lock arms 104 , 106 and 108 in the unfolded position shown in FIGS. 8 and 9 , a set of locking pins 122 which mate with alignable holes in two of the arms are provided. As shown in FIGS. 8 and 9 , these pins 122 lock the position of arm 104 relative to arm 106 , and arm 106 relative to arm 108 . When these pins 122 are retracted (or removed), the arms 104 , 106 and 108 can easily be folded into the position shown in FIG. 10 .
The foregoing description is not intended to be limiting, but rather to explain attributes of the invention and how they can be implemented. The invention is only limited by the claims recited below. | A multi-purpose attachment for work vehicles comprises a unique bucket shape and tine arrangement permitting the attachment to be used when performing a variety of jobs at a job site. The attachment may also include a thumb that can be extended over the open front of the bucket, retracted and even folded when not in use. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to manufacturing shaped filter pieces having adsorbent properties by using activated carbon fibers. The term “shaped filter pieces” is used herein to mean self-supporting filter pieces of non-planar shape.
[0002] The invention relates specifically to making shaped pieces of clothing, e.g. gloves, socks, under-garments, caps, . . . for use by civilian or military personnel to protect them against aggression, in particular of nuclear, biological, or chemical origin.
[0003] Nevertheless, the method of the invention can be used in other applications, for example to make filter pieces having special shapes, such as sleeves, spherical caps, or the like.
BACKGROUND OF THE INVENTION
[0004] Various materials have been proposed for making nuclear, biological, chemical (NBC) protective garments.
[0005] Thus, it is known to make protective suits out of thick rubber, typically isobutyl rubber. Such suits are particularly uncomfortable and difficult to bear when the temperature is relatively high since they retain respiration.
[0006] Proposals have also been made to use particles of active charcoal dispersed in a foam, e.g. a polyurethane foam. Suits or garments made in this way are thick. They also present the drawbacks of being difficult to wash and of behaving poorly in the presence of fire, because of the presence of the foam. In addition, if they need to be laminated on a shaped substrate in order to be used, then porosity and breatheability can be affected. In addition, under moist conditions, e.g. because of sweating, the adsorption ability of active charcoal is diminished.
[0007] Proposals have also been made to use activated carbon fibers. Their mechanical properties make it difficult to subject them to textile operations such as spinning, weaving, knitting, sewing, braiding, . . . in order to make shaped pieces of clothing. It might be thought that activated carbon fibers could be assembled onto a substrate having the shape of the garment to be made, but that returns to the drawbacks mentioned above concerning pores becoming obstructed and a reduction in breatheability.
[0008] In order to solve the problem posed by carbon fibers being unsuitable for textile operations, document FR 2 599 761 A proposes using a composite thread comprising a core having the required mechanical properties, for example a metal core, with carbon precursor fibers being wound or lapped thereon. The composite thread can be used for making a cloth prior to carbonizing the carbon precursor fibers and activating them. According to document FR 2 599 761 A, the resulting cloth can be used for making protective pieces of clothing. A drawback of that method lies in the complexity and the cost involved in making the composite thread. Another drawback lies in the presence of metal reinforcement in the resulting pieces of clothing which makes them very stiff, and that can be penalizing from the discretion point of view for military applications.
[0009] Activated carbon cloth is known and used for filter piece applications. Document FR 2 741 363 A and WO 989/41678 A describe the making of such cloth. Nevertheless, making shaped pieces of clothing from that cloth requires a sewing operation. Unfortunately, stitches made in activated carbon cloth give rise to a significant local increase in stiffness, giving rise to discomfort. In addition, by leading to pores of non-uniform size, stitches provide easy passages for the toxins that ought to be retained.
OBJECTS AND SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a method enabling shaped filter pieces to be made, and particularly but not exclusively pieces of clothing for NBC protection, but without encountering the above-specified drawbacks.
[0011] More particularly, the invention seeks to obtain such shaped filter pieces that are made integrally out of activated carbon fibers, that are washable, thermally stable, and capable of retaining good adsorption properties under moist conditions, while intrinsically presenting good mechanical strength and offering pores that are free from any preferred passages for the medium that is to be filtered.
[0012] These objects are achieved by a method comprising the steps consisting in:
[0013] using a textile manufacturing method to make a preform of the piece to be manufactured out of a coherent fabric of carbon precursor fibers; and
[0014] performing carbonization and activation treatment so as to obtain directly the desired shaped piece made of activated carbon fibers;
[0015] the preform being dimensioned so as to take account of shrinkage during the carbonization and activation treatment.
[0016] The invention is remarkable in that the filter piece is obtained directly after carbonizing and activating a preform of carbon precursor fibers that have previously been worked using a textile method to give a shape corresponding to that of the piece that is to be made.
[0017] The textile method used for shaping the preform can be constituted, at least in part, by knitting, sewing a two-dimensional fabric, or braiding. The term “two-dimensional fabric” is used herein to mean in particular a woven cloth or a multidirectional web.
[0018] The preform is made in particular as a cellulose fiber fabric, e.g. using rayon fibers, thus making it possible to obtain carbon fibers of high purity and to obtain a large specific surface area, for example greater than 800 square meters per gram (m 2 /g), or indeed greater than 1200 m 2 /g.
[0019] In a first implementation of the method, the carbonization and activation treatment comprises:
[0020] a carbonizing step comprising heat treatment under an inert atmosphere up to a temperature lying in the range 250° C. to 500° C.; and
[0021] a step of activating the carbonized preform performed at a temperature lying in the range 750° C. to 950° C.
[0022] Activation is performed under an oxidizing atmosphere such as water vapor and/or carbon dioxide.
[0023] In a second implementation of the method, the carbonization and activation sequence comprises:
[0024] a step of impregnating the preform with a composition containing at least one ingredient having a function of promoting cellulose decomposition; and
[0025] heat treatment at a temperature lying in the range 350° C. to 500° C. so that a filter piece of activated carbon fibers is obtained directly.
[0026] The invention also provides a piece of clothing of the kind that can be obtained by the method, i.e. a shaped piece of clothing characterized in that it is made as a single piece of coherent fabric constituted by activated carbon fibers.
[0027] Such a piece of clothing is remarkable in that it intrinsically presents the strength needed to enable it to be used, while nevertheless being made of activated carbon fibers.
[0028] In addition, since they are made of carbon, pieces of clothing of the invention present good characteristics in the presence of fire and they are thermally stable. Because of their conductivity, carbon fibers enable static electricity to be evacuated. They are also easily washable. Compared with particles of active charcoal, pieces made of activated carbon fibers present very limited loss of performance due to moisture. The vast majority of the pores in activated carbon fibers are micropores that are not suitable for becoming filled with water by capillarity. In addition, because they are much smaller in size than particles of active charcoal, activated carbon fibers present a much greater outside surface area to a flow of gas for a given weight of carbon. For given performance, the thickness of the pieces concerned can be greatly reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention will be better understood on reading the following description given by way of non-limiting indication and with reference to the accompanying drawing, in which:
[0030] [0030]FIG. 1 shows the successive steps in a method constituting an implementation of the invention;
[0031] [0031]FIG. 2 shows the successive steps in a method constituting a variant of the FIG. 1 implementation; and
[0032] [0032]FIG. 3 is a photograph showing a preform for a glove knitted using a viscose thread, and the activated carbon fiber glove obtained after applying carbonization and activated treatment to the preform.
DETAILED DESCRIPTION OF EMBODIMENTS
[0033] In the description below, reference is made to manufacturing protective pieces of clothing. As mentioned above, the invention is nevertheless not limited to this application and it covers, more generally, making shaped filter pieces.
[0034] A first step 10 of the method shown in FIG. 1 consists in making a preform of the piece to be made, using a textile manufacturing process.
[0035] The preform is made using carbon precursor fibers which are in the form of thread or yarn. Various types of precursor can be used such as preoxidized polyacrylonitrile (PAN), pitch, phenol compounds. Preferably a cellulose precursor is used, in particular a viscose, e.g. rayon.
[0036] The preform is shaped to have a shape corresponding to that of the piece that is to be made, while nevertheless allowing for shrinkage that occurs during carbonization and activation treatment.
[0037] The shaping can be implemented directly using the threads or yarns of carbon precursor fiber, in particular by knitting or braiding.
[0038] It is also possible to begin by making a two-dimensional fabric from the carbon precursor fiber threads or yarns, e.g. a woven cloth or a multidirectional web, with the preform then being shaped by being cut and stitched using a thread of the same kind. A multidirectional web is formed by superposing a plurality of unidirectional webs made up of threads or yarns extending parallel to a given direction. The unidirectional webs are superposed to extend in different directions and they are optionally bonded to one another, e.g. by stitching or by light needling.
[0039] A second step 20 of the method consists in carbonizing the preform. Carbonizing comprises a stage of heat treatment in an inert atmosphere at a temperature lying in the range 250° C. to 500° C., for example a temperature equal to about 400° C., this stage being performed with a slow rise in temperature, typically at a rate of 0.01° C. per minute (min) to 0.5° C./min over a relatively long duration of several days to several weeks.
[0040] A final stage of heat treatment can subsequently be performed at a higher temperature, e.g. up to 600° C. to 900° C., likewise under an inert atmosphere, for a duration that is much shorter, for example a few minutes.
[0041] Additional heat treatment at a temperature that is even higher, e.g. lying in the range 1000° C. to 1300° C. and under reduced pressure, e.g. pressure lying in the range 5 Pascals (Pa) to 60 Pa may optionally be performed for a relatively short duration, about 1 minute, in order to encourage elimination of impurities that are entrained with the gaseous effluent.
[0042] A third step 30 of the method consists in activating the resulting carbon fiber preform. Activation is performed by subjecting the carbon fiber preform to heat treatment under an oxidizing atmosphere such as water vapor or preferably carbon dioxide or a mixture of carbon dioxide and water vapor. Reference can be made to above-cited document FR 2 741 363 A. The heat treatment temperature lies in the range 750° C. to 950° C., and preferably in the range 850° C. to 950° C., and its duration preferably lies in the range 50 min to 300 min as a function of the desired specific surface area. It is thus possible to obtain an activated carbon fiber piece presenting a specific surface area greater than 800 m 2 /g, or even greater than 1200 m 2 /g.
[0043] A final step 40 of post-treatment may optionally be performed, as a function of the intended use for the piece. By way of example, one kind of post-treatment may consist in forming a very fine deposit so as to fix any particles of carbon and prevent them coming off when the piece is in use. This deposition can be performed by spraying elastomer or latex.
[0044] Another type of post-treatment may consist in associating the piece with a lining whose function is not to give strength to the piece but to avoid direct contact between the piece and the skin of the user. The lining may be aerated so as to avoid affecting porosity and permeability and it need be connected to the piece via a few points only, e.g. by adhesive.
[0045] [0045]FIG. 2 shows a variant implementation of the method suitable for use with a preform of cellulose precursor fibers. This variant differs from the method of FIG. 1 in that steps 20 and 30 of carbonization and of activation are replaced by a step 20 ′ of impregnating the preform with a composition containing an ingredient that promotes dehydration of cellulose, and a heat treatment step 30 ′ that serves to obtain the piece made of activated carbon fibers directly.
[0046] Impregnation is performed using a composition containing at least one ingredient that promotes dehydration of cellulose, such as an inorganic ingredient selected from phosphoric acid, zinc chloride, potassium sulfate, potassium hydroxide, diammmonia phosphate, and ammonium chloride. Impregnation is preferably performed using a composition containing phosphoric acid so that the mass of acid fixed on the preform lies in the range 10% to 22% by weight of the dry preform. The heat treatment comprises raising temperature at a rate lying in the range 1° C./min to 15° C./min followed by a pause which is preferably performed at a temperature lying in the range 350° C. to 500° C. under an inert atmosphere or under an atmosphere containing a reaction activator such as carbon dioxide or water vapor. The resulting piece is preferably subsequently washed. Such a method is described in above-mentioned international patent application WO 98/41678. A piece made of activated carbon fibers is thus obtained directly.
EXAMPLE 1
[0047] Glove preforms of the kind shown on the left in the photograph of FIG. 3 were made by knitting a 330 decitex (dtex) rayon thread with stocking stitch, the edging of the gloves being made using a 167 dtex rayon thread.
[0048] The preforms were placed on frames in a kiln and subjected to heat treatment for about 2 weeks. Temperature was raised very slowly, less than 0.1° C./min, until a level of about 400° C. was reached.
[0049] The resulting preforms were subsequently subjected again to heat treatment up to a temperature of about 700° C. for a period of about 15 min so as to stabilize the carbon lattice.
[0050] The carbonized preforms were activated in a rotary autoclave at a temperature of about 850° C. under an atmosphere of carbon dioxide (CO 2 ) for a period of about 1 hour (h).
[0051] The resulting gloves were like the gloves shown in the photograph of FIG. 3 (on the right). They presented the following mean characteristics:
[0052] specific surface area approximately equal to 1500 m 2 /g;
[0053] breaking strength in traction equal to about 1.5 decanewtons per centimeter (daN/cm);
[0054] breaking elongation: about 50%;
[0055] carbon content: about 95%;
[0056] diameter of the activated carbon fibers (filaments): about 17 micrometers (μm).
[0057] The shrinkage caused by carbonization and activation was on average 32%. This shrinkage needs to be taken into account in order to make preforms that give rise to gloves of the desired sizes.
[0058] It should be observed that depending on the textile manufacturing process used and the shapes of the pieces, shrinkage is not necessarily uniform throughout a piece and in all directions. The shape to be given to the preform is preferably determined by testing, which tests can enable simulation models to be devised.
[0059] In order to avoid direct contact with the skin, the activated fiber carbon glove can be put on over an underglove, e.g. of cotton. The underglove and the glove can be connected together by means of a few spots of adhesive.
[0060] The resulting assembly is directly insertable in an overglove, e.g. made of leather. In operation, only the subassembly formed by the activated carbon fiber glove and any underglove is consumable. It is also easy to incinerate without giving off toxic effluent.
EXAMPLE 2
[0061] Glove preforms such as those of Example 1 were impregnated by being immersed in a 20% by volume solution of phosphoric acid H 3 PO 4 in water. The impregnated preforms were baked at a temperature lying in the range 70° C. to 90° C. to drive off the water, and the quantity of phosphoric acid fixed on the preforms constituted about 16% by weight relative to the weight of the dried preforms.
[0062] The preforms were then inserted continuously into a heat treatment oven through which they traveled while supported on a belt, e.g. made of glass fibers. The heat treatment comprised a rise in temperature at a rate of about 5° C./min, followed by a level temperature of about 200° C. The heat treatment was performed under an inert atmosphere (nitrogen) for a total duration of about 90 min.
[0063] The resulting gloves were washed in demineralized water at a temperature of about 90° C.
[0064] The activated carbon fiber gloves made in this way presented the following characteristics:
[0065] specific surface area approximately equal to 800 m 2 /g;
[0066] traction breaking strength equal to about 1.2 daN/cm;
[0067] breaking elongation about 50%;
[0068] carbon content about 80%.
[0069] The measured shrinkage on average was 28%.
TESTS
[0070] Tests of effectiveness against mustard gas were performed using the gloves obtained in Example 1.
[0071] A vapor phase test was performed with mustard gas at 37° C.
[0072] No passage through the protective barrier constituted by the glove was observed after more than 8 h.
[0073] A liquid phase test was performed using mustard gas at ambient temperature (20° C.). The mustard gas was put into contact with the gloves in the form of drops, with the quantity of contamination used representing 10 g/m 2 of the surface of the gloves. The quantity of mustard gas that pass through the gloves was measured by extracting a flow of air at a speed of 0.2×10 −2 meters per second (m/s) from the inside of the gloves. After 24 h, the measured quantity that had penetrated lay in the range 0.2 micrograms per square meter (μg/m 2 ) to 1.02 μg/m 2 .
[0074] These tests show the remarkably effective protection obtained due to the adsorption properties of activated carbon fibers. | The method comprises the steps consisting in making a preform of the piece to be manufactured out of a coherent fabric of carbon precursor fibers, by using a manufacturing process such as knitting, stitching the two-dimensional fabric, or braiding; and performing carbonization and activation treatment to obtain directly the desired shaped piece made of activated carbon fibers; the preform being dimensioned so as to take account of shrinkage during the carbonization and activation treatment. The method can be used in particular for making pieces of clothing to provide protection against attack such as nuclear, biological, or chemical attack. | 1 |
OBJECT OF THE INVENTION
The object of the present invention relates to a new thread twist system for twisting and spinning machines.
BACKGROUND OF THE INVENTION
In the thread twisting industry, one of the most traditional machines that provides the torsion for one or more threads or fibres is the twister and the spinner.
The twisting and rolling or folding process on the reel of these machines is carried out by a rotating spindle system and the ring that guides the runner, the rocker that distributes the thread along the spindle, filling the reel, and the thread feeding. The ratio of the spindle speed to the thread feed speed is constant throughout the reel filling process and corresponds to the theoretical torsion of the programmed thread.
These conventional machines work (amongst others) with some working parameters such as torsions per meter of thread, thread feed speed and spindle revolutions per minute, and fulfills the theoretical expression:
Torsions per meter (THEORETICAL)=spindle speed (rpm)/spindle lineal speed (m/min)
This means that in the case of wanting to increase or reduce the spindle lineal speed, the spindle rotation speed increases or reduces by the same proportion, without varying the torsion, for the purpose of keeping constant the theoretical programmed tension value.
Therefore, even though it is known that on these machines the working speeds can be varied during the reel filling for the purpose, amongst others, of reducing the thread breakages, they have always fulfilled this formula and have always changed in the same proportion and at the same time the spindle rotational speed and the thread lineal speed and the (theoretical) torsion per meter value has always been kept constant.
Owing to the imperfect working principle of the system, during this twisting and reel filling process, actually a series of torsion divergences are produced on the thread compared to the programmed theoretical torsion. This means that having a programmed theoretical torsion on the machine, the real torsion on the thread once twisted is always different and variable depending on the portion of thread chosen from the reel.
These torsion variations depend on the runner that moves at a different turning speed to that of the spindle and which is variable throughout the reel filling. Said runner speed depends and is basically related to the spindle speed, the thread feed speed, the speed and the direction (up-down) of the rocker movement and the thread rolling diameter at a specific moment.
This variation of runner speed makes the thread roll onto the reel along the formation of the reel with a real torsions per meter value different to that which is theoretically programmed, as on the conventional machines it is always fulfilled the expression:
Torsions per meter (THEORETICAL)=spindle speed (rpm)/thread lineal speed (m/min)
Certainly with this ‘conventional’ working system, actually when the machine operator programmes the torsions per meter of thread to be processed, to a large extent it is unknown that actually the real torsions on the thread will be different to those programmed (theoretical). This ignorance and the ever increasing need to process threads with greater twist quality, less torsion variation, and as a consequence the improved mechanical properties that are the result once having been twisted have brought about the development of this invention.
DESCRIPTION OF THE INVENTION
In order to remedy the above mentioned irregularities the present invention has been developed, that is applicable to twisting and spinning machines in which the traditional theoretical torsion parameter has been replaced by the new real torsion parameter, which allows the thread to be actually and exactly produced and twisted with the real torsion required and kept throughout the reel filling process.
The system consists of the obtaining of the rotational speed of the runner during the process by means of suitable detection and/or calculation, and to keep constant the following ratio:
The torsions per meter (REEL) is directly proportional to the rotational speed of the runner and inversely proportional to the thread feed speed.
Being constant throughout the reel filling process in an instantaneous manner by modifying the thread feed speed or the spindle(s) speed, making said variation instantly and dynamically on one of these two movements or the two in combination at the same time for the purpose of maintaining the programmed real torsion instructions. Unlike other current systems in the state of the art, in the filed invention the fact of working on the spindle speed and/or the feed speed has the object of bringing about a correction on the theoretical torsion of the thread and converting into real.
In this way improvements in the mechanical properties of the twisted threads are obtained on processing them with much smaller (theoretically nil) torsion variation to that in the ‘conventional’ system.
In the event of wanting to vary the working speed throughout the reel filling, with this working system that is the object of the invention, the above described ratio is maintained, varying the runner speed and the thread lineal speed in the same proportion and at the same time and thus maintaining the instruction torsion per meter (real) value.
Other characteristics and advantages of the present invention will become clear from the description of the preferred embodiment, which is not exclusive, shown in the drawings by way of illustration but without being in any way limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a twisting and spinning machine according to the invention.
Preferred Embodiment of the Invention
In a first preferred embodiment, and referring to FIG. 1 , a distinction can be made between the following parts of the machine:
The spindle ( 1 ) with the reel ( 2 ) that turns on its own axis at the spindle speed in RPM ( 10 ), the rocker ( 3 ) with the ring ( 4 ) and the runner ( 5 ) turning guided by the ring at the “runner speed in RPM” ( 11 ) and driven by the thread ( 6 ), the thread ( 6 ) feed speed with its feed pulley ( 7 ) at the speed “feed VEL m/min ( 9 )” and the thread guide ( 8 ).
The required value, amongst others, is introduced into the machine corresponding to the degree of real torsion on the thread that is to be processed as to the feed speed ( 9 ). The revolutions per minute for the runner ( 11 ) at which the runner ( 5 ) must rotate are calculated from the above mentioned expression which stated in another way is:
Runner speed (rpm)=Torsion per meter (REAL)*thread feed speed (m/min)
Said runner speed instruction will be the one which must be maintained by the read value of the runner ( 11 ) RPM, signal which is received from the machine by means that will be described later, and is sent directly to the machine processor or directly to the frequency converter that governs the concerned motor, which in a dynamic and instantaneous manner regulates and varies the speed of the spindles ( 10 ) and/or the feed speed ( 9 ) of the pulley ( 7 ) by the corresponding frequency converters so as to dynamically maintain said signal. The fact of acting on the speed of the spindles ( 10 ) and/or the feed speed ( 9 ) makes it bring about a correction on the theoretical torsion and converts it into real.
There are different ways, within the state of the art, so as to be able to calculate, measure and obtain the runner RPM ( 11 ) in the machine whilst it is filling the reel ( 2 ). Whatever the system is for measuring or calculating the runner RPM, it is not an essential part and it can be used in any practical embodiment of the present invention.
To be highlighted:
In FIG. 1 : An ultrasound technology sensor ( 12 ) located on the rocker at the runner ( 5 ) level on top of the ring ( 4 ) and orientated perpendicular to the reel ( 2 ) axis, it gives off an analogue signal proportional to the distance between the sensor and the body in which it is aimed (in this case, the average distance, gives information related to the diameter of the reel ( 2 ) filling at a specific moment). Therefore, we can extrapolate by formulas and know the value for the runner ( 11 ) RPM at all times of the reel filling.
There are also completely indirect ways of calculating or knowing the runner speed without any type of sensor, by formulas in which there are other parameters and data at all times, such as the initial and final diameter of the reel, the position of the rocker, the direction and speed of movement of the rocker up and down, the final meters and dimensions of the full reel, the dimensions of cylindrical and conical part of the reel, and if one has these data the runner speed can be calculated in an indirect way. In these cases it is also considered as a preferred embodiment of the invention as the working methods of the machine keep being the claimed.
If the kinematic scheme that makes up the machine, is one or several spindle motors and one or several feed motors, but all of the spindles and feeds working in a collective manner, this means at the same speed for all of the spindles and the same speed for all of the feeds, with one sensor ( 10 ) at least on a spindle can be enough to make it work.
In the case the machine can process with different torsions for each spindle or groups of spindles, one sensor ( 10 ) will be needed for each one of these spindles or groups of spindles.
The machine can work with any of the reel formats, which can be cylindrical reel, conical reel, double cone reel, and others without changing the result of the present invention, once knowing the format to be worked.
The advantages of the invention developed are that on processing or twisting the thread with real torsion, the torsion variability on the thread is very small (theoretically it is nil), with which the mechanical characteristics of the twisted thread are increased when compared with the traditional system in which there are very high torsion variabilities. | Thread twist system for twisting and spinning machines which comprises means ( 12 ) for measuring and/or calculating directly or indirectly the rotation speed ( 11 ) of the runner ( 5 ), in such a way that the working movements and parameters of the machine keep real twisting constant throughout the process of filling the reel ( 2 ) in a dynamic and instantaneous way, by acting on the angular speed ( 10 ) of the spindles ( 1 ) and/or the feeding ( 9 ) speed of the thread ( 6 ), with the objective of correcting the theoretical twisting on the thread itself ( 6 ) and converting it into real twisting. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a reconfigurable optical add-drop multiplexer (ROADM) for WDM network applications that utilizes switches and a wavelength-tuning device.
BACKGROUND OF THE INVENTION
[0002] The increasing demand for high-speed voice and data communications has led to an increased reliance on optical communications, especially optical fiber communications. The use of optical signals as a vehicle to carry channeled information at high speed is preferred in many instances to carrying channeled information at other electromagnetic wavelengths/frequencies in media such as microwave transmission lines, coaxial cable lines, and twisted copper pair transmission lines. Advantages of optical media include higher channel capacities (bandwidth), greater immunity to electromagnetic interference, and lower propagation loss. In fact, it is common for high-speed optical systems to have signal rates in the range of approximately several megabits per second (Mbit/s) to approximately several tens of gigabits per second (Gbit/s), and greater. However, as the communication capacity is further increased to transmit greater amounts of information at greater rates over fiber, maintaining signal integrity can be exceedingly challenging.
[0003] The emergence of optical communications as a useful approach for short and long-haul data and voice communications has led to the development of a variety of optical amplifiers. One type of optical amplifier is the rare-earth element doped optical amplifier (i.e., an optical amplifier that has a host material doped with rare earth elements). One such rare-earth element optical amplifier is based on erbium-doped silica fiber. The erbium doped fiber amplifier (EDFA) has gained great acceptance in the telecommunications industry.
[0004] Another type of optical amplifier is a Raman amplifier. Raman amplifiers utilize optical transmission fiber as their gain medium. Both erbium-doped fiber amplifiers (EDFA) and Raman fiber amplifiers are useful in a variety of optical communication systems.
[0005] One way to more efficiently utilize available resources in the quest for high-speed information transmission is known as multiplexing. One particular type of multiplexing is wavelength division multiplexing (WDM). In WDM, several information streams (voice and/or data streams) share a particular transmission medium, such as an optical fiber. Each high-speed information channel is transmitted at a designated wavelength along the optical fiber. At the receiver end, the interleaved channels are separated (de-multiplexed) and may be further processed by electronics. (By convention, when the number of channels transmitted by such a multiplexing technique exceeds approximately four, the technique is referred to dense WDM or DWDM).
[0006] Dense Wavelength Division Multiplexing (DWDM) has been widely accepted as the technology of choice for the next generation optical communication systems to meet the increasing demand for information bandwidth. In order to reduce network cost, future DWDM networks will need to route signals of specific wavelengths through the optical communication system without performing optical to electric and electric to optical conversions. The increasing demand for bandwidth attracted considerable interest in utilization of optical add/drop multiplexers (ADM) to implement add/drop functionality for DWDM networks.
[0007] Considerable efforts have been made to design fixed (i.e. non-reconfigurable and/or non-tunable) wavelength optical add/drop multiplexers (OADMs) using various techniques. These fixed OADMs generally include a combination of circulators and gratings, Mach-Zehnders and gratings, or phasar and thermo-optic switches. However, such devices have no way of re-configuring the optical network based on changing need, short of replacing the existing OADMs with another set of OADMs. This is both time-consuming and expensive.
[0008] One suggested approach to this problem is utilization of reconfigurable optical add/drop multiplexers (ROADMs). With ROADM, reconfigurable add/drop nodes can be implemented to form the basis of optical networks, in which customers can pay-on-demand. Such ROADM is described, for example, in the article entitled “A Hitless Reconfigurable Add/Drop Multiplexer for WDM Network Utilizing Planar Waveguide, Thermo-Optic Switches and UV-reducing Gratings,” by R. E. Scott et al, WHI, OFC'1998. However, although the disclosed add/drop multiplexer is reconfigurable, it is not tunable. That is, the disclosed device can operate only on a predetermined set of wavelengths. This device allows someone to re-route a specific wavelength, but does not allow the device to be tuned so as to allow one to re-route a different wavelength with the same ROADM.
SUMMARY OF THE INVENTION
[0009] According to one aspect of the present invention a tunable, reconfigurable optical add/drop multiplexer comprises a first signal routing component and at least one wavelength selective switch device having an input port and an output port. The input port is optically coupled to the first signal routing component. The wavelength signal selective switch is wavelength tunable, so as to allow a selected wavelength to be routed to the first signal routing component and the rest of the wavelengths to be routed to the output port. According to an embodiment of the present invention the first signal routing component is an optical circulator.
[0010] According to one embodiment of the present invention, a wavelength tunable switching device comprises (a) an input port and an output port; (b) a first optical waveguide located between the input port and the output port; (c) a second optical waveguide located between the input port and the output port, the second optical waveguide having a wavelength tunable, wavelength selectable optical component; (d) a first switch selectively coupled to the first or the second optical waveguide for coupling signal light from the input port into one of the optical waveguides; and (e) a second switch selectively coupled to the first or the second optical waveguide for coupling the signal light from one of the first and second optical waveguides into the output port.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The invention is best understood from the following detailed description when read with the accompanying figures. It is emphasized that the various features are not necessarily drawn to scale. In fact, the dimensions may be arbitrarily increased or decreased for clarity of discussion.
[0012] [0012]FIG. 1 is a schematic diagram of a reconfigurable add/drop multiplexer RADM.
[0013] [0013]FIG. 2 is a schematic diagram of a tunable wavelength selective switch device incorporated in the RADM of FIG. 1.
[0014] [0014]FIGS. 3A and 3B are schematic diagrams illustrating 2×2 switches of the selective, tunable switch device of FIG. 2.
[0015] [0015]FIG. 4 is a schematic drawing of a tunable wavelength selective switch device of a second embodiment.
[0016] [0016]FIG. 5 is a schematic diagram illustrating a multi-channel ROADM incorporating a wavelength selective switch device of FIG. 2.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] In the following detailed description, for purposes of explanation and not limitation, exemplary embodiments disclosing specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one having ordinary skill in the art that the present invention may be practiced in other embodiments that depart from the specific details disclosed herein. In other instances, detailed descriptions of well-known devices and methods may be omitted so as not to obscure the description of the present invention.
[0018] [0018]FIG. 1 illustrates an exemplary reconfigurable optical add/drop multiplexer (ROADM) 10 that is also tunable. The tunable ROADM 10 is formed by two signal routing components, (for example circulators 14 , 16 ) and a wavelength selective (tunable) switch WSS device 15 that includes either a fiber Bragg grating 18 , a dielectric filter, or another tunable wavelength filtering component. In this embodiment, the tunable ROADM 10 adds or drops a channel corresponding to the Bragg grating's wavelength of reflection. Because fiber Bragg grating 18 is tunable, the network provider can select which channel (i.e., a specific optical signal's wavelength) is being dropped or passed through by the ROADM 10 . This can be done by either remotely located network operator or via a routing algorithm. In the event of drop, another channel at the same wavelength may be added to the signal channels. Generally, the added signal would be provided to the WSS device 15 through its output port 15 B, for example, via the circulator 16 . As stated above, the add/drop channel corresponds to the specific reflection wavelength of the Bragg grating 18 . The Bragg grating 18 is tuned by temperature, or strain, or other means so as to select a different drop channel (corresponding to the reflected wavelength λ d ). Thus, active temperature tuning or stress tuning can be used to achieve wavelength selection. More specifically, the local refractive index of the grating 18 is modified, thereby shifting the Bragg wavelength (reflection wavelength λ d ) by stretching, compressing or heating of the optical fiber containing the Bragg grating 18 .
[0019] The tunable ROADM 10 includes a pass-through path 25 , which enables non-interruptive reconfiguration and an alternative pass 23 . The term “non-interrupting” reconfiguration means that when a particular add/drop channel is switched between the two states (the two states being add/drop and pass-through states), the power of channels that are not being dropped or added is not impacted during switching. More specifically, the non-interruptive reconfiguration is accomplished by the tunable wavelength selective switch (WSS) device 15 of the ROADM 10 (see FIG. 1 and FIG. 2) as described below. The tunable WSS device 15 includes two synchronized 1×2 or 2×2 switches 22 A, 22 B. In this embodiment switches 22 A, 22 B are bending fiber coupler switches. The switches 22 A, 22 B vary the coupling ratio of the signal between the two paths 25 and 23 . When both switches 22 A, 22 B are in bar state, the WSS device 15 is off and the signal is directed through the alternative channel selection path 23 corresponding to an optical fiber 24 with Bragg grating 18 . Thus, the device operates in normal OADM configuration. When both switches 22 A, 22 B are in cross-bar state, the WSS device 15 is on and the signal is re-directed through a pass-through path 25 while the Bragg gratings 18 is being tuned to reflect the desired wavelength λ d . The pass-through path 25 corresponds to the optical fiber 28 . The optical fiber 28 may be transmission fiber, for example SMF-28™ fiber, available from Corning Inc. of Corning, NY.
[0020] The bar state of the switch is the state of the switch when input 1 is routed to the output port # 1 and input 2 is routed to output port # 2 . This is illustrated in FIG. 3A. The cross-bar state of a switch is the state of the switch when input 1 is routed to the output port # 2 and input 2 is routed to the output port # 1 . This is illustrated in FIG. 3B. Thus, as described above, the two bending switches 22 A, 22 B couple the optical signal S either through the channel selection path or through the reconfiguration path and in conjunction with the grating 18 and the fibers 24 , 28 form the tunable non-interferometric WSS switch device 15 . During the switching state of the WSS device 15 , when the signal light is switched from fiber 24 to 28 , the optical phase relation between the two paths 23 , 25 is maintained in order to ensure that during switching the intensity of the output signal remains constant in each channel. Therefore, the optical transmittance of the optical signal will have no significant change during the transition state. That is, the optical transmittance of the WSS device 15 will stay below 10% and preferably at or below 5%. The optical transmittence is defined as P out /P in , where P out is the optical output power of the device and P in is the device's optical input power. It is preferable to operate at low switching speed (more than 10 msec) to fully benefit from active path length stabilization so as to avoid the noise (i.e. intensity variation at the output port due to phase mismatch during switching) generated during switching state. Minimal optical path length change and active compensation during the switching states (e.g. heating) maintain the optical phase difference between the two paths 23 , 25 . Because the WSS device 15 is non-interferometric switch in static state, there is minimal penalty from phase variance induced noise. A static state is the state of the device operation when the WSS device 15 is not being switched.
[0021] An alternative embodiment of a tunable WSS switch device 15 of the ROADM 10 is shown in FIG. 4. This tunable WSS switch device 15 is similar to the one shown in FIG. 2, but is in a planar configuration. More specifically, the planar WSS switch device 15 of FIG. 4 utilizes two 1×2 thermo-optic switches 22 A, 22 B and two optical waveguides 24 ′ and 28 ′, assembled in a Mach-Zehnder (MZ) configuration. One arm of the MZ contains a Bragg grating 18 that is tunable via a channel selector which includes a channel activator such as a heating electrode 30 A, for example. Similar electrode 30 B is located along the optical waveguide 24 ′ to keep the phase matching constant when the grating 18 is being tuned. Switching heaters 22 A, 22 B activate the thermo-optic switches 22 A, 22 B and the electrode 30 B keeps the WSS device 15 phase matched during switching.
[0022] To achieve accurate channel selection, channel selector 30 , 30 A is utilized through an active wavelength control of the Bragg grating 18 with a feedback loop 32 . This is shown in FIGS. 1, 2 and 4 . The channel selector in conjunction with a feed back loop 32 measures the reflectance wavelength of the Bragg grating 18 . The channel selector gives signal to an actuator to apply either less or more pressure, strain or heat to the Bragg grating 18 . The channel selector 30 may utilize, as an actuator, a heating coil or compression applying device. After the selection of add/drop channel the optical signal is switched back to the original add/drop route (path 23 ) without intensity interruption at the output port. Thus, the tunable ROADM can reconfigure an optical node to add/drop a variety of channels corresponding to different wavelength, without interruption of any service.
[0023] Reconfiguration and tuning of the ROADM is accomplished in following three steps: (1) Turn on WSS device 15 . (put it in pass-through state), routing signal light along the path 25 , through fiber 28 . This can be done remotely, by a network operator or by a routing algorithm. (2) While the signal light is routed through the fiber 28 , tune grating 26 to select the drop channel a specific wavelength that is being dropped. (3) Turn off WSS device 15 (put in add/drop state), by routing the signal light through the channel selection path 23 . More specifically, the steps to tune and switch ROADM 10 are as follows:
[0024] 1. Put WSS device 15 in pass-through state by putting 2×2 switches ( 22 A, 22 B) in cross-state. This will route the signal S entering the input port 15 A along fiber 28 and out of the output port 15 B (see FIG. 2);
[0025] 2. Tune grating 18 to a desired spectral channel. For example, a fiber Bragg Grating may be thermally tuned, or alternatively tuned by tensioning or compression via a wavelength tuning actuator 20 . A planar Bragg grating waveguide may also be thermally tuned in a similar manner.
[0026] 3. Switch WSS device 15 to the add/drop state by putting 2×2 switches into bar state. This would route the signal S through the optical fiber 28 towards the grating 18 . The grating 18 is tuned to reflect a specific wavelength of light λ d back towards the circulator 14 , and the signal corresponding to this wavelength λ d is then dropped through the drop port 14 A of the circulator 14 . The rest of the signal wavelengths pass through the grating and the fiber 18 and enter the circulator 16 .
[0027] The tunable ROADM architecture described here forms the basis of a simple all-fiber tunable add/drop module. Depending on the network requirements for tuning range and tuning speed, one can utilize a split-band configuration to achieve a wider channel selection range.
[0028] The split-band configuration utilizes a plurality of tunable concatenated ROADMs (FIG. 5). Each WSS device 15 A′, 15 B′, 15 C′ can select a single channel within a certain band of wavelengths by tuning an individual grating. Thus, the applicants achieve a simple architecture for TOADM based non-interferometric switches and an active wavelength selector. The technique offers flexibility in implementing all-fiber, tunable add/drop function to a wide spectrum of OADM devices. The added functionality includes non-interruptive channel selection and wavelength stabilization. The architecture provides a tunable optical add/drop multiplexer and provides an important advantage of flexibility for future optical network applications.
[0029] It will be apparent to those skills in the art that various modifications and variations can be made to the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover modifications and variations of this invention provided they come within scope of the appended claims and their equivalents. | A tunable, reconfigurable optical add/drop multiplexer comprises a first signal routing component and at least one wavelength selective switch having an input port and an output port. The input port is optically coupled to the first signal routing component. The wavelength signal selective switch is wavelength tunable, so as to allow a selected wavelength to be routed to the first signal routing component and the rest of the wavelengths to be routed to the output port. According to an embodiment of the present invention the first signal routing component is an optical circulator. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to skylights, and more particularly to tubular skylights, which include a reflective tube extending downwardly from the dome.
Tubular skylights have acquired increasing popularity as a means of introducing natural light into a building interior. These skylights include a dome with flashing mounted on the building roof, a light diffuser mounted in the building ceiling, and a reflective tube interconnecting the dome and the diffuser. Natural light entering the skylight through the dome reflects downwardly through the tube to the diffuser. The tube in a sense acts as a gigantic optical fiber. Typically, the domes are fabricated of clear plastic; and the tube is fabricated of aluminum with a reflective coating.
The efficiency of such skylights (i.e. the amount of natural light reaching the building interior) is primarily a function of the amount of light passing through the dome into the tube and of the reflective efficiency of the tube. It is desirable to channel or steer as much light as possible downwardly through the tube to illuminate the building interior. One such approach is seen in U.S. Pat. No. 5,655,339, issued Aug. 12, 1998, to DeBlock et al, and entitled "Tubular Skylight with Improved Dome." This approach utilizes a series of prisms along one portion of the outer surface of a hemispherical dome to reflect light downwardly into the tube. The prisms converge near the top of the hemisphere. However, in direct light the converging prisms cast shadows which can be seen on the underside of the diffuser. Additionally, although the prisms are a significant improvement in directing the light downwardly, improved efficiencies are still desired. Further, the dome is aesthetically deficient when mounted on the roof.
SUMMARY OF THE INVENTION
The aforementioned problems are overcome in the present invention wherein the dome of a tubular skylight has a curved front face and a substantially vertical rear face, the rear face having a prismatic portion to direct light downwardly into the tube.
Preferably, in the northern hemisphere, the dome is positioned so that the rear face is the northern portion of the dome. Consequently, sunlight entering the southern portion or the front face, and to a lesser extent the eastern and western portions, of the dome at relatively low angles is reflected by the prismatic surface on the rear face. In the southern hemisphere, the dome is preferably positioned so that the rear face is the southern portion of the dome.
Even when the sun is higher in the sky, the light rays do not enter the dome through the rear face containing the prismatic portion. Thus, no shadow is cast by the prisms on the underside of the diffuser in direct light.
Additionally, the rear face of the dome is offset inwardly from the reflective tube to allow light trapped in the prismatic portion between the exterior and interior surfaces of the dome to escape downwardly into the tube, thus increasing the percentage of light reaching the entrance of the skylight tube.
In the disclosed embodiment, the dome has a curved front face, a flat top face and a substantially vertical rear face, which provide a pleasing profile when the dome is mounted on a roof. The prismatic portion includes a plurality of vertical grooves each extending from the base of the rear face to the top edge of the rear face. The rear face is offset inwardly from the perimeter of the reflective tube such that the prismatic portion is positioned above the interior of the tube; thus, light trapped in the prismatic portion between the exterior and interior surfaces of the dome may escape downwardly into the reflective tube. 5 These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a tubular skylight having the dome of the present invention mounted within a building;
FIG. 2 is a perspective exploded view of the tubular skylight;
FIG. 3 is a top plan view of the dome;
FIG. 4 is a sectional view of the dome taken along line IV--IV in FIG. 3;
FIG. 5 is a fragmentary sectional view of the prismatic portion of the dome showing the grooves in the exterior surface;
FIG. 6 is a schematic illustration of noon-day sun rays near the vernal and autumnal equinoxes;
FIG. 7 is an expanded view of the rear face of the dome from FIG. 6;
FIG. 8 is a schematic illustration of morning sun rays near the vernal and autumnal equinoxes; and
FIG. 9 is an expanded view of the rear face of the dome from FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A tubular skylight constructed in accordance with a preferred embodiment of the invention is illustrated in FIGS. 1 and 2 and generally designated 10. As perhaps most clearly illustrated in FIG. 2, the skylight includes a dome assembly 12, a diffuser assembly 14, and a tube assembly 16 interconnecting the dome and diffuser assemblies 12 and 14. The skylight 10 is installed in a building B having roof R and ceiling C. More particularly, the dome assembly 12 is mounted within the roof R; and the diffuser assembly 14 is mounted within the ceiling C. The tubular assembly 16 extends between the dome assembly 12 and the diffuser assembly 14 to channel light from the dome assembly 12 to the diffuser assembly 14. With the exception of the dome, the skylight 10 is generally well known to those skilled in the art.
The dome assembly 12 includes a dome 20 and a roof flashing 22. The dome 20, which is new, will be described in greater detail below. The flashing 22 mounts within a building roof R to provide a structural support for the dome 20. The roof flashing 22 includes a stepped curb 24 and an integral flashing flange 26 extending therefrom. The roof flashing 22 is available in a variety of constructions to accommodate shingle roofs, tile roofs, and other selected applications.
The diffuser assembly 14 includes a diffuser 30, a ceiling trim ring 32, and a tube/ring seal 34. The diffuser 30 is a prismatic light diffuser although other diffuser styles may be used. Diffuser styles may be a personal preference or aesthetic choice. The ceiling trim ring 32 supports the diffuser 30 within the ceiling C. The tube/ring seal 34 fits about the tube assembly 16 as will be described and provides a mechanical interlock between the tube assembly 16 and the diffuser assembly 14.
The tube assembly 16 includes upper and lower adjustable tubes 40 and 42 respectively, and an interconnecting extension tube 44. The upper adjustable tube 40 fits within the roof flashing 22, and the lower adjustable tube 42 connects to the ceiling trim ring 32 by way of the tube/ring seal 34 as will be described. The extension tube 44 telescopically interfits with both of the adjustable tubes 40 and 42 to accommodate a variety of heights of the roof R above the ceiling C. Additional extension tubes 44 can be used as necessary to accommodate unusual heights between the roof R and the ceiling C.
Again, as thus far described, the tubular skylight components are conventional and generally well known to those in the relevant art. The novelty of the present invention resides in the dome 20 to be described hereinafter.
The dome 20 is illustrated most clearly in FIGS. 3 and 4. The dome includes a circular base 60 and an upper portion 62 extending upwardly therefrom. The base 60 includes steps 64 and 65 that fit over and receive the stepped curb 24 of the roof flashing 22 (see FIG. 2). The second step 65 rests on the top of the curb 24 and is defined by four pairs of fingers 66 located at 90° intervals around the perimeter 68 of the base 60. Holes 70 are provided to receive fasteners (not shown) to secure the dome 20 to the stepped curb 24.
The upper portion 62 of the dome 20 includes an interior surface 72 and an exterior surface 74 which define an interior 75. The upper portion 62 includes a curved front face 76, a flat top face 78, and a substantially vertical rear face 80 extending downwardly from the top face 78. The rear face 80 preferably is inclined approximately 10 degrees from the vertical, and the rear face 80 preferably extends over no more than approximately one inch over the span of a fourteen inch diameter dome. The rear face 80 and the top face 78 meet at a sharp-cornered junction preferably having a rounded edge for aesthetic purposes.
The upper portion 62 includes a prismatic surface or portion 82 and a nonprismatic surface or portion 84. The prismatic portion 82 comprises the rear face 80 of the dome 20. The prismatic portion 82 is illustrated perhaps most clearly in FIG. 3 and includes the patterned surface covering a portion of the rear face 80 as described below. The interior surface 72 has an interior radius 86 in the area of the rear face 80 and a radius 88 in the remainder 89 of the upper portion 62. And the exterior surface 74 has an exterior radius 90 in the area of the rear face 80 and a radius 92 in the remainder 89 of the upper portion 62. The radius 92 is slightly greater than the radius 90.
Additionally, in the preferred embodiment, the radius 90 is 0.5 inches smaller than the interior radius 94 of the tube assembly 16 (seen best in FIG. 6). Thus, the interior and exterior surfaces 72 and 74 in the vicinity of the rear face 80 are positioned above the interior of the tube assembly 16. The lower edge 95 of the rear face 80 is connected to the base 60 by a right angle flange portion 97.
The remainder 89 of the upper portion 62 is generally uniform in thickness between the interior surface 72 and the exterior surface 74. The rear face 80 has an increased thickness from the prismatic portion 82. Because the prismatic portion 82 is uneven (i.e. grooved) the distance between the interior surface 72 and the exterior surface 74 varies. The minimum thickness in the prismatic portion 82 is approximately equal to the thickness in the remainder 89 of the upper portion 62, and the maximum thickness in the prismatic portion 82 is approximately twice the thickness of the remainder 89.
The shape and configuration of the prismatic portion 82 is perhaps best illustrated in FIGS. 3 and 5. The prismatic portion 82 includes a plurality of grooves 100 that are molded, cut, or otherwise formed in the exterior surface 74. Each of the grooves 100 extends from the base 60 to a location short of the top edge 102 of the rear face 80. In the preferred embodiment, 37 first grooves 104 are formed at 4° intervals, and 38 second grooves 106 are formed at 4° intervals offset 2° from the first set of grooves 104 so that each first groove 104 is bracketed by a pair of second grooves 106. As currently contemplated, the grooves 100 are formed by molding; however, other forming techniques, such as cutting, can be used.
The exterior angle between the walls of a groove 100 when using the preferred material is preferably in the range of 86° to 94°, with the most preferred angle being 92°. The groove angles may change with other materials depending on their indices of refraction. The angle is selected so that direct light from the dome interior is reflected by the internal reflection of the prism--not refracted--as it strikes the interior side of the groove walls. The structure and effect of the described technique is disclosed in U.S. Pat. No. 4,839,781, issued Jun. 13, 1989 to Barnes et al, and entitled "Reflector/Refractor."
The entire dome 20 is preferably fabricated of injection-molded acrylic although other techniques, such as thermo-forming, may be used. The currently preferred materials are those sold under the designations V825UVA-5A, ICI CP-75 UVA, ICI CP-75 HID, or A to Haas V825 HID by Rohm & Haas. For a dome 14 inches in diameter, the dome portion 20 is 0.114 inch thick in the nonprismatic portion 84 and up to 0.204 inch thick in the prismatic portion 82. Other UV stable materials suitable for skylight domes may be used and include polycarbonates and nylons. Other materials may be used if they provide the light transmittance. strength characteristics, and resistance to yellowing required in skylight domes
The particular pattern of the prism will depend on the performance desired and the anticipated location of the skylight. The illustrated dome 20 has been designed for use at 40° latitude as representative of a "normal" U.S. location. The pattern follows the highest path of the sun, which of course occurs during the summer.
The light reflectance provided by the prismatic portion 82 is perhaps best illustrated in FIG. 5. Each of the grooves 100 provides two apparent reflective surfaces to light rays striking the surfaces from inside the dome because of the high index of refraction. Consequently, light impinging on the grooves 100 from the interior of the dome 20 are reflected back into the interior of the dome 20.
Turning specifically to FIG. 5, a light ray L from the interior of the dome passes through the interior surface 72, then reflects off the surfaces of two grooves 100 to be returned to the dome interior. Consequently, light at low angles which would pass directly through the dome 20 is instead reflected back into the dome interior.
The prismatic portion 82 does not significantly block ambient light from passing through the dome 20. Therefore, the dome 20 does not significantly reduce the amount of ambient light; and the dome 20 does not decrease the amount of direct light passing into the skylight. The only losses (approximately 8% in the preferred material) are due to the material from which the dome 20 is fabricated.
Assembly and Operation
The tubular skylight 10 is installed within a building in conventional fashion. Holes, preferably vertically aligned to provide the best light transmission, are cut in the roof R and the ceiling C. The roof flashing 22 is installed in the roof R. The upper adjustable tube 40 is fitted onto the stepped curb 24 of the roof flashing 22 and slid downwardly until the upper edges of both are aligned. The dome 20 is fitted over the stepped curb 24 (with the upper adjustable tube 40 fitted therein) and secured in position using screws (not shown).
The ceiling trim ring 32 is secured to the underside of the ceiling C. The tube/ring seal 34 is placed over the lower adjustable tube 42, and the assembly is pushed into the ceiling trim ring 32 from above the ceiling C. The extension tube 44 is then slid as necessary to a connecting position between the upper and lower adjustable tubes 40 and 42, which provide angular alignment for the extension tube 44. All seams are taped with duct tape. Finally, the diffuser 30 is installed within the trim ring 32 using a partial-turn coupling.
FIGS. 6-9 illustrate the functional performance of the new dome 20. Turning first to FIG. 6, the dome 20 and tube assembly 16 are schematically illustrated. Direct light rays 150 are shown entering the skylight when the sun is high in the sky. When the sun is at this angle, virtually all of the direct rays 150 pass through the non-prismatic portion 84 of the dome 20 to enter the skylight 10 in conventional fashion. The reflected rays 150' are illustrated in dotted lines and illustrate how the light is reflected downwardly through the skylight assembly.
The light rays enter the dome primarily through the front and top faces 76 and 78, avoiding the substantially vertical rear face 80. Thus, the prismatic portion 82 does not cast shadows on the underside of the diffuser 30.
However, as can be seen in FIG. 6 and more easily in FIG. 7, a portion of the light rays 150 entering the dome pass through the interior surface 72 of the rear face 80 and are reflected by the prismatic surface 82. Rather than passing back through the interior surface 72 and into the interior of the dome 20, a portion of the rays 150" become trapped between the interior and exterior surfaces 72 and 74 due to the refractive index of the material. The amount of light which is trapped depends on the index of refraction of the material.
As the rays 150" are reflected by one surface 72 or 74 towards the other, the rays 150" descend through the interior 75 of the rear face 80, eventually exiting from the interior 75 of the rear face 80 through the offset lower edge 95 and into the tube assembly 16. Exiting through the lower edge 95 allows the rays 150" to have a more centrally located reflection angle, which enables a greater percentage of light to reach the diffuser. Reflective coatings on the adjustable tubes 40 and 42 and on the extension tube 44 are unable to reflect 100% of the available light, and depending on the reflective material, a portion of the light is absorbed rather than reflected. Thus, it is preferable to have a centrally located reflection angle so that the light ray 150 is reflected fewer times in the tubes 40, 42, and 44 to preserve the quantity of light arriving at the diffuser 30. Enabling these additional rays 150" to escape the interior 75 of the rear face 80 provides 6-10% additional light into the tube assembly 16. If the light rays 150" were unable to escape the interior 75 of the rear face 80, such as if the edge 95 were not offset inwardly, they would be reflected between the interior and exterior surfaces 72 and 74 until they are eventually absorbed by the material.
FIG. 8 illustrates the performance of the skylight dome when the sun is relatively low in the sky. Specifically, the direct sunlight rays 150 arrive at the skylight dome 20 only slightly inclined from the horizontal. The direct rays 150 pass directly through the non-prismatic portion 84. Without the prismatic portion 82 of the present invention, the direct rays 150 would continue to pass through the skylight dome 20 so that none of those rays 150 would pass downwardly into the tube assembly 16. Instead, the prismatic portion 82 reflects the direct rays 150 downwardly through the dome 20 at a variety of angles. The reflected rays 150' are illustrated as dashed lines and pass downwardly at a variety of reflected angles.
As seen more easily in FIG. 9, the light rays 150" slightly inclined from the horizontal may also pass through the interior surface 72 and become trapped between the interior and exterior surfaces 72 and 74 similarly to the light rays 150" seen in FIGS. 6-7. However, these rays 150" also descend through the interior 75 of the rear face 80 and eventually exit from the interior 75 through the offset lower edge 95 and into the tube assembly 16. Additionally, these rays 150" then have a more centrally located reflection angle, allowing for fewer reflections as they descend the tube assembly 16.
The object of the present invention is to increase the amount of light which reaches the diffuser 30 by allowing rays 150 trapped within the interior 75 of the rear face 80 to exit downwardly into the tube assembly 16 and to lessen any shadowing effect created by the prismatic surface 82 on the underside of the diffuser 30.
The present invention greatly enhances the performance of the tubular skylight by directing or steering a larger percentage of the available light downwardly through the tube assembly 16. The placement of the prismatic surface 82 on the substantially vertical rear face 80 additionally lessens the shadow effect on the underside of the diffuser 30.
The above description is that of a preferred embodiment of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. | A tubular skylight having an improved dome improving the efficiency of the skylight and reducing the shadows cast by the skylight. The dome includes a substantially vertical rear face having an integral prism in a portion of its outer surface, and the rear face is offset inwardly from the perimeter of the reflective tube, thus allowing light to escape from the bottom edge of the rear face downwardly into the reflective tube. The integral prism does not extend to the top or front face of the dome, thus reducing the prevalence of shadows created by light rays entering the dome through the prism. | 4 |
FIELD OF THE INVENTION
[0001] In general, the invention relates to a cutting insert and a cutting tool, and in particular to a cutting insert for a milling cutter that contact with each other in an area where high cutting forces occur so as to help distribute the loads (stresses) encountered in the cutting operation, as well as provide protection of the insert pocket in case of insert failure.
BACKGROUND OF THE INVENTION
[0002] One problem encountered with conventional tool holders is that of holding the cutting insert securely in the pocket of the tool holder. At the beginning of a cutting operation, the sudden transition from no load to extreme pressure load on the insert can cause the insert to shift position in the holder and thereby affect the accuracy of the planned cut. At the end of the cutting operation, the sudden disengagement of the cutting insert from the workpiece causes the pressure load suddenly to be removed from the insert. This sudden change in load can cause the insert to shift and distress any repeatable dimensional accuracy, which is essential for most tool holders, especially cutting inserts used in Numerically Controlled machines, to meet.
[0003] During the cutting operation, loads of up to 35,000 pounds may be encountered on the cutting insert which, if the insert is not precisely located and firmly held in the holder to begin with, can also cause shifting of the insert during the cutting operation. It is, therefore, important to provide a tool holder that can precisely and securely seat a cutting insert and then securely hold the cutting insert in location during all phases of the heavy duty cutting operation.
SUMMARY OF THE INVENTION
[0004] In one aspect of the invention, a cutting insert comprises two opposing end surfaces, two opposing minor side surfaces extending between the two opposing end surfaces, and two opposing major side surfaces extending between the end surfaces and the minor side surfaces. Each end surface has four corners including two lowered corners and two raised corners. The two lowered corners are diagonally opposite each other, and the two raised corners are diagonally opposite each other. The cutting insert further includes two opposing major edges formed at an intersection of each end surface and the major side surfaces, two opposing minor edges formed at an intersection of each end surface and the minor side surfaces, and two opposing corner edges formed at an intersection of each the corner side surfaces and the major side surfaces. The cutting insert further includes a major cutting edge formed at an intersection of each major edge and the end surface, and a minor cutting edge formed at an intersection of each minor edge and the end surface, and a corner cutting edge formed at an intersection of the major and minor cutting edges. Each end surface includes a shim abutment surface that extends from one lowered corner to the diagonally opposite lowered corner.
[0005] In another aspect, a combination cutting insert and a shim for heavy machining operations. The cutting insert comprises two opposing end surfaces, two opposing minor side surfaces extending between the two opposing end surfaces, and two opposing major side surfaces extending between the end surfaces and the minor side surfaces. Each end surface has four corners including two lowered corners and two raised corners. The two lowered corners are diagonally opposite each other, and the two raised corners are diagonally opposite each other. Each end surface includes a shim abutment surface that extends from one lowered corner to the diagonally opposite lowered corner. The shim comprises two opposing end surfaces, two opposing minor side surfaces extending between the two opposing end surfaces. Two opposing major side surfaces extend between the end surfaces and the minor side surfaces. One end surface has four corners comprising two lowered corners and two raised corners. The two lowered corners are diagonally opposite each other, and the two raised corners are diagonally opposite each other. One of the end surfaces of the shim has an insert abutment surface that extends entirely from one raised corner to the diagonally opposite raised corner of the shim for contacting the shim abutment surface of the cutting insert.
[0006] In another aspect, a milling cutter comprises a plurality of insert pockets, wherein the cutting insert and the shim of the invention are seated in each of the plurality of insert pockets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] While various embodiments of the invention are illustrated, the particular embodiments shown should not be construed to limit the claims. It is anticipated that various changes and modifications may be made without departing from the scope of this invention.
[0008] FIG. 1 is an isometric view of an exemplary embodiment of a cutting insert of the invention;
[0009] FIG. 2 is an end view of the exemplary embodiment of the cutting insert of FIG. 1 ;
[0010] FIG. 3 is a top view of the exemplary embodiment of the cutting insert of FIG. 1 ;
[0011] FIG. 4 is a front view of the exemplary embodiment of the cutting insert of FIG. 1 ;
[0012] FIG. 5 is a cross-sectional view of the exemplary embodiment of the cutting insert taken along line 5 - 5 of FIG. 3 ;
[0013] FIG. 6 is a cross-sectional view of the exemplary embodiment of the cutting insert taken along line 6 - 6 of FIG. 3 ;
[0014] FIG. 7 is an isometric view of an exemplary embodiment of a shim of the invention;
[0015] FIG. 8 is another isometric view of an exemplary embodiment of the shim of FIG. 7 ;
[0016] FIG. 9 is an end view of the exemplary embodiment of the shim of FIG. 7 ;
[0017] FIG. 10 is another end view of the exemplary embodiment of the shim of FIG. 7 ;
[0018] FIG. 11 is a side view of the exemplary embodiment of the shim of FIG. 7 ;
[0019] FIG. 12 is a cross-sectional view of an exemplary embodiment of the cutting insert and the shim; and
[0020] FIG. 13 is an isometric view of an exemplary embodiment of a milling cutter with the combination cutting insert and shim seating in insert pockets.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring now to FIGS. 1-6 , a cutting insert 10 is shown according to an embodiment of the invention. In general, the cutting insert 10 is tangential and indexable. The cutting insert 10 is typically manufactured by form-pressing and sintering carbide powders using methods well-known in the art. The cutting insert 10 is generally rectangular in shape and has two identical opposing end surfaces 12 , two identical opposing minor side surfaces 14 extending between the two opposing end surfaces 12 , two identical opposing major side surfaces 16 extending between the end surfaces 12 and the minor side surfaces 14 . Each end surface 12 has 180° rotational symmetry about a first central axis A1 passing through the two end surfaces 12 , each minor side surface 14 has 180° rotational symmetry about a second central axis A2 passing through the two minor side surfaces 14 , and each major side surface 16 has 180° rotational symmetry about a third central axis A3 passing through the two major side surfaces 16 . The second central axis A2 is perpendicular to the first central axis A1, and the third central axis A3 is perpendicular to the first central axis A1 and to the second central axis A2. The cutting insert 10 also includes four opposed corner side surfaces 18 between the minor and major side surfaces 14 , 16 and the end surfaces 12 .
[0022] Each end surface 12 has four corners; two diagonally opposite lowered corners 20 and two diagonally opposite raised corners 22 . The lowered corners 20 are closer to the second central axis A2 than the raised corners 22 . Each corner side surface 18 extends between the raised corner 22 of one of the two opposing end surfaces 12 and the lowered corner 20 of the other one of the two opposing end surfaces 12 .
[0023] Two opposing major edges 32 are formed at the intersection of each end surface 12 and the major side surfaces 16 , two opposing minor edges 34 are formed at the intersection of each end surface 12 and the minor side surfaces 14 , and two opposing corner edges 36 are formed at the intersection of each the corner side surfaces 18 and the major side surfaces 16 . A major cutting edge 38 is formed at the intersection of each major edge 32 and the end surface 12 and extends along substantially the entire length of its associated major edge 32 . A minor cutting edge 40 is formed at the intersection of each minor edge 34 and the end surface 14 and extends along its associated minor edge 34 . A corner cutting edge 42 is formed at the intersection of the major and minor cutting edges 38 , 40 . The section of the major cutting edge 38 proximate the raised corner 22 constitutes a leading end 44 of the major cutting edge 38 , whereas the section of the major cutting edge 38 proximate the lowered corner 20 constitutes a trailing end 46 of the major cutting edge 38 , as shown in FIG. 4 . Because the cutting insert 10 is symmetric about all three axes, A1, A2 and A3, the cutting insert 10 has a total of four major cutting edges 38 , four minor cutting edges 40 and four corner cutting edges 42 .
[0024] Referring now to FIGS. 3 , 5 and 6 , one aspect of the invention is that each end surface 12 of the cutting insert 10 has a shim abutment surface 30 for contacting a shim 60 ( FIG. 7 ) that extends entirely from one lowered corner 20 to the diagonally opposite lowered corner 20 of the cutting insert 10 . In the illustrated embodiment, the shim abutment surface 30 is in the form of a U-shaped groove having side support walls 30 a , 30 b , and a bottom wall 30 c formed between the two side support walls 30 a , 30 b with a radius R. The two side support walls 30 a , 30 b extend from the bottom wall 30 c to the surface 26 of each raised member 24 , as shown in FIG. 3 .
[0025] As shown in FIG. 5 , the two side support walls 30 a , 30 b are formed at an angle 48 with respect to the second central axis A2. That is, the two side support walls 30 a , 30 b are non-parallel to the third central axis A3 of the cutting insert 10 , unlike conventional cutting inserts. The angle 48 can be greater than zero (0) degrees and less than ninety (90) degrees. In the illustrated embodiment, the angle 48 is about sixty (60) degrees. However, it will be appreciated that the invention is not limited by the magnitude of the angle 48 , and that the invention can be practiced with any desirable angle between the two side support walls 30 a , 30 b to provide sufficient contact between the insert 10 and the shim 60 . In an alternate embodiment, the radiused bottom wall 30 c can be omitted and the abutment surface 30 can have a substantially V-shaped profile with only the side supports surfaces 30 a , 30 b , rather than a substantially U-shaped profile of the illustrated embodiment.
[0026] As shown in FIGS. 5 and 6 , a distance 50 between the bottom wall 30 c and the third central axis A3 remains constant across the entire length of the abutment surface 30 . In other words, the bottom wall 30 c of the shim abutment surface 30 is substantially coplanar along its entire length from one lowered corner 20 to the diagonally opposite lowered corner 20 .
[0027] As shown in FIG. 3 , the bottom wall 30 c has a substantially constant width along its entire length from one lowered corner 20 to the diagonally opposite lowered corner 20 . On the other hand, the side support walls 30 a , 30 b have a continuously varying width 52 along their entire length from one lowered corner 20 to the diagonally opposite lowered corner 20 . Specifically, the width 52 of the side support walls 30 a , 30 b are inversely proportional to each other. For example, the width of the side support wall 30 a is a minimum, while the width 52 of the side support wall 30 b is a maximum at the lowered corner 20 , and the width 52 of the side support wall 30 a is a maximum, while the width 52 of the side support wall 30 b is a minimum at the diagonally opposite lowered corner 20 . It is noted that the width 52 of each side support wall 30 a , 30 b is approximately equal to each other at a point where the first central axis A1 and the third central axis A3 intersect each other, as shown in FIG. 3 .
[0028] Referring now to FIGS. 7-11 , a shim 60 is shown according to an embodiment of the invention. In general, the shim 60 is generally rectangular in shape and has two opposing end surfaces 62 , two identical opposing minor side surfaces 64 extending between the two opposing end surfaces 62 , two identical opposing major side surfaces 66 extending between the end surfaces 62 and the minor side surfaces 64 . Each minor side surface 64 is asymmetric about a second central axis A2 passing through the two minor side surfaces 64 , and each major side surface 66 has 180° rotational symmetry about a third central axis A3 passing through the two major side surfaces 66 . The second central axis A2 is perpendicular to the first central axis A1, and the third central axis A3 is perpendicular to the first central axis A1 and to the second central axis A2. The cutting insert 10 also includes four opposed corner side surfaces 68 between the minor and major side surfaces 64 , 66 and the end surfaces 62 .
[0029] Similar to the cutting insert 10 , one of the end surfaces 62 has four corners; two diagonally opposite lowered corners 70 and two diagonally opposite raised corners 72 . Unlike the cutting insert 10 , the other end surface 62 is substantially planar for engaging the rear wall of the insert pocket, as described below. The lowered corners 70 are closer to the second central axis A2 than the raised corners 72 . Each corner side surface 68 extends between the raised corner 72 of one of the two opposing end surfaces 62 and the lowered corner 70 of the other one of the two opposing end surfaces 62 . One of the end surfaces 62 is provided with a raised abutment member 74 having an insert abutment surface 76 for contacting the insert 10 , and two lowered members 78 , each lowered member 78 having a surface 80 . The insert abutment surface 76 extends entirely from one raised corner 72 to the diagonally opposite raised corner 72 of the shim 60 . As seen in FIG. 7 , the insert abutment surface 76 is planar and perpendicular to the first central axis A1, and parallel to both the second central axis A2 and the third central axis A3.
[0030] Two opposing major edges 82 are formed at the intersection of each end surface 62 and the major side surfaces 66 , two opposing minor edges 84 are formed at the intersection of each end surface 62 and the minor side surfaces 64 , and two opposing corner edges 86 are formed at the intersection of each the corner side surfaces 68 and the major side surfaces 66 .
[0031] As shown in FIG. 10 , another aspect of the invention is that one of the end surfaces 62 of the shim 60 has an insert abutment surface 76 that extends entirely from one raised corner 72 to the diagonally opposite raised corner 72 of the shim 60 for contacting the shim abutment surface 30 of the cutting insert 10 . In the illustrated embodiment, the insert abutment surface 76 is in the form of a U-shaped protrusion having substantially planar side support walls 76 a , 76 b , and a substantially planar top wall 76 c formed between the two side support walls 76 a , 76 b . The two side support walls 76 a , 76 b extend from the top wall 76 c to the surface 80 of each lowered member 78 , as shown in FIG. 10 .
[0032] As shown in FIGS. 7 , 9 and 10 , the two side support walls 76 a , 76 b are formed at an angle 88 with respect to the second central axis A2. That is, the two side support walls 76 a , 76 b are non-parallel to the second central axis A2 of the shim 60 , unlike conventional shims. The angle 88 can be greater than zero (0) degrees and less than ninety (90) degrees. In the illustrated embodiment, the angle 88 is about sixty (60) degrees. However, it will be appreciated that the invention is not limited by the magnitude of the angle 88 , and that the invention can be practiced with any desirable angle between the two side support walls 76 a , 76 b to provide sufficient contact between the insert 10 and the shim 60 . In one embodiment, the angle 88 is approximately equal to the angle 52 of the side support walls 30 a , 30 b of the shim abutment surface 30 of the cutting insert 10 . Similar to the bottom wall 30 c of the shim abutment surface 30 , the top wall 76 c of the insert abutment surface 76 has a constant width.
[0033] Referring now to FIG. 12 , the insert 10 and the shim 60 interact with each other to provide additional support to permit proper seating and reduce rotation of the cutting insert 10 during heavy machining applications, as compared to conventional cutting inserts and shims. Specifically, the side support walls 30 a , 30 b of the shim abutment surface 30 of the cutting insert 10 engage the side support walls 76 a , 76 b of the insert abutment surface 76 of the shim 60 along the entire length of the cutting insert 10 and the shim 60 , thereby increasing the contact area between the cutting insert 10 and the shim 60 . It is noted that the bottom surface 30 c of the shim abutment surface 30 of the cutting insert 10 does not contact the top surface 76 c of the insert abutment surface 76 of the shim 60 . In addition, the diagonal opposite engagement of the cutting insert 10 and the shim 60 along the entire length aids in centering the cutting insert 10 with respect to the shim 60 . Further, the large contact area between the cutting insert 10 and the shim 60 is located in an area where high cutting forces occur during heavy machining applications. Because the cutting insert 10 and the shim 60 contact each other in the area where high cutting forces (and high stress) occur, additional support to permit proper seating and reduced rotation of the cutting insert 10 is provided by the cutting insert 10 and shim 60 of the invention.
[0034] Referring now to FIG. 13 , a milling cutter 100 is shown according to an embodiment of the invention. The milling cutter 100 has an axis of rotation 101 , and a cutter body 102 with a plurality of insert pockets 104 . In each insert pocket 104 , the cutting insert 10 and the shim 60 of the invention is tangentially mounted to the cutter body 102 by means of a clamping screw 106 , 108 , respectively. As can be seen, each cutting insert 10 is seated so that there is a clearance between a workpiece (not shown) and the minor side surface 14 of the cutting insert 10 , the minor side surface 64 of the shim 60 and the face 110 of the milling cutter 100 .
[0035] The insert pocket 104 includes a side wall 112 and a rear wall 114 generally transverse to a bottom wall 116 . Each wall 112 , 114 , 116 is generally planar. When seated in the insert pocket 104 , one of the minor side surfaces 14 of the cutting insert 10 is adjacent and engages the side wall 112 , and one of the major side surfaces 16 of the cutting inset 10 is adjacent and engages the bottom wall 116 of the insert pocket 104 . Similarly, one of the minor side surface 64 of the shim 60 is adjacent and engages the side wall 112 , and one of the major side surfaces 66 of the shim 60 is adjacent and engages the bottom wall 116 of the insert pocket 104 . In addition, the shim abutment surface 36 on the end surface 12 of the cutting insert 10 engages the insert abutment surface 76 of the shim 60 to permit proper seating and reduced rotation of the cutting insert 10 during heavy machining operations.
[0036] The patents and publications referred to herein are hereby incorporated by reference.
[0037] Having described presently preferred embodiments the invention may be otherwise embodied within the scope of the appended claims. | A combination of a cutting insert and a shim. The cutting insert and shim have two opposing end surfaces, two identical opposing major side surfaces and two identical opposing minor side surfaces. Each end surface of the insert has a shim abutment surface for contacting the shim. One end surface of the shim has an insert abutment surface for contacting the insert. The abutment surfaces contact each other along an entire length of the cutting insert and shim so as to help distribute the loads encountered in the cutting operation, as well as provide protection of the insert pocket in case of insert failure. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of high speed short-channel complementary MOS (CMOS) transistor structures and process of fabricating such CMOS transistor structures.
2. Description of the Prior Art
Complementary metal-oxide-semiconductor (CMOS) transistors are well-known in the art, and are often used in applications where low power consumption and high noise immunity are required. However, the channel lengths of either p-channel MOS transistors or n-channel MOS transistors of prior art CMOS transistors are generally determined by the precision of photolithographic and etching techniques during diffusion steps, and are practically limited to about four or five microns. Therefore, short-channel lengths of one micron are extremely difficult to obtained. Very high speed operations employing prior art CMOS integrated circuits have not been realized. In addition to the photolithographic limitation in achieving short-channel lengths, punch-through breakdown mechanism and short-channel effects in a short-channel device post severe problems in providing desired device characteristics.
SUMMARY AND OBJECTS OF THE INVENTION
The present invention obviates the foregoing disadvantages of the prior art by providing a self-alignment short-channel V-groove complementary MOS which has laterally disposed source and drain regions for both N-channel and P-channel MOS transistors.
According to the preferred embodiment of the present invention, there is provided a CMOS device comprising a lightly N-doped semiconductor substrate having a surface and a lightly P-doped tub therein; first and second P-type regions disposed between a first V-groove exposed by the opposite side surfaces of the first V-groove in the N-type semiconductor substrate; first and second N-type regions disposed between a second V-groove exposed by the opposite side surfaces of the second V-groove; a first P-type layer having a higher impurity doping concentration than the P-type tub terminating on all four sides of the second V-groove; N + and P + contacts regions to the substrate and the tub respectively; a channel stopper layer in the substrate and the tub respectively; a thin insulating layer over the first and second V-grooves; a relatively thick oxide layer of substantially uniform thickness covering the entire wafer, and appropriate conductor means.
It is therefore, an essential object of the present invention to provide an improved high speed complementary V-groove MOS for use in integrated circuits.
It is another object of the invention to provide an improved CMOS device in which the threshold voltage of the n-channel device can be directly controlled by ion implantation.
It is another object of the invention is provide an improved CMOS device in which punch-through breakdown voltage is high.
It is another object of the invention to provide an improved CMOS device in which the short-channel effects are significantly reduced.
It is another object of the invention to provide an improved CMOS device in which the channel region is precisely aligned to the source and drain regions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic, cross sectional view of a preferred short-channel self-aligned complementary V-groove MOS device made in accordance with the present invention.
FIG. 2A to 2H are cross sectional views showing the successive steps in fabricating the CMOS device of FIG. 1.
FIG. 3 shows a schematic cross sectional view of a second preferred CMOS made in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows one of the preferred embodiments of the present complementary MOS (CMOS) transistor 10 invention. A lightly N-doped semiconductor substrate 11, usually silicon, having a (100) surface 9 and an impurity concentration in the range of 10 13 to 10 15 atoms per cubic centimeter is first provided, and a lightly p-coped tub 12 having a typical doping concentration of 10 14 - 5×10 15 atoms/cm 3 is diffused therein. Spaced N + regions 13 and 14 are diffused into the p-type tub 12, forming source and drain regions of an n-channel MOS transistor N1, respectively. A mesa 15 projecting from the surface 9 of the p-type tub 12 lying between N + source and drain regions 13 and 14, with portions of source and drain 13 and 14 in said mesa 15, is provided. A p-type layer 17 having a typical impurity concentration in the range of 5×10 15 to 10 18 atoms/cm 3 is provided lying immediately underneath and adjacent to portions of the N + regions 13 and 14 in said mesa 15, forming an effective channel layer of the transistor N1. A V-groove 16 having two side surfaces and two end surfaces extending from the mesa 15 into the p-type tub 12 is provided exposing the effective channel layer 17 and the p-type tub 12 on all four surfaces thereof. N + regions 13 and 14 are exposed by the two side surfaces of the V-groove 16 in the present example. A dielectric layer 18 of appropriate thickness is provided over the V-groove 16 forming a gate dielectric layer of the transister N1. A conducting layer 19 such as aluminum, p-doped polycrystalline silicon or N-doped polycrystalline silicon is provided over the gate dielectric layer 18 forming a gate electrode of transistor N1.
P + regions 20 and 21 are diffused into the N-type substrate 11 forming drain and source regions of a p-channel MOS transistor P1, respectively. A V-groove 22 lying between regions 20 and 21 having two side surfaces and two end surfaces is provided into n-type substrate 11 exposing the P + drain region 20 with a first side surface and the P + source region 21 with a second side surface. A conducting layer 24 is provided over a gate dielectric layer 23 formed over the V-groove 22. A P + region 25 and an N + region 26 are diffused into the p-type tub 12 and the n-type substrate 11, respectively, to provide ohmic contacts regions therein, thus form a tub-contact region and a substrate-contact region, respectively. A relatively thick field dielectric layer 27 is provided over the surface of the substrate 11 and the tub 12. Contact apertures 28, 29, 30, 31, 32 and 33 are etched through the field dielectric layer 27, and through these apertures, conductor means 34, 35, 36, 37, 38 and 39 are provided over regions 25, 13, 14, 20, 21 and 26 respectively. A p-type layer 40 underlying the thick field dielectric 27 in the p-type tub 12 encircling the N-channel transistor N1 and the p-type tub 12 forms a channel stopper layer for transistor N1. An N-type layer underlying the field dielectric layer 27 encircling the p-channel device P1 forms a channel stopper layer for the transistor P1.
In usual operations, the P + tub-contact region 25 and the N + source region 13 of transistor N1 are connected to a ground potential V ss ; the P + source region 21 and the N + substrate-contact region 26 are connected to a positive voltage V dd ; the N + drain region 14 of transistor N1 and the P + drain region 20 of transistor P1 are connected to an output electrode V out ; the gate conductors 19 and 24 are connected to an input electrode V in . When an applied input voltage at the input electrode V in is at a high potential (exceeding the threshold voltage of the transistor N1), the transistor N1 become conductive while the transistor P1 is nonconductive to render the output signal at V out low (V SS ). When an applied input voltage at the input electrode V in is at a low level (V SS ), the transistor N1 is "turned-off" while transistor P1 is "turned-on" to render the output signal at the output electrode V out high (V DD ). Thus, the present CMOS invention, in this particular example, provides an inverter logic operation.
Referring now, again, to FIG. 1, V-shaped channels and gates are provided between source regions and drain regions of both the p-channel transistor P1 and N-channel transistor N1. Owing to the V-shaped structure, punch-through breakdown voltages are greatly enhanced (5-10 times) over conventional planar MOS transistors having same effective channel lengths and impurity concentrations. In conventional planar MOS transistor structures, it is difficult to provide channel length having a dimension of less than 3 microns. One reason is due to the low punch-through breakdown voltage limitation. A second reason is short-channel effects, such as, the threshold voltage become extremely sensitive to channel length variations and applied drain voltages. The present CMOS device provides solution to both these two problems. Thus, CMOS employing the present invention having channel length (or V-groove width) of 1 micron can be successfully fabricated. The present CMOS, thus, provides higher speeds than prior art CMOS devices. In addition, the N-channel transistor N1 of the present invention has extremely high gains since the effective channel length is formed by the thickness of the effective channel layer 17 which can be accurately controlled to less than 0.5 micron by ion implantation.
Referring now to FIGS. 2A to 2H, the successive steps in manufacturing the CMOS device of FIG. 1 are illustrated. Referring now, particularly to FIG. 2A, a lightly n-doped silicon substrate 11, having a donor dopant concentration of 10 14 atoms/cm 3 and a (100) surface 9 is provided. A layer of silicon dioxide 50 in the order of approximately 5,000 A in thickness is first grown over the surface 9 of the substrate 11. Utilizing a first mask (not shown) in conjunction with conventional photolithographic and etching techniques, an oxide window 51 is opened, and a lightly p-doped tub 12 having an impurity level of about 1×10 15 /cm 3 is formed through the window 51. The p-type tub 12 can be formed by first implanting boron ions into the semiconductor substrate 11 with a typical dose of 1×10 12 ions/cm 2 at an energy of 200 Kev, and than by diffusing or redistributing the implanted ions into the substrate 11 to a desired depth such as 8 microns.
Next, referring to FIG. 2B, the silicon dioxide layer 50 is first removed by a buffered HF solution. A thin layer of silicon dioxide 52 in the order of 600 A is thermally grown over the semiconductor surface. A layer of silicon nitride 53 in the order of 1,000 A is then deposited on the silicon dioxide layer 52 by chemical vapor deposition. Next, referring FIG. 2C, utilizing a second mask, an n-type layer 41 is formed through openings 55 by a phosphorus ion implantation at an energy of 200 Kev and a dose of 3×10 12 ions/cm 2 . The hardened photoresist 54 serves as a mask against the ion implantation. The portion of the silicon nitride layer 53 in the openings 55 is then removed.
Next, referring to FIG. 2D, with the hardened photoresist 54 first removed, an oxide layer 56 of approximately 5,000 A in thickness is grown over openings 55. Utilizing a third mask in conjunction with conventional photolithographic and etching techniques, openings 57 are formed with a region 58 between the openings 57 defining a first gate region. Boron diffusion is then performed to form a P + region 25 in the p-type tub, and apaced P + regions 20 and 21 in the n-type substrate 11. The typical junction depth of P + regions 20 and 21 is about 1.5 to 2.5 micron.
Next, referring to FIG. 2E, an oxide layer of approximately 5,000 A is grown in windows 57. Utilizing a fourth mask in conjunction with conventional photolithographic and etching techniques, openings 59 are formed with a region 60 between the openings defining a second gate region. By diffusing suitable n-type impurities, such as phosphorus, N + region 26 in the n-type substrate 11 and spaced N + regions 13 and 14 in the p-type tub 12 are formed. The typical junction depth is about 1 micron.
Next, referring to FIG. 2F, using a fifth mask with hardened photoresist 61 covering the gate region 60 and the regions outside the p-tub, the exposed nitride layer is removed; a blanket boron ion implantation at a typical dose of 1×10 13 /cm 2 and energy of 200 Kev is performed to form a p-type layer 40.
Next, referring to FIG. 2G, a relatively thick oxide layer 27 of 15,000 A is grown with the silicon nitride layer at regions 60 and 58 as an oxidation mask. It is to be noted that the relatively thick oxide layer is of substantially uniform thickness. It is again to be noted that the edges of the masking nitride layer are lifted up due to oxidation in the lateral direction. Using a sixth mask with the hardened photoresist 62 covering the gate region 58, a boron ion implantation with a dose of 4×10 12 /cm 2 and at an energy of 100 Kev is performed to form an effective channel layer 17.
Next, referring to FIG. 2H, the hardened photoresist 62, the silicon nitride layer and the thin oxide layer of 600 A in the gate regions 58 and 60 are removed.
Next, anisotropic etching of silicon is performance to form V-grooves 16 and 22. A thin gate oxide layer 18 and 23 of approximately 600 A is grown over the V-grooves respectively.
Next, contact apertures 28, 29, 30, 31, 32 and 33 are opened utilizing a seventh mask in conjunction with conventional photolithographic and etching techniques. Aluminum is then deposed and defined through an eighth mask in conjunction with conventional photolithographic and etching techniques to form a device of FIG. 1.
A second embodiment of the present invention is shown in FIG. 3. An n-channel MOS transistor N2 similar to the n-channel transistor N1 of FIG. 1 is disposed in a p-type substrate 70, and a p-channel MOS transistor P2 similar to that of FIG. 1 is disposed in an n-type tub 71. It is to be noted that an p-type polycrystalline silicon 72 and 73 can be used as gate electrodes to achieve low threshold voltages, for example, 1 volt or less for the p-channel device P2. The impurity concentration for the effective channel layer 74 is preferred to be low, for example, ranges from 5×10 15 -5×10 16 /cm 3 in order to obtain low threshold voltages (1 volt or less) for the n-channel transistor N2.
The fabrication and device characteristics of the device of FIG. 3 is similar to those of FIG. 1.
What is claimed and desired to be secured by Letter Patent. What I claim: | An improved short-channel complementary MOS transistor structure is provided. The problems of low punch-through voltage breakdown, and "short-channel effects" are particularly addressed and solved. Accurate and precise field protection of all area surrounding the channel, source and drain regions of both the p-channel MOS transistor device and the n-channel transistor device is simply and effectively accomplished. The threshold voltage of the n-channel MOS transistor device is precisely controlled by a boron implantation.
The method of manufacturing such device is disclosed. | 8 |
FIELD OF THE INVENTION
[0001] The present invention is directed to a method for preprocessing audio data in order to improve the quality of the music decoded at receiving terminals such as mobile phones; and more particularly, to a method for preprocessing audio data in order to mitigate a degradation to music signal that can be caused when the audio data is encoded/decoded in a wireless communication system using speech codecs optimized only for human voice signals.
BACKGROUND OF THE INVENTION
[0002] The channel bandwidth of a wireless communication system is much narrower than that of a conventional telephone communication system of 64 kbps, and thus audio data in a wireless communication system is compressed before being transmitted. Methods for compressing audio data in a wireless communication system include QCELP (QualComm Code Excited Linear Prediction) of IS-95, EVRC (Enhanced Variable Rate Coding), VSELP (Vector-Sum Excited Linear Prediction) of GSM (Global System for Mobile Communication), PRE-LTP (Regular-Pulse Excited LPC with a Long-Term Predictor), and ACELP (Algebraic Code Excited Linear Prediction). All of these listed methods are based on LPC (Linear Predictive Coding). Audio compressing methods based on LPC utilize a model optimized to human voices and thus are efficient to compress voice at a low or middle encoding rate. In a coding method used in a wireless system, to efficiently use the limited bandwidth and to decrease power consumption, audio data is compressed and transmitted only when speaker's voice is detected by using what is called the function of VAD (Voice Activity Detection).
[0003] Recently, several services for providing music to wireless phone uses became available. One of which is what is called “Coloring service” which enables a subscriber to designate a tune of his/her choice so that callers who make a call to the subscriber would hear music instead of a traditional ringing tone while the subscriber is not answering the phone. Since this service became very popular first in Korea where it originated and then in other countries, transmission of music data to a cellular phone has been increasing. However, as explained above, the audio compression method based on LPC is suitable for human voice that has limited frequency components. When music or signals having frequency components in most of the audible frequency range (20˜20,000 Hz) are processed in a conventional LPC based codec and transmitted through a cellular phone, signal distortion occurs, which causes a pause in music or makes sound having only part of the original frequency components.
[0004] There are various reasons why the sound quality of audio data is degraded after audio data is compressed using audio codecs based on LPC, especially EVRC codecs. The sound quality degradation occurs in the following way.
[0005] (i) Complete loss of frequency components in a high-frequency bandwidth
[0006] (ii) Partial loss of frequency components in a low-frequency bandwidth
[0007] (iii) Intermittent pause of music
[0008] The first cause of the degradation cannot be avoided as long as the high-frequency components are removed using a 4 kHz (or 3.4 kHz) lowpass filter when audio data are compressed using narrow bandwidth audio codec.
[0009] The second phenomenon is due to the intrinsic characteristic of the audio compression methods based on LPC. According to the LPC-based compression methods, a pitch and a formant frequency of an input signal are obtained, and then an excitation signal for minimizing the difference between the input signal and the composite signal calculated by the pitch and the formant frequency of the input signal, is derived from a codebook. It is difficult to extract a pitch from a polyphonic music signal, whereas it is each in case of human voice. In addition, the formant component of music is very different from that of a person's voice. Consequently, it is expected that the prediction error signal for music data would be much larger than those of human speech signal, and thus many frequency components included in the original audio data are lost. The above two problems, that is, loss of high and low frequency components are due to inherent characteristic of audio codec optimized to voice signals, and inevitable to a certain degree.
[0010] The pauses in audio signal are caused by the variable encoding rate used by EVRC. An EVRC encoder processes the audio data with three rates (namely 1, ½, and ⅛). Among these rates, ⅛ rate means that the EVRC encoder determines that the input signal is a noise, and not a voice signal. Because sounds of a percussion instrument, such as a drum, include spectrum components that tend to be perceived as noises by audio codecs, music including this type of sounds is frequently paused. Also, audio codecs consider sounds having low amplitudes as noises, which also degrade the sound quality.
SUMMARY OF THE INVENTION
[0011] The present invention provides a method for preprocessing audio signal to be transmitted via wireless system in order to improve the sound quality of audio data received at a receiving terminal of a subscriber. The present invention provides a method for mitigate the deterioration of music sound quality occurring when the music signal is processed by codes optimized for human voice, such as EVRC codecs. Another object of the present invention is to provide a method and system for preprocessing audio data in a way that does not interfere with the existing wireless communication system. Accordingly, the preprocessing method of the present invention is useful in that it can be used without modifying an existing system. The present invention can be applied in a similar manner to other codecs optimized for human voice other than EVRC as well.
[0012] In order to achieve the above object, the present invention provides a method for preprocessing audio data to be processed by a codec having variable coding rate, comprising the steps of:
[0013] classifying the audio data based on the characteristic of the audio data; and
[0014] preprocessing frames of audio data selected based on the classification.
[0015] In another aspect of the invention, a method for preprocessing audio data to be processed by a codec having variable coding rate is provided, which comprises the steps of:
[0016] classifying the audio data based on the characteristic of the audio data;
[0017] in case the audio data includes monophonic sound, performing AGC (automatic gain control) preprocessing of all frames; and
[0018] in case the audio data includes polyphonic sound, performing AGC preprocessing of selected frames.
[0019] According to a preferred embodiment of the present invention, AGC preprocessing of selected frames include deciding whether a frame in the audio data includes noise signal or not.
[0020] In yet another aspect of the invention, a method for preprocessing audio data to be processed by a codec having variable coding rate is provided, which comprises the steps of:
[0021] deciding an interval of audio data that is to be encoded in a low bit rate in said codec; and
[0022] adjusting the amplitude of audio data of the decided interval, such that the audio data in the interval may not be encoded in said low bit.
[0023] According to another preferred embodiment of the present invention, the adjusting step comprises the steps of:
[0024] calculating signal levels of the audio data;
[0025] deciding smoothed gain coefficients based on signal levels; and
[0026] generating preprocessed audio data by multiplying the smoothed gain coefficients to the audio data in the decided interval.
DESCRIPTION OF THE DRAWINGS
[0027] The above object and features of the present invention will become more apparent from the following description of the preferred embodiments given in conjunction with the accompanying drawings.
[0028] [0028]FIG. 1 is a block diagram of an EVRC encoder.
[0029] [0029]FIG. 2A is a graph showing a frame residual signal for a signal having a dominant frequency component.
[0030] [0030]FIG. 2B is a graph showing a frame residual signal for a signal having a variety of frequencies.
[0031] [0031]FIG. 3A is a graph showing autocorrelation of residual for a signal having a dominant frequency component.
[0032] [0032]FIG. 3B is a graph showing autocorrelation of residual for a signal having a variety of frequencies.
[0033] [0033]FIG. 4 is a flow chart for performing AGC (Automatic Gain Control) preprocessing according to the present invention.
[0034] [0034]FIG. 5 is a flow chart for performing frame-selective AGC preprocessing according to the present invention.
[0035] [0035]FIG. 6 is a block diagram for performing AGC according to the present invention.
[0036] [0036]FIG. 7 is a graph showing a sampled audio signal and its signal level.
[0037] [0037]FIG. 8 is a graph for explaining the calculation of a forward-direction signal level according to the present invention.
[0038] [0038]FIG. 9 is a graph for explaining the calculation of a backward-direction signal level according to the present invention.
[0039] FIGS. 10 A- 10 D are graphs showing results of AGC preprocessing.
DETAILED DESCRIPTION OF THE INVENTION
[0040] As a way to solve the problem of intermittent pauses, the present invention provides a method of preprocessing audio data before it is subject to audio codec. Certain type of sounds (such as one of a percussion instrument) include spectrum components that tend to be perceived as noises by audio codecs optimized for human voice (such as codes for wireless system), and audio codecs consider the portions of music having low amplitudes as noises. This phenomenon is shown commonly in all systems employing DTX (discontinuous transmission) based on VAD (Voice Activity Detection) such as GSM (Global System for Mobile communication). In case of EVRC, if data is determined as noise, that data is encoded with a rate ⅛ among the three predetermined rates of ⅛, ½ and 1. The music data is decided as noise by the encoding system, the transmitted data basically cannot be heard at the receiving end, thus severely deteriorating the quality of sound.
[0041] This problem can be solved by preprocessing audio data so that the encoding rates of EVRC codec may be decided as 1 (and not ⅛) for frames of music data. According to the present invention, the encoding rate of music signals can be increased through preprocessing, and therefore, the pauses of music at the receiving terminal caused by EVRC are reduced. Although the present invention is explained with regard to EVRC codec, a person skilled in the art would be able to apply the present invention to other compression system using variable encoding rate, especially a codec optimized for human voice (such as an audio codec for wireless transmission).
[0042] With reference to FIG. 1, RDA (Rate Decision Algorithm) of EVRC will be explained. EVRC will be explained as an example of a compression system using a variable encoding rate for compressing a data to be transmitted via wireless network where the present invention can be applied. Understanding of the rate decision algorithm of the conventional codec used in a existing system is important because the present invention is based on an idea that, in a conventional codec, some music data may be encoded at a data rate that is too low for music data (though maybe adequate for voice data), and by increasing the data rate for the music data, the quality of the music after the coding, transmission and decoding can be improved.
[0043] [0043]FIG. 1 is a high-level block diagram of an EVRC encoder. In FIG. 1, an input may be an 8 k, 16 bit PCM (Pulse Code Modulation) audio signal, and an encoded output may be digital data whose size can be 171 bits (when the encoding rate is 1), 80 bits (when the encoding rate is ½), 16 bits (when the encoding rate is ⅛), or 0 bit (blank) per frame according to the encoding rate decided by the RDA. The 8 k, 16 bit PCM audio is coupled to the EVRC encoder in units of frames where each frame has 160 samples (corresponding to 20 ms). The input signal s[n] (i.e. an n th input frame signal) is coupled to a noise suppression block 110 , which checks the input frame signal s[n]. In case the input frame signal is considered noise in the noise suppression block 160 , it multiplies a gain less than 1 to the signal and thereby suppresses the input frame signal. And then, s′[n] (i.e. a signal which has passed through the block 110 ) is coupled to an RDA block 120 , which selects one rates from predefined set of encoding rates (1, ½, ⅛, and blank in the embodiment explained here). An encoding block 130 extracts proper parameters from the signal according to the encoding rate selected by the PDA block 120 , and a bit packing block 140 packs the extracted parameters to conform to a predetermined output format.
[0044] As shown in the following table, the encoded output can have 171, 80, 16 or 0 bits per frame depending on the encoding rate selected by RDA.
TABLE 1 Frame type Bits per frame Frame with encoding rate 1 171 Frame with encoding rate ½ 80 Frame with encoding rate ⅛ 16 Blank 0
[0045] The RDA block 120 divides s′[n] into two bandwidths (f(1) of 0.3˜2.0 kHz and f(2) of 2.0˜4.0 kHz) by using a bandpass filter, and selects the encoding rate for each bandwidth by comparing an energy value of each bandwidth with a rate decision threshold decided by a Background Noise Estimate (“BNE”). The following equations are used to calculate the two thresholds for f(1) and f(2).
T 1 =k 1 ( SNR f(i) ( m− 1)) B f(i) ( m− 1) Eq. (1a)
T 2 =k 2 ( SNR f(i) ( m− 1)) B f(i) ( m− 1) Eq. (1b)
[0046] Wherein k 1 and k 2 are threshold scale factors, which are functions of SNR (Signal-to-Noise Ratio) and increase as SNR increases. Further, B f(i) (m−1) is BNE (background noise estimate) for f(i) band in the (m−1) th frame. As described in the above equations, the rate decision threshold is decided by multiplying the scale coefficient and BNE, and thus proportional to BNE.
[0047] On the other hand, the band energy may be decided by 0 th to 16 th autocorrelation coefficients of audio data belonging to each frequency bandwidth.
BE f ( i ) = R w ( 0 ) R f ( i ) ( 0 ) + 2.0 ∑ k = 1 L h - 1 R w ( k ) R f ( i ) ( k ) Eq . ( 2 )
[0048] Wherein BE f(i) is an energy value for i th frequency bandwidth (i=1, 2), R w (k) is a function of autocorrelation coefficients of input audio data, and R f(i) (k) is an autocorrelation coefficient of an impulse response in a bandpass filter. L h is a constant of 17.
[0049] Then, the update of an estimated noise (B f(i) (m−1)) will be explained. The estimated noise (B f(i) (m)) for i th frequency band (or f(i)) of m th frame is decided by the estimated noise (B f(i) (m−1)) for f(i) of (m−1) th frame, smoothed band energy (E SM f(i) (m)) for f(i) of m th frame, and a signal-to-noise ratio (SNR f(i) (m−1)) for f(i) of (m−1) th frame, which is represented in the pseudo code.
if ( < 0.30 for 8 or more consecutive frames) B f(i) (m)=min{E sm f(i) (m), 80954304, max{1.03B f(i) (m−1), B f(i) (m−1)+1}} else{ if (SNR f(i) (m−1) > 3) B f(i) (m)=min{E SM f(i) (m), 80954304, max{1.0054B f(i) (m−1), B f(i) (m−1)+1}} else B f(i) (m)=min{E SM f(i) (m), 80954304, B f(i) (m−1)} } if (B f(i) (m) < lownoise(i)) B f(i) (m) = lownoise(i) }
[0050] As described above, if the value of □, a long-term prediction gain (how to decide □ will be explained later) is less than 0.3 for more than 8 frames, the lowest value among (i) the smoothed band energy, (ii) 1.03 times of the BNE of the prior frame, and (iii) a predetermined maximum value of a BNE (80954304 in the above) is selected as the BNE. Otherwise (if the value of □ is not less than 0.3 in any of the 8 consecutive frames), if SNR of the prior frame is larger than 3, the lowest value among (i) the smoothed band energy, (ii) 1.00547 multiplied by BNE of the prior frame, and (iii) a predetermined maximum value of a BNE is selected as the BNE for this frame. If SNR of the prior frame is not larger than 3, the lowest value among (i) the smoothed band energy, (ii) the BNE of the prior frame, and the predetermined maximum value of BNE is selected as the BNE for this frame.
[0051] Therefore, in case of an audio signal, the BNE tends to increases as time passes, for example, by 1.03 times or by 1.00547 times from frame to frame, and decreases only when the BNE becomes larger than the smoothed band energy. Accordingly, if the smoothed band energy is maintained within a relatively small range, the BNE increases as time passes, and thereby the value of the rate decision threshold increases (see Eq. (1)). As a result, it becomes more likely that a frame is encoded with a rate of ⅛. In other words, if music signal is played for a long time, pauses tend to occur more frequently.
[0052] The long-term prediction gain (□) is defined by autocorrelation of residuals as follows.
β = max { o , min { 1 , R max R ɛ ( 0 ) } } Eq . ( 3 )
[0053] Wherein □ is a prediction residual signal, R max is a maximum value of the autocorrelation coefficients of the prediction residual signal, and R □ (0) is a 0 th coefficient of an autocorrelation function of the prediction residual signal.
[0054] According to above equation, in case of monophonic signal or a voice signal where a dominant pitch exists, the value of □ would be larger, but in case of music including several pitches, the value of □ would be smaller.
[0055] The prediction residual signal (□) is defined as follows:
ɛ [ n ] = s ′ [ n ] - ∑ i = 1 10 a i [ k ] s ′ [ n - i ] Eq . ( 4 )
[0056] wherein s′[n] is an audio signal preprocessed by the noise suppression block 110 , and a i [k] is an interpolated LPC coefficient of the k th segment of a current frame.
[0057] That is, the prediction residual signal is a difference between a signal reconstructed by the LPC coefficients and an original signal.
[0058] The frame residual signal looks regular in case there exists a dominant frequency component in the frame (see FIG. 2A), while it is irregular in case there exist various frequency components in the frame (see FIG. 2B). Accordingly, in the former case, a regulated maximum peak value of autocorrelation coefficients (that is long-term prediction gain □) would become a larger value (such as □=0.6792, see FIG. 3A), while in the latter case, it becomes a smaller value (such as □=0.2616, see FIG. 3B). In these FIGS. 3A and 3B, the autocorrelation coefficients are normalized by R(0). In FIGS. 2A and 2B, x-axis represents sample numbers and y-axis represents the amplitude of signal residual where the numbers on the graph are values normalized depending on the system requirement (for example, how many bits are used to represent the value), which applies to other graphs in this application (such as FIGS. 7 - 10 ).
[0059] How to decide the encoding rate will be explained. For each of the two frequency bands, if the band energy is higher than the two threshold values, the encoding rate is 1, if the band energy is between the two threshold values, the encoding rate is ½, and if the band energy is lower than both of the two threshold values, the encoding rate is ⅛. After encoding rates are decided for two frequency bands, the higher of two encoding rates decided for the frequency bands is selected as an encoding rate for that frame. In an actual system, coding at a rate of ⅛ may mean that the relevant signal is decided as noise and very little data is transmitted; coding at a rate of 1 may mean that the signal is decided as valid human voice; and coding at a rate of ½ happens for a short interval during the transition between ⅛ and 1.
[0060] Up to now, it was explained how the encoding rate is decided in an EVRC codec, which is an example of variable rate coding system where the present invention can be applied. From the foregoing, it can be understood that the encoding rate of a frame can be maximized to 1 as much as possible by (i) increasing the band energy and/or (ii) decreasing the threshold value for the encoding rate decision.
[0061] The present invention uses an AGC (Automatic Gain Control) method for increasing the band energy. AGC is a method for adjusting current signal gain by predicting signals for a certain interval (ATTACK interval). For example, if music is played in speakers having different dynamic ranges, it cannot be processed properly without AGC (without AGC, some speakers will operate in the saturation region.) Therefore, it is necessary to perform AGC preprocessing based on the characteristic of the sound generating device, such as a speaker, an earphone, or a cellular phone.
[0062] In case of a cellular phone, while it will be ideal to measure the dynamic range of the cellular phone and perform AGC in order to ensure best sound quality, it is impossible to design AGC optimized for all cellular phones because the characteristic of a cellular phone would vary depending on a manufacturer and also on particular model. Therefore, it is necessary to design an AGC generally applicable to all cellular phones.
[0063] [0063]FIG. 4 is a high-level flow chart for performing AGC preprocessing according to one embodiment of the present invention. At first, audio data are obtained in step 410 , and then the audio data is classified based on the characteristic of the audio data in step 420 . The audio data would be processed in different ways depending on the classification because, for certain type of audio data, it is preferable to enhance the energy of all frames, while in other cases, it works better to enhance only the band energy of frames that are encoded with a low frame rate in the variable coding rate encoder (such EVRC). The right part 440 of the flow chart shows enhancement of energy of all frames. In case of classical music or monophonic audio data having one pitch, it is preferable that the right part 440 of the flow chart is performed. The left part 430 of the flow chart shows enhancing the band energy of such frames that are encoded with a low frame rate. In case of polyphonic audio data, such as rock music, it is preferable that the right part 430 of the flow chart is performed.
[0064] [0064]FIG. 5 is a flow chart for the frame-selective AGC for preprocessing frames that would be encoded with low rate without the preprocessing. AGC is performed in different ways depending on the energy of frames of music signals. The interval in which the energy of frames of the audio data (before the EVRC coding) is low (i.e. lower than 1,000) is defined as a “SILENCE” interval where no preprocessing is performed. For the frames not in the “SILENCE” interval, EVRC encoding is pre-performed to detect the encoding rate for each frame. For such intervals where the frames having encoding rate of ⅛ occur frequently (which means such intervals are considered a noise by EVRC encoder), the band energy of the frames is locally increased. When enhancing the energy for certain frames, interpolation with other frames would be necessary (in this regard, what is referred to “envelop interpolation” will be explained later) to prevent discontinuity of sound amplitude between the enhanced frames and non-enhanced neighboring frames.
[0065] [0065]FIG. 6 is a block diagram for AGC in accordance with one embodiment of the present invention. In this embodiment, AGC is a process for adjusting the signal level of the current sample based on a control gain decided from a set of sample values in look-ahead window. At first, a “forward-direction signal level”. l f [n] and a “backward-direction signal level” l b [n] are calculated using the sampled audio signal s[n] in a way explained later, and from them, a “final signal level” l[n] is calculated. After l[n] is calculated, processing gain per sample (G[n]) is calculated using l[n], and then output y[n] is obtained by multiplying G[n] and s[n].
[0066] In the following, the functions of the blocks in FIG. 6 will be described in more detail.
[0067] [0067]FIG. 7 shows an exemplary signal level (l[n]) calculated from the sampled audio signal (s[n]). The envelope of the signal level l[n] varies depending on how to process signals by using forward-direction exponential suppression (“ATTACK”) and backward direction exponential suppression (“RELEASE”). In FIG. 7, L max and L min refer to the maximum and minimum values of the output signal after the AGC preprocessing.
[0068] A signal level at time n is obtained by calculating forward-direction signal levels (for performing RELEASE) and calculating backward-direction signal levels (for performing ATTACK.) Time constant of an “exponential function” characterizing the exponential suppression will be referred to as “RELEASE time” in the forward-direction and as “ATTACK time” in the backward-direction. ATTACK time is a time taken for a new output signal to reach a proper output amplitude. For example, if an amplitude of an input signal decreases by 30 dB abruptly, ATTACK time is a time for an output signal to decrease accordingly (by 30 dB). RELEASE time is a time to reach a proper amplitude level at the end of an existing output level. That is, ATTACK time is a period for a start of a pulse to reach a desired output amplitude whereas RELEASE time is a period for an end of a pulse to reach a desired output amplitude.
[0069] In the following, how to calculate a forward-direction signal level and a backward-direction signal level will be described with reference to FIGS. 8 and 9.
[0070] With reference to FIG. 8, a forward-direction signal level is calculated by the following steps.
[0071] In the first step, a current peak value and a current peak index are initialized (set to 0), and a forward-direction signal level (l f [n]) is initialized to |s[n]|, an absolute value of s[n].
[0072] In the second step, the current peak value and the current peak index are updated. If |s[n]| is higher than the current peak value (p[n]), p[n] is updated to |s[n]|, and the current peak index (i p [n]) is updated to n (as shown in the following pseudo code.)
[0073] if (|s[n]|>p[n]) {
[0074] p[n]=|s[n]|
[0075] i p [n]=n
[0076] In the third step, a suppressed current peak value is calculated. The suppressed current peak value p d [n] is decided by exponentially reducing the value of p[n] according to the passage of time as follows.
p d [n]=p[n ]*exp(− TD/RT )
TD=n−i p [n] Eq. (5)
[0077] Wherein RT stands for RELEASE time.
[0078] In the fourth step, a larger values out of p d [n] and |s[n]| is decided as a forward-direction signal level, as follows.
l f [n ]=max( p d [n], |s[n]|) Eq. (6)
[0079] Next, the above second to fourth steps are repeated to obtain a forward-direction signal level (l f [n]) as n increases by one at a time.
[0080] With reference to FIG. 9, a backward-direction signal level is calculated by the following steps.
[0081] In the first step, a current peak value is initialized into 0, a current peak index is initialized to AT, and a backward-direction signal level (l b [n]) is initialized to |s[n]|, an absolute value of s[n].
[0082] In the second step, the current peak value and the current peak index are updated. A maximum value of s[n] in the time window from n to n+AT is detected and the current peak value p(n) is updated as the detected maximum value. Also i p [n] is updated as the time index for the maximum value.
p[n ]=max({| s[ ]|})
I p [n ]=(an index of s [ ], where | s [ ]| has its maximum value) Eq. (7)
[0083] Wherein the index of s[ ]can have values from n to n+AT.
[0084] In the third step, a suppressed current peak value is calculated as follows.
p d [n]=p[n ]*exp(− TD/AT )
TD=i p [n]−n Eq.(8)
[0085] Wherein AT stands for ATTACK time.
[0086] In the fourth step, a larger value from p d [n] and |s[n]| is decided as a backward-direction signal level.
l b [n ]=max( p d [n], |s[n ]|) Eq. (9)
[0087] Next, the above second to fourth steps are repeated to obtain a backward-direction signal level (l b [n]) as n increases by one at a time.
[0088] The final signal level (l[n]) is defined as a maximum value of the forward-direction signal level and the backward-direction signal level for each time index.
l[n ]=max( l f [n], l b [n ]) for t=0, . . . , t max Eq. (10)
[0089] Wherein t max is a maximum time index.
[0090] ATTACK time/RELEASE time is related to the sound quality/characteristic. Accordingly, when calculating signal levels, it is necessary to set ATTACK time and RELEASE TIME properly so as to obtain sound optimized to the characteristic of a media. If the sum of ATTACK time and RELEASE time is too small (i.e. the sum is less than 20 ms), a distortion in the form of vibration with a frequency of 1000/(ATTACK time+RELEASE time) can be heard to a cellular phone user. For example, if ATTACK time and RELEASE time are 5 ms each, a vibrating distortion with a frequency of 100 Hz can be heard. Therefore, it is necessary to set the sum of ATTACK time and RELEASE time longer than 30 ms so as to avoid vibrating distortion.
[0091] For example, if ATTACK is slow and RELEASE is fast, sound with wider dynamic range would be obtained. When RELEASE time is long, the high frequency component of output signal is suppressed the resulting signal sound dull. However, if RELEASE time becomes very fast (meaning of being “fast” in this regard may vary depending on the characteristic of music), in the output signal processed by AGC follows the low frequency component of the input waveform. In this case, the fundamental component of the signal is suppressed or may even be substituted by a certain harmonic distortion (the fundamental component means the most important frequency component that a person can hear, which is same as a pitch.) As ATTACK and RELEASE times become longer, pauses are well prevented but the sound become dull (loss of high frequency). Accordingly, there is a trade-off between the sound quality and the number of pauses.
[0092] To emphasize the effect of a percussion instrument, such as a drum, ATTACK time should be lengthened. However, in case of a person's voice, shortening ATTACK time would help in preventing the starting portion's gain from decreasing unnecessarily. It is important to decide ATTACK time and RELEASE time properly to ensure the sound quality in AGC processing, and they are decided considering the characteristic of music.
[0093] The preprocessing method of the present invention does not involve very complicated calculation and can be performed with very short delay (in the order of ATTACK and RELEASE time), and thus when broadcasting a music program, almost real-time preprocessing is possible.
[0094] As to which frames (or intervals) should be processed using the AGC in accordance with the present invention, it is preferable to process intervals with both low and high (compared to a certain standard) amplitude. When audio data having a wide dynamic range is encoded and transmitted in a wireless communication system and played by a cellular phone, the sound quality becomes degraded because the sound with low amplitudes tends not to be heard. Thus, for such frames with low amplitude, the amplitude should be increased for better quality signal. And, in case of interval (frames) with high amplitudes, the amplitude should be reduced to avoid the saturation of the sounds played. To achieve both goals, in one embodiment of the present invention, two limit values (L min and L max ) are set, and then the intervals, in which signal levels are lower than L min or higher than L max , are processed.
[0095] As explained above, to avoid the sudden change in amplitude between the processed (by AGC) and not processed intervals, it is necessary to adjust the control gain properly to prevent abrupt change in amplitude. Also, after the AGC, the maximum level cannot exceed the maximum limit value (L max ), and therefore, without gain value smoothing, the envelope of music signals may be fixed at the maximum limit value. If the envelope is fixed to the maximum limit value, the sound quality of processed intervals would be different from that of non-processed intervals.
[0096] Considering the above, processing gain per each sample signals (G[n]) is decided by the following equation.
G[n]=c *( L/l[n] )+(1 −c ) Eq. (11)
[0097] Wherein c is a gain coefficient, which has a value between 0 and 1. And, L is set to be L min or L max depending on the characteristic of the signal in intervals to be processed.
[0098] The processed signal (s′[n]) is decided by a multiplication of the signal before AGC (s[n]) and the processing gain.
s′[n]=G[n]*s[n] Eq. (12)
[0099] From the above equations (Eq. 11 and Eq. 12) one can know that as c becomes closer to 1, the output envelope would be fixed to the limit value, and as c become closer to 0, the envelope of the resultant signal after AGC (using the gain in the above Equation) would become similar to the input envelope.
[0100] By using the method explained above, the encoding rate of music signals can be enhanced, and thereby the problem of music pause caused by EVRC can be sufficiently improved.
[0101] Experiment results regarding the above explained method will be explained. 8 kHz, 16 bit sampled monophonic music signals with CD quality are used in this experiment.
[0102] FIGS. 10 A- 10 D show comparison between the coded signals in case of using AGC preprocessing of the present invention and in the case of not using the AGC preprocessing. In FIGS. 10 A- 10 D, the horizontal axis is a time axis, and the vertical axis represent a signal amplitude. FIG. 10A shows the original signal, FIG. 10B shows AGC processed signal, FIG. 10C shows EVRC encoded signal from the original signals, and FIG. 10D shows EVRC encoded signal from the AGC preprocessed signals. In the signal having wide dynamic range as shown in FIG. 10A, more pauses tend to occur, especially for the period of low amplitude that would be considered noise. In FIG. 10C, one can note that signal with low amplitudes would not be heard. The original signal is AGC preprocessed using parameters in Table 2, and the preprocessed signal is shown in FIG. 10B. After EVRC coding/decoding, the AGC preprocessed signal becomes one in FIG. 10D. As shown in FIG. 10D, AGC preprocessing enhances the signal portion having low amplitude so that after EVRC coding/decoding the signal may not be paused. As shown in Table 3, through AGC preprocessing, the number of the frames encoded with an encoding rate of ⅛ decreases from 356 to 139.
TABLE 2 ATTACK sample number 160 RELEASE sample number 2000 Minimum limit value 5000 Maximum limit value 30000 Gain smoothing coefficient 0.5
[0103] [0103] TABLE 3 Original signals AGC preprocessed signals Number of frames with 356 139 an encoding rate of ⅛
[0104] MOS (mean opinion score) test to a test group of 11 people at the age of 20s and 30s has been performed for the comparison between original music and music preprocessed by the suggested AGC preprocessing algorithm. Samsung Anycall™ cellular phones are used for the test. Non-processed and preprocessed music signals had been encoded and provided to a cell phone in random sequence, and evaluated by the test group by using a five-grade scoring scheme as follows:
[0105] (1) bad (2) poor (3) fair (4) good (5) excellent
[0106] Three songs were used for the test, and Table 4 shows the result of the experiment. According to the test result, through AGC preprocessing, average points for the songs are increased from 3.000 to 3.273, from 1.727 to 2.455, and from 2.091 to 2.727.
TABLE 4 Title of songs Genre of Average points for Average points for (Composer) songs original songs preprocessed songs Girl's Prayer Piano Solo 3.000 3.273 (Badarczevska) Sonata Pathetic Piano Solo 1.727 2.455 Op 13 (Beethoven) Fifth Symphony 2.091 2.727 symphony (Fate) (Beethoven)
[0107] In one embodiment of the invention, conventional telephone and wireless phone may be serviced by one system for providing music signal. In that case, a caller ID is detected at the system for processing music signal. In a conventional telephone system, a non-compressed voice signal with 8 kHz bandwidth is used, and thus, if 8 kHz/8 bit/a-law sampled music is transmitted, music of high quality without signal distortion can be heard. In one embodiment of the invention, a system for providing music signal to user terminal determines whether a request for music was originated by a caller from a conventional telephone or a wireless phone, using a caller ID. In the former case, the system transmits original music signal, and in the latter case, the system transmits AGC preprocessed music.
[0108] It would be apparent to the person in the art that the pre-processing method of the present invention can be implemented by using either software or a dedicated hardware. Also, in one embodiment of the invention VoiceXLM system is used to provide music to the subscribers, where audio contents can be changed frequently. In such a system, AGC preprocessing of the present invention can be performed on-demand basis. To perform this, a non-standard tag, such as <audio src=“xx.wav” type=“music/classical/”>, can be defined to determine whether to perform preprocessing or types of preprocessing to be performed.
[0109] The application of the present invention includes any wireless service that provides music or other non-human-voice sound through a wireless network (that is, using a codec for a wireless system). In addition, the present invention can also be applied to another communication system where a codec used to compress the audio data is optimized to human voice and not to music and other sound. Specific services where the present invention can be applied includes, among others, “coloring service” and “ARS (Audio Response System).”
[0110] The pre-processing method of the present invention can be applied to any audio data before it is subject to a codec of a wireless system (or any other codec optimized for human voice and not music). After the audio data is preprocessed in accordance with the pre-processing method of the present invention, the pre-processed data can be processed and transmitted in a regular wireless codec. Other than adding the component necessary to perform the pre-processing method of the present invention, no other modification to the wireless system is necessary. Therefore, the pre-processing method of the present invention can be easily adopted by an existing wireless system.
[0111] Although the present invention is explained with respect to the EVRC codec, in other embodiment of the present invention, it can be applied in a similar manner to other codecs having variable encoding rate.
[0112] The present invention is described with reference to the preferred embodiments and the drawings, but the description is not intended to limit the present invention to the form disclosed herein. It should be also understood that a person skilled in the art is capable of using a variety of modifications and another embodiments equal to the present invention. Therefore, only the appended claims are intended to limit the present invention. | Recently, with the wider use of cellular phones, more and more users listen to music via their cellular phones, and thus, the sound quality of music provided via the cellular phones became more critical. Since music signals are encoded by a voice encoding method optimized to human voice signals such as EVRC (Enhanced Variable Rate Coding) in a cellular communication system, the music signals are often distorted by such encoding method, and listeners experience pauses in music caused by such voice-optimized encoding method. To improve the sound quality of music, a method for preprocessing audio data is provided in order to prevent the problem of pause in music signals in a cellular phone. In particular, AGC (Automatic Gain Control) preprocessing is performed to the audio data having low dynamic range. By this method, the number of pauses in music signal is reduced, and the sound quality of the music is improved. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a configurable logic circuit arrangement comprising at least one multiplexer for switching logic signals, said multiplexer comprising one or more data inputs and one or more control signal inputs.
2. Description of the Related Art
A multiplexer enables the selection of one of n data lines by means of log to the base 2 of (n)+1 control lines. This is connected to the output of the MUX and it forwards the logic signals in this way. Programmable logic devices (PLD) acquire their flexibility through the configurability of the data processing (logic block) and the wiring (paths). In a typical PLD, the area proportion of the paths is approximately 75% and that of the logic elements is about 25%.
Path multiplexers (or router mux), that is to say multiplexers in which active signal paths with propagation-time-variant signal values are connected, are widespread in programmable logic devices. Multiplexers which are also referred to as data selectors serve for changing over from one of a plurality of inputs to an output. Multiplexer structures of this type are used in programmable logic devices for routing the signals. Here a data input is selected before operation of the circuit, which data input carries signal values that change during operation, while the selection of the data input, that is to say of the signal value source, remains constant.
Multiplexers are thus the crucial components in the case of the configurable wiring. In the simplest case, a binary-value input of a multiplexer controls the assignment of at least two data inputs to an output.
It is known to configure paths having multiplexers in a configuration or programming operation by means of configuration signals. This operation has to take place before operation of the circuit. With this type of multiplexer, also referred to as router mux, a nonvolatile configuration of the control inputs is performed, for example by means of a mask, a fuse, a flash cell or a transistor configured in nonvolatile fashion, so that during normal operation, that is to say during the propagation time of the data signals, the multiplexer cannot be changed. Devices also exist whose configuration is based on the storage of the items of information in volatile SRAM cells. Operating means for propagation time configuration are not provided, however. Although structures of this type have proved worthwhile overall, it is regarded as a disadvantage that very many lines are needed for the configuration of the control inputs and a configurable multiplexer correspondingly requires a considerable peripheral area. The case may even arise wherein the circuit outlay for the configuration is higher than the outlay for the logic processing in the logic block. A further disadvantage can be seen in the fact that the lines required for the configuration and their logic devices are subsequently, that is to say after the configuration, no longer available for some other utilization in the course of operation (normal operation).
A very large portion of the configuration lines and of the associated logic elements possibly remain unutilized in conventional logic circuit arrangements.
The following multiplexer structures occur in logic blocks: logic mux, switch mux, LUT mux. Parameters that distinguish these MUX are: configuration operation; number of memory cells; what remains configurable. It follows from this that either the storage of the data and configurations are absent or, in the course of operation, a reconfiguration or change of the signals is not possible and the assigned periphery cannot be utilized any further.
SUMMARY OF THE INVENTION
Therefore, the invention is based on the problem of providing a configurable logic circuit arrangement which eliminates the disadvantages mentioned and can be used more flexibly.
In order to solve this problem, in the case of a configurable logic circuit arrangement of the type mentioned in the introduction, it is provided according to the invention that the at least one multiplexer can be configured by means of one or more external control signal transmitter elements of the circuit arrangement in a propagation-time-variant manner during the operation of the circuit by means of configuration signals that can be applied to the control inputs and forwards logic signals that can be applied to the data inputs in a propagation-time-variant manner during the operation of the circuit, it being possible to perform a propagation-time-variant configuration of at least one memory cell.
The possibility for storing the configuration signals is maintained in this case.
In this case, external control signal elements shall be understood such that a signal from the respective element/device or by feeding into the respective element performs the control, that is to say that this signal or its generation lies outside the circuit arrangement.
The invention is based on the insight of utilizing the infra-structure required for the configuration not only initially during the configuration operation but also during the propagation time of the signals in normal operation. Accordingly, the logic circuit arrangement according to the invention has to be configured very often and very rapidly. The infrastructure required for the configuration is not left unused, but rather continues to be utilized for the configuration as required during operation.
A particularly important advantage of the invention can be seen in the fact that in the case of path multiplexers, in particular, the outlay for selecting a data line in the course of operation is greatly reduced. It is possible to select a data line during normal operation without logic blocks and the outlay for this n:1 selection is minimal. In this case, outlay is to be understood to mean the product of silicon area (including the resources remaining unutilized e.g. in the routing), delay time and power loss or a quantity proportional to these three parameters. While the delay time remains approximately constant, the parameters of silicon area and power loss are significantly reduced in the case of the embodiment according to the invention since the selection of the data line is performed dynamically by the multiplexer or multiplexers in the data bus. By contrast, this selection has to be performed by additional logic blocks in the case of known logic circuit arrangements.
Essentially the same holds true for logic mux as for the path multiplexers. The gain is afforded here by savings in the network which configures the logic mux memory cells.
For LUT mux, a flexibility enhancement is achieved by virtue of logic blocks being configured as registers whose contents can be changed in a variant manner. The register outputs are passed to a logic block (possibly a plurality) connected as MUX. The gain is afforded here by savings in the network which configures the LUT mux memory cells, and the saving of logic blocks.
For switch mux, a flexibility enhancement of the inputs is not made possible since these are already maximally enhanced with respect to flexibility. The outlay for buffering the output and/or the input is obviated, however.
The configuration of the logic circuit arrangement according to the invention thus achieves the advantage, in particular, that existing multiplexers need not be enlarged and a propagation-time-variant configuration be achieved thereby, rather a flexibility enhancement of the multiplexer function is achieved by a reconfiguration with respect to the propagation time. The consequence of this is that either the same task can be achieved by fewer components/transistors or more tasks, that is to say a higher flexibility, can be achieved with the same number of elements/transistors. What is essential in this case is that this can be achieved by a propagation-time-variant (re)configuration of the at least one memory cell (for the configuration required).
It is particularly advantageous if, in the case of the logic circuit arrangement according to the invention, the or each input of the multiplexer is connected to a nonvolatile memory cell which can change in nanoseconds in the course of operation. It is not necessary for all the control inputs to be connected to a nonvolatile memory cell since configurations in which the configuration is only partially stored are also possible. In general, however, it will be expedient for a memory cell to be assigned to each input.
It is particularly expedient for the memory cell assigned to an input to be configurable by means of dynamic, and that is to say propagation-time-variable, signals which originate from the device. The space requirement of the entire logic circuit arrangement can thereby be considerably reduced, and, moreover, each memory cell can be reconfigured dynamically, that is to say that it can be reprogrammed during operation. The data and also the stored configurations are retained in the memory cell. A new configuration is possible in each clock cycle, however; the configurability remains variant. This affords the advantage that the number of logic circuit arrangements on a chip can decrease.
Memory cells using magnetoresistive technology, which is also referred to as XMR technology, are particularly suitable for the configurable logic circuit arrangement according to the invention. As an alternative, memory cells using OUM technology (ovonic unified memory) or FRAM (ferroelectric random access memory) are also taken into consideration.
An even higher flexibility can be obtained if the external control signal transmitter element is another multiplexer. Different multiplexers can be connected in a cascaded manner in this way. With a construction of this type, logic combinations can already be realized in the routing region.
The configurable logic circuit arrangement according to the invention may be connected to further logic circuit arrangements in a cascade-like manner. In this way, all of the data and control inputs can be selected by multiplexers connected upstream from available signals on the data bus or configuration bus, so that cascades of multiplexers with a known propagation time exist. In the prior art, the configuration bus is used as a configuration possibility for routing and the logic blocks. The signals are routed through a cascade of multiplexers to the corresponding pins of the chips. The configuration bus together with the cascade is left unused in the course of operation. The configuration bus of the subject matter of the invention partly comprises the architecture as in the prior art, particularly if the alternative according to the invention is not technically practical. Moreover, the configuration bus is enhanced in terms of flexibility and connected to the data bus, thereby enabling the controlled changeover.
It is particularly preferred for the configurable logic circuit device according to the invention to be part of a field programmable gate array (FPGA) or a complex programmable logic device (CPLD).
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Further advantages and details of the invention are explained on the basis of an exemplary embodiment with reference to the figures. The figures are schematic illustrations and show:
FIG. 1 illustrates a conventional 2:1 multiplexer without a configuration possibility;
FIG. 2 illustrates a conventional field programmable gate array with a plurality of logic blocks connected as multiplexers as selection region;
FIG. 3 illustrates a configurable logic circuit arrangement according to the invention; and
FIG. 4 illustrates a further configurable logic circuit arrangement according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a conventional 2:1 multiplexer having a binary-value control input S 0 and two data inputs E 0 and E 1 (switching symbol). A respective one of the data inputs E 0 or E 1 is connected to the output A, the assignment of the data inputs E 0 and E 1 to the output A being controlled via the control input S 0 . If the signal “0” is present at the control input S 0 , E 0 is connected to A. If the signal “1” is present at the control input S 0 , E 1 is connected to A. The multiplexer 1 generally serves for changing over from one of a plurality of inputs to an output. Multiplexers of this type are known and therefore do not require more extensive explanation.
FIG. 2 shows an exemplary embodiment of a conventional field programmable gate array (FPGA) having a plurality of logic blocks connected as multiplexers as selection region. Intermediate results arise in this circuit and are available on the data bus 2 . Two of said intermediate results are intended to be selected and processed. The intermediate results which are selected are decided on during the propagation time. The selection region of the circuit shown in FIG. 2 comprises four logic blocks which are connected as multiplexers 3 and are connected in parallel and the outputs of which are connected to the inputs of logic blocks 4 connected as multiplexers. The logic blocks connected as multiplexers 3 are in each case connected to selection lines 5 . The selection lines 5 are used to stipulate whether a multiplexer 3 forwards the signal of the input E 0 or of the input E 1 . It is only because the selection lines 5 can be influenced dynamically that the data which are processed can be decided on during the propagation time.
The logic blocks connected as multiplexer 4 analogously have selection lines 6 connected to the control inputs. The two selected signals pass from the multiplexers 4 to an execution block 7 . Here, too, a selection can take place during the propagation time only by means of correspondingly connected logic blocks. After the processing in the execution block 7 , the result is again passed onto the data bus and can be processed further.
The construction shown in FIG. 2 is favorable for small logic blocks and a complex processing, that is to say processing comprising many logic blocks. The logic blocks used for selection serve as multiplexers since they select from the data bus in each case one input signal from two possible input signals with the aid of a control line. The use of multiplexers in routing is ruled out here since, although these multiplexers are very numerous, they only operate in a propagation-time-static manner. A dynamic changeover of the source is not possible. The large number of required logic blocks 3 , 4 which are connected as multiplexers is therefore to be regarded as disadvantageous.
For large, high-performance logic blocks, it may be more favorable to expend the fewest possible logic blocks for a router region and instead to define a plurality of processing blocks whose outputs can then be selected by means of the control lines.
FIG. 3 shows a configurable logic circuit arrangement according to the invention in the form of a multiplexer 8 . In terms of its basic construction, the multiplexer 8 corresponds to the multiplexer illustrated in FIG. 1 , apart from the fact that the multiplexer 8 has four inputs (E 0 , E 1 , E 2 , E 3 ) which are each connected to a nonvolatile memory cell 9 . The control inputs S 0 and S 1 of the multiplexer 8 are each connected to memory cells 10 . The memory cells 9 , 10 are formed as XMR cells, that is to say that magnetoresistive memories are involved. However, alternative embodiments are also conceivable in which memory cells using OUM logic (ovonic unified memory, FRAM) or using GMR or TMR technology are employed. The memory cells 9 , 10 are in each case connected to external control signal transmitter elements via selection lines 11 , 17 of the configuration bus, so that they can be configured in a propagation-time-variant manner. The external control signal transmitter element is another multiplexer. In a departure from the exemplary embodiment illustrated, it is additionally possible for some or all of the memory cells 9 to be connected to selection lines, so that, besides the memory cells 10 connected to the control inputs S 0 and S 1 , the memory cells 9 connected to the data inputs E 0 to E 3 can also be reprogrammed during the propagation time.
The logic circuit arrangement having nonvolatile memories 9 , 10 as illustrated in FIG. 3 is particularly distinguished by its high integration density since no additional circuit outlay is required in order to select a specific data line from the data bus. Accordingly, the space requirement and the number of logic elements required are comparatively small. It can be assumed that savings of up to 1/3 of the logic elements can be obtained in comparison with conventional circuits.
FIG. 4 shows an exemplary embodiment of the logic circuit arrangement according to the invention. This circuit comprises two multiplexers 12 , 13 which, analogously to the circuit shown in FIG. 2 , obtain intermediate results which are available on the data bus 14 . The multiplexers 12 , 13 are connected to the configuration bus via lines 15 . In contrast to the circuit shown in FIG. 2 , the selection of the intermediate results required is performed in the routing region, that is to say that this function is performed directly by the multiplexers 12 , 13 present, which are parts of the data bus system, so that the circuit outlay for the selection of the data lines is obviated. In the case of the known circuit in accordance with the circuit illustrated in FIG. 2 , this function is performed by additional logic blocks (multiplexers 3 , 4 ) in the selection region. The results pass from the multiplexers 12 , 13 to an execution block 16 , which outputs the result of the logic combination to the data bus again.
The utilization of the multiplexers formed according to the invention in routing makes it unnecessary, therefore, to utilize the logic blocks as dynamic path multiplexers. Since the multiplexers are already present in routing and are only extended in terms of their usability or flexibility, this consequently results in the area gain discussed and, coupled with this, the reduction of the power loss. | A configurable logic circuit arrangement includes at least one multiplexer for switching logic signals. The multiplexer includes one or more data inputs and one or more control signal inputs. The at least one multiplexer ( 8, 12, 13 ) can be configured by one or more external control signal transmitter elements of the circuit arrangement during the operation of the circuit in a run-time variable manner by configuration signals that are applied to the control inputs and forwards the logical signals that are applied to the data inputs during operation of the circuit in a run-time variable manner. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a turbine generator system capable of sufficiently lubricating bearings in a binary turbine utilizing waste heat.
[0003] 2. Background Art
[0004] In recent years, a binary turbine generator system which uses as a heat source waste heat such as discharged hot water which has a temperature lower than 100 degrees C. and is generated in a large quantity in manufacturing processes in iron mills, ceramic engineering, etc, has attracted an attention, as a system intended to achieve energy saving and reduction of warming gases by using as a working medium, a medium with a low boiling point, other than water. In such a binary turbine generator system, in a case where the working medium itself has a lubricating ability, the working medium is supplied from a condenser to constituents to be lubricated, such as bearings in a turbine generator, to lubricate the bearings (see patent literature 1).
[0005] Patent Literature 1 Japanese Laid-Open Patent Application Publication No. 2008-175212
SUMMARY OF THE INVENTION
[0006] In the above mentioned binary turbine generator system, it is necessary to mix a lubricant into the working medium if the working medium does not have a lubricating ability. However, in a method in which the working medium is supplied from the condenser to the bearings like the technique disclosed in patent literature 1, the lubricant remains in the evaporator, because the working medium is easily evaporated in the evaporator but the lubricant is not easily evaporated therein. This results in a lowered lubricant concentration of the working medium in the condenser. In addition, because of a low pressure of the working medium, the lubricated state of the bearings becomes degraded. If a large quantity of lubricant is mixed into the working medium to improve the lubricated state of the bearings in the turbine generator, heat transmissibility of the evaporator and the condenser is impeded, which is undesirable.
[0007] An object of the present invention is to provide a turbine generator system capable of sufficiently lubricating constituents to be lubricated in the turbine generator without impeding heat transmissibility of the evaporator and the condenser.
[0008] To achieve the above object, a turbine generator system of the present invention comprises a turbine power generation unit including a generator and a turbine for driving the generator; a working medium including a lubricant and causing the turbine power generation unit to operate; an evaporator which evaporates the working medium by heat exchange with a heat source and supplies the evaporated working medium to the turbine power generation unit; a condenser which liquefies the working medium which has flowed through the turbine; a medium feeding pump which raises a pressure of the liquefied working medium and feeds the liquefied working medium to the evaporator; and a feeding passage through which the working medium in a liquid phase extracted from the evaporator is supplied to a constituent to be lubricated in the turbine power generation unit.
[0009] In accordance with the above configuration of the turbine generator system, the working medium converted into a vapor phase in the evaporator is supplied to the turbine power generation unit, while the lubricant is not easily evaporated, and therefore the working medium in a liquid phase with a high lubricant concentration remains at the lower portion of the evaporator. Since the working medium in a liquid phase with a high lubricant concentration is supplied from the evaporator having a high pressure to the constituent to be lubricated in the turbine power generation unit through the feeding passage, the constituent to be lubricated can be sufficiently lubricated. Therefore, it is not necessary to mix a large quantity of lubricant into the working medium for the purpose of enhancing its lubricating ability, and as a result, heat transmissibility of the evaporator and the condenser is not impeded.
[0010] The turbine generator system preferably further comprises a return passage through which the working medium discharged from the constituent to be lubricated is returned to the condenser. In accordance with this configuration, the working medium is not released to outside and therefore, does not negatively affect surrounding environment. Thus, the working medium can be circulated and utilized within a closed system.
[0011] The turbine generator system may further comprise a circulating pump which takes out the working medium from a lower portion of the evaporator and injects the working medium into an inside of the evaporator through an injection port provided at an upper portion of the evaporator. The feeding passage may branch at an outlet of the circulating pump and serve to feed the working medium to the constituent to be lubricated. In accordance with this configuration, the circulating pump normally feeds the working medium with a constant flow rate unlike a medium feeding pump which varies the flow rate of the working medium according to the output of the system. Therefore, the working medium with a high lubricant concentration can be supplied to the constituent to be lubricated with an invariable quantity through the feeding passage which branches at the outlet of the circulating pump.
[0012] The turbine generator system preferably comprises a depressurizing device provided on the feeding passage, for evaporating a part of the working medium by depressurization. In accordance with this configuration, the lubricant concentration in the working medium increases due to the evaporation in the evaporator and the temperature of the lubricant decreases due to latent heat of the evaporation, thereby resulting in increased viscosity. Therefore, a high lubricating capability can be maintained, and cooling of the constituent to be lubricated is facilitated.
[0013] The turbine generator system preferably comprises a cooler provided on the feeding passage, for cooling the working medium. By providing the cooler on the feeding passage, the temperature of the working medium within the feeding passage can be decreased, the lubricating capability can be improved due to reduced viscosity of the lubricant, and cooling is facilitated.
[0014] In the turbine generator system, a bottom surface of the evaporator is preferably disposed above an inlet through which the working medium is fed to the constituent to be lubricated. In accordance with this configuration, since the evaporator has a high pressure and the bottom surface of the evaporator is disposed above the inlet through which the working medium is fed to the constituent to be lubricated, the working medium can be stably supplied to the inlet through which the working medium is fed to the constituent to be lubricated, without using a pump.
[0015] In the turbine generator system, the lubricant preferably has compatibility with a main medium. Thus, since the main medium and the lubricant in the working medium are not separated from each other in a liquid phase inside the evaporator, the working medium with a constant lubricant concentration can be taken out from a desired portion of the liquid phase of the evaporator.
[0016] In the turbine generator system, the working medium is preferably a mixture of HFE (hydrofluoroether) and a lubricant composed of fluorinated oil. HFE is an excellent working medium which has a low global warming potential and will not deplete an ozone layer, but has no lubricating ability. Accordingly, the lubricant composed of the fluorinated oil is mixed into the HFE to enable the working medium to have a lubricating ability. In addition, the HFE and the lubricant composed of the fluorinated oil have high compatibility.
[0017] In the above turbine generator system, preferably, the constituent to be lubricated is, for example, a bearing in the turbine power generation unit, and the turbine generator system comprises an oil container which reserves the supplied working medium in the liquid phase to immerse a lower portion of the bearing in the working medium. In this configuration, since the bearing rotates in a state where its lower portion is immersed in the working medium in the oil container, the entire bearing is sufficiently lubricated.
[0018] In the above turbine generator system, preferably, the constituent to be lubricated is, for example, a bearing in the turbine power generation unit, and the turbine generator system comprises an injection unit for injecting the supplied working medium in the liquid phase to the bearing. In this a configuration, since the working medium in the liquid phase is forcibly injected in a large quantity under a pressurized state from the injection unit to the bearing, the bearing can be lubricated and cooled effectively even for a case where high-speed rotation is necessary and a heat generation amount of the bearing is great.
[0019] In accordance with the above described present invention, the working medium converted into a vapor phase in the evaporator having a high pressure is supplied to the turbine power generation unit, while the lubricant is not easily evaporated, and therefore the working medium in a liquid phase with a high lubricant concentration remains at the lower portion of the evaporator. Since the working medium in a liquid phase with a high lubricant concentration is supplied from the evaporator having a high pressure to the constituent to be lubricated in the turbine power generation unit through the feeding passage, the constituent to be lubricated can be sufficiently lubricated. Therefore, it is not necessary to mix a large quantity of lubricant into the working medium for the purpose of enhancing its lubricating ability, and as a result, heat transmissibility of the evaporator and the condenser is not impeded.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic view showing a configuration of a turbine generator system according to Embodiment 1 of the present invention.
[0021] FIG. 2 is a table showing comparison of properties of a medium used in the present invention and other media.
[0022] FIG. 3 is a schematic view showing a configuration of a turbine generator system according to Embodiment 2 of the present invention.
[0023] FIG. 4 is a schematic view showing a configuration of a turbine generator system according to Embodiment 3 of the present invention.
[0024] FIG. 5 is a cross-sectional view showing a detailed structure of an injection unit of FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.
The First Embodiment
[0026] Referring to FIG. 1 , a turbine generator system according to Embodiment 1 of the present invention comprises a turbine power generation unit U including a generator 10 and turbines 13 for driving the generator 10 . On a medium passage 30 through which a working medium M for the turbines 13 is circulated, an evaporator 16 of a full liquid type, a condenser 17 and a medium feeding pump 18 are provided. The evaporator 16 is configured to receive heat from a heat source 15 by heat exchange to evaporate the working medium M and supplies the working medium M in a vapor phase to the turbine power generation unit U via a vapor phase medium feeding passage 30 a . After rotating the turbines 13 in the turbine power generation unit U, the working medium M is fed to the condenser 17 via a vapor phase medium recovery passage 30 b . The working medium M is liquefied in the condenser 17 , and supplied to the evaporator 16 after its pressure is raised by the medium feeding pump 18 attached to a liquid phase medium feeding passage 30 c while flowing through the liquid phase medium feeding passage 30 c . The medium passage 30 which is a circulating passage includes the vapor phase medium feeding passage 30 a , the vapor phase medium recovery passage 30 b and the liquid phase medium feeding passage 30 c.
[0027] The generator 10 includes a generator rotor 11 and a generator stator 12 . The turbines 13 , 13 are disposed at both ends of the generator rotor 11 and the generator stator 12 . The generator rotor 11 is coupled to the turbines 13 , 13 by means of a single rotary shaft 21 . The rotary shaft 21 is rotatably supported by two bearings 19 arranged between the generator 10 and the two turbines 13 , 13 . The two turbines 13 , 13 are disposed to face in different directions and have a mirror-image form, which allows an axial thrust applied to the turbines 13 , 13 to be cancelled. Thus, thrust bearings are omitted or simplified. Therefore, the bearings 19 mainly receive a radial load applied by the rotary shaft 21 .
[0028] The working medium M is a mixture of a lubricant and a main medium with a low boiling point, as described later. A part of the working medium M is used to cool the bearings 19 which are one constituents to be lubricated in the turbine power generation unit U.
[0029] The heat source 15 is, for example, waste heat such as hot water which is generated in a large quantity in manufacturing processes in iron mills, ceramic engineering, etc. The hot water which has been derived from the heat source 15 is introduced into heat transmission pipes 16 a inside the evaporator 16 through a heating medium feeding passage 15 a and thereafter is returned from the heat transmission pipes 16 a to the heat source 15 side through a heating fluid recovery passage 15 b.
[0030] The condenser 17 has a known structure, containing a pipe of a cooling medium C inserted into the interior thereof. The condenser 17 is configured to cool the working medium M in a vapor phase using the cooling medium C, after the working medium M has rotated the turbines 13 .
[0031] Below each bearing 19 , an oil container 25 is provided. The oil container 25 is coupled to the lower portion of the evaporator 16 by means of a feeding passage 20 . Although in Embodiment 1, a cooler 22 is provided on the feeding passage 20 to cool the working medium M in a liquid phase which is supplied to the bearings 19 , the cooler 22 may be omitted.
[0032] Each bearing 19 is coupled to the condenser 17 , to be more specific, each oil container 25 is coupled to the inlet of the condenser 17 , by means of a return passage 23 used for returning the working medium M in a liquid phase discharged from the bearing 19 , to the condenser 17 . The working medium M in a liquid phase is returned to the condenser 17 through the return passage 23 and joined to the working medium M which has been fed through the vapor phase medium recovery passage 30 b , in the interior of the condenser 17 .
[0033] As shown, the bottom surface of the evaporator 16 is disposed above the inlet through which the working medium M is fed to the bearing 19 , i.e., the inlet through which the working medium M flows into the oil container 25 . Since the evaporator 16 has a higher pressure than a normal pressure and the bottom surface of the evaporator 16 is disposed above the inlet through which the working medium M is fed to the bearing 19 , the working medium M can be stably supplied from the evaporator 16 to the inlet through which the working medium M is fed to the bearing 19 , without using a pump. Alternatively, the bottom surface of the evaporator 16 need not be disposed above the inlet through which the working medium M is fed to the bearing 19 , and the working medium M can be supplied to the bearing 19 having a normal pressure, by the pressure of the evaporator 16 .
[0034] As the main medium of the working medium used in the turbine generator system, there are HFE(hydrofluoroether), i.e., substances which are obtained by substituting a part of H with F in a general expression C n H 2n+1 —O—C m H 2m+1 , have boiling points higher than 25 degrees C. and lower than 100 degrees C. in a normal pressure, and contain carbons C which are not more than seven in number, for example, C 3 F 7 OCH 3 (HFE7000), C 4 F 9 OCH 3 (HFE7100), C 4 F 9 OC 2 H 5 (HFE7200), C 6 F 13 OCH 3 (HFE7300) and CHF 2 —CF 2 —O—CH 2 —CF 3 (HFE-S7). Among these, a specific example of C 3 F 7 OCH 3 is available from 3M under the trade name of Novec 7000. As other alternative media, there are HFC (hydrofluorocarbon) obtained by substituting a part of H with F in C n H 2n+2 , FE(fluoroether) obtained by substituting all of H with F in a general expression C n H 2n+1 —O—C m H 2m+1 , and fluorinated alcohol obtained by substituting a part of H other than OH with F in C n H 2n+1 —OH.
[0035] Hereinafter, the reason why the medium represented by the above mentioned HFE (hydrofluoroether) is suitable for use as the main medium in the turbine generator system will be explained with reference to the table showing comparison of properties of the media shown in FIG. 2 . FIG. 2 exemplarily shows CFC (chlorofluorocarbon), HCFC (hydrochlorofluorocarbon), HFC (hydrofluorocarbon), and one kind of HFE which has a boiling point of about a room temperature (15˜30 degrees C.) in a normal pressure. FIG. 2 also shows 3FE (trifluoroethanol: C 2 F 3 H 2 OH) as one kind of the fluorinated alcohol. As can be clearly seen from the table showing property comparison, medium name HFE7000 (chemical formula: C 3 F 7 OCH 3 ) is decomposed in the atmosphere because of the presence of oxygen O in an ether compound, will not deplete an ozone layer because of ozone depletion potential ODP=0, has a low global warming potential GWP=370, has excellent environmental friendliness, and has no toxicity. 3FE has excellent properties except for its low combustibility, and therefore may satisfactorily be used as the main medium. On the other hand, CFC, HCFC, and HFC are inferior in environmental friendliness and toxicity. Nonetheless, HFC which is excellent in ozone depletion potential, may also be used as the main medium. As other medium having excellent environmental friendliness, like HFE, there is HFO (hydrofluoroolefin), for example, HFO-1234yf (CF 3 CF═CH 2 ), which may also be used as the main medium.
[0036] As the lubricant mixed into the main medium, fluorinated oil expressed as the following chemical formulae, having a polymerized structure in which base oil of the lubricant or additive is partially or all terminated by fluorine.
[0000]
[0037] The fluorinated oil expressed as the chemical formula I is, for example, available from Dupont under the trade name of Krytox. This fluorinated oil is highly compatible with the main medium such as the above HFE. In a liquid phase state, the main medium and the fluorinated oil are not separated from each other.
[0038] As described above, in the present invention, the working medium M which is a mixture of the main medium such as HFE and the fluorinated oil as the lubricant is used. This HFE is an excellent medium which has a low global warming potential and will not deplete the ozone layer, but has no lubricating ability. Accordingly, the lubricant composed of the fluorinated oil is mixed into the HFE to enable the working medium M to have a lubricating ability.
[0039] The operation of the turbine generator system configured as described above will be described with reference to FIG. 1 . The hot water which has been derived from the heat source 15 is introduced into the evaporator 16 via the heating medium feeding passage 15 a , and the working medium M inside the evaporator 16 is evaporated into a high-pressure vapor phase of about 1.4 atmospheric pressure, by heat exchange with the introduced hot water, in other words, by receiving the heat from the heat source 15 . On the other hand, the lubricant is not easily evaporated, and therefore remains at the lower portion of the evaporator 16 , as the working medium M in a liquid phase with a high lubricant concentration.
[0040] The working medium M converted into a vapor phase is taken out from the upper portion of the evaporator 16 and supplied to the pair of turbines 13 , 13 in the turbine power generation unit U through the vapor phase medium feeding passage 30 a . The working medium M drives both of the turbines 13 , 13 . Thereupon, the generator 10 coupled to the turbines 13 by means of the rotary shaft 21 is driven to generate electric power. The working medium M, which has released energy in the turbines 13 , flows into the condenser 17 through the vapor phase medium recovery passage 30 b and is cooled and liquefied by heat exchange with the cooling medium C. The working medium M converted into a liquid phase, is raised in pressure by the medium feeding pump 18 while flowing through the liquid phase medium feeding passage 30 c , and returned to the evaporator 16 .
[0041] On the other hand, the working medium M in a liquid phase with a high lubricant concentration, which remains at the lower portion of the evaporator 16 , is supplied to the oil containers 25 of the bearings 19 which are the constituents to be lubricated in the turbine power generation unit U, through the feeding passage 20 . In this case, the working medium M is cooled by the cooler 22 provided on the feeding passage 20 . This makes it possible to lower the temperature of the working medium M and improve its property including the viscosity of the lubricant. The working medium M in a liquid phase which has been supplied to the oil containers 25 is a working medium containing a large quantity of lubricant and having a high lubricant concentration. During the rotation of the turbine generator, the bearings 19 are sufficiently lubricated all the time by the working medium M having a high lubricant concentration. Since the bearings 19 rotate in a state where their lower portions are immersed in the working medium M in the oil containers 25 , the working medium M is supplied to the entire bearings 19 and lubricate them. In this way, since the bearings 19 can be lubricated by the working medium M with a high lubricant concentration, it is not necessary to mix a large quantity of lubricant into the working medium to enhance lubricating ability. As a result, heat transmissibility of the evaporator 16 and the condenser 17 is not impeded.
[0042] It is sufficient that the working medium M with a quantity required to lubricate the bearings 19 is be reserved in the oil containers 25 , and a surplus working medium is discharged from the oil containers 25 to the return passage 23 and returned to the condenser 17 through the return passage 23 . Therefore, the working medium M is circulated and utilized in a closed system, without being discharged to outside the system and negatively affecting surrounding environment. In some cases, a part of the working medium M is converted into a vapor phase, due to temperature rise in the bearings 19 . In those cases, the working medium M containing a mixture of a liquid phase and a vapor phase enters the condenser 17 through the return passage 23 . Since the inlet of the condenser 17 is in about a normal pressure state, the working medium M is smoothly recovered from the oil containers 25 in a slightly high-pressure state, to the condenser 17 . Alternatively, the downstream end of the return passage 23 may be coupled to the vapor phase medium recovery passage 30 b instead of the inlet of the condenser 17 .
The Second Embodiment
[0043] FIG. 3 shows a turbine generator system according to Embodiment 2 of the present invention. In Embodiment 2, the same constituents as those of Embodiment 1 shown in FIG. 1 are designated by the same reference characters and will not be described repetitively in detail. Although in Embodiment 1, the evaporator 16 of a full liquid type is used as shown in FIG. 1 , an evaporator 16 of a falling liquid film type is used in Embodiment 2 as shown in FIG. 3 . The evaporator 16 of a falling liquid film type is configured in such a manner that a circulating pump 27 provided on a circulating passage 29 disposed for allowing communication between the lower portion and the upper portion of the evaporator 16 causes the working medium M in a liquid phase to be taken out from the lower portion of the evaporator 16 and to be showered to the heat transmission pipes 16 a inside the evaporator 16 through an injection port of an injection pipe 26 disposed at the upper portion inside the evaporator 16 , thus facilitating heat exchange.
[0044] A feeding passage 20 A branches at the outlet of the circulating pump 27 and serves to feed the working medium M in a liquid phase to the oil containers 25 of the bearings 19 . Therefore, the working medium M having a higher pressure than the working medium M used in Embodiment 1 is supplied to the bearings 19 , which are lubricated more smoothly. The feeding passage 20 A is provided with depressurizing devices 28 including throttles such as orifices or pressure reducing valves. The depressurizing device 28 is configured to evaporates a part of the working medium M in a liquid phase by depressurization, thereby increasing a lubricant concentration and decreasing the temperature of the working medium M due to latent heat of the evaporation.
[0045] The operation of Embodiment 2, which is identical to that of Embodiment 1, will not be described repetitively, and only a different operation will be described. In Embodiment 1, since the medium feeding pump 18 varies the flow rate of the working medium M such that a liquid level in the evaporator 16 is kept constant, and thus the pressure inside the evaporator 16 is varied, the amount of the working medium M supplied to the bearings 19 is varied. On the other hand, Embodiment 2 has an advantage that since the circulating pump 27 is operated to feed the working medium M with a constant flow rate, the working medium M in a liquid phase with a high lubricant concentration can be supplied to the bearings 19 with an invariable amount through the feeding passage 20 A which branches at the outlet of the circulating pump 27 .
[0046] In Embodiment 2, in addition, the pressurizing device 28 provided on the feeding passage 20 A evaporates a part of the working medium M, thereby increasing the lubricant concentration of the working medium M and decreasing the temperature of the working medium M due to latent heat of the evaporation, which results in increased viscosity of the lubricant in the working medium M. As a result, a high lubricating capability is maintained.
[0047] The feeding passage 20 A of Embodiment 2 may be provided with the cooler 22 in Embodiment 1, instead of or in addition to the depressurizing device 28 . In the same manner, the depressurizing device 28 in Embodiment 2 is applicable to Embodiment 1.
The Third Embodiment
[0048] FIG. 4 shows a turbine generator system according to Embodiment 3 of the present invention. Embodiment 3 uses the evaporator 16 of a falling liquid film type, similarly to Embodiment 2. In FIG. 4 , the same constituents as those of Embodiment 2 shown in FIG. 3 are designated by the same reference characters and will not be described repetitively in detail, but only different constituents will be described.
[0049] In Embodiment 2 shown in FIG. 3 , the working medium M in a liquid phase is supplied to the bearings 19 through the feeding passage 20 A which branches at the outlet of the circulating pump 27 provided on the circulating passage 29 for allowing communication between the upper portion and the lower portion of the evaporator 16 . On the other hand, in Embodiment 3 shown in FIG. 4 , each bearings 19 is provided with an injection unit 33 for injecting the working medium M in a liquid phase to the bearing 19 , the lower portion of the evaporator 16 is coupled to the injection unit 33 by means of a feeding passage 20 B, and an injection pump 34 is provided on the feeding passage 20 B to feed the working medium M in a liquid phase to the injection unit 33 under a pressurized state. A return passage 35 couples the bearing 19 to the vapor phase medium recovery passage 30 b to recover the working medium M in a liquid phase discharged from the bearing 19 during the lubrication.
[0050] FIG. 5 shows a detailed structure of the injection unit 33 . As shown in FIG. 5 , an inner ring spacer 36 secured to the rotary shaft 21 and an outer ring spacer 37 secured to a housing H are disposed between the pair of right and left bearings 19 , 19 , and an injection nozzle 38 is provided in the outer ring spacer 37 . The injection nozzle 38 includes an inflow port 38 a at the center and injection passages 38 b which branch at the inflow port 38 a and extend toward the pair of right and left bearings 19 , 19 . The tip end of the injection passage 38 b opens in a bearing space 19 d between an inner ring 19 a and an outer ring 19 b of the bearing 19 . Through the bearing space 19 c , the working medium M in a liquid phase is injected from the injection passage 38 b to a rollable element 19 d . The housing H is formed with a downstream portion of the feeding passage 20 B through which the working medium M in a liquid phase is supplied to the injection unit 33 , and an upstream portion of the return passage 35 for the working medium M. One or two injection nozzles 38 is/are provided for respective of the bearings 19 , 19 .
[0051] In Embodiment 3, as shown in FIG. 4 , the working medium M in a liquid phase is taken out from the lower portion of the evaporator 16 , flows through the feeding passage 20 B, and is injected from the injection unit 33 as a high-speed jet to lubricate the bearings 19 , 19 . Therefore, the bearings 19 can be lubricated and cooled effectively even for a case where a high-speed rotation is necessary and a heat generation amount of the bearings is great.
[0052] Although the preferred embodiments have been described above with reference to the drawings, various alternations and modification are easily made by persons skilled in the art within an obvious scope of the invention with reference to the present specification. Therefore, such alternations and modifications are to be construed as those within a scope of the invention defined by the attained claims.
REFERENCE SIGNS LIST
[0000]
C cooling medium
M working medium
U turbine power generation unit
10 generator
13 turbine
15 heat source
16 evaporator
16 a heat transmission pipe
17 condenser
18 medium feeding pump
19 bearing
20 , 20 A, 20 B feeding passage
22 cooler
26 injection pipe
27 circulating pump
28 depressurizing device
29 circulating passage
30 medium passage
30 a vapor phase medium feeding passage
30 b vapor phase medium recovery passage
30 c liquid phase medium feeding passage
33 injection unit
34 injection pump
35 return passage
38 injection nozzle
38 a inflow port
38 b injection passage | Provided is a turbine generator system capable of sufficiently lubricating a bearing without impeding heat transmissibility of an evaporator and a condenser. The turbine generator system comprises a turbine power generation unit including a generator and a turbine for driving the generator, an evaporator which receives heat from a heat source and supplies the working medium in a vapor phase containing a lubricant to the turbine power generation unit, a condenser which condenses the working medium which has flowed through the turbine a medium feeding pump which raises a pressure of the condensed working medium and feeds the working medium to the evaporator, and a feeding passage through which the working medium extracted from the evaporator is supplied to bearings in the turbine power generation unit. | 5 |
FIELD OF THE INVENTION
The present invention relates to gas distribution plates (GDPs) which distribute gases into a processing chamber such as an etch chamber used in the etching of material layers on a semiconductor wafer substrate during the fabrication of integrated circuits on the substrate. More particularly, the present invention relates to an anodized aluminum gas distribution plate having an alumina anodized coating or layer to impart durability to the plate and reduce particle generation during etching or other processes.
BACKGROUND OF THE INVENTION
Integrated circuits are formed on a semiconductor substrate, which is typically composed of silicon. Such formation of integrated circuits involves sequentially forming or depositing multiple electrically conductive and insulative layers in or on the substrate. Etching processes may then be used to form geometric patterns in the layers or vias for electrical contact between the layers. Etching processes include “wet” etching, in which one or more chemical reagents are brought into direct contact with the substrate, and “dry” etching, such as plasma etching.
Various types of plasma etching processes are known in the art, including plasma etching, reactive ion (RI) etching and reactive ion beam etching. In each of these plasma processes, a gas is first introduced into a reaction chamber and then plasma is generated from the gas. This is accomplished by dissociation of the gas into ions, free radicals and electrons by using an RF (radio frequency) generator, which includes one or more electrodes. The electrodes are accelerated in an electric field generated by the electrodes, and the energized electrons strike gas molecules to form additional ions, free radicals and electrons, which strike additional gas molecules, and the plasma eventually becomes self-sustaining. The ions, free radicals and electrons in the plasma react chemically with the layer material on the semiconductor wafer to form residual products which leave the wafer surface and thus, etch the material from the wafer.
Referring to the schematic of FIG. 1 , a conventional plasma etching system, such as an Mxp+Super-E etcher available from Applied Materials, Inc., is generally indicated by reference numeral 10 . The etching system 10 includes a reaction chamber 12 having a typically grounded chamber wall 14 . An electrode, such as a planar coil electrode 16 , is positioned adjacent to a dielectric plate 18 which separates the electrode 16 from the interior of the reaction chamber 12 . Plasma-generating source gases are provided by a gas supply (not shown) and flow into the reaction chamber 12 through openings 18 a in the gas distribution plate 18 . Volatile reaction products and unreacted plasma species are removed from the reaction chamber 12 by a gas removal mechanism, such as a vacuum pump 24 through a throttle valve 26 .
Electrode power such as a high voltage signal is applied to the electrode 16 to ignite and sustain a plasma in the reaction chamber 12 . Ignition of a plasma in the reaction chamber 12 is accomplished primarily by electrostatic coupling of the electrode 16 with the source gases, due to the large-magnitude voltage applied to the electrode 16 and the resulting electric fields produced in the reaction chamber 12 . Once ignited, the plasma is sustained by electromagnetic induction effects associated with time-varying magnetic fields produced by the alternating currents applied to the electrode 16 . The plasma may become self-sustaining in the reaction chamber 12 due to the generation of energized electrons from the source gases and striking of the electrons with gas molecules to generate additional ions, free radicals and electrons. A semiconductor wafer 34 is positioned in the reaction chamber 12 and is supported by a water platform or ESC (electrostatic chuck) 36 . The ESC 36 is typically electrically-biased to provide ion energies that are independent of the RF voltage applied to the electrode 16 and that impact the wafer 34 .
Typically, the voltage varies as a function of position along the coil electrode 16 , with relatively higher-amplitude voltages occurring at certain positions along the electrode 16 and relatively lower-amplitude voltages occurring at other positions along the electrode 16 . A relatively large electric field strength is required to ignite plasmas in the reaction chamber 12 . Accordingly, to create such an electric field it is desirable to provide the relatively higher-amplitude voltages at locations along the electrode 16 which are close to the grounded chamber wall 14 .
As discussed above, plasma includes high-energy ions, free radicals and electrons which react chemically with the surface material of the semiconductor wafer to form reaction produces that leave the wafer surface, thereby etching a geometrical pattern or a via in a wafer layer. Plasma intensity depends on the type of etchant gas or gases used, as well as the etchant gas pressure and temperature and the radio frequency generated at the electrode 16 . If any of these factors changes during the process, the plasma intensity may increase or decrease with respect to the plasma intensity level required for optimum etching in a particular application. Decreased plasma intensity results in decreased, and thus incomplete, etching. Increased plasma intensity, on the other hand, can cause overetching and plasma-induced damage of the wafers. Plasma-induced damage includes trapped interface charges, material defects migration into bulk materials, and contamination caused by the deposition of etch products on material surfaces. Etch damage induced by reactive plasma can alter the qualities of sensitive IC components such as Schottky diodes, the rectifying capability of which can be reduced considerably. Heavy-polymer deposition during oxide contact hole etching may cause high-contact resistance.
The gas distribution plate 18 illustrated in FIG. 1 may serve multiple purposes and have multiple structural features, as is well known in the art. For example, the gas distribution plate 18 may include features in addition to the openings 18 a for introducing the source gases into the reaction chamber 12 , as well as those structures associated with physically separating the electrode 16 from the interior of the chamber 12 . The openings 18 a typically have a diameter of about 0.5 mm, and the gas distribution plate 18 is constructed of quartz.
One of the limitations inherent in the quartz gas distribution plate 18 is that plasma may damage or corrode the gas distribution plate 18 during plasma processes carried out in the chamber 12 . Furthermore, over prolonged periods of use the quartz gas distribution plate 18 deteriorates and generates particles which have the potential to contaminate a wafer 34 processed in the reaction chamber 12 . Accordingly, a new and improved gas distribution plate which is characterized by enhanced durability and resistance to damage and deterioration is needed for a reaction chamber.
According to the present invention, an anodized aluminum gas distribution plate is provided which is durable and resistant to plasma-induced damage and deterioration. Anodizing is a type of electrolysis by which a protective oxide coating is formed on a metal. Anodizing may serve several purposes, including forming a tough coating on a metal as well as imparting electrical insulation and corrosion resistance to the metal. Anodized aluminum and magnesium are commonly used in airplanes, trains, ships and buildings.
Anodizing processes are carried out in an electrolyte solution, in which the metal to be anodized acts as an anode or positive pole of the cell. Negatively charged oxide ions pass through the electrolyte solution and oxidize the surface of the metal. Aluminum is typically anodized in a sulfuric acid electrolyte solution, whereas magnesium is often anodized in a dichromate electrolyte solution. The thickness of the anodized coating is a function of the magnitude of the electric current which is passed through the solution. The anodized metal surface may be subjected to special treatments to give the metal a porous layer that can absorb dyes which are incapable of being rubbed or scratched off the surface.
An object of the present invention is to provide a new and improved gas distribution plate for a process chamber.
Another object of the present invention is to provide a new and improved gas distribution plate which is characterized by longevity and durability.
Still another object of the present invention is to provide a new and improved gas distribution plate which is suitable for use in etch chambers used in the fabrication of integrated circuits on semiconductor wafers.
Yet another object of the present invention is to provide a new and improved, anodized aluminum gas distribution plate.
A still further object of the present invention is to provide a method of fabricating an anodized aluminum gas distribution plate.
SUMMARY OF THE INVENTION
In accordance with these and other objects and advantages, the present invention is generally directed to a new and improved, anodized aluminum gas distribution plate for process chambers, particularly an etch chamber. The gas distribution plate includes an aluminum body having multiple gas flow openings extending therethrough and an alumina anodized coating or layer on the plate. The gas distribution plate is characterized by enhanced longevity and durability and resists particle-forming deterioration and damage throughout prolonged use.
According to a preferred method of fabricating the gas distribution plate, the plate body is constructed of aluminum and is immersed in a hard anodizing electrolyte solution such that all surfaces of the plate body are exposed to the electrolyte solution. The anodizing electrolyte solution has a concentration of typically about 15%, a current density of about 2-2.5 A/dm 2 and a voltage of about 20-60V, and the solution is maintained at a temperature of about 0-3 degrees C. during the anodizing process. The hard anodizing electrolyte may be sulfuric acid, although chromic acid or other anodizing electrolytes known by those skilled in the art may be used.
The alumina anodized coating or layer on the anodized aluminum plate body may be about 0.04 mm thick. Typically, the gas distribution plate includes about 88 gas flow openings. Each of the gas flow openings may have a diameter of about 0.78 mm to about 0.82 mm, and preferably, about 0.8 mm.
The present invention further includes a gas distribution plate fabricated by providing a plate body of aluminum and providing an alumina anodized layer on the plate body by immersing the plate body in an anodizing electrolyte solution and passing a current through the anodizing electrolyte solution while maintaining the solution at a selected temperature. The anodizing electrolyte is typically a hard anodizing electrolyte such as sulfuric acid, although alternative electrolytes such as chromic acid may be used. The sulfuric acid may have a concentration of about 15%, and the sulfuric acid bath is typically maintained at a temperature of about 0-3 degrees C. The current passed through the bath may be on the order of about 20-60V, and the electrolyte bath may have a current density of about 2-2.5 A/dm 2 .
Preferably, the gas distribution plate fabricated according to the foregoing method has about 88 gas flow openings extending therethrough. Each of the gas flow openings may have a diameter of about 0.78 mm to about 0.82 mm, and preferably, about 0.8 mm. The alumina anodized layer may have a thickness of about 0.04 mm.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a cross-sectional, partially schematic view of a typical conventional etch chamber for processing semiconductor wafers;
FIG. 2 is a top view of an illustrative embodiment of the anodized aluminum gas distribution plate of the present invention;
FIG. 3 is a cross-sectional view of the anodized aluminum gas distribution plate, taken along section lines 3 — 3 in FIG. 2 ;
FIG. 4 is an enlarged cross-sectional view of the anodized aluminum gas distribution plate, taken along section line 4 in FIG. 3 ;
FIG. 5 is a cross-sectional, partially schematic view of a conventional process chamber in implementation of the present invention;
FIG. 6 is a schematic view of an anodizing electrolyte bath in typical fabrication of the anodized aluminum gas distribution plate of the present invention; and
FIG. 7 is a flow diagram which summarizes typical steps in fabrication of the anodized aluminum gas distribution plate of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to an anodized aluminum gas distribution plate which is particularly applicable to etch chambers, particularly the MxP etch chamber available from Applied Materials, Inc. of Santa Clara, Calif. However, the anodized aluminum gas distribution plate of the present invention may be applicable to other types of process chambers used for the fabrication of integrated circuits on semiconductor wafer substrates.
Referring initially to FIGS. 2-4 , an illustrative embodiment of the anodized aluminum gas distribution plate (GDP) of the present invention is generally indicated by reference numeral 40 . The GDP 40 includes a circular, aluminum plate body 42 having a top surface 44 , a bottom surface 46 and a circular edge 48 . Multiple gas flow openings 50 extend through the thickness of the plate body 42 and open onto the top surface 44 and the bottom surface 46 , respectively. In a preferred embodiment, the plate body 42 includes eighty-eight ( 88 ) of the gas flow openings 50 . However, it is understood that any desired number of the gas flow openings 50 may be provided in the plate body 42 in any desired pattern. An alumina anodized layer 52 is coated on the top surface 44 and the bottom surface 46 , as well as the edge 48 and opening surfaces 51 inside the gas flow openings 50 . In a preferred embodiment, the alumina anodized layer 52 has a thickness of about 0.04 mm, leaving each of the gas flow openings 50 with a diameter of typically from about 0.78 mm to about 0.82 mm.
Referring next to FIGS. 6 and 7 , the anodized aluminum GDP 40 may be fabricated in the following manner. First, the aluminum plate body 42 is fabricated with the multiple gas flow openings 50 extending therethrough in a selected pattern, according to the knowledge of those skilled in the art. Next, an anodizing electrolyte bath 58 is prepared by placing an anodizing electrolyte solution 56 in an electrolyte tank 54 . In a preferred embodiment, the anodizing electrolyte solution 56 is sulfuric acid (H 2 SO 4 ) However, it is understood that other suitable anodizing electrolyte solutions known by those skilled in the art may be used instead. The plate body 42 is completely immersed in the anodizing electrolyte solution 56 , with the top surface 44 , the bottom surface 46 , the edge 48 and the opening surfaces 51 ( FIG. 4 ) directly exposed to the anodizing electrolyte solution 56 . As the anodizing electrolyte solution 56 is maintained at a temperature of typically about 0-3 degrees C., an electric current of typically about 20-60 volts is transmitted through the electrolyte solution 56 , with a current density of typically about 2-2.5 A/dm 2 . The anodizing process is carried out for about 60-200 minutes in order to form the alumina anodized layer 52 having a thickness of about 0.04 mm. The fabrication steps for the anodized aluminum gas distribution plate 40 are summarized in FIG. 7 .
Referring next to FIG. 5 , the anodized aluminum GDP 40 may be installed in a reaction chamber 62 of a conventional plasma etching system 60 such as an Mxp+Super-E etcher available from Applied Materials, Inc. The reaction chamber 12 includes a typically grounded chamber wall 64 . An electrode, such as a planar coil electrode 66 , is positioned adjacent to the gas distribution plate 40 which separates the electrode 66 from the interior of the reaction chamber 62 . A semiconductor wafer 68 is positioned in the reaction chamber 70 and is supported by a wafer platform or ESC (electrostatic chuck) 70 . The ESC 70 is typically electrically-biased to provide ion energies that are independent of the RF voltage applied to the electrode 66 and that impact the wafer 68 . Plasma-generating source gases are provided by a gas supply (not shown) and flow into the reaction chamber 62 through the gas flow openings 50 in the gas distribution plate 40 . Volatile reaction products and unreacted plasma species are removed from the reaction chamber 62 by a gas removal mechanism, such as a vacuum pump (not shown) through a throttle valve (not shown), in conventional fashion.
Ignition of a plasma in the reaction chamber 62 is accomplished primarily by electrostatic coupling of the electrode 66 with the source gases, due to the large-magnitude voltage applied to the electrode 66 and the resulting electric fields produced in the reaction chamber 62 . Once ignited, the plasma is sustained by electromagnetic induction effects associated with time-varying magnetic fields produced by the alternating currents applied to the electrode 66 . The plasma may become self-sustaining in the reaction chamber 12 due to the generation of energized electrons from the source gases and striking of the electrons with gas molecules to generate additional ions, free radicals and electrons. The plasma contacts the wafer 68 and etches material layers from the wafer 68 to define an electrically conductive circuit pattern on the wafer 68 , as is known by those skilled in the art. It will be appreciated by those skilled in the art that the alumina anodized layer 52 on the plate body 42 prevents plasma-induced corrosion, deterioration and/or damage to the anodized aluminum GDP 40 , thereby preventing generation of particles which would otherwise potentially contaminate the circuits being fabricated on the wafer 68 and prolonging the time intervals needed for periodic maintenance of the aluminum GDP 40 . Furthermore, the anodized aluminum GDP 40 is capable of withstanding RF powers of up to 1200 watts, whereas conventional quartz GDPs can withstand RF powers of up to about 650 watts. In the event that it wears thin or becomes depleted due to prolonged use of the anodized aluminum GDP 40 , the alumina anodized layer 52 can be replaced on the plate body 42 by re-subjecting the plate body 42 to the aluminum anodizing process heretofore described with respect to FIGS. 6 and 7 .
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications can be made in the invention and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A new and improved, anodized aluminum gas distribution plate for process chambers, particularly an etch chamber. The gas distribution plate includes an aluminum body having multiple gas flow openings extending therethrough and an alumina anodized coating or layer on the plate. The gas distribution plate is characterized by enhanced longevity and durability and resists particle-forming deterioration and damage throughout prolonged use. | 8 |
PRIORITY INFORMATION
This application claims the benefit of U.S. Provisional Application No. 60/339,030 on Oct. 30, 2001.
FIELD OF THE INVENTION
The field of this invention is inflatable packers and more particularly those that can be deflated and subsequently advanced downhole without swabbing.
BACKGROUND OF THE INVENTION
Saving trips in a completion procedure saves money. Recently, screens have been run into open hole and expanded as a technique to replace the need to gravel pack. In these situations it is desirable to isolate the formation pressure from the upper part of the well as the screens are run in. The problem in the past has been that once the inflatable is deflated, trying to advance it further into the wellbore to total depth can cause a condition known as swabbing. In an inflatable, the element has a lower movable collar, which rides uphole as the element is inflated. When the element is deflated the lower collar is free to move on the mandrel. Thus if the screen, which had before deflation been tagged into the inflatable, is advanced with the deflated inflatable, the lower collar will ride up when any portion of the element engages the borehole wall. The element will then ball up in a phenomenon known as swabbing.
The present invention addresses this problem by using the downhole force to advance the deflated inflatable with the screen to also keep the deflated element in a stretched condition to avoid swabbing. Those skilled in the art will appreciate the scope of the invention from the illustrative example of the preferred embodiment, which appears below and more particularly for the appended claims based thereon.
SUMMARY OF THE INVENTION
A latching assembly for a lower collar on an inflatable is provided. After deflation, the lower collar is engaged to the mandrel so that the deflated inflatable can be advanced with other connected downhole equipment, such as screens to be expanded, in a location further downhole without swabbing.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view, showing the inflatable being run in;
FIG. 2 shows the inflatable being set;
FIG. 3 shows a screen assembly being tagged into the set inflatable;
FIG. 4 shows the inflatable being deflated;
FIG. 5 shows the assembly of the de3flated inflatable and the screen advanced downhole, where the screen is to be deployed;
FIG. 6 is a half section view of the inflatable and the latch system in the run in position;
FIG. 7 is the view of FIG. 6 with the inflatable set;
FIG. 8 is the view of FIG. 7 with the inflatable deflated and latched
FIG. 9 is the view of FIG. 8 with the deflated element stretched out from being advanced downhole.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The overview of the present invention is shown in FIGS. 1-5 . The inflatable 10 is run in the wellbore 12 on drill pipe, coiled tubing or electric wireline 14 . It is set, as shown in FIG. 2 , effectively isolating the top of the wellbore 12 from the formation below the now set inflatable 10 . At this time, other downhole equipment can be run into the wellbore 12 without the use of a lubricator at the surface. In FIG. 3 , a screen assembly 15 is tagged into the inflated inflatable 10 . At the conclusion of the tagging procedure, the inflatable is deflated by mandrel manipulation, in a known manner. As will be later explained, the deflation of the inflatable 10 secures its inflatable element 16 to the mandrel 18 via a latch system 20 (see FIG. 8 ). Thereafter, as shown in FIGS. 5 and 9 , the element 16 is stretched to its run in position, as the mandrel 18 is advanced downhole with the screen assembly 15 . Those skilled in the art will appreciate that other equipment can be tagged into the inflatable 10 than screen assembly 15 . The inflatable 10 can be run downhole and inflated in a variety of ways. The new feature of the latch system 20 can be executed in a variety of ways to allow a stretching force to be transmitted to the element 16 after it is deflated. This stretching force prevents the element 16 from swabbing, as it is advanced downhole after being inflated and deflated.
In the preferred embodiment, the latching system is in the form of a ratchet. As shown in FIG. 6 , in the run in position, the inflatable 10 has its element 16 in the stretched position to facilitate insertion. Typically the element 16 has a slidably mounted lower collar 22 , which rides up when the element 16 is inflated, as shown in FIG. 7 . In the present invention, the mandrel 18 has an extension 24 secured at thread 26 . Extension 24 has ratchet teeth 28 . Collar 22 has a sleeve 30 attached at thread 32 . Sleeve 30 supports teeth 34 , which selectively engage teeth 28 , as will be explained below. Teeth 34 are retained by end cap 36 , which is secured to sleeve 30 at thread 38 .
As the element 16 is inflated, the collar 22 and sleeve 30 both ride up. This movement, shown in FIG. 7 , tends to bring teeth 34 further away from teeth 28 . It should be noted that during run in and set, there has been no engagement of the teeth 34 and 28 .
When the screen assembly 15 has been tagged into the inflatable 10 (see FIG. 3 ), the inflatable is deflated in a known manner by setting down weight and then picking up. As shown in FIG. 8 , when the pickup force is applied the teeth 28 ratchet past teeth 34 . Subsequent downhole movement of the mandrel 18 with the extension 24 pulls teeth 34 down, since opposed relative movement is precluded by the orientation of teeth 28 and 34 . As shown in FIG. 9 , the downward force on the mandrel 18 and extension 24 , pulls the deflated element 16 toward its retracted or run in position. The occurs because the lower collar 22 is forcibly pulled down by the latch system 20 while the upper collar (not shown) on the element 16 remains in position with respect to the advancing mandrel 18 carrying with it the lower collar 22 .
Those skilled in the art will appreciate that the element 16 will not swab if it is stretched out using the latch system 20 of the present invention. The screen assembly 15 can then be run further downhole and expanded into place against the open hole. Those skilled in the art will appreciate that the present invention encompasses all techniques to grab the element and stretch it out after deflation. The ratchet teeth engagement depicted in the Figures is but one embodiment that is preferred. The full scope of the invention is delineated in the claims, which appear below. Modifications from the embodiment described above are clearly contemplated to be within the scope of the invention particularly if the result is an extension of the element after deflation so that upon further advancement into the wellbore, it will be prevented from swabbing. Apart from ratchets, the stretching of the element can be accomplished with a pressure responsive piston, a J-slot mechanism, or engaging a thread, to mention a few variations.
While the preferred embodiment has been described above, those skilled in the art will appreciate that other mechanisms are contemplated to accomplish the task of this invention, whose scope is delimited by the claims appended below, properly interpreted for their literal and equivalent scope.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | A latching assembly for a lower collar on an inflatable is provided. After deflation, the lower collar is engaged to the mandrel so that the deflated inflatable can be advanced with other connected downhole equipment, such as screens to be expanded, in a location further downhole without swabbing. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of copending International Application No. PCT/DE01/00191, filed Jan. 17, 2001, which designated the United States and which was not published in English.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention relates to a digital frequency divider circuit.
Frequency divider circuits are among the basic circuits of digital technology. Frequency dividers are digital circuits wherein the input frequencies are integer multiples of the output frequencies. Such circuits are used for example in radiofrequency technology, where there exists continual demand for the development of circuits with ever higher clock rates or frequencies. In order to realize frequency divider circuits, usually a plurality of gates are connected in series in a combinatorial part of the circuit, so that, for each state change of the input signal, many gates are switched within one clock period.
Such a frequency divider is described for example in U.S. Pat. No. 5,065,415 and German patent DE 40 08 385 C2. In order to generate an output signal, a plurality of prescalers are cascaded, of which each prescaler can be changed over between the operating modes divide-by-2 and divide-by-3. Each prescaler is connected to a device which enables the state of the respective prescaler to be set in such a way that, within a division cycle of the frequency divider: the individual prescalers divide by 2 or by 3 in a first time period within the division cycle and divide by 2 in the subsequent time period within the same division cycle.
The maximum possible input frequency of a frequency divider is thus limited by the sum of the signal propagation times of the series-connected gates.
In the past, essentially two solution approaches have emerged for combating this problem. Firstly, attempts are made to further develop the semiconductor technology used such that the signal propagation times become ever shorter. Another procedure consists in reducing as far as possible the number of gates to be traversed. This is possible for example by using a PN (pseudo noise) code.
However, even the use of fast semiconductor technology or the use of PN codes often no longer satisfies the requirements for ever higher-frequency circuits. In particular the demands for frequency divider circuits with an arbitrarily adjustable divider ratio and demands for an adjustable duty ratio (duty cycle) of the output signal cause the known methods to encounter frequency limits.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a frequency divider, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which provides for a frequency divider with an adjustable divider ratio that can process higher clock rates.
With the foregoing and other objects in view there is provided, in accordance with the invention, a frequency divider, comprising:
an input terminal for receiving an input signal with a first clock frequency and an output terminal for an output signal;
a state register, encompassing n bits, for storing a register state from a multiplicity of register states;
a decoder connected to the state register, the decoder assigning to the register states in each case an m-bit word, a plurality of second n-bit words, and state-dependent variables;
a loading device connected to the state register and configured to write, depending on an adjustable divider ratio and the state-dependent variables, one of the n-bit words to the state register at a second clock frequency corresponding to the frequency of the input signal divided by m; and
a parallel-serial converter connected to the loading device for reading in the m-bit words in parallel at the second clock frequency and outputting the m-bit words serially as the output signal.
In accordance with a further feature of the invention, there is provided, for the special case divider ratios of TV=2 and TV=3, respective additional circuitry for bypassing the register and the decoder, connected to an internal bus connected between an input and the output of the multiplexer.
In other words, the objects of the invention are achieved with a frequency divider that comprises: a terminal for an input signal with a first clock frequency and a terminal for an output signal, a state register, comprising n bits (n is an integer), for storing a register state from a multiplicity of register states, a decoder, which is connected to the state register, and which assigns to the register states in each case an m-bit word, a plurality of second n-bit words and state-dependent variables, a loading device, which, depending on an adjustable divider ratio and the state-dependent variables, writes one of the n-bit words to the state register with a second clock frequency, which corresponds to that of the input signal divided by m and a parallel-serial converter, which reads in the m-bit words in parallel in the second clock frequency and outputs them serially as output signal.
The invention is based on the principle that the output signal of a frequency divider is not generated and output in a bitwise manner, rather the output signal is decomposed into blocks each of m bits. Consequently, a time which is m times as long as the clock time of the input signal is available for forming each such m-bit word. Consequently, higher clock rates can be processed. The m-bit words are joined together at an output of the circuit and output serially.
The frequency divider according to the invention has a state register having a multiplicity of counter states. In each case an m-bit word is combined with the states of the state register which word is read in in a parallel-serial converter and is output serially. The state register is consequently operated with a clock which is m times as slow as the input clock. Consequently, for the formation of the m-bit words, and for the formation of further variables respectively dependent on the counter state, the m-fold time is available, relative to a conventional frequency divider circuit wherein in each case a multiplicity of gates must be traversed per input clock period in the combinatorial part of the circuit. The assignment of the state-dependent variables and of further n-bit words is effected in a decoder. The n-bit state register is loaded anew with a subsequent state by the loading device in each case after a slow clock period has elapsed. For this, the loading device requires the n-bit words generated in the decoder, the loading of the state register being dependent, of course, on the divider ratio set. This is because the loading of the state register with a new n-bit word can be equated to jumping to a new state, after which in each case new, dependent one- and multi-bit variables are again generated.
The counter states of the n-bit state register can be coded with a selectable code. Of course, the state-dependent further n-bit words which define the respective succeeding state must then likewise be defined in accordance with the code used in the state register.
The present circuit advantageously has an adjustable duty ratio. At the same time, however, the present frequency divider circuit manages with a limited number of register states since, although the order of the register states that are respectively loaded one after the other depends on the divider ratio set, the divider nonetheless has recourse, in principle, independently of the duty ratio set, to the same set of register states, only in a different order.
Since most of the circuit according to the invention is operated with a comparatively slow clock, that is to say a clock with a frequency m times slower than the input frequency, the circuit design is simplified to a significant extent with regard to drivers and line lengths. The present frequency divider continues to operate correctly even when the divider ratio is changed over to a different value at an arbitrary point in time while the frequency divider is operating.
In accordance with an added feature of the invention, the parallel-serial converter is realized as a multiplexer. Multiplexer circuits are known to be extremely reliable.
In accordance with an additional feature of the invention, the bit width of the counter states is equal to the bit width of the m-bit words, and consequently the relationship m=n holds true. By way of example, the use of 4-bit blocks is advantageous for achieving significantly higher clock frequencies, with the result that the decoder circuit can be operated with a quarter of the input clock frequency. Consequently, quadruple the time is available for the formation of the 4-bit blocks. Given the same bit width of the state register, 2 n =2 4 =16 follows for the number of register states of the state register.
In accordance with another feature of the invention, the duty ratio (duty cycle) of the output signal of the frequency divider can be set in a simple manner by defining the coding of the m-bit words of the register in accordance with the desired duty ratio.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a frequency divider, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, 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 block diagram of a frequency divider according to the invention;
FIG. 2 is a schematic diagram of an exemplary embodiment of the charging device block of FIG. 1;
FIG. 3 is a schematic diagram of an exemplary embodiment of the multiplexer block of FIG. 1;
FIG. 4 is a schematic diagram of an exemplary embodiment of the register block of FIG. 1;
FIG. 5 is a schematic diagram of an exemplary embodiment of the NREG block of FIG. 2; and
FIG. 6 is a schematic diagram of an exemplary embodiment of the DIV block of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown an embodiment of the present invention using a block diagram which can be divided into a plurality of interconnected blocks. The blocks include a state register REG, which has a multiplicity of register states D, C, B, A, a decoder DEC, a multiplexer MUX, a loading device or loading unit LU, and additionally an auxiliary divider DIV. The circuit configuration of a frequency divider according to the invention as shown in FIG. 1 has a signal input C and also a signal output OUT. A bus input for setting a divider ratio TV, and a clock signal LC, with which a new divider ratio TV can be written to the loading unit LU, can be fed to the loading unit LU.
Both the state register REG and the blocks RO which can be fed to the multiplexer MUX have a width of 4 bits in each case in the exemplary embodiment.
The auxiliary divider DIV provides a clock signal C 4 , which has a frequency 4 times lower than the input clock signal C. Both the register REG and, in dependence thereon, the decoder DEC and also the loading unit LU are operated with this slow frequency C 4 . Apart from the output-side part of the multiplexer MUX and the input of the auxiliary divider DIV, the entire circuit configuration according to the invention is clocked with the slower clock signal C 4 . On the one hand, 4-bit blocks RO and on the other hand a plurality of state-dependent variables LOAD, MODN, MODNM 1 , MODNM 2 and MODNM 3 are formed in the decoder DEC, in a manner dependent on the register state bits A, B, C, D, by logic combinations thereof. The 4-bit words RO are placed one after the other in the multiplexer MUX and output in a bitwise manner at the output OUT. The loading device LU supplies the state register REG with a subsequent state via the bus TOREG. Said subsequent state depends, of course, on the divider ratio TV set, but also on the state-dependent variables LOAD, MODN, MODNM 1 , MODNM 2 and MODNM 3 provided in the decoder. Via the bus NM 4 , the register REG has the possibility of itself passing its subsequent state to the loading device LU, which can write said state to the state register REG via the bus TOREG again under specific preconditions.
FIG. 2 shows a diagrammatic embodiment possibility for the block loading unit LU of FIG. 1 . The bus NM 4 is passed on to the bus TOREG only when the loading variable LOAD switches the input D 1 of the 2:1 multiplexer ADRMUX through to the output. In all other cases, that is to say when LOAD=0, a 4-bit word dependent on the divider ratio TV, and also on the 4-bit words NM 3 , NM 2 or NM 1 , or the divider ratio TV itself is passed to the register REG as subsequent state for the register REG. The divider ratio TV is stored in the register NREG in this case. Each of these last-mentioned 4-bit words is in each case combined with a variable MODN, MODNM 1 , MODNM 2 and MODNM 3 , assigned to it, via an AND gate. The outputs of the AND gates in turn are connected via an OR module having 4 inputs to the input D 0 of the multiplexer ADRMUX.
The multiplexer MUX from FIG. 1 is explained using a diagrammatic example in FIG. 3 . As main input, the multiplexer has the bus RO, which has a width of 4 bits. The multiplexer MUX is accorded the task of outputting these four bits of the bus input RO serially and in a bitwise manner one after the other at the output OUT. For this purpose, the input clock signal C of the frequency divider according to the invention is applied, of course, to the output module of the multiplexer. In addition, the circuit of the multiplexer also requires the slow clock C 4 , and the intermediate clock C 2 . C 2 has half the frequency of C, and C 4 half the frequency of C 2 . Since the present 4-bit frequency divider is intended to enable arbitrary divider ratios of two to sixteen, and the blocks at the output of the decoder DEC have a width of four bits, for the special cases “by two” and “by three”, provision is made of an auxiliary circuit, and also an additional internal bus INT in the multiplexer. For the case where the divider ratio TV is equal to 2, the variable DIVBY 2 is set to the value 1, and for the case where the divider ratio TV is equal to 3, the variable DIVBY 3 is correspondingly set to the value 1. In the special case of divider ratio TV equal to 2, the output signal OUT at the multiplexer must continually output the bit sequence 010101 . . . For this purpose, INT( 1 ) and INT( 3 ) are set to the value 1 via OR modules. In the case where the divider ratio TV is equal to 3, that is to say that a bit sequence 001001 . . . is to be output at the output OUT, an additional circuitry is provided for generating this bit sequence, and is likewise connected to the internal bus INT of the multiplexer MUX.
Such circuits for frequency dividers with divider ratios TV=2 or TV=3 are not directly part of the present invention, but rather merely advantageously supplement it by those divider ratios TV which are less than the bit width m of the output block RO, for which TV<m thus holds true. In applications of a frequency divider wherein the occurrence of divider ratios TV<m is precluded, these additional circuits and also the internal bus of the multiplexer can be omitted. FIG. 4 describes the register REG, with the 4-bit input bus TOREG and the output bus A, B, C, D. It can readily be seen that the state register REG is clocked with the clock signal C 4 , that is to say the slow clock.
The situation is similar with the circuit configuration illustrated in FIG. 5, which describes the block NREG of FIG. 2 in more detail using an exemplary embodiment. The input bus divider ratio TV, which has a width of 4 bits, is forwarded to an output of the register NREG. The circuit is clocked with the loading clock signal LC.
Finally, FIG. 6 shows a simple by-2 and by-4 frequency divider circuit, at whose input the input clock signal C is present and at whose outputs the clock signal C 2 , which has half the frequency of C, and the clock signal C 4 , which has half the clock frequency of C 2 , are present. This realization of the block DIV from FIG. 1 provides the slower clock signals required for the rest of the circuit.
In order to elucidate the drawing illustrated in FIGS. 1 to 6 , by way of example the division operation “by ten” will now be explained in more detail. For this purpose, a table is specified which describes all 2 4 =16 register states of the state register REG and contains the state-dependent variables LOAD, MODN, MODNM 1 , MODNM 2 , MODNM 3 assigned to the register bits D, C, B, A by means of the logic combinations described, and also the 4-bit word RO and the subsequent states NM 1 , NM 2 , NM 3 and NM 4 .
The following abbreviations are applicable in the following state table:
D
C
B
A
(1)
(2)
(3)
(4)
(5)
RO
NM1
NM2
NM3
NM4
:16
0
0
0
0
1
0
0
0
0
0000
0001
0010
0011
0100
:15
0
0
0
1
1
0
0
0
0
0000
0010
0011
0100
0101
:14
0
0
1
0
1
0
0
0
0
0000
0011
0100
0101
0110
:13
0
0
1
1
1
0
0
0
0
0000
0100
0101
0110
0111
:12
0
1
0
0
1
0
0
0
0
0000
0101
0110
0111
1000
:11
0
1
0
1
1
0
0
0
0
0000
0110
0111
1000
1001
:10
0
1
1
0
1
0
0
0
0
0000
0111
1000
1001
1010
:9
0
1
1
1
1
0
0
0
0
0000
1000
1001
1010
1011
:8
1
0
0
0
1
0
0
0
0
0000
1001
1010
1011
1100
:7
1
0
0
1
1
0
0
0
0
0000
1010
1011
1100
1101
:6
1
0
1
0
1
0
0
0
0
0000
1011
1100
1101
1110
:5
1
0
1
1
1
0
0
0
0
0000
1100
1101
1110
1111
:4
1
1
0
0
0
1
0
0
0
0001
1101
1110
1111
0000
:3
1
1
0
1
0
0
1
0
0
0010
1110
1111
0000
0001
:2
1
1
1
0
0
0
0
1
0
0100
1111
0000
0001
0010
1
1
1
1
0
0
0
0
1
1000
0000
0001
0010
0011
(1): LOAD
(2): MODN
(3): MODNM1
(4): MODNM2
(5): MODNM3
The table presented above will now be explained by way of example with reference to the division operation “by ten”. Since TV=10 holds true, firstly the state D, C, B, A=0110 is loaded into the register REG, which corresponds to the row TV :10 in the table. Since the variable LOAD=1, NM 4 =1010 is written as subsequent state to the register REG. At the same time, RO=0000 is fed to the multiplexer at the output.
The subsequent state 1010 corresponds to the row :6 of the table, DCBA=1010 holding true. Since LOAD=1 in this case as well, the subsequent state 1110 is passed on. At the same time, RO=0000 is written to the output. The new state is now DCBA=1110, which corresponds to the row :2 in the table. In this case, MODNM 2 =1 now holds true, and it follows from this that the subsequent state is formed from divider ratio minus two: TV−2=10−2=8. The subsequent state is thus the row :8 where DCBA=1000. At the same time RO=0100 is passed to the output. LOAD=1 and RO=0000 hold true in the row :8. The subsequent state is 1100. This subsequent state corresponds to the row :4 of the table where DCBA=1100 and RO=0001. MODN=1 furthermore holds true in this row. Together with the set divider ratio TV=10 being taken into account, precisely this divider ratio is taken over as the new state. This means that a jump has now been made to the row :10 again in the table, the sequence described having begun with this row. Thus, in the case of a divider ratio: 10, in the case of an output word width of 4 bits, the original conditions are established again after 5 slow clock cycles have been run through. The output sequence, formed by stringing together the 5 output words RO which each have a width of 4 bits, consequently reads 0000 0000 0100 0000 0001 which corresponds to a correct signal with divider ratio TV=10.
The above-described circuit configuration of a frequency divider functions analogously to the sequence described by way of example for the divider ratio TV=10 also for other divider ratios between 2 and 16 inclusive.
For even higher frequencies, it is also conceivable to take the parallelization of the output signal still further, for example by increasing the bit width of the output word RO, for example from 4 to 8 bits. The number of register states of 16 with a width of 4 bits is also not restricted to these 4 bits, but can be altered.
The register states can also be coded in any other code desired, deviating from the binary code shown in the exemplary embodiment. In this case, however, it must be ensured that the words NM 1 , NM 2 , NM 3 and NM 4 are likewise formed in accordance with this other code.
The duty cycle (duty ratio) of the output sequence can easily be altered by means of the invention described. Replacing the last five rows of the column RO of the table above by
_RO
0001
0011
0110
1100
1000
enables, for example, a modification of the duty cycle from 4:5 to 3:5.
The 4-bit words NM 1 , NM 2 and NM 3 depend on the four register state bits in accordance with the following logic specifications. In this case, the times dot “·” represents logic AND, the plus “+” represents logic OR, the “x” represents the EXCLUSIVE-OR function XOR and “/” represents inversion; (3) designates the left bit, (0) the right bit:
NM 1 (3)=A·B·CxD
NM 1 (2)=A·BxC
NM 1 (1)=AxB
NM 1 (0)=/A
NM 2 (3)=B·CxD
NM 2 (2)=BxC
NM 2 (1)=/B
NM 2 (0)=A
NM 3 (3)=(A+B)·CxD
NM 3 (2)=(A+B)xC
NM 3 (1)=AxB
NM 3 (0)=/A
NM 4 (3)=CxD
NM 4 (2)=/C
NM 4 (1)=B
NM 4 (0)=A
The frequency divider described in the exemplary embodiment makes it possible to realize input frequencies of 4 GHz compared with the 2.7 GHz possible hitherto. | The novel frequency divider has an adjustable divider ratio. Such circuits are subject to demands for ever higher clock frequencies. The circuit generates the output signal in a blockwise manner and converts it into a sequential signal in a parallel-serial converter on the output side and outputs it in a bitwise manner. As a result, the essential part of the frequency divider circuit can be operated with a slower frequency than the input frequency, which in turn enables higher input frequencies. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
Reference is made to commonly assigned, co-pending U.S. patent application Ser. No. 09/535,703 by Chu et al., filed concurrently herewith entitled “Ink Jet Recording Element”; the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to an ink jet printing method. More particularly, this invention relates to an ink jet printing method employing an ink jet recording element containing encapsulated particles.
BACKGROUND OF THE INVENTION
In a typical ink jet recording or printing system, ink droplets are ejected from a nozzle at high speed towards a recording element or medium to produce an image on the medium. The ink droplets, or recording liquid, generally comprise a recording agent, such as a dye or pigment, and a large amount of solvent. The solvent, or carrier liquid, typically is made up of water, an organic material such as a monohydric alcohol, a polyhydric alcohol or mixtures thereof.
An ink jet recording element typically comprises a support having on at least one surface thereof an ink-receiving or image-forming layer, and includes those intended for reflection viewing, which have an opaque support, and those intended for viewing by transmitted light, which have a transparent support.
While a wide variety of different types of image-recording elements for use with ink jet devices have been proposed heretofore, there are many unsolved problems in the art and many deficiencies in the known products which have limited their commercial usefulness.
It is well known that in order to achieve and maintain photographic-quality images on such an image-recording element, an ink jet recording element must:
Be readily wetted so there is no puddling, i.e., coalescence of adjacent ink dots, which leads to non-uniform density
Exhibit no image bleeding
Exhibit the ability to absorb high concentrations of ink and dry quickly to avoid elements blocking together when stacked against subsequent prints or other surfaces
Exhibit no discontinuities or defects due to interactions between the support and/or layer(s), such as cracking, repellencies, comb lines and the like
Not allow unabsorbed dyes to aggregate at the free surface causing dye crystallization, which results in bloom or bronzing effects in the imaged areas
Have an optimized image fastness to avoid fade from contact with water or radiation by daylight, tungsten light, or fluorescent light
An ink jet recording element that simultaneously provides an almost instantaneous ink dry time and good image quality is desirable. However, given the wide range of ink compositions and ink volumes that a recording element needs to accommodate, these requirements of ink jet recording media are difficult to achieve simultaneously.
Ink jet recording elements are known that employ porous or non-porous single layer or multilayer coatings that act as suitable image receiving layers on one or both sides of a porous or non-porous support. Recording elements that use non-porous coatings typically have good image quality but exhibit poor ink dry time. Recording elements that use porous coatings typically contain colloidal particulates and have poorer image quality but exhibit superior dry times.
While a wide variety of different types of porous image-recording elements for use with ink jet printing are known, there are many unsolved problems in the art and many deficiencies in the known products which have severely limited their commercial usefulness. The challenge of making a porous image-recording layer is to achieve a high gloss level without cracking, high color density, and a fast drying time.
EP 813,978 relates to an ink jet recording element wherein an ink absorption layer is used comprising fine particles, a hydrophilic binder and oil drops. However, there is a problem with this element in that the oil drops will migrate to the surface and cause changes in the appearance of the image.
It is an object of this invention to provide an ink jet printing method using an ink jet recording element that has a fast ink dry time. It is another object of this invention to provide an ink jet printing method using an ink jet recording element that has good image quality.
SUMMARY OF THE INVENTION
These and other objects are achieved in accordance with the invention which comprises an ink jet printing method comprising the steps of:
A) providing an ink jet printer that is responsive to digital data signals;
B) loading the printer with ink jet recording elements comprising a substrate having thereon an image-receiving layer comprising inorganic particles encapsulated with an organic polymer having a Tg of less than about 20° C., the weight ratio of the inorganic particles to the organic polymer being from about 20 to about 0.2;
C) loading the printer with an ink jet ink composition; and
D) printing on the ink jet recording element using the ink jet ink in response to the digital data signals.
The ink jet recording element obtained by the process of the invention provides a fast ink dry time and good image quality.
DETAILED DESCRIPTION OF THE INVENTION
The substrate used in the invention may be porous such as paper or non-porous such as resin-coated paper; synthetic paper, such as Teslin® or Tyvek®; an impregnated paper such as Duraform®; cellulose acetate or polyester films. The surface of the substrate may be treated in order to improve the adhesion of the image-receiving layer to the support. For example, the surface may be corona discharge treated prior to applying the image-receiving layer to the support. Alternatively, an under-coating or subbing layer, such as a layer formed from a halogenated phenol or a partially hydrolyzed vinyl chloride-vinyl acetate copolymer, can be applied to the surface of the support.
Any inorganic particle may be used in the invention, such as metal oxides or hydroxides. In a preferred embodiment of the invention, the metal oxide is silica available commercially as Nalco® (Nalco Co.), Ludox® (DuPont Corp), Snowtex® (Nissan Chemical Co.), alumina, zirconia or titania. In another preferred embodiment of the invention, the particle size of said particles is from about 5 nm to about 1000 nm.
The encapsulated particles used in the invention may be prepared by silane coupling chemistry to modify the surface of inorganic colloids, followed by emulsion polymerization which can be found in “Emulsion Polymerization and Emulsion Polymers”, edited by P. A. Lovell and M. S. El-Aassar, John Wiley and Sons, 1997.
Silane coupling agents useful for the modification of inorganic colloids include 3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyldiethoxymethylsilane, 3-aminopropyldimethoxymethylsilane, 3-aminopropylethoxydimethylsilane, 3-aminopropylmethoxydimethylsilane, N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, N-(2-aminoethyl)-3-aminopropyltriethoxysilane, N-(2-aminoethyl)-3-aminopropylmethyl dimethoxysilane, N-(2-aminoethyl)-3-aminopropylmethyldiethoxysilane, 4-aminobutyltriethoxysilane, 4-aminobutyltrimethoxysilane, N-(2-aminoethyl)-3-aminoisobutylmethyldimethoxysilane, and other silane coupler agents listed in Gelest catalogue, pp.105-259(1997). Most preferred silane coupling agents for the modification of inorganic colloids used in the invention include 3-aminopropyl-triethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyl-diethoxymethylsilane, 3-aminopropyldimethoxymethylsilane, N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, N-(2-aminoethyl)-3-aminopropyltriethoxysilane, N-(2-aminoethyl)-3-aminopropylmethyldimethoxysilane, N-(2-aminoethyl)-3-aminopropylmethyldiethoxysilane.
The organic polymer used for encapsulation of the inorganic particles employed in the invention has a Tg of less than about 20° C. preferably from about −50° C. to about 20° C. Examples of these polymers which may be used in the invention include homo- and copolymers derived from the following monomers: n-butyl acrylate, n-ethylacrylate, 2-ethylhexylacrylate, methoxyethylacrylate, methoxyethoxy-ethylacrylate, ethoxyethylacrylate, ethoxyethoxyethylacrylate, 2-ethylhexyl-methacrylate, n-propylacrylate, hydroxyethylacrylate, etc. and cationic monomers such as a salt of trimethylammoniumethyl acrylate and trimethylammoniumethyl methacrylate, a salt of triethylammoniumethyl acrylate and triethylammonium-ethyl methacrylate, a salt of dimethylbenzyl-ammoniumethyl acrylate and dimethylbenzylammoniumethyl methacrylate, a salt of dimethylbutylammonium-ethyl acrylate and dimethylbutylammoniumethyl methacrylate, a salt of dimethylhexylammoniumethyl acrylate and dimethylhexylammoniumethyl methacrylate, a salt of dimethyloctyl-ammoniumethyl acrylate and dimethyloctyl-ammoniumethyl methacrylate, a salt of dimethyldodeceylammoniumethyl acrylate and dimethyldocecyl-ammoniumethyl methacrylate, a salt of dimethyloctadecyl-ammoniumethyl acrylate and dimethyloctadecylammoniumethyl methacrylate, etc. Salts of these cationic monomers which can be used include chloride, bromide, methylsulfate, triflate, etc.
Examples of the organic polymers which can be used in the invention include poly(n-butylacrylate-co-vinylbenzyltrimethylammonium chloride), poly(n-butylacrylate-co-vinylbenzyltrimethylammonium bromide),poly(n-butylacrylate-co-vinylbenzyldimethylbenzylammonium chloride) and poly(n-butylacrylate-co-vinylbenzyldimethyloctadecylammonium chloride). In a preferred embodiment of the invention, the polymer can be poly(n-butyl acrylate), poly(2-ethylhexyl acrylate) poly(methoxyethylacrylate), poly(ethoxy-ethylacrylate), poly(n-butylacrylate-co-trimethylammoniumethyl acrylate), poly(n-butylacrylate-co-trimethylammoniumethyl methacrylate) or poly(n-butylacrylate-co-vinylbenzyltrimethylammonium chloride).
Following are examples of inorganic particles encapsulated with an organic polymer which can be used in the invention:
Encapsulated
Organic Polymer Shell
Particles
Inorganic Particle (wt. %)
(wt. %)
1
Nalco ® 2329(83.3)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
methacrylate)(11.1:5.6)
2
Nalco ® 2329(83.3)
Poly(n-butylacrylate-co-
dimethylbenzylamonium
ethylacrylate) (11.1:5.6)
3
Nalco ® 2329(83.3)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
acrylate) (11.1:5.6)
4
Nalco ® 2329(70)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
methacrylate)(15:15)
5
Nalco ® 2329(50)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
methacrylate)(25:25)
6
Nalco ® 2329(80)
Poly n-butylacrylate (20)
7
Nalco ® 2329(90)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
methacrylate)(5:5)
8
Nalco ® 2329(80)
Poly(n-butylacrylate-co-
vinylbenzyltrimethylammo-
nium chloride)(10:10)
9
Nalco ® 2329(70)
Poly(n-butylacrylate-co-
vinylbenzyltrimethylammo-
nium chloride)(15:15)
10
Nalco ® 2329(80)
Poly n-ethylhexylacrylate (20)
11
Ludox ® C1(83.3)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
methacrylate)(11.1:5.6)
12
Ludox ® C1(88.2)
Poly n-butylacrylate (11.8)
13
Ludox ® C1(83.3)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
acrylate) (11.1:5.6)
14
Ludox ® C1(70)
Poly n-butylacrylate (30)
15
Snowtex ® OL(83.3)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
methacrylate)(11.1:5.6)
16
Snowtex ® OL (88.2)
Poly n-butylacrylate (11.8)
17
Snowtex OL (83.3)
Poly(n-butylacrylate-co-
trimethylammonium ethyl
acrylate) (11.1:5.6)
18
Snowtex ® OL (70)
Poly n-butylacrylate (30)
A binder can also be used in the image-recording layer employed in the process of the invention, e.g., a water soluble polymer such as poly(vinyl alcohol), gelatin, poly(vinyl pyrrolidone), poly(2-ethyl-2-oxazoline), poly(2-methyl-2-oxazoline), poly(acrylamide), Chitosan, methylcellulose, ethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, etc. Other binders can also be used such as low Tg polymer latexes such as poly(styrene-co-butadiene), a polyurethane latex, a polyester latex, poly(n-butyl acrylate), poly(n-butyl methacrylate), poly(2-ethylhexyl acrylate), a copolymer of n-butylacrylate and ethylacrylate, a copolymer of vinylacetate and n-butylacrylate, etc.
Other additives may also be included in the image-recording layer such as PH-modifiers like nitric acid, cross-linkers, rheology modifiers, surfactants, UV-absorbers, biocides, lubricants, dyes, dye-fixing agents or mordants, optical brighteners etc.
The ink jet coating may be applied to one or both substrate surfaces through conventional pre-metered or post-metered coating methods such as blade, air knife, rod, roll coating, etc. The choice of coating process would be determined from the economics of the operation and in turn, would determine the formulation specifications such as coating solids, coating viscosity, and coating speed.
The image-receiving layer thickness may range from about 1 to about 60 μm, preferably from about 5 to about 40 μm.
After coating, the ink jet recording element may be subject to calendering or supercalendering to enhance surface smoothness. In a preferred embodiment of the invention, the ink jet recording element is subject to hot, soft-nip calendering at a temperature of about 65° C. and a pressure of 14000 kg/m at a speed of from about 0.15 m/s to about 0.3 m/s.
Ink jet inks used to image the recording elements employed in the process of the present invention are well-known in the art. The ink compositions used in ink jet printing typically are liquid compositions comprising a solvent or carrier liquid, dyes or pigments, humectants, organic solvents, detergents, thickeners, preservatives, and the like. The solvent or carrier liquid can be solely water or can be water mixed with other water-miscible solvents such as polyhydric alcohols. Inks in which organic materials such as polyhydric alcohols are the predominant carrier or solvent liquid may also be used. Particularly useful are mixed solvents of water and polyhydric alcohols. The dyes used in such compositions are typically water-soluble direct or acid type dyes. Such liquid compositions have been described extensively in the prior art including, for example, U.S. Pat. Nos. 4,381,946; 4,239,543 and 4,781,758, the disclosures of which are hereby incorporated by reference.
The following examples further illustrate the invention.
EXAMPLES
Example 1
Synthesis of Encapsulated Particle 1
150 g of Nalco® 2329 colloidal silica and 150 g of distilled water were mixed in a 500 mL 3-neck round bottom flask equipped with a mechanical stirrer and nitrogen inlet. 3 g of 3-aminopropylmethyldiethoxysilane was added over one min. The pH of the mixture was adjusted slowly to 4.0 with 1N HCl. The viscosity of the dispersion increased first in the beginning but reduced again with the addition of acid. 1.2 g of cetyltrimethylammonium bromide(CTAB) and 0.6 g of Triton X-100® were added. The dispersion was stirred one hour at room temperature.
The solution was heated to 80° C. in a constant temperature bath and purged with nitrogen for 30 min. 0.12 g of 2,2′azobis(2-methylpropionamidine) dihydrochloride was added to the reactor. A monomer emulsion comprising 8 g of n-butyl acrylate, 5 g of trimethylammonium ethylmethacrylate( methylsulfate salt, 80% solid), 0.24 g CTAB, 0.12 g 2,2′azobis(2-methylpropionamidine) dihydrochloride, and 40 g deionized water was fed to the reactor over one hour to encapsulate the Nalco® 2329. The % solid was 20.1 % and the particle size of the encapsulated particle was 45 nm.
Example 2
Element 1
To prepare the paper base, a coating suspension was made by mixing 93 parts precipitated calcium carbonate pigment (Alboglos-S®, Specialty Minerals Inc.) and 7 parts poly(vinyl alcohol) (Airvol 540®, Air Products and Chemicals) in an aqueous medium. The suspension was applied to a Georgia-Pacific 1 00# paper base by Meyer Rod with a dry thickness of 50 μm. The coating was oven dried at 60° C. An aqueous dispersion of the above encapsulated particle 1 was coated on the prepared base by Meyer Rod with a dry thickness of 10 μm. The coating was oven dried at 60° C.
Element 2
This element was prepared the same way as in Element 1 except that the coating was an aqueous dispersion comprising 80 parts of colloidal silica (Nyacol® IJ 222, Akzo Nobel) and 20 parts of the above encapsulated particle 1.
Comparative Element 1
This element was prepared the same way as in Element 1 except that the coating was an aqueous dispersion of colloidal silica (Nyacol® IJ 222, Akzo Nobel).
Comparative Example 2
This element was prepared the same way as in Element 1 except that the coating was an aqueous dispersion comprising 85 parts of colloidal silica (Nyacol® IJ 222, Akzo Nobel) and 15 parts of a polyurethane latex (Witcobond® W-213, Witco Corp.)
Comparative Example 3
This element was prepared the same way as in Element 1 except that the coating was an aqueous dispersion comprising 90 parts of colloidal silica (Nalco® 2329, Nalco Co.) and 10 parts of polyvinyl alcohol (Airvol® 540, Air Products and Chemicals).
Printing
Images were printed using an Epson Stylus Color 740 printer for dye-based inks using Color Ink Cartridge S020191/IC3CL01. The images comprised a series of cyan, magenta, yellow, black, green, red and blue strips, each strip being in the form of a rectangle 0.8 cm in width and 20 cm in length.
Dry Time
Immediately after ejection from the printer, a piece of bond paper was placed over the printed image and rolled with a smooth, heavy weight. Then the bond paper was separated from the printed image. The length of dye transfer on the bond paper was measured to estimate the time needed for the printed image to dry. The dry time was rated as 1 when there was no transfer of the inks to the bond paper. If there was a full transfer of at least one color strip, the dry time was rated as 5. Intermediate transfer lengths were rated in between 1 and 5.
Image Quality
The image quality was evaluated subjectively. Coalescence refers to the non-uniformity or puddling of the ink in solid filled areas. Bleeding refers to the inks flowing out of its intended boundaries.
Coating Appearance
The coatings were visually examined for cracking defects. The following results were obtained:
TABLE 1
Coating
Dry
Element
Appearance
Image Quality
Time
1
Non-cracked
Fair density and image
2
quality
2
Non-cracked
Sharp image, high density
1
Comparative 1
Cracked, scaled up
Sharp image, low density
1
Comparative 2
Cracked
Poor image, low density
4
Comparative 3
Slightly cracked
Poor image, bleeding
5
The above results show that the elements employed in the process of the invention had good dry time, no cracking and good image quality as compared to the control elements which had poorer dry times, had cracking and poorer image quality.
This invention has been described with particular reference to preferred embodiments thereof but it will be understood that modifications can be made within the spirit and scope of the invention. | An ink jet printing method, comprising the steps of:
A) providing an ink jet printer that is responsive to digital data signals;
B) loading the printer with ink jet recording elements comprising a substrate having thereon an image-receiving layer comprising inorganic particles encapsulated with an organic polymer having a Tg of less than about 20° C., the weight ratio of the inorganic particles to the organic polymer being from about 20 to about 0.2;
C) loading the printer with an ink jet ink composition; and
D) printing on the ink jet recording element using the ink jet ink in response to the digital data signals. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a device for crimping large filament groups, consisting of a channel for moving filaments in a surrounding gas stream to which a barred cage as a compressing chamber is concentrically attached.
It has been shown to be particularly economical if in the post treatment of the filaments many filament bands are brought together. The crimping provides difficulties in the process, as with an increasing number of filaments the compressing chamber must become larger, in which process there results in the compressing chamber the known meandering deposit, as a result of which predominantly large crimping arcs result with which the desired effect is no longer to be achieved in the thread produced therefrom.
A device for texturing is known in which a conical extension of a nozzle changes over directly into a cylindrical compressing chamber, which consists of round bars arranged at a distance from each other along the exit outlet.
The disadvantage of this device consists in that it is only suitable for crimping with yarn titres up to 3,000 dtex. Post treatment of each individual filament band is however economically too expensive.
SUMMARY OF THE INVENTION
The object of the invention is to find a device which is suitable for carrying out sufficient texturing in the course of subsequent treatment even in filament bands of 10 3 -10 8 filaments, in particular of 10 4 -10 6 filaments, wherein a dampness content of 2-60% by weight must still be processable.
The object is solved according to the invention in that in the region between the outlet rim of the channel and the rod lying further out at least some short obstacles, narrow in a tangential direction, are arranged.
For example, a filament group previously loosened up and strongly braked as a result of the divergence of the channel, separates through the obstacles, which are preferably arranged on lines parallel to the cage and/or outlet rim, into several supply streams. The central filaments, arriving at the centre and rolling from side to side because of the braking effect, collide in the centre of the thread stopper and are thereby crimped. The outer filaments, after leaving the nozzle, lie immediately against the obstacle conditioned by the lateral gas, in which process as a result of the strong twisting (less than 180° C.), intensive shaping takes place. While the filaments present in the ring region lying in between seek the path to the exterior bars between or over the obstacles and are there crimped by penetrating into the gaps.
In contrast to the meandering depositing of the crimped filaments, the yarn stopper is here pushed on axially in the compressing chamber through the central air division. The obstacles of 4-40 mm, in particular 5-15 mm in height are therein always released again, in which process the slipping is moderated by a possible inclination (2°-15°) of the normally round bars (1.5-6 mm).
The directing of gas outwards can be still further improved by a face wall rising in steps or gradually from the outlet rim to the exterior bars, wherein it may be advantageous to arrange several barriers in a ring shape and possibly displaced relative to each other for the generating of flow shadows. By means of these two measures (face wall design and staggered barriers) it is possible to intensify the crimping and to smooth or adjust it in a defined way.
BRIEF DESCRIPTION OF THE DRAWING
Examples of the invention are represented in the diagrams and will be more closely described in the following. In the diagrams:
FIG. 1 shows a longitudinal section through nozzle and compressing chamber,
FIG. 2 shows a view of the open side of the compressing chamber,
FIG. 3 shows a longitudinal section through nozzle with step wise face wall of the compressing chamber,
FIG. 4 shows a view of the open side of the compressing chamber,
FIG. 5 shows a longitudinal section through nozzle with slanting face wall of the compressing chamber.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1 and 2 the nozzle is represented, possessing in its interior an elongated hollow space 2, which goes over into a diverging channel 3.
At the outlet rim 4 a face wall 6 connects perpendicularly to the axis 5 with the compressing chamber 7, in which bars 8, round outside and cold drawn, and in the intervening region 9 obstacles in the form of round short elements 10, are inserted. Further, groove-like depressions 11 are provided at the outlet rim.
In FIGS. 3 and 4 a nozzle 1 is drawn, in which after a central cylindrical hollow space 2 with post diverging channel 3 the face wall 12 is designed in steps 13 projecting outwards, which accepts a cage with long round bars 14 outside and two rows of short elements 15 inside parallel to the axis 5.
In FIG. 5 a longitudinal section is represented, in which after the hollow space 2 and the diverging channel 3 a conical expansion 16 follows. Bars 17 extend in an outward direction, elements 18 are inserted in parallel to the axis 5. Elements 18 also extend outwardly but at an angle to axis 5.
The elongated hollow space or channel 2 has a longitudinal axis 5 and the rods 18 of the second cage are outwardly angled 2°-15° relative to that axis. Also, the rods 17 of the first cage are 2-25 mm longer than the rods 18 of the second cage. | A compressing chamber (7) for directed crimping consists of step-shaped bars (8) by way of increasing outwards in length. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/845,228, filed May 13, 2004, now U.S. Pat. No. 6,847,492, which is a continuation of application Ser. No. 10/050,366, filed Jan. 16, 2002 now abandoned, which is a continuation of application Ser. No. 09/449,318, filed Nov. 24, 1999, now U.S. Pat. No. 6,388,813, the entire contents of which are expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to the following areas of technology: Apparel—Guards and Protectors; for wearer's head and face; eye shields such as goggles having a lens-cover plate; and windshield covers.
2. Description of the Prior Art
Face shields are employed in environments where contamination of the eyes may occur. It is well known in the art that flexible transparent lenses affixed by numerous methods are overlaid on the face shield for protection. The lenses are easily removed and discarded when visibility is reduced from the accumulation of dirt or other contaminants. In motor sports for instance, multiple layers of transparent lenses are overlaid on the face shield, each being sequentially removed as they become contaminated, because they reduce the visibility of the operator. The drawback of the lenses in the prior art is that each transparent lens applied over the face shield is itself a hindrance to good visibility due to its optical index of refraction. Most common materials used as plastics have optical indexes of refraction ranging from 1.47 to 1.498. The index mismatch between the removable lens and air (air has an optical index of 1.00) causes a reflection of 4% of the light that would normally come to the operator's eyes. This reflection effect is additive for each additional surface to air interface. Then for each removable lens having two surfaces, the reflections are 8%. Thus a stack of seven lenses would reflect 42% of the light away from the operator thereby reducing the brightness of the objects viewed. A second optical phenomenon occurs simultaneously that also reduces visibility. The reflections are bi-directional and thus make the lens stack appear as a semi-permeable mirror to the operator. This mirror effect further reduces visibility, because the light that passes through the lens stack reflects off of the operator's face and then reflects off of the lens stack into the operator's eyes. The effect to the operator is that he sees his own image on the inside of the stack nearly as brightly as the objects viewed on the outside. This significantly reduces visibility.
Another drawback to this stacking arrangement is that moisture exhaled by the operator's breath can cloud or fog-up the lenses also reducing visibility. The air spaces between each lens allows the moisture to enter this area.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a series of easily removable optically clear lens stacks that do not cause reflection to the operator's eyes. The prior art discloses reflective lens stacks that do cause reflections to the operator's eyes. An example of this type of prior art of reflective lens stacks is disclosed in U.S. Pat. No. 5,592,698 issued on Jan. 14, 1997 to Woods.
Refraction is the change in the direction in which waves travel when they pass from one kind of matter into another. Waves are refracted (bent) when they pass at an angle from one medium into another in which the velocity of light is different. The amount that a ray of a certain wavelength bends in passing from one medium to another is indicated by the index of refraction between the two mediums for that wavelength. The index of refraction indicates the amount that a light ray bends as it passes out of one substance and into another. When light passes from air to a denser substance, such as Mylar film, it slows down. If the light ray enters the Mylar film at any angle except a right angle, the slowing down causes the light ray to bend at the point of entry. This bending is called refraction. The ratio of the speed of light in air to its speed in the Mylar film is the Mylar film's index of refraction.
The present invention includes a series of alternating optically clear films whose indexes of refraction are matched to within 0.2 and which will nearly eliminate all reflections to the operator's eyes. The layers of film are adhesively laminated to one another and are compliant so there is no air between the layers. The film layers can be large and generally rectangular in shape with a tab extending from each of the film layers. The tabs can be staggered so that the user can remove the top most layer and then the next succeeding layer. This embodiment of the present invention can be applied to race car windshields, windows, visors or direct view displays such as ATM machines that are subject to contaminating environments. Accordingly, the present invention is an adhesively laminated multi-layered clear film adapted to be used on a racer's face shield, or on the windshield of a race car to keep the viewing area clean during the course of a race.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an off-road wearer's helmet showing one embodiment of the present invention affixed to the face shield of the helmet.
FIG. 2 is a front elevational view of the helmet shown in FIG. 1 showing the tab portion without any adhesive for allowing the wearer of the helmet to easily grasp the tab and peel-off the soiled top layer of the present invention.
FIG. 3 is a partial sectional view taken along line 3 — 3 in FIG. 2 . This view shows the tension post extending outwardly from the face shield with the left-side end tab portion of the present invention.
FIG. 4 is a front elevational view illustrating the present invention before it is affixed to the face shield of the helmet.
FIG. 5 . is a top view of the stackable lenses illustrating seven layers of lens held together by an adhesive applied between each lens with the thicknesses of the layers of each lens and applied adhesive highly exaggerated to clearly show the relationship between the lenses and the adhesive and also to show the end portions that do not have any adhesive between each lens layer for forming the removable tab portions at both ends of the present invention.
FIG. 6 illustrates a 60″ wide roll of film, which will be used to cut out the optical stacks that are illustrated in FIG. 4 . The gray stripes illustrate the clear adhesive, and the clear stripes illustrate the clear film without adhesive. It is to be understood that the gray stripes are for illustration purposes only, because the adhesive is clear.
FIG. 7 is an exploded perspective view illustrating seven sheets of film layer and seven layers of clear adhesive interposed between each sheet of film layer. This embodiment is used for windshields, windows and the like.
FIG. 8 is a view of the laminated sheets illustrated in FIG. 7 having a rectangular shape with a series of six tabs for removing each top layer of the lenses successively as the uppermost exposed lens layer becomes soiled or otherwise contaminated.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be discussed in detail. As stated above, FIG. 4 is a front elevational view illustrating the present invention 10 before it is affixed to the face shield of the helmet. The top view in FIG. 5 illustrates 7 layers of lenses 15 adhesively affixed to each successive lenses. The adhesive layer is numbered 20 . The material used to form the lenses is preferably a clear polyester. The lens layers are fabricated from sheets of plastic film sold under the registered trademark Mylar owned by the DuPont Company. The several trademark registrations for the mark Mylar list several types of products sold under that mark, and include polyester film. The type of Mylar used in the present invention is made from the clear polymer polyethylene terephalate, commonly referred to as PET, which is the most important polyester. PET is thermoplastic—that is, it softens and melts at high temperatures. Uses of PET film include magnetic tapes and shrink wrap. The adhesive 20 used to laminate the lenses together sequentially is a clear optical low tack material. The thickness of each lens will range from 0.5 mil to 7 mil (1 mil is 0.001″). The preferred thickness will be 2 mil. Even after the adhesive material is applied to a 2 mil thickness lens, the thickness of the 2 mil thickness lenses will still be 2 mil. The adhesive has nominal thickness. As illustrated in FIG. 5 , after the seven layers of film and the six layers of adhesive are laminated together, the overall thickness of the end product is 15 mils. The term “wetting” can be used to describe the relationship between the laminated film layers. When viewing through the laminated layers, it appears to be one single piece of plastic film. No reflections are evident. The end tab portions without the adhesive exhibit reflections are not a hindrance to the user, because these end portions are folded back over the posts as illustrated in FIG. 3 , and do not affect the visibility of the user.
The adhesive material 20 will be a water-based acrylic optically clear adhesive or an oil based clear adhesive, with the water based adhesive being the preferred embodiment. After the seven layers are laminated or otherwise bonded together with the adhesive layers, the thickness of each adhesive layer is negligible even though the adhesive layers are illustrated in FIGS. 4 and 5 as distinct layers. FIG. 5 . is a top view of the stackable lenses illustrating seven layers of lens held together by an adhesive applied between each lens with the thicknesses of the layers of lenses and applied adhesive highly exaggerated to clearly show the relationship between the lenses and the adhesive and also to show the end portions that do not have any adhesive between each lens layer for forming the removable tab portions 25 at both ends of the present invention.
The individual stackable lenses package, illustrated in FIG. 5 for use with racing helmets, can be fabricated from a roll of film as illustrated in FIG. 6 . The film in FIG. 6 includes seven layers of clear polyester film, and having the water-based acrylic adhesive laminating the seven film layers to one another. Keep in mind that each layer of the lenses can be easily peeled away as the top layer exposing the next clean lens. Each succeeding lens layer can be removed as the top lens becomes contaminated with dirt and grime during racing conditions.
Referring back now to FIG. 3 . As previously stated, FIG. 3 illustrates the tension post 60 extending outwardly from the face shield 55 with the left side end tab portion 25 of the present invention illustrated. The face shield 55 has a left tension post 60 and a right tension post 65 . The present invention 10 has the following dimensions: 18″ in length; 2½″ in height; and about 15 mils in thickness (1 mil is 0.001″). The present invention is symmetrical about it vertical medial axis and about its horizontal medial axis. The left end has a removable tab portion 25 , and the right end has a removable tab portion 35 . The area 15 indicates where the adhesive 20 is applied to the layers of the lens 15 . The bilateral demarcation lines 31 and 41 indicate where the adhesive stops on either side. The demarcation lines 31 and 41 also indicate where the tab portions begin. The present invention has a pair of bilateral keyhole-shaped slots 27 and 37 for demountably engaging the two helmet posts 60 and 65 respectively. The curved distance between the two helmet posts 60 and 65 is the same as the distance between the centers of the pair of slots 27 and 37 . The user secures the lenses to the face shield by positioning the slots adjacent the helmet posts and passing the posts through the slots. It is preferable that the remainder of the tab portion outboard from the slot be folded back upon itself so that the finger hole is also passed through the helmet post. This is illustrated in FIG. 3 . The proper installation of the present invention on the helmet requires the user to position the bottom lens of the stack through the post hole by passing the post through the slot, then folding back the remainder of the tab portion 25 so that post passes through the finger hole 29 . This is done for each lens working from the bottom up until the tab portion 25 of the top lens extends unfolded as illustrated in FIG. 2 . In this manner, the helmet wearer can easily put his index finger through the finger hole topmost lens layer. The clean layer below the removed layer is then exposed and the removal tab portion on the exposed layer will spring back to the unfolded position to expose the finger hole so that the helmet wearer can easily remove that layer after it becomes soiled and contaminated. The plastic material forming the lenses is resilient and will spring back to its unfolded position and extend outwardly from the face shield. The thicknesses of the layered lenses and folded tab portions illustrated in FIG. 3 are highly exaggerated to clearly show the folding relationship. In actual practice seven lenses and seven tab portions with be stacked into the space between the end of the post and the outer surface of the face shield. Remember that there is no adhesive between the tab portions. This allows the removal tab portions to fan out. They do not stick to one another.
The present invention as shown in the Drawing Figures has removal tab portions at both ends. This allows a right or left-handed person to easily remove the topmost layer. It also allows the driver to pull the tab with either hand depending on the circumstances of the race. It is to be understood that the present invention includes a laminated lenses with only a left tab portion 25 , or only a right tab portion 35 , or both a left and a right tab portion.
The windshield embodiment 100 illustrated in FIGS. 7 and 8 will now be discussed in detail. An optical stack of removable lenses for affixing to an optical window such as a racing car windshield is disclosed in FIG. 8 . The embodiment 100 has a plurality of seven generally rectangular superposed removable lenses 105 adhesively affixed to one another. The outer perimeter is continuous. Each of the removable lens 105 is held to each successive lens with a clear uninterrupted adhesive layer 110 interposed between each of the removable lens. The perimeter has at least one generally straight edge portion 115 . In the embodiment illustrated in FIG. 8 , the perimeter is rectangular and has four straight edge portions, one for each side. It is to be understood that the invention could be practiced with only one generally straight edge portion. The area adjacent to the straight edge portion 115 has a banded portion 120 that does not have any adhesive affixed to any of the layers of film to assist in allowing each said film layer 105 to be peeled off successively along the straight edge portion. A plurality of staggered tabs 125 are affixed to the film layers one-at-a-time. The tabs 125 extend from the straight edge portions 120 to assist the user in removing the uppermost soiled and grimy film layer, and to successively remove each next clean layer as the top exposed layer becomes contaminated.
The adhesive layer can be foreshortened so as to expose successively a portion of the lens layers without optical wetting to create a grasping tab.
The stack of removable lenses as illustrated in FIGS. 7 and 8 can have an optically clear adhesive as the bottom last layer to aid in mounting the stack of lenses to the windshield. The stack is affixed to the windshield in much the same way that tinted window plastic film is affixed to a window. The windshield is sprayed with water and the bottom adhesive layer with the stack is then applied to the windshield. Air bubbles and the like are eliminated with a squeegee appliance. The bottom layer becomes “wetted” to the windshield.
The stack of removable lenses 100 can be applied to any type of optical window such as windshield, window, face shield, or a video display. It is common at an ATM terminal to have a video display for the customer. The surface of the display can be kept clear by using the present invention. herein in what is conceived to be the best mode contemplated, it is recognized that departures may be made therefrom within the scope of the invention which is therefore not to be limited to the details disclosed herein, but is to be afforded the full scope of the invention. | A stack of laminated transparent lenses consists of two alternating optically clear materials in intimate contact. The materials are a plastic lens and clear adhesive. The adhesive is uninterrupted. The lens and the adhesive have refraction mismatch of less than 0.2. A tab portion is part of each lens acts as an aid in peeling away the outermost lens after contamination of the lens layer during racing conditions. The lens stack can be mounted to the posts on the face shield or laminated directly to a windshield. | 1 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/581,629 filed Oct. 16, 2006 and U.S. patent application Ser. No. 11/435,906 filed May 17, 2006.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a medical device and more particularly to an ophthalmic drug delivery device using a shape memory alloy.
[0003] Several diseases and conditions of the posterior segment of the eye threaten vision. Age related macular degeneration (ARMD), choroidal neovascularization (CNV), retinopathies (e.g., diabetic retinopathy, vitreoretinopathy), retinitis (e.g., cytomegalovirus (CMV) retinitis), uveitis, macular edema, glaucoma, and neuropathies are several examples.
[0004] These, and other diseases, can be treated by injecting a drug into the eye. Such injections are typically manually made using a conventional syringe and needle. FIG. 1 is a perspective view of a prior art syringe used to inject drugs into the eye. In FIG. 1 , the syringe includes a needle 105 , a luer hub 110 , a chamber 115 , a plunger 120 , a plunger shaft 125 , and a thumb rest 130 . As is commonly known, the drug to be injected is located in chamber 115 . Pushing on the thumb rest 130 causes the plunger 120 to expel the drug through needle 105 .
[0005] In using such a syringe, the surgeon is required to puncture the eye tissue with the needle, hold the syringe steady, and actuate the syringe plunger (with or without the help of a nurse) to inject the fluid into the eye. The volume injected is typically not controlled in an accurate manner because the vernier on the syringe is not precise relative to the small injection volume. Fluid flow rates are uncontrolled. Reading the vernier is also subject to parallax error. Tissue damage may occur due to an “unsteady” injection. Reflux of the drug may also occur when the needle is removed from the eye.
[0006] An effort has been made to control the delivery of small amounts of liquids. A commercially available fluid dispenser is the ULTRA™ positive displacement dispenser available from EFD Inc. of Providence, R.I. The ULTRA dispenser is typically used in the dispensing of small volumes of industrial adhesives. It utilizes a conventional syringe and a custom dispensing tip. The syringe plunger is actuated using an electrical stepper motor and an actuating fluid. Parker Hannifin Corporation of Cleveland, Ohio distributes a small volume liquid dispenser for drug discovery applications made by Aurora Instruments LLC of San Diego, Calif. The Parker/Aurora dispenser utilizes a piezo-electric dispensing mechanism. Ypsomed, Inc. of Switzerland produces a line of injection pens and automated injectors primarily for the self-injection of insulin or hormones by a patient. This product line includes simple disposable pens and electronically-controlled motorized injectors.
[0007] U.S. Pat. No. 6,290,690 discloses an ophthalmic system for injecting a viscous fluid (e.g. silicone oil) into the eye while simultaneously aspirating a second viscous fluid (e.g. perflourocarbon liquid) from the eye in a fluid/fluid exchange during surgery to repair a retinal detachment or tear. The system includes a conventional syringe with a plunger. One end of the syringe is fluidly coupled to a source of pneumatic pressure that provides a constant pneumatic pressure to actuate the plunger. The other end of the syringe is fluidly coupled to an infusion cannula via tubing to deliver the viscous fluid to be injected.
[0008] It would be desirable to have a portable hand piece for injecting a drug into the eye that includes reliable technology using few parts. Shape memory alloy provides a technology that can be adapted for such use. The hand piece may be a single piece unit or a two-piece device. Placing the more expensive components, including electronics and a drive mechanism, in a reusable assembly, while keeping the sterile components in a disposable assembly, improves the efficiency and cost-effectiveness of a drug delivery system. However, a single piece device with a relatively simple structure is also feasible. Such a system provides numerous benefits over prior art injectors.
SUMMARY OF THE INVENTION
[0009] In one embodiment consistent with the principles of the present invention, the present invention is an ophthalmic injection system having a tip segment and a limited reuse assembly. The tip segment includes a dispensing chamber housing, a needle fluidly coupled to a dispensing chamber, and a first housing at least partially enclosing the dispensing chamber housing. The dispensing chamber housing is made of a shape memory alloy. The inner surface defines a dispensing chamber for receiving a quantity of a substance. The limited reuse assembly includes a power source for providing current to the dispensing chamber housing, a controller for controlling the power source, and a second housing at least partially enclosing the power source and the controller. The controller directs a first current to the dispensing chamber housing to heat the substance contained in the dispensing chamber and a second current to the dispensing chamber housing to alter the shape of the dispensing chamber housing to deliver the substance.
[0010] In another embodiment consistent with the principles of the present invention, the present invention is an ophthalmic injection device having a dispensing chamber housing, a needle fluidly coupled to a dispensing chamber, a power source for providing current to the dispensing chamber housing, a controller for controlling the power source, and a housing at least partially enclosing the dispensing chamber housing, the power source, and the controller. The dispensing chamber housing is made of a shape memory alloy and has an inner surface defining a dispensing chamber for receiving a quantity of a substance. The controller directs a first current to the dispensing chamber housing to heat the substance contained in the dispensing chamber and a second current to the dispensing chamber housing to alter the shape of the dispensing chamber housing to deliver the substance.
[0011] In another embodiment consistent with the principles of the present invention, the present invention is a method of delivering a substance into an eye including receiving a first input indicating that a substance is to be heated, in response to the first input, sending a first current to a dispensing chamber housing made of a shape memory alloy to heat the substance contained therein, receiving a second input indicating that the substance is to be delivered, and sending a second current to the dispensing chamber housing to deliver the substance.
[0012] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide further explanation of the invention as claimed. The following description, as well as the practice of the invention, set forth and suggest additional advantages and purposes of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention.
[0014] FIG. 1 is a perspective view of a prior art syringe.
[0015] FIG. 2 is one view of an ophthalmic medical device including a disposable tip segment and a limited reuse assembly according to an embodiment of the present invention.
[0016] FIG. 3 is another embodiment of a limited reuse assembly according to the principles of the present invention.
[0017] FIG. 4 is cross section view of a disposable tip segment and a limited reuse assembly according to an embodiment of the present invention.
[0018] FIGS. 5A and 5B are exploded cross section views of disposable tip segments for an ophthalmic medical device according to an embodiment of the present invention.
[0019] FIG. 6 is a cross section view of an ophthalmic injection device according to the principles of the present invention.
[0020] FIG. 7 is a flow chart of one method of delivering a substance into an eye using a shape memory alloy.
[0021] FIG. 8 is a flow chart of one method of delivering a substance into an eye using a shape memory alloy.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Reference is now made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like parts.
[0023] FIG. 2 is one view of an ophthalmic medical device including a disposable tip segment and a limited reuse assembly according to an embodiment of the present invention. In FIG. 2 , the medical device includes a tip segment 205 and a limited reuse assembly 250 . The tip segment 205 includes a needle 210 , a housing 215 , and an optional light 275 . The limited reuse assembly 250 includes a housing 255 , a switch 270 , a lock mechanism 265 , and a threaded portion 260 .
[0024] Tip segment 205 is capable of being connected to and removed from limited reuse assembly 250 . In this embodiment, tip segment 205 has a threaded portion on an interior surface of housing 215 that screws onto the threaded portion 260 of limited reuse assembly 250 . In addition, lock mechanism 265 secures tip segment 215 to limited reuse assembly 250 . Lock mechanism 265 may be in the form of a button, a sliding switch, or a cantilevered mechanism. Other mechanisms for connecting tip segment 205 to limited reuse assembly 250 , such as those involving structural features that mate with each other, are commonly known in the art and are within the scope of the present invention.
[0025] Needle 210 is adapted to deliver a substance, such as a drug, into an eye. Needle 210 may be of any commonly known configuration. Preferably, needle 210 is designed such that its thermal characteristics are conducive to the particular drug delivery application. For example, when a heated drug is to be delivered, needle 210 may be relatively short (several millimeters) in length to facilitate proper delivery of the drug.
[0026] Switch 270 is adapted to provide an input to the system. For example, switch 270 may be used to activate the system or to turn on a heater. Other switches, buttons, or user-directed control inputs are commonly known and may be employed with limited reuse assembly 250 and/or tip segment 205 .
[0027] Optional light 275 is illuminated when tip segment 205 is ready to be used. Optional light 275 may protrude from housing 215 , or it may be contained within housing 215 , in which case, optional light 275 may be seen through a clear portion of housing 215 . In other embodiments, optional light 275 may be replaced by an indicator, such as a liquid crystal display, segmented display, or other device that indicates a status or condition of disposable tip segment 205 . For example, optional light 275 may also pulse on and off to indicate other states, such as, but not limited to a system error, fully charged battery, insufficiently charged battery or faulty connection between the tip segment 205 and limited use assembly 250 . While shown on tip segment 205 , optional light 275 or other indicator may be located on limited reuse assembly 250 .
[0028] FIG. 3 is another embodiment of a limited reuse assembly according to the principles of the present invention. Limited reuse assembly 250 includes a button 308 , a display 320 , and a housing 330 . Disposable tip segment 205 attaches to end 340 of limited reuse assembly 250 . Button 308 is actuated to provide an input to the system. As with switch 270 , button 308 may activate a heater or other temperature control device or initiate actuation of a plunger. Display 320 is a liquid crystal display, segmented display, or other device that indicates a status or condition of disposable tip segment 205 or limited reuse assembly 250 .
[0029] FIG. 4 is cross section view of a disposable tip segment and a limited reuse assembly according to an embodiment of the present invention. FIG. 4 shows how tip segment 205 interfaces with limited reuse assembly 250 . In the embodiment of FIG. 4 , tip segment 205 includes dispensing chamber housing 425 , tip segment housing 215 , thermal sensor 460 , needle 210 , dispensing chamber 405 , interface 530 , and tip interface connector 453 . Limited reuse assembly 250 includes power source 505 , controller 305 , limited reuse assembly housing 255 , interface 535 , and limited reuse assembly interface connector 553 .
[0030] In FIG. 4 , dispensing chamber housing 425 is tubular or cylindrical in shape and is made of a shape memory alloy (“SMA”). Shape memory alloys, such as various Nitinol (a nickel-titanium alloy) alloys, hold a deformed shape at room temperature. When heated to a higher temperature, the SMA reverts to its non-deformed shape. In other words, a shape memory alloy (also known as a smart alloy or memory metal) is a metal that “remembers” its geometry. After an SMA has been deformed from its original atomic configuration, it regains its original geometry by itself during heating. These properties are due to a temperature-dependent martensitic phase transformation from a low-symmetry to a highly symmetric crystallographic structure. Those crystal structures are known as martensite and austenite. The three main types of SMA are copper-zinc-aluminum, copper-aluminum-nickel, and nickel-titanium (Ni—Ti) alloys. The temperatures at which the SMA changes its crystallographic structure are characteristic of the alloy, and can be tuned by varying the elemental ratios.
[0031] For a dispensing chamber housing 425 made out of Nitinol, the Nitinol is in a deformed shape at room temperature. In this deformed shape, the Nitinol has a martenistic crystal structure. In this deformed shape, dispensing chamber 405 has a higher volume and can hold a substance. When a current is passed through dispensing chamber housing 425 , its temperature rises. When the temperature of the Nitinol dispensing chamber housing 425 reaches 60 or 70 degrees Celsius, the Nitinol will revert to its non-deformed shape. In this process, the Nitinol changes from a martenistic crystal structure to an austenic crystal structure. In this non-deformed shape, dispensing chamber 405 has a lower volume than in the deformed shape. Therefore, a current can be passed through dispensing chamber housing 425 to initially heat a substance in it, and then to change the shape of dispensing chamber 405 to expel that substance.
[0032] Needle 210 is fluidly coupled to dispensing chamber 405 . As such, a substance contained in dispensing chamber 405 can pass through needle 210 and into an eye. Interface 530 connects dispensing chamber housing 425 with tip interface connector 453 .
[0033] Optional thermal sensor 460 provides temperature information to assist in controlling the operation of dispensing chamber housing 425 . Thermal sensor 460 may be located near dispensing chamber housing 425 and measure a temperature near dispensing chamber housing 425 or may be located in thermal contact with dispensing chamber housing 425 , in which case it measures a temperature of dispensing chamber housing 425 . Thermal sensor 460 may be any of a number of different devices that can provide temperature information. For example, thermal sensor 460 may be a thermocouple or a resistive device whose resistance varies with temperature. Thermal sensor is also electrically coupled to interface 530 or other similar interface.
[0034] In limited reuse assembly 250 , power source 505 is typically a rechargeable battery, such as a lithium ion battery, although other types of batteries may be employed. In addition, any other type of power cell is appropriate for power source 505 . Power source 505 provides current to dispensing chamber housing 425 to heat it and change its shape. Optionally, power source 505 can be removed from housing 255 through a door or other similar feature (not shown).
[0035] Controller 305 is typically an integrated circuit with power, input, and output pins capable of performing logic functions. In various embodiments, controller 305 is a targeted device controller. In such a case, controller 305 performs specific control functions targeted to a specific device or component, such as a temperature control device or a power supply. For example, a temperature control device controller has the basic functionality to control current delivered to dispensing chamber housing 425 . In other embodiments, controller 305 is a microprocessor. In such a case, controller 305 is programmable so that it can function to control more than one component of the device. In other cases, controller 305 is not a programmable microprocessor, but instead is a special purpose controller configured to control different components that perform different functions. While depicted as one component in FIG. 4 , controller 305 may be made of many different components or integrated circuits.
[0036] Controller 305 is connected via interface 535 to limited reuse assembly interface connecter 553 . Limited reuse assembly interface connecter 553 is located on a top surface of limited reuse assembly housing 255 . In this manner, limited reuse assembly interface connector 553 is adapted to be connected with tip interface connector 453 to provide an electrical connection between tip segment 205 and limited reuse assembly 250 .
[0037] An interface between power source 505 and controller 305 allows controller 305 to control operation of power source 505 . In such a case, controller 305 may control the charging and the discharging of power source 505 when power source 505 is a rechargeable battery.
[0038] In operation, when tip segment 205 is connected to limited reuse assembly 250 , controller 305 controls the operation of dispensing chamber housing 425 . Controller 305 directs current from power source 505 to dispensing chamber housing 425 . When dispensing chamber housing 425 is made of Nitinol, a first current is sent to it to increase its temperature and heat a substance contained in dispensing chamber 405 . A second, higher current is subsequently sent to dispensing chamber housing 425 to cause it to change its shape and expel the substance through needle 210 .
[0039] A substance to be delivered into an eye, typically a drug suspended in a phase transition compound, is located in dispensing chamber 405 . In this manner, the drug and phase transition compound are contacted by the inner surface of dispensing chamber housing 425 . The phase transition compound is in a solid or semi-solid state at lower temperatures and in a more liquid state at higher temperatures. Such a compound can be heated by the application of current to dispensing chamber housing 425 to a more liquid state and injected into the eye where it forms a bolus that erodes over time.
[0040] In one embodiment of the present invention, the substance located in dispensing chamber 405 is a drug that is preloaded into the dispensing chamber. In such a case, tip segment 205 is appropriate as a single use consumable product. Such a disposable product can be assembled at a factory with a dosage of a drug installed.
[0041] FIGS. 5A and 5B are exploded cross section views of disposable tip segments for an ophthalmic medical device according to an embodiment of the present invention. In FIG. 5A , dispensing chamber housing 425 is in its deformed shape (its crystalline structure is martenistic). In FIG. 5B , dispensing chamber housing is in its non-deformed shape (its crystalline structure is austenic). In FIGS. 5A and 5B , an optional luer is also picture to secure needle 210 .
[0042] In FIG. 5A , a first current is applied to dispensing chamber housing 425 . This first current is less than that required to heat dispensing chamber housing 425 to a point at which it changes shape. However, this first current heats dispensing chamber housing 425 to a temperature above room temperature but below the temperature at which it changes shape. In this manner, a substance located in dispensing chamber 425 is heated because it is in thermal contact with the interior surface of dispensing chamber housing 425 .
[0043] For example, when dispensing chamber housing is made of Nitinol, a first current may raise the temperature of dispensing chamber housing 425 to 50 degrees Celsius. At this temperature, a phase transition compound located in dispensing chamber housing can be “melted” to a more liquid state or to a viscosity suitable for injection into an eye. However, at this point, the dispensing chamber housing maintains its deformed shape (and the dispensing chamber 405 has a higher volume).
[0044] A second current can be applied to raise the temperature of dispensing chamber housing 425 (made of Nitinol) to above 60 or 70 degrees Celsius. At this temperature, dispensing chamber housing 425 changes shape as depicted in FIG. 5B . The volume of dispensing chamber 405 is reduced, thus expelling a substance 559 that was contained in dispensing chamber 405 . In other words, after the phase transition compound located in dispensing chamber 405 is heated, the second current causes the volume of dispensing chamber 405 to decrease and expel the phase transition compound through needle 210 and into an eye.
[0045] The first current applied to the dispensing chamber housing 425 can be regulated to control the temperature of the substance contained in dispensing chamber 405 . For example, the amount of current (typically DC current) can be controlled to precisely control the temperature of dispensing chamber housing 425 . The more current applied to dispensing chamber housing 425 , the greater its temperature. Thermal sensor 460 provides temperature information to controller 305 , so that it can control the amount of current sent to dispensing chamber housing 425 . Controller 305 may employ any of a number of different control algorithms, such as, for example, a PID algorithm.
[0046] Likewise, the second current applied to dispensing chamber housing 425 can be regulated to control a dosage and rate of delivery of the substance in dispensing chamber 405 . A shape metal alloy, such as Nitinol, may transform its shape gradually over a temperature range. For example, the shape of dispensing chamber 425 may change over a range of 5 or 10 degrees Celsius. The precise control of the current applied to dispensing chamber housing 425 results in the precise control of the temperature of dispensing chamber housing 425 . In this manner, the transition of dispensing chamber housing 425 from a deformed state to a non-deformed state can be controlled. The control of the change in shape results in control of the rate of delivery of the substance.
[0047] FIG. 6 is a cross section view of an ophthalmic injection device according to the principles of the present invention. In FIG. 6 , the injection device is integrated into a single unit. The single piece device of FIG. 6 operates in the same manner as the two piece device previously described. In FIG. 6 , the device includes dispensing chamber housing 425 , dispensing chamber 405 , needle 210 , thermal sensor 460 , interface 536 , controller 305 , power source 505 , and housing 216 . In FIG. 6 , a single interface 536 is used instead of two separate interfaces ( 530 and 535 ) and two separate connectors ( 453 and 553 ). Housing 216 encloses the components pictured.
[0048] FIG. 7 is a method of delivering a substance into an eye using a shape memory alloy. In 710 , a first input indicating that a substance is to be heated is received. In 720 , a first current is directed to an SMA dispensing chamber housing to heat the substance in the dispensing chamber. In 730 , a second input is received indicating that the substance is to be delivered. In 740 , after the substance is heated, a second current is directed to the SMA dispensing chamber housing to change its shape and dispense the substance.
[0049] FIG. 8 is a method of delivering a substance into an eye using a shape memory alloy. In 805 , a connection between a tip segment and a limited reuse assembly is recognized. In 810 , a first input indicating that a substance is to be heated is received. In 815 , a first current is sent to the dispensing chamber housing. In 820 , a determination is made as to whether the substance has reached the proper temperature. If the substance has not reached the proper temperature, then in 825 the first current is controlled to properly heat the substance. If the substance has reached the proper temperature, then in 830 , a second current is sent to the dispensing chamber housing to change its shape and deliver the substance. In 835 , a determination is made as to whether the proper dosage has been delivered. If the proper dosage has been delivered, then in 840 an indication that the substance has been delivered is provided. If the proper dosage has not been delivered, then in 845 a failure indication is provided.
[0050] From the above, it may be appreciated that the present invention provides an improved system and methods for delivering precise volumes of a substance into an eye. The present invention provides a dispensing chamber housing made of a shape memory alloy that can heat and expel a substance. In one embodiment, a disposable tip segment that interfaces with a limited reuse assembly is employed. In another embodiment, a single unit is employed. The present invention is illustrated herein by example, and various modifications may be made by a person of ordinary skill in the art.
[0051] While the present invention is described in the context of a single-use drug delivery device, the present invention encompasses any injection device. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. | An ophthalmic injection device has a dispensing chamber housing, a needle fluidly coupled to a dispensing chamber, a power source for providing current to the dispensing chamber housing, a controller for controlling the power source, and a housing at least partially enclosing the dispensing chamber housing, the power source, and the controller. The dispensing chamber housing is made of a shape memory alloy and has an inner surface defining a dispensing chamber for receiving a quantity of a substance. The controller directs a first current to the dispensing chamber housing to heat the substance contained in the dispensing chamber and a second current to the dispensing chamber housing to alter the shape of the dispensing chamber housing to deliver the substance. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improvements in methods and apparatus for aspirating a predetermined volume of liquid from a container (e.g., a test tube or vial) with an aspirating probe or needle. More particularly, it relates to improvements in methods and apparatus for assuring that the aspirating probe is safely positioned within the liquid sample during the entire liquid-aspirating process to avoid an unintentional introduction of air into the aspirated volume. The invention is particularly useful in the fields of hematology, fluorescence flow-cytometry and blood chemistry where it is often necessary to aspirate and dispense, with high precision, relatively minute volumes (of the order of microliters) of blood and liquid reagents used for the analysis of such blood.
2. Discussion of the Prior Art
Automated hematology instruments typically include apparatus for automatically aspirating a blood sample from a sealed test tube and for dispensing one or more precise aliquots of the aspirated sample to a workstation for processing. In such instruments, a hollow sample-aspirating needle is automatically advanced downwardly, usually along a vertical path coincident with the longitudinal axis of the blood-containing test tube. During such movement, the sharp distal end or tip of the aspirating needle punctures the septum that seals the tube, travels through a volume of air positioned between the sample and the septum, and eventually enters into the blood sample to be aspirated. Thereafter, a vacuum pump is activated for a predetermined time interval to aspirate a desired volume (e.g., 250 microliters) of sample into and through an internal lumen of the aspirating needle to which the vacuum pump is operatively connected by a suitable conduit. The aspirated sample is typically segmented (e.g., by a conventional blood-sampling valve of the type disclosed in the commonly owned U.S. Pat. No. 4,896,546 to Cabrera et al.) to provide a plurality of relatively small aliquots (each being between about 5 and 75 microliters) which are then dispensed and mixed with suitable reagents in which the sample aliquots are analyzed. Alternatively, the aspirated sample can also be segmented by means of a positive-displacement (syringe-type) pump in a system in which the aspirating probe also functions as a dispensing probe.
In blood-aspirating apparatus of the above type, it will be appreciated that the preciseness of the sample volume aspirated requires that the probe tip be completely submerged in the blood sample at all times during the aspiration process. Should the aspirating vacuum force be applied to the probe for a period of time while the probe tip is positioned outside the sample volume, e.g., within the air pocket above the sample, air will be drawn into the probe, and the precision of the aspiration will be compromised. This condition is exacerbated in a sample aspirate/dispense system of the above-mentioned type since such a “suck and spit” system does lend itself to the use of an in-line bubble detector. Various schemes have been proposed and used to date for avoiding the aspiration of air into the sample line. For example:
In the commonly owned U.S. Pat. No. 4,341,736 to Drbal et al., a fluid (i.e., liquid) transfer mechanism is disclosed for aspirating biological fluid samples from a series of open cuvettes or containers. This patent discloses two different schemes for signaling that the tip of a fluid-aspirating probe is safely submerged within a fluid sample so that aspiration can occur without drawing air into the aspirated sample. Both schemes make use of the electrical properties of the fluid sample in generating the signal. According to a first scheme, the probe is constructed from a non-conductive plastic tube. The tube supports a pair of spaced, parallel electrodes that run along the entire tube interior and terminate at the aspirating end of the tube. The opposite ends of the electrodes are connected across an electrical power supply. As the electrode ends on the probe tip move towards and eventually contact the sample fluid, an electrical circuit is completed through the sample fluid; thus, a signal is produced indicating that the probe tip has now entered the sample fluid and aspiration can safely occur. According to the second scheme, the aspirating probe is made of stainless steel, and the sample fluid is contained either in an electrically conductive container, or if the container is non-conductive, the container is supported on a conductive base. The steel probe is electrically connected to an AC power source, and the conductive container or base is electrically grounded. As the probe tip moves towards and eventually contacts the surface of the sample fluid, a change in electrical capacitance occurs between the probe tip and container (or base), as determined by the dielectric properties of the intervening sample fluid. This capacitance change is detected in a bridge circuit that signals that the probe has contacted and entered the sample fluid.
In using liquid level-sensing apparatus of the type noted above, a problem can arise when the liquid sample to be aspirated is subject to foaming when agitated. In the field of hematology, it is common to continuously rock, and thereby agitate, a blood sample in a test tube to assure, for example, the homogeneity of the sample during analysis. The continuous movement of the blood forward and backward in the vial can eventually lead to the formation of a bubbly mixture of air and blood (i.e., foam) on the surface of the sample. Unfortunately, the electrical properties of the foam differs little from the sample itself. Thus, in the above apparatus, as soon as the electrodes or conductive aspirating probe contacts the foam, a signal is generated indicating that the probe is in a position ready for sample aspiration. When this occurs, air bubbles can be drawn into the aspirated sample, thereby making the aspirated volume uncertain. Further, in liquid level sensors of the capacitance level-sensing type, it is usually necessary to maintain the test tube (when it is non-conductive) in a generally upright orientation at all times. This orientation assures that the counter electrode (the conductive base on which the test tube rests) is in close proximity to the sample liquid. Thus, this liquid level-sensing scheme is not useful in instruments in which the test-tube is inverted (with its seal facing downward) during sample aspiration.
SUMMARY OF THE INVENTION
In view of the foregoing discussion, an object of the present invention is to provide an improved liquid-aspirating method and apparatus for aspirating liquid from a container with a liquid-aspirating probe.
Another object of this invention is to provide a liquid-aspirating apparatus of the type described that is capable of distinguishing a layer of foam or bubbles atop a liquid surface from the underlying liquid itself in a container.
Another object of the invention is to provide an improved liquid-aspirating probe assembly that is adapted for use in an apparatus for sensing the submersion of the tip of an aspiration probe in a liquid sample to be aspirated.
According to a first aspect of the invention, a method for aspirating a liquid from a container comprises the steps of (a) mounting a thermistor proximate the tip of a liquid-aspirating probe, (b) applying a predetermined constant current to the thermistor to cause the temperature of the thermistor to rise to a predetermined level higher than the ambient temperature surrounding the thermistor, (c) advancing the probe tip towards and into the liquid to be aspirated while sensing the resistance of the thermistor, and (d) applying a vacuum force to the aspirating probe to cause liquid to be aspirated into the probe upon sensing that the thermistor resistance indicates that the thermistor has passed through any foam atop the liquid to be aspirated and has entered the body of liquid to be aspirated.
According to a second aspect of the invention, a new and improved liquid-aspirating apparatus comprises a liquid-aspirating probe supporting a thermistor element proximate its distal, liquid-aspirating end. A bias circuit operates to heat the thermistor to a level above ambient (room temperature), while a bridge circuit or the like operates to monitor the thermistor temperature and heat loss occasioned by the movement of the distal end of the probe into a liquid sample to be aspirated. A control circuit is responsive to the output of the second circuit to apply a vacuum force to the probe to aspirate liquid therein.
According to a third aspect of the invention, new and improved liquid-aspirating probe assemblies are provided. Such assemblies comprise an elongated cylindrical aspiration probe, e.g., a cannula, preferably having a sharpened distal end that is adapted to pierce seals on liquid sample containers, and a thermistor mounted on the probe proximate its distal end. According a first embodiment, the probe has internal walls that define at least a pair of elongated channels or lumens that extend generally parallel to the probe axis, terminating in the vicinity of the distal tip of the probe. One lumen is used to aspirate liquid through the probe, and the other lumen is used to contain the electrical lead(s) by which the thermistor, mounted within such other lumen in the vicinity of the probe tip, can be connected to a remotely located control circuit that serves to both heat the thermistor to a desired initial temperature, as well as to monitor the thermistor temperature, as reflected by its instantaneous resistance, as the probe tip moves towards a liquid volume to be aspirated. According to a second embodiment, the thermistor leads are contained within an elongated groove or channel formed in the exterior wall of the probe and extending parallel to the probe's longitudinal axis.
The invention and its advantages will be better understood from the ensuing detailed description of preferred embodiments, reference being made to the accompanying drawings in which like reference characters denote like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a liquid-aspirating apparatus embodying the invention;
FIG. 2 is a graph illustrating changes in temperature and resistance of the liquid-sensing thermistor element used in the apparatus of FIG. 1 ;
FIG. 3 is an electrical schematic drawing of a preferred control circuit for processing an electrical signal resulting from changes in the resistance of a thermistor;
FIGS. 4A , 4 B and 4 C are enlarged perspective, side and cross-sectional illustrations, respectively, of a first preferred liquid-aspirating probe assembly structured in accordance with the present invention;
FIGS. 5A , 5 B and 5 C are enlarged perspective, side and cross-sectional illustrations, respectively, of a second preferred liquid-aspirating probe assembly structured in accordance with the present invention; and
FIG. 6 is a flow chart illustrating a preferred program carried out by a microprocessor comprising the FIG. 1 apparatus.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 illustrates a liquid-aspirating apparatus 10 for aspirating a liquid L, such as whole blood, from a container C. The container may be in the form of a sealed test tube or vial V, as shown, or in the form of an open cuvette. Apparatus 10 comprises an aspirating probe 12 , e.g., a hollow needle or cannula that is supported for vertical movement by a movably-mounted carriage 14 . The latter is operatively coupled, in a conventional manner, to a threaded lead screw 16 that is selectively rotated by a bi-directional stepper motor 18 . As the threaded lead screw rotates, its rotational motion is translated to linear movement of the carriage by a threaded nut 19 carried by the carriage. Operation of the stepper motor is controlled by a suitably programmed microprocessor comprising a central processing unit CPU.
In accordance with the invention, probe 12 carries a conventional thermistor element 20 at its tip or distal end 12 A. As described below, the thermistor is used as a liquid-level sensor for the purpose of assuring that the aspirating portion of the probe is safely submerged within the liquid sample L at all times during the aspiration process. A particularly preferred thermistor for this application is that made and sold by Thermometrics, Inc. under Part No. B10KA103K. Such a thermistor is encapsulated in a tiny glass bead having a diameter of about 0.010 inch (0.25 mm); it is adapted to operate at a power level up to {fraction (1/10)} watt.
Prior to liquid aspiration, the thermistor element 20 is pre-heated by the application of a suitable electrical bias current to a temperature at which its internal resistance reflects a temperature somewhat higher, preferably about 5 to 10 degrees Fahrenheit higher, than the ambient room temperature. This electrical biasing renders the thermistor more sensitive to relatively small changes in temperature levels at or near room temperature, as is needed to reliably sense the submersion of the thermistor in a liquid at ambient (room) temperature. The thermistor bias current is provided by the output of the above-noted central processing unit. A bridge circuit 22 or the like serves to monitor changes in the thermistor temperature (i.e., its resistance), as occasioned by the liquid aspiration process. The manner in which the invention operates will be best appreciated by referring to FIG. 2 .
In describing the operation of the invention, it is assumed that the liquid container is sealed by a rubber stopper S or the like, that the container is held in a vertically upright position, and that the aspiration probe is moved downward so that the tip thereof penetrates the stopper. However, from the ensuing description, it will be appreciated that the container need not be sealed for the inventive apparatus to operate, nor need the container be held vertically upright. Further, for the sake of illustration, it is assumed that the container is not completely filled, there being an air mass AM between the liquid and the bottom of the stopper, and that there is a layer of bubbles or foam F atop the liquid surface. Again, it will be appreciated that such an air mass need not be provided. Thus, as the tip of the aspirating probe moves downwardly from a position vertically above the liquid container, it first passes through the stopper S, then the air mass AM, then the foam layer F and finally enters the body of liquid L to be aspirated. Referring to FIG. 2 , at time to, the thermistor temperature is set by the CPU at its initial bias temperature T B , several degrees above room temperature T R . At this time, the thermistor resistance, as determined by its temperature, will be at the bias level R B . Note, as shown by the oppositely directed arrows on the right and left ordinates of the graph, the thermistor resistance is inversely proportional to its temperature; thus, as the temperature of the thermistor increases, its resistance decreases. At time t 1 , the thermistor, as mounted proximate the tip of the downwardly-moving aspirating probe, enters and moves through the penetrable stopper S, and frictional forces presented by the dynamic stopper/thermistor interaction will cause the thermistor temperature to begin to rise above its initial bias temperature T B . At time t 2 , when the probe tip emerges from the stopper and enters the air mass AM above the liquid sample, the thermistor temperature will begin to return towards its initial bias temperature T B , albeit at a relatively slow rate due to the relatively low heat-transfer characteristics of air. As the probe tip enters the foam layer F at time t 3 , the thermistor temperature will suddenly drop and stabilize at a level determined by the heat-transfer characteristics of the foam. As shown, the thermistor temperature will rapidly and randomly vary while passing through the foam layer, and its instantaneous level will be determined by whether the thermistor is in an air pocket (bubble) or in the liquid forming the air pocket. When in a space primarily comprising air, the thermistor temperature will rise towards the bias level; conversely, when the thermistor is in a space primarily composed of liquid, the thermistor temperature will drop towards the temperature of the liquid (i.e., room temperature). At time t 4 , the probe tip enters the liquid sample and, owing to the much higher thermal conductivity of the liquid (cf. to foam), the thermistor temperature drops relatively precipitously to a steady-state level between T B and T R . Note, while the temperature of the liquid is room temperature, the bias current applied to the thermistor will cause it to indicate a somewhat higher temperature. Upon receiving an input from circuit 22 that the thermistor temperature has remained at this steady state level for a predetermined time interval measured from time t 4 , the CPU produces a signal causing a vacuum force to be applied to the probe, whereby liquid aspiration begins. In the event that the thermistor temperature (as reflected by the thermistor resistance) begins to increase during aspiration, thereby indicating that the thermistor is no longer submerged in the liquid sample, an abort signal is generated by the CPU and the aspirated sample is discarded. This event may occur when either the level of liquid in the container has dropped below that required for aspirating the volume of liquid desired, or there has been relative movement between the container and probe during aspiration. The flow chart of FIG. 6 illustrates the program carried out by the system's microprocessor in implementing the above-described series of steps.
In FIG. 3 , a preferred control circuit 22 is shown for monitoring the thermistor temperature and for providing a signal by which the position of the aspiration probe can be controlled. Circuit 22 includes a voltage divider network, comprising resistor R 0 and the thermistor resistance R T , that is driven by a DC voltage source V S . The output V(t) of the voltage divider network is amplified and filtered by an amplifier circuit 24 which serves to amplify the input signal to levels compatible with the input signal range of an analog-to-digital circuit 26 . The filter circuit within amplifier 24 eliminates unwanted, spurious signals outside a desired frequency spectrum. The digital output of circuit 26 is processed by the digital signal processing circuit 28 using a software algorithm resident therein. The function of the algorithm is to provide a first output flag ( 1 ) to the CPU when the waveform pattern of V(t) indicates that the thermistor is in contact with either air or foam, in which case the thermistor resistance TR is above a threshold level R TH and/or that the signal is rapidly varying and unstable. When the thermistor is submerged in liquid, the software algorithm provides a second flag ( 0 ) to the CPU, indicating that the stepper motor has moved the aspirating port of the aspiration probe sufficiently far into the liquid vial that aspiration can be safely initiated. Preferably, the criteria used to discriminate foam from liquid are based on the amplitude of the fluctuations of F(t).
Referring to FIGS. 4A-4C , a preferred liquid-aspirating probe assembly PA is shown to include a cannula 30 comprising a tubular housing 32 , and a thermistor element 20 mounted in close proximity to the cannula's distal end 30 A. Tubular housing 32 is preferably made of stainless steel, and its outside diameter is preferably between about 1.0 and 2.0 mm. Tubular housing 32 defines a central bore hole or lumen 32 A of about 0.20 mm. in diameter that extends axially along the entire length of the housing. Thus, the wall of housing 32 has a thickness between about 0.4 mm and 0.9 mm. Liquid is aspirated through the central lumen when a vacuum is applied thereto and its distal end 36 is submerged in liquid. The outer wall of housing 32 defines an elongated groove or channel 34 extending parallel to the tube axis A. The depth of channel 34 is preferably about 0.375 mm, and its transverse cross-section is shaped to receive a pair of electrical leads L 1 ,L 2 by which thermistor 20 is connectable to the remotely positioned bias and temperature-monitoring circuit 22 . The thermistor element 20 is arranged at the distal end of channel 34 ; this corresponds to an axial location slightly above the tapered portion 30 A of the cannula. Being located vertically above the aspiration port of the cannula, the aspiration port will always be submerged in the liquid when the thermistor temperature indicates that the thermistor is submerged in the liquid. The thermistor and its leads are held in channel 34 by a suitable epoxy adhesive 36 that extends along the entire length of channel 34 .
FIGS. 5A-5C illustrate another preferred embodiment of the probe assembly PA. Here, the probe assembly comprises a stainless steel cannula 40 having three internal lumens 41 , 42 , and 43 formed therein. The outboard lumens 41 and 43 serve, respectively, to aspirate liquid and to vent the container (in the event the container is sealed). The central lumen 42 is concentric with the cannula axis A over most of its length, and is used to house the thermistor leads L 1 , L 2 used to bias and detect temperature changes in the thermistor element 20 . A small angularly-directed channel 42 A allows channel 42 to communicate with the exterior of the probe, and the thermistor 20 is affixed at the external surface of the probe using a suitable epoxy material.
While the invention has been described with reference to particularly preferred embodiments, it will be apparent that changes can be made without departing from the spirit of the invention. Such changes are intended to fall within the scope of the appended claims. | A method and apparatus for aspirating a liquid (e.g., blood) from a container uses an electrically biased thermistor element, mounted proximate the tip of a liquid-aspirating probe, to determine that the probe is safely submerged within a body of liquid to be aspirated at all times during the aspiration process. Also disclosed are different aspiration probe assemblies that are useful in the method and apparatus of the invention. | 8 |
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This disclosure relates in general to a landing system for aircraft, and more particularly to a retractable air cushion landing system for aircraft.
2. Description of the Prior Art
It is already known in the prior art to provide a cushioned landing system for certain aircraft using inflatable air bags. Present air cushion landing system concepts consist of providing an air bag shaped like an elongated donut. This air bag is commonly called the trunk. The trunk of the air cushioned landing system is usually inflated and provides a skirt to contain air pressure between the ground and the aircraft fuselage. The trunk also functions to attenuate landing impact of the aircraft at the time of touchdown.
The main difficulty with the above described system which includes an impact absorbing trunk concerns retraction of the trunk after takeoff of the aircraft.
For remotely piloted vehicles, the problem has been avoided by utilizing two trunks -- one for takeoff, and an alternate or spare trunk for recovery of the aircraft. In this dual trunk system, a remotely piloted vehicle will lift off with the recovery trunk folded and stored in a bag beneath the takeoff trunk. After lift off, the takeoff trunk is dropped from the aircraft. When the remotely piloted vehicle lands, the recovery trunk is inflated from engine bleed air lines, and "pops out" of the bag which had previously contained it during takeoff and cruise. After landing is accomplished, the recovery trunk is replaced by hand folding. The present invention concerns a novel system which facilitates retraction of the air cushion bags and has other advantages that will be apparent forthwith.
Other attempts to solve the problem of retraction of the air cushion landing system includes using an elastic trunk. The purpose in using an elastic trunk is to facilitate storing of the trunk when it is not in use. When the trunk is not in use it remains unpressurized and deflated, and is contracted against the fuselage of the aircraft. Many difficulties arise, however, from the use of elastic trunks. The elastic trunks are relatively expensive and also cause various dynamic problems during operation of the aircraft.
Other retraction systems in the prior art for retracting the trunk portion of an air cushion landing system require a large volume for trunk storage and involve a complex web of cables and pulleys for retraction.
A novelty search of the prior art relating to air cushion landing systems discovered the following U.S. Patents:
______________________________________U.S. Patent No. Classification Inventor______________________________________2,944,771 244/100 O. J. Bush3,258,080 180/127 G.H. Williams, et.al.3,297,280 180/116 Shao-Tang LEE3,384,197 180/117 A.E. Bingham, et.al.3,802,602 244/100 F.W. Wilson3,826,449 244/100 Nelson, et.al.3,865,332 244/100 A.V. Coles3,869,103 180/124 Nelson, et.al.Also, one British patent was discovered:BR 1,089,464 180/127 Rowland Hunt______________________________________
A close approach to the proposed construction of the present invention was not observed in the above cited patents. Perhaps of most merit are U.S. Pat. Nos. 3,869,103, 3,258,080 and British Pat. No. 1,089,464. U.S. Pat. No. 3,869,103 describes a system for retracting the "elongated donut" trunk. This system, however, requires a relatively complex array of cables and pulleys which are not needed in the present invention. U.S. Pat. No. 3,258,080 and British Pat. No. 1,089,464 show rigid pivoted structures and air bag means employed in various arrangements. In these patents, however, the simplicity and effectiveness inherent in the present invention is lacking.
SUMMARY OF THE INVENTION
The present invention provides an air cushion landing system which includes a pair of rigid arms having a first and second portion. The first portions of the rigid arms are mounted to the fuselage of the aircraft toward its underside. The second portions of the rigid arms are mounted to the ends of the first portions of the rigid arms. A first pair of inflatable bags is sealably mounted to the underside of each rigid arm. A second inflatable bag is located under the center of the body of the aircraft. Flaps are provided between the first and second inflatable bags at each end of the assembly. The inflatable bags can be inflated from engine bleed air and serve to cushion the aircraft at landing. An actuating system is provided which retracts or extends the first and second portions of the rigid arms. Preferably, the actuating system consists of a rotary gear or hydraulic actuator connected to appropriate linkage to the rigid arms so that the first and second portions of the rigid arms may be folded in upon each other after the inflatable bags are deflated. The rigid arms and inflatable bags can then be stored compactly along the side of the aircraft in provided containment spaces. The first and second portions of the rigid arms are locked in place by locking hinges. Along with the inflatable bags mounted to the underside of the rigid arms, a second pair of inflatable bags to further cushion the landing of the aircraft may be sealably mounted to the top side of the rigid arms and the aircraft fuselage. This second pair of inflatable bags would deflate and compactly fold into the containment space for the system during cruise operation of the aircraft.
The inflatable air bags may be made to extend along the side of the aircraft for some length. Storage of the bags and arms would be accomplished using the retracting and extension system described herein.
Accordingly, it is the object of the present invention to provide an air cushion landing system for an aircraft which effectively cushions landing of the aircraft using inflatable bags which can be compactly stored in the fuselage of the aircraft.
A further object of the present invention is to provide an air cushion landing system for an aircraft which has a relatively simple yet effective retraction and extension system.
Another object of the present invention is to provide an air cushion landing system for an aircraft which can assist the recovery of remotely piloted aircraft on soft terrain or unimproved runways.
Still another object of the present invention is to provide an air cushion landing system for an aircraft which requires a relatively small volume for inflatable bag storage.
Another object of the present invention is to provide an air cushion landing system for an aircraft which has means to contain air pressure between the aircraft and the ground, resulting, therefore, in a cushioning effect upon taxi and takeoff.
These and other objects and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a remotely piloted vehicle showing the air cushion landing assembly of the present invention retracted.
FIG. 2 is a front view of a remotely piloted vehicle showing the air cushion landing assembly of the present invention extended.
FIG. 3 is a side view of a remotely piloted vehicle showing the air cushion assembly of the present invention extended for landing.
FIG. 4 is a front view of a remotely piloted vehicle showing the air cushion landing assembly of the present invention including a pair of secondary air bags.
FIG. 5A is a front view of a remotely piloted vehicle showing the air cushion landing assembly of the present invention in the first stage of retraction.
FIG. 5B is a front view of a remotely piloted vehicle showing the air cushion assembly of the present invention in the second stage of retraction.
FIG. 5C is a front view of a remotely piloted vehicle showing the air cushion assembly of the present invention in the third stage of retraction.
FIG. 6A is a front view of a remotely piloted vehicle showing the air cushion assembly of the present invention, including secondary air bags, in the first stage of retraction.
FIG. 6B is a front view of a remotely piloted vehicle showing the air cushion assembly of the present invention, including secondary air bags, in the second stage of retraction.
FIG. 6C is a front view of a remotely piloted vehicle showing the air cushion assembly of the present invention, including secondary air bags, in the second stage of retraction.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, a remotely piloted vehicle generally designated as 2 is shown. The vehicle 2 has wings 4 mounted to a fuselage 6. At the aft end of the vehicle 2, stabilizing fins 8 are located. A pair of vertical stabilizers 10 are attached to fins 8. Mounted on the top of the fuselage 6 is engine 12 which is used to propel the vehicle 2.
Located in fuselage 6 is a compartment 14 which houses the air cushion assembly, generally designated as 16, which cushions landing of the vehicle 2. The air cushion assembly 16 is shown in its extended position in FIG. 2 used for landing of the vehicle 2.
Referring to FIG. 2, a more detailed view of air cushion assembly 16 is shown. Assembly 16 consists in part of a pair of rigid arms generally designated as 18. Arms 18 are symmetrical and the following description will be for only one arm. The other arm is alike in all its mechanical and operational aspects. Arm 18 is divided into two portions: a fore portion 20, an aft portion 22. Aft portion 22 of rigid arm 18 is mounted to the fuselage 6 of the vehicle 2 by suitable mounting means (not shown). The aft portion 22 of the rigid arm 18 is then connected by suitable connecting means to the fore portion 20. The connecting means 24 are constructed so that the two portions of rigid arm 18 may be folded one upon the other.
Mounted in a sealed fashion to the underside of rigid arm 18 is inflatable bag 26. Inflatable bag 26 is inflated for landing purposes via duct 28 from a source (not shown) located within remotely piloted vehicle 2. The underside of inflatable bag 26 has suitable tread 30 such as standard rubber tire tread to reduce wear on the bag 26 during landing. Inflatable bags 26 may be inflated with any suitable gas, such as air, nitrogen or an inert gas.
A flap means 32 is mounted on the underside of the aft portion 22 of rigid arm 18. Flap means 32 may be inflatable, and made of material similar to bag 26. The flap means 32 is located on each end of the air cushion assembly 16 as seen best in FIG. 3. In this case the rearward flap means would be mounted to the underside of a rigid arm (not shown) located at the rear of assembly 16. The rearward rigid arm would in all respects be similar to the arm 18 shown in FIG. 2. Actuator 33 mounted to the aft portion 22 of rigid arm 18 is provided to rotate flap means 32 during the extension and retraction of assembly 16.
A center body inflatable bag 34 is mounted in a sealable fashion to the underside of the aft portion 22 of rigid arm 18, adjacent to the flap means 32. The center body inflatable bag 34 may be inflated from a source (not shown) located in the fuselage 6 of the aircraft. Bag 34 provides primary attenuation of the aircraft upon landing. A plurality of holes 36 are located along the center line of bag 34. The holes 36 allow gas to escape from bag 36, and form a fluid cushion bounded by the outside bags 26 and the flap means 32 during landing. The cushion provided thus smooths the landing of the aircraft to a greater degree relative to a simple inflatable bag system without the cushion feature.
Actuator 38 is provided to extend and retract the assembly 16. Actuator 38 is attached to rigid arm 18, preferably to the aft portion 22, as shown in FIG. 2 and serves to initiate and complete extension and retraction of the cushion assembly 16. Actuator 38 may be a standard hydraulic actuator or a rotary gear driven actuator. Actuator 38 is connected to a power source (not shown) which causes actuation of its moving parts.
To facilitate extension and retraction of the fore portion 20 of rigid arm 18, a second actuator 40 may be provided. The actuator is preferably a rotary gear actuator located at the point where the fore and aft portion of rigid arm 18 meet. The rotary gear actuator would be capable of rotating the fore portion 20 relative to the aft portion 22 of arm 18.
Referring to FIGS. 5A, 5B, and 5C, the retraction of the cushion assembly 16 is shown in three stages. In FIG. 5A, inflatable bags 26 have been deflated, along with flap means 32. The fore portion 20 of rigid arm 18 is rotated upwardly by rotary actuator 40. Flap means 32 are also rotated upwardly over the aft portion 22 of rigid arm 18 by actuator 33. FIG. 5B shows the second stage of retraction in which the fore portion 20 or rigid arm 18 is completely folded over the aft portion 22. At this point the center body inflatable bag 34 is deflated slightly. The final step in retracting the assembly consists of activating actuator 38 which folds the rigid arm up into compartment 14. The center body inflatable bag 34 is stretched across the underside of the fuselage 6.
The cushion assembly 16 is extended in the reverse sequence relative to its retraction. Actuator 38 is actuated to produce a rotation of the rigid arm 18. Actuator 40 then is activated producing a rotation of the fore portion 20 of rigid arm 18 relative to the aft portion 20 until the fore and aft portion of rigid arm 18 are aligned. Flap means 32 is then rotated downward into position by actuator 33. At this point inflatable bags 26 and 34 are inflated, and if flap means 32 is inflatable, it is also inflated.
Assuming the aircraft is in normal cruise operation and desires to land, the cushion assembly 16 is extended as described above. The initial impact is attenuated primarily by the center body inflatable bag 34. The inflatable bags 26 serve to attentuate the initial impact in a lesser degree. After initial impact, gas is allowed to escape from the center body bag 34 via holes 36. The flap means 32 and inflatable bags 26 form a boundary for the gas escaping from bag 34 and due to the pressure on the ground from the escaping gas form a gas cushion which smooths the landing of the vehicle. Tread 30 provided on bags 26 reduces the wear on these bags. Eventually the vehicle decelerates to a very low ground speed due to the friction acting on the vehicle. At this point holes 36 may be closed and the vehicle completely stopped by both the center body and bag 34 and bag 30 contacting the ground.
The above description describes only one embodiment of the invention, and many other embodiments of the invention may be contemplated without departing from the scope of the inventive concept.
One alternative to the embodiment described above is shown in FIG. 4. In this embodiment the assembly 16 has an additional set of secondary inflatable bags 42. Bags 42 provide additional attenuation upon impact and serve to further stabilize the entire assembly during the cushioned landing.
FIGS. 6A, 6B, and 6C show the retraction of the assembly 16 with the addition of secondary bags 42. As shown in FIG. 6A inflatable bags 26 have been deflated along with flap means 32. Secondary inflatable bags 42 are also beginning to be deflated. The fore portion 20 of rigid arm 18 is rotated upwardly by rotary actuator 40. Flap means 32 is also rotated upwardly over the aft portion 22 of rigid arm 18 by actuator 33.
FIG. 6B shows the second stage of retraction in which the fore portion 20 of rigid arm 18 is completely folded over the aft portion 22. At this point the center body bag is deflated slightly. The final step in retracting the assembly is activating actuator 38 which folds the rigid arm up into compartment 14. The center body bag 34 is stretched across the underside of the fuselage 6. Secondary bag 42 is folded up with the rigid arm portions.
The cushion assembly 16 with secondary bags 42 is extended in the reverse sequence relative to its retraction. Actuator 38 is actuated to produce a rotation of the rigid arm 18. Actuator 40 then is activated, producing a rotation of the fore portion 20 of rigid arm 18 relative to the aft portion 20 until the fore and aft portions of rigid arm 18 are aligned. Flap means 32 is then rotated downwardly into position by actuator 33. At this point inflatable bags 26, 34, and 42 are inflated. Flap means 32 also is inflated if it is of an inflatable construction.
Although a couple of arrangements of the invention have been illustrated above by way of example, it is not intended that the invention be limited thereto. Accordingly, the invention should be considered to include any and all modifications, alterations or equivalent arrangements falling within the scope of the annexed claims. | An air cushion landing system for an aircraft. The landing system has an air cushion assembly which is stored in the fuselage of the aircraft during cruise and which extends for landing. The assembly consists of a rigid arm with two folding portions, inflatable bags attached to the underside of the arm, and flaps to define an area of cushion air. The inflatable bags provide primary attenuation of landing impact. Actuators are provided to retract the assembly following takeoff and extend it for landing. | 1 |
This application is a National Stage Application of International Application No. PCT/IN2014/000504, filed 31 Jul. 2014, which claims benefit of Serial No. 2526/MUM/2013, filed 31 Jul. 2013 in India and which applications are incorporated herein by reference. To the extent appropriate, a claim of priority is made to each of the above disclosed applications.
FIELD OF THE INVENTION
The present invention relates to production of recombinant proteins in a host cell, and more particularly to an expression vector for production of recombinant proteins or their analogues in prokaryotic cells.
DESCRIPTION OF THE RELATED ART
Recombinant DNA (rDNA) technology has been used to clone, express and purify several proteins of therapeutic or other economic value from prokaryotic cells e.g., bacterial cells. The major advantages of producing recombinant proteins in bacterial cells are shorter time to express proteins coupled with lower costs for production of them. The proteins may be produced in bacterial cells either intracellularly as soluble proteins or inclusion bodies, or extracellularly by secretion into periplasm or nutrient media. Despite the wide applications in production of different types of recombinant proteins, the bacterial production of heterologous proteins continues to face major challenges pertaining to low yields or expression of the recombinant protein like Insulin, Granulocyte Colony Stimulating Factor (GCSF) etc.
There have been attempt in designing expression constructs or plasmid vectors that increase the expression of recombinant gene introduced in them. From the various strategies of increasing expression of recombinant gene in a host cell by way of increasing production of inclusion bodies include incorporating active promoters, optimising codons, including leader sequences or a combination of these and other strategies known in the art.
The inclusion of leader peptides in an expression construct finds favour since it directly leads to increase in production of inclusion bodies and may be attached to a purification or expression sequence tag for simplifying purification of recombinant protein during downstream processing. Further, the leader peptide may be cleaved using enzymatic methods.
Currently available leader peptides come with host of difficulties. One of them being overall incompatibility with large number of recombinant proteins and being very specific to a particular protein. There are fewer universal leader peptides and expression constructs based on them.
Accordingly, there is a need to develop expression constructs that are substantially universal in application with respect to expression of recombinant proteins in prokaryotic host cells and provide uniformly high expression for range of recombinant proteins of therapeutic and non-therapeutic value.
SUMMARY OF THE INVENTION
In view of the foregoing, the embodiments herein, provide an expression vector having a leader peptide sequence that results in higher production of inclusion bodies.
In an aspect, an expression vector for production of a recombinant protein in a host cell is provided. The expression vector includes a nucleotide sequence of Sequence ID No 2 encoding for a leader peptide of sequence ID No 3.
The expression vector expresses said recombinant protein as a fusion protein comprising fusion of said leader peptide of SEQ ID NO 3 and said recombinant protein and the host cell is bacteria, preferably E. coli . The leader peptide has Methionine at N-terminus, followed by Glycine to impart stability to fusion of said recombinant protein and said leader peptide.
The expression vector further includes DNA sequence encoding for a cleavage site or Restriction Enzyme (RE) site ligated to DNA sequence of said leader peptide. The expression vector further includes a DNA sequence encoding a multiple cloning site (MCS) in upstream region of said leader peptide, a DNA sequence of said heterologous protein is cloned in said MCS; a DNA sequence encoding ribosome binding site (RBS) ligated to N-terminus of said leader peptide, a DNA sequence encoding a promoter or operator in the downstream of said ribosome binding site and DNA sequence encoding an antibiotic selection marker in upstream region of said promoter/operator sequence.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the embodiments herein, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples:
FIG. 1 illustrates an expression construct according to an embodiment herein;
FIGS. 2 a and 2 b illustrates comparison of SDS PAGE analysis and densitometry data of GCSF as expressed in the expression vector of FIG. 1 and as expressed in a control vector; and
FIGS. 3 a and 3 b illustrates comparison of GCSF expression, as measured by MALDI-TOF, in a control vector and in vector of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention.
The terms “a” or “an”, as used herein, are defined as one or more than one. The term “plurality”, as used herein, is defined as two or 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).
Vector Deposition
The vector pBGBactX is deposited for the patent purposes under Budapest Treaty at the MTCC (Microbial Type of Culture Collection) Chandigarh, India. The deposit was made on Mar. 21, 2013 and accorded deposit number as MTCC 5818. The sequence was characterised using DNA Sequencer.
As mentioned, there is a need for universal plasmid vectors which lead to high yield of heterologous proteins through simple purification processes. The embodiments herein provide a plasmid vector having nucleotide sequence listed under SEQ ID NO. 1.
The expression construct of FIG. 1 includes a DNA sequence, of SEQ ID NO 2 encoding for the leader peptide of SEQ ID NO. 3. The leader peptide of SEQ ID NO. 2 includes DNA sequence encoding for Methionine in its N-terminal end. The DNA sequence for Methionine is followed up by addition of DNA sequence encoding for Glycine. The addition of Glycine provides stability to the protein-leader peptide fusion.
The leader peptide of SEQ ID NO 2 is a neutral peptide with nearly as many hydrophobic amino acids as hydrophilic amino acids. In one embodiment, the leader peptide has 49% amino acids as hydrophobic. The neutrality of the leader peptide enables formation of stable inclusion bodies when the expression construct of FIG. 1 is expressed in the bacterial cells.
The DNA sequence for the protein of interest is inserted in the Multiple Cloning Site (MCS) of the expression vector as shown in FIG. 1 . Multiple cloning site or polylinker constitutes a short segment of DNA which contains a number of (generally up to 20) Restriction Enzyme (RE) sites—a standard feature of engineered plasmids.
In a preferred embodiment, the leader peptide and the MCS are custom synthesised as single stranded oligonucleotides, which are used for synthesis of double stranded DNA fragment by PCR. In one embodiment, the overlapping PCR method is used to synthesise double stranded DNA. Optionally, the leader peptide and the MCS may be directly synthesised as double stranded DNA fragments.
Further, the RE sites were incorporated at 5′ end and the 3′ end of the synthesised DNA fragment. Furthermore, a Promoter/Operator region, a Ribosome Binding Site (RBS), an origin of replication and a antibiotic resistant gene were ligated with the PCR amplified DNA sequence coding for leader peptide, followed by MCS containing unique restriction enzyme sites. In one embodiment, the leader peptide is cloned downstream of the RBS, between Nco1 and EcoR1 restriction sites in the MCS.
The protein of interest may include filgrastim, interferon, human growth hormone, trypsin, carboxypeptidase, transferrin and various such recombinant proteins and peptides of therapeutic and non-therapeutic significance. A cleavage site may be included between the leader peptide and the protein of interest to cleave off the leader peptide and purify recombinant protein from the inclusion bodies. The expression vector of the embodiments herein has a sequence of SEQ ID No 1. The gene of interest may be inserted in any of the cleavage sites in the MCS.
The embodiments above are further explained through way of examples as follows:
EXAMPLES
Example 1: Construction of Vector
The nucleotide sequence coding the leader peptide and the multiple cloning sites (MCS) were custom synthesized as single stranded oligonucleotides. The single stranded oligonucleotides were utilized for the synthesis of double stranded DNA fragment by overlapping PCR method. The restriction enzyme (RE) sites were incorporated at 5′ end and 3′ end of the synthesized DNA fragment. The Promoter/Operator region, Ribosome binding site (RBS), origin of replication and antibiotic resistant gene were cleaved and ligated with the PCR amplified leader peptide sequence in MCS region containing unique restriction enzyme sites. The DNA fragment was cloned downstream of RBS between the Nco I and Xho I restriction site. Thereafter, the positive clones were screened by PCR method and the nucleotide sequence of the cloned Leader sequence and MCS were confirmed by DNA sequencing for the correctness of nucleotides. The construction of vector employs standard techniques, reagents and/or kits.
Example 2: SDS PAGE Analysis of GCSF Expressed from the Vector Described Herein
The sequence encoding for GCSF was incorporated in the MCS of the expression vector described herein along with in a control vector devoid of any leader sequence. In the vector described herein, an enzymatic site for Enterokinase is inserted between the leader sequence and the GCSF sequence. The expression vector was cloned in bacterial cells and the GCSF inclusion bodies were obtained. The leader peptide was cleaved off by enzymatic and/or chemical means and the expression of GCSF from both the vectors was analysed on SDS PAGE as shown in FIG. 2 a . Lane 1 shows Medium molecule weight marker, Lane 2 shows expression sample GCSF from control vector, Lane 3 shows GCSF expression sample from pBG-BactX vector. As may be observed, there is negligible expression of GCSF from the control vector. FIG. 2 b illustrates gel densitometry data comparison for expression of GCSF in control vector and in the vector as described herein. Lane 1 shows Medium molecule weight marker, Lane 2 shows densitometry data for GCSF expression in the control vector and Lane 3 shows densitometry data for GCSF expression in the vector as described herein.
Example 3: Comparison of Expression Levels of GCSF by MALDI TOF Analysis
FIGS. 3 a and 3 b illustrates comparison of GCSF expression in a control vector with GCSF expression in vector of FIG. 1 , according to an embodiment herein. The expression level in control vector is negligible whereas the expression level in the vector described herein has expression level of 30%. | An expression vector for production of a recombinant protein in a host cell is provided. The expression vector includes a nucleotide sequence of Sequence ID No 2 encoding for a leader peptide of sequence ID No 3. | 2 |
[0001] This is divisional of U.S. patent application Ser. No. 10/307,187, filed on Nov. 29, 2002, which is a divisional of U.S. patent application Ser. No. 09/461,653, filed on Dec. 14, 1999 (now issued as U.S. Pat. No. 6,489,403).
BACKGROUND OF THE INVENTION
[0002] It is highly desirable for tires to exhibit good traction characteristics on both dry and wet surfaces. However, it has traditionally been very difficult to improve the traction characteristics of a tire without compromising its rolling resistance and tread wear. Low rolling resistance is important because good fuel economy is virtually always an important consideration. Good tread wear is also an important consideration because it is generally the most important factor that determines the life of the tire.
[0003] The traction, tread wear, and rolling resistance of a tire is dependent to a large extent on the dynamic viscoelastic properties of the elastomers utilized in making the tire tread. In order to reduce the rolling resistance of a tire, rubbers having a high rebound have traditionally been utilized in making the tire's tread. On the other hand, in order to increase the wet skid resistance of a tire, rubbers which undergo a large energy loss have generally been utilized in the tire's tread. In order to balance these two viscoelastically inconsistent properties, mixtures of various types of synthetic and natural rubber are normally utilized in tire treads. For instance various mixtures of styrene-butadiene rubber and polybutadiene rubber are commonly used as a rubber material for automobile tire treads. However, such blends are not totally satisfactory for all purposes.
[0004] The inclusion of styrene-butadiene rubber (SBR) in tire tread formulations can significantly improve the traction characteristics of tires made therewith. However, styrene is a relatively expensive monomer and the inclusion of SBR is tire tread formulations leads to increased costs.
[0005] Carbon black is generally included in rubber compositions which are employed in making tires and most other rubber articles. It is desirable to attain the best possible dispersion of the carbon black throughout the rubber to attain optimized properties. It is also highly desirable to improve the interaction between the carbon black and the rubber. By improving the affinity of the rubber compound to the carbon black, physical properties can be improved. Silica can also be included in tire tread formulations to improve rolling resistance.
[0006] U.S. Pat. No. 4,843,120 discloses that tires having improved performance characteristics can be prepared by utilizing rubbery polymers having multiple glass transition temperatures as the tread rubber. These rubbery polymers having multiple glass transition temperatures exhibit a first glass transition temperature which is within the range of about −110° C. to −20° C. and exhibit a second glass transition temperature which is within the range of about −50° C. to 0° C. According to U.S. Pat. No. 4,843,120, these polymers are made by polymerizing at least one conjugated diolefin monomer in a first reaction zone at a temperature and under conditions sufficient to produce a first polymeric segment having a glass transition temperature which is between −110° C. and −20° C. and subsequently continuing said polymerization in a second reaction zone at a temperature and under conditions sufficient to produce a second polymeric segment having a glass transition temperature which is between −20° C. and 20° C. Such polymerizations are normally catalyzed with an organolithium catalyst and are normally carried out in an inert organic solvent.
[0007] U.S. Pat. No. 5,137,998 discloses a process for preparing a rubbery terpolymer of styrene, isoprene, and butadiene having multiple glass transition temperatures and having an excellent combination of properties for use in making tire treads which comprises: terpolymerizing styrene, isoprene and 1,3-butadiene in an organic solvent at a temperature of no more than about 40° C. in the presence of (a) at least one member selected from the group consisting of tripiperidino phosphine oxide and alkali metal alkoxides and (b) an organolithium compound.
[0008] U.S. Pat. No. 5,047,483 discloses a pneumatic tire having an outer circumferential tread where said tread is a sulfur cured rubber composition comprised of, based on 100 parts by weight rubber (phr), (A) about 10 to about 90 parts by weight of a styrene, isoprene, butadiene terpolymer rubber (SIBR), and (B) about 70 to about 30 weight percent of at least one of cis 1,4-polyisoprene rubber and cis 1,4-polybutadiene rubber wherein said SIBR rubber is comprised of (1) about 10 to about 35 weight percent bound styrene, (2) about 30 to about 50 weight percent bound isoprene and (3) about 30 to about 40 weight percent bound butadiene and is characterized by having a single glass transition temperature (Tg) which is in the range of about −10° C. to about −40° C. and, further the said bound butadiene structure contains about 30 to about 40 percent 1,2-vinyl units, the said bound isoprene structure contains about 10 to about 30 percent 3,4-units, and the sum of the percent 1,2-vinyl units of the bound butadiene and the percent 3,4-units of the bound isoprene is in the range of about 40 to about 70 percent.
[0009] U.S. Pat. No. 5,272,220 discloses a styrene-isoprene-butadiene rubber which is particularly valuable for use in making truck tire treads which exhibit improved rolling resistance and tread wear characteristics , said rubber being comprised of repeat units which are derived from about 5 weight percent to about 20 weight percent styrene, from about 7 weight percent to about 35 weight percent isoprene, and from about 55 weight percent to about 88 weight percent 1,3-butadiene, wherein the repeat units derived from styrene, isoprene and 1,3-butadiene are in essentially random order, wherein from about 25% to about 40% of the repeat units derived from the 1,3-butadiene are of the cis-microstructure, wherein from about 40% to about 60% of the repeat units derived from the 1,3-butadiene are of the trans-microstructure, wherein from about 5% to about 25% of the repeat units derived from the 1,3-butadiene are of the vinyl-microstructure, wherein from about 75% to about 90% of the repeat units derived from the isoprene are of the 1,4-microstructure, wherein from about 10% to about 25% of the repeat units derived from the isoprene are of the 3,4-microstructure, wherein the rubber has a glass transition temperature which is within the range of about −90° C. to about −70° C., wherein the rubber has a number average molecular weight which is within the range of about 150,000 to about 400,000, wherein the rubber has a weight average molecular weight of about 300,000 to about 800,000, and wherein the rubber has an inhomogeneity which is within the range of about 0.5 to about 1.5.
[0010] U.S. Pat. No. 5,239,009 reveals a process for preparing a rubbery polymer which comprises: (a) polymerizing a conjugated diene monomer with a lithium initiator in the substantial absence of polar modifiers at a temperature which is within the range of about 5° C. to about 100° C. to produce a living polydiene segment having a number average molecular weight which is within the range of about 25,000 to about 350,000; and (b) utilizing the living polydiene segment to initiate the terpolymerization of 1,3-butadiene, isoprene, and styrene, wherein the terpolymerization is conducted in the presence of at least one polar modifier at a temperature which is within the range of about 5° C. to about 70° C. to produce a final segment which is comprised of repeat units which are derived from 1,3-butadiene, isoprene, and styrene, wherein the final segment has a number average molecular weight which is within the range of about 25,000 to about 350,000. The rubbery polymer made by this process is reported to be useful for improving the wet skid resistance and traction characteristics of tires without sacrificing tread wear or rolling resistance.
[0011] U.S. Pat. No. 5,061,765 discloses isoprene-butadiene copolymers having high vinyl contents which can reportedly be employed in building fires which have improved traction, rolling resistance, and abrasion resistance. These high vinyl isoprene-butadiene rubbers are synthesized by copolymerizing 1,3-butadiene monomer and isoprene monomer in an organic solvent at a temperature which is within the range of about −10□C to about 100□C in the presence of a catalyst system which is comprised of (a) an organoiron compound, (b) an organoaluminum compound, (c) a chelating aromatic amine, and (d) a protonic compound; wherein the molar ratio of the chelating amine to the organoiron compound is within the range of about 0.1:1 to about 1:1, wherein the molar ratio of the organoaluminum compound to the organoiron compound is within the range of about 5:1 to about 200:1, and herein the molar ratio of the protonic compound to the organoaluminum compound is within the range of about 0.001:1 to about 0.2:1.
[0012] U.S. Pat. No. 5,405,927 discloses an isoprene-butadiene rubber which is particularly valuable for use in making truck tire treads, said rubber being comprised of repeat units which are derived from about 20 weight percent to about 50 weight percent isoprene and from about 50 weight percent to about 80 weight percent 1,3-butadiene, wherein the repeat units derived from isoprene and 1,3-butadiene are in essentially random order, wherein from about 3% to about 10% of the repeat units in said rubber are 1,2-polybutadiene units, wherein from about 50% to about 70% of the repeat units in said rubber are 1,4-polybutadiene units, wherein from about 1% to about 4% of the repeat units in said rubber are 3,4-polyisoprene units, wherein from about 25% to about 40% of the repeat units in the polymer are 1,4-polyisoprene units, wherein the rubber has a glass transition temperature which is within the range of about −90° C. to about −75° C., and wherein the rubber has a Mooney viscosity which is within the range of about 55 to about 140.
[0013] U.S. Pat. No. 5,654,384 discloses a process for preparing high vinyl polybutadiene rubber which comprises polymerizing 1,3-butadiene monomer with a lithium initiator at a temperature which is within the range of about 5° C. to about 100° C. in the presence of a sodium alkoxide and a polar modifier, wherein the molar ratio of the sodium alkoxide to the polar modifier is within the range of about 0.1:1 to about 10:1; and wherein the molar ratio of the sodium alkoxide to the lithium initiator is within the range of about 0.05:1 to about 10:1. By utilizing a combination of sodium alkoxide and a conventional polar modifier, such as an amine or an ether, the rate of polymeriztion initiated with organolithium compounds can be greatly increased with the glass transition temperature of the polymer produced also being substantially increased. The rubbers synthesized using such catalyst systems also exhibit excellent traction properties when compounded into tire tread formulations. This is attributable to the unique macrostructure (random branching) of the rubbers made with such catalyst systems.
[0014] U.S. Pat. Nos. 5,620,939, U.S. Pat. No. 5,627,237, and U.S. Pat. No. 5,677,402 also disclose the use of sodium salts of saturated aliphatic alcohols as modifiers for lithium initiated solution polymerizations. Sodium t-amylate is a preferred sodium alkoxide by virtue of its exceptional solubility in non-polar aliphatic hydrocarbon solvents, such as hexane, which are employed as the medium for such solution polymerizations. However, using sodium t-amylate as the polymerization modifier in commercial operations where recycle is required can lead to certain problems. These problems arise due to the fact that sodium t-amylate reacts with water to form t-amyl alcohol during steam stripping in the polymer finishing step. Since t-amyl alcohol forms an azeotrope with hexane, it co-distills with hexane and thus contaminates the feed stream.
[0015] Tire rubbers which are prepared by anionic polymerization are frequently coupled with a suitable coupling agent, such as a tin halide, to improve desired properties. Tin-coupled polymers are known to improve treadwear and to reduce rolling resistance when used in tire tread rubbers. Such tin-coupled rubbery polymers are typically made by coupling the rubbery polymer with a tin coupling agent at or near the end of the polymerization used in synthesizing the rubbery polymer. In the coupling process, live polymer chain ends react with the tin coupling agent thereby coupling the polymer. For instance, up to four live chain ends can react with tin tetrahalides, such as tin tetrachloride, thereby coupling the polymer chains together.
[0016] The coupling efficiency of the tin coupling agent is dependant on many factors, such as the quantity of live chain ends available for coupling and the quantity and type of polar modifier, if any, employed in the polymerization. For instance, tin coupling agents are generally not as effective in the presence of polar modifiers. However, polar modifiers such as tetramethylethylenediamine, are frequently used to increase the glass transition temperature of the rubber for improved properties, such as improved traction characteristics in tire tread compounds. Coupling reactions that are carried out in the presence of polar modifiers typically have a coupling efficiency of about 50-60% in batch processes. Lower coupling efficiencies are typically attained in continuous processes.
[0017] Each tin tetrahalide molecule or silicon tetrahalide molecule is capable of reacting with up to four live polymer chain ends. However, since perfect stoichiometry is difficult to attain, some of the tin halide molecules often react with less than four live polymer chain ends. The classical problem is that if more than a stoichiometric amount of the tin halide coupling agent is employed, then there will be an insufficient quantity of live polymer chain ends to totally react with the tin halide molecules on a four-to-one basis. On the other hand, if less than a stoichiometric amount of the tin halide coupling agent is added, then there will be an excess of live polymer chain ends and some of the live chain ends will not be coupled. It is accordingly important for the stoichiometry to be exact and for all to the living polymer chain-ends to react with the coupling agent.
[0018] Conventional tin coupling results in the formation of a coupled polymer that is essentially symmetrical. In other words, all of the polymer arms on the coupled polymer are of essentially the same chain length. All of the polymer arms in such conventional tin-coupled polymers are accordingly of essentially the same molecular weight. This results in such conventional tin-coupled polymers having a low polydispersity. For instance, conventional tin-coupled polymers normally having a ratio of weight average molecular weight to number average molecular weight which is within the range of about 1.01 to about 1.1
[0019] U.S. Pat. No. 5,486,574 discloses dissimilar arm asymmetric radical or star block copolymers for adhesives and sealants. U.S. Pat. No. 5,096,973 discloses ABC block copolymers based on butadiene, isoprene and styrene and further discloses the possibility of branching these block copolymers with tetrahalides of silicon, germanium, tin or lead.
SUMMARY OF THE INVENTION
[0020] It has been unexpectedly found that coupling efficiency can be significantly improved by conducting the coupling reactions in the presence of a lithium salt of a saturated aliphatic alcohol, such as lithium t-amylate. In the alternative coupling efficiency can also be improved by conducting the coupling reaction in the presence of a lithium halide, or a lithium phenoxide.
[0021] This invention discloses a process for coupling a living rubbery polymer that comprises reacting the living rubbery polymer with coupling agent selected from the group consisting of tin halides and silicon halides in the presence of a lithium salt of a saturated aliphatic alcohol. The lithium salt of the saturated aliphatic alcohol can be added immediately prior to the coupling reaction or it can be present throughout the polymerization and coupling process.
[0022] Many metal salts of saturated aliphatic alcohols, react with water to produce alcohols during steam stripping. For instance, lithium t-amylate can react with water to produce t-amyl alcohol during steam stripping. Since t-amyl alcohol forms an azeotrope with hexane, it co-distills with hexane and can contaminate recycle feed streams. This problem of recycle stream contamination can be solved by using metal salts of cyclic alcohols that do not co-distill with hexane or form compounds during steam stripping which co-distill with hexane. Thus, the use of metal salts of cyclic alcohols is preferred because they solve the problem of recycle stream contamination and are considered to be environmentally safe. Lithium mentholate is a highly preferred lithium salt of a cyclic alcohol that can be used in the practice of this invention.
[0023] The present invention further discloses a process for coupling a living rubbery polymer that comprises reacting the living rubbery polymer with a coupling agent selected from the group consisting of tin halides and silicon halides in the presence of a member selected from the group consisting of lithium halides and lithium phenoxides.
[0024] The subject invention also reveals a stabilized lithium initiator system which is comprised of (1) an alkyl lithium compound selected from the group consisting of secondary alkyl lithium compounds and tertiary alkyl lithium compounds, (2) a lithium salt of a saturated aliphatic alcohol, and (3) a hydrocarbon solvent.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Virtually any type of rubbery polymer prepared by anionic polymerization can be coupled in accordance with this invention. In fact, the techniques of this invention can be used to couple virtually any type of rubbery polymer synthesized by anionic polymerization. The rubbery polymers that can be coupled will typically be synthesized by a solution polymerization technique utilizing an organolithium compound as the initiator. These rubbery polymers will accordingly normally contain a “living” lithium chain end.
[0026] The polymerizations employed in synthesizing the living rubbery polymers will normally be carried out in a hydrocarbon solvent. Such hydrocarbon solvents are comprised of one or more aromatic, paraffinic or cycloparaffinic compounds. These solvents will normally contain from about 4 to about 10 carbon atoms per molecule and will be liquid under the conditions of the polymerization. Some representative examples of suitable organic solvents include pentane, isooctane, cyclohexane, methylcyclohexane, isohexane, n-heptane, n-octane, n-hexane, benzene, toluene, xylene, ethylbenzene, diethylbenzene, isobutylbenzene, petroleum ether, kerosene, petroleum spirits, petroleum naphtha, and the like, alone or in admixture.
[0027] In the solution polymerization, there will normally be from 5 to 30 weight percent monomers in the polymerization medium. Such polymerization media are, of course, comprised of the organic solvent and monomers. In most cases, it will be preferred for the polymerization medium to contain from 10 to 25 weight percent monomers. It is generally more preferred for the polymerization medium to contain 15 to 20 weight percent monomers.
[0028] The rubbery polymers that are coupled in accordance with this invention can be made by the homopolymerization of a conjugated diolefin monomer or by the random copolymerization of a conjugated diolefin monomer with a vinyl aromatic monomer. It is, of course, also possible to make living rubbery polymers that can be coupled by polymerizing a mixture of conjugated diolefin monomers with one or more ethylenically unsaturated monomers, such as vinyl aromatic monomers. The conjugated diolefin monomers which can be utilized in the synthesis of rubbery polymers which can be coupled in accordance with this invention generally contain from 4 to 12 carbon atoms. Those containing from 4 to 8 carbon atoms are generally preferred for commercial purposes. For similar reasons, 1,3-butadiene and isoprene are the most commonly utilized conjugated diolefin monomers. Some additional conjugated diolefin monomers that can be utilized include 2,3-dimethyl-1,3-butadiene, piperylene, 3-butyl-1,3-octadiene, 2-phenyl-1,3-butadiene, and the like, alone or in admixture.
[0029] Some representative examples of ethylenically unsaturated monomers that can potentially be synthesized into rubbery polymers which can be coupled in accordance with this invention include alkyl acrylates, such as methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate and the like; vinylidene monomers having one or more terminal CH2=CH— groups; vinyl aromatics such as styrene, α-methylstyrene, bromostyrene, chlorostyrene, fluorostyrene and the like; α-olefins such as ethylene, propylene, 1-butene and the like; vinyl halides, such as vinylbromide, chloroethane (vinylchloride), vinylfluoride, vinyliodide, 1,2-dibromoethene, 1,1-dichloroethene (vinylidene chloride), 1,2-dichloroethene and the like; vinyl esters, such as vinyl acetate; α,β-olefinically unsaturated nitriles, such as acrylonitrile and methacrylonitrile; α,β-olefinically unsaturated amides, such as acrylamide, N-methyl acrylamide, N,N-dimethylacrylamide, methacrylamide and the like.
[0030] Rubbery polymers which are copolymers of one or more diene monomers with one or more other ethylenically unsaturated monomers will normally contain from about 50 weight percent to about 99 weight percent conjugated diolefin monomers and from about 1 weight percent to about 50 weight percent of the other ethylenically unsaturated monomers in addition to the conjugated diolefin monomers. For example, copolymers of conjugated diolefin monomers with vinylaromatic monomers, such as styrene-butadiene rubbers which contain from 50 to 95 weight percent conjugated diolefin monomers and from 5 to 50 weight percent vinylaromatic monomers, are useful in many applications.
[0031] Vinyl aromatic monomers are probably the most important group of ethylenically unsaturated monomers which are commonly incorporated into polydienes. Such vinyl aromatic monomers are, of course, selected so as to be copolymerizable with the conjugated diolefin monomers being utilized. Generally, any vinyl aromatic monomer which is known to polymerize with organolithium initiators can be used. Such vinyl aromatic monomers typically contain from 8 to 20 carbon atoms. Usually, the vinyl aromatic monomer will contain from 8 to 14 carbon atoms. The most widely used vinyl aromatic monomer is styrene. Some examples of vinyl aromatic monomers that can be utilized include styrene, 1-vinylnaphthalene, 2-vinylnaphthalene, α-methylstyrene, 4-phenylstyrene, 3-methylstyrene and the like.
[0032] Some representative examples of rubbery polymers which can be coupled in accordance with this invention include polybutadiene, polyisoprene, styrene-butadiene rubber (SBR), α-methylstyrene-butadiene rubber, α-methylstyrene-isoprene rubber, styrene-isoprene-butadiene rubber (SIBR), styrene-isoprene rubber (SIR), isoprene-butadiene rubber (IBR), α-methylstyrene-isoprene-butadiene rubber and α-methylstyrene-styrene-isoprene-butadiene rubber. In cases where the rubbery polymer is comprised of repeat units that are derived from two or more monomers, the repeat units which are derived from the different monomers will normally be distributed in an essentially random manner. In other words, the rubbery polymer will not be a block copolymer.
[0033] The polymerizations employed in making the rubbery polymer are typically initiated by adding an organolithium initiator to an organic polymerization medium that contains the monomers. Such polymerizations are typically carried out utilizing continuous polymerization techniques. In such continuous polymerizations, monomers and initiator are continuously added to the organic polymerization medium with the rubbery polymer synthesized being continuously withdrawn. Such continuous polymerizations are typically conducted in a multiple reactor system.
[0034] The organolithium initiators which can be employed in synthesizing rubbery polymers which can be coupled in accordance with this invention include the monofunctional and multifunctional types known for polymerizing the monomers described herein. The multifunctional organolithium initiators can be either specific organolithium compounds or can be multifunctional types which are not necessarily specific compounds but rather represent reproducible compositions of regulable functionality.
[0035] The amount of organolithium initiator utilized will vary with the monomers being polymerized and with the molecular weight that is desired for the polymer being synthesized. However, as a general rule, from 0.01 to 1 phm (parts per 100 parts by weight of monomer) of an organolithium initiator will be utilized. In most cases, from 0.01 to 0.1 phm of an organolithium initiator will be utilized with it being preferred to utilize 0.025 to 0.07 phm of the organolithium initiator.
[0036] The choice of initiator can be governed by the degree of branching and the degree of elasticity desired for the polymer, the nature of the feedstock and the like. With regard to the feedstock employed as the source of conjugated diene, for example, the multifunctional initiator types generally are preferred when a low concentration diene stream is at least a portion of the feedstock, since some components present in the unpurified low concentration diene stream may tend to react with carbon lithium bonds to deactivate initiator activity, thus necessitating the presence of sufficient lithium functionality in the initiator so as to override such effects.
[0037] The multifunctional initiators which can be used include those prepared by reacting an organomonolithium compounded with a multivinylphosphine or with a multivinylsilane, such a reaction preferably being conducted in an inert diluent such as a hydrocarbon or a mixture of a hydrocarbon and a polar organic compound. The reaction between the multivinylsilane or multivinylphosphine and the organomonolithium compound can result in a precipitate which can be solubilized, if desired, by adding a solubilizing monomer such as a conjugated diene or monovinyl aromatic compound, after reaction of the primary components. Alternatively, the reaction can be conducted in the presence of a minor amount of the solubilizing monomer. The relative amounts of the organomonolithium compound and the multivinylsilane or the multivinylphosphine preferably should be in the range of about 0.33 to 4 moles of organomonolithium compound per mole of vinyl groups present in the multivinylsilane or multivinylphosphine employed. It should be noted that such multifunctional initiators are commonly used as mixtures of compounds rather than as specific individual compounds.
[0038] Exemplary organomonolithium compounds include ethyllithium, isopropyllithium, n-butyllithium, sec-butyllithium, tert-octyllithium, n-eicosyllithium, phenyllithium, 2-naphthyllithium, 4-butylphenyllithium, 4-tolyllithium, 4-phenylbutyllithium, cyclohexyllithium and the like.
[0039] Exemplary multivinylsilane compounds include tetravinylsilane, methyltrivinylsilane, diethyldivinylsilane, di-n-dodecyldivinylsilane, cyclohexyltrivinylsilane, phenyltrivinylsilane, benzyltrivinylsilane, (3-ethylcyclohexyl) (3-n-butylphenyl)divinylsilane and the like.
[0040] Exemplary multivinylphosphine compounds include trivinylphosphine, methyldivinylphosphine, dodecyldivinylphosphine, phenyldivinylphosphine, cyclooctyldivinylphosphine and the like.
[0041] Other multifunctional polymerization initiators can be prepared by utilizing an organomonolithium compound, further together with a multivinylaromatic compound and either a conjugated diene or monovinylaromatic compound or both. These ingredients can be charged initially, usually in the presence of a hydrocarbon or a mixture of a hydrocarbon and a polar organic compound as a diluent. Alternatively, a multifunctional polymerization initiator can be prepared in a two-step process by reacting the organomonolithium compound with a conjugated diene or monovinyl aromatic compound additive and then adding the multivinyl aromatic compound. Any of the conjugated dienes or monovinyl aromatic compounds described can be employed. The ratio of conjugated diene or monovinyl aromatic compound additive employed preferably should be in the range of about 2 to 15 moles of polymerizable compound per mole of organolithium compound. The amount of multivinylaromatic compound employed preferably should be in the range of about 0.05 to 2 moles per mole of organomonolithium compound.
[0042] Exemplary multivinyl aromatic compounds include 1,2-divinylbenzene, 1,3-divinylbenzene, 1,4-divinylbenzene, 1,2,4-trivinylbenzene, 1,3-divinylnaphthalene, 1,8-divinylnaphthalene, 1,3,5-trivinylnaphthalene, 2,4-divinylbiphenyl, 3,5,4′-trivinylbiphenyl, m-diisopropenyl benzene, p-diisopropenyl benzene, 1,3-divinyl-4,5,8-tributylnaphthalene and the like. Divinyl aromatic hydrocarbons containing up to 18 carbon atoms per molecule are preferred, particularly divinylbenzene as either the ortho, meta or para isomer and commercial divinylbenzene, which is a mixture of the three isomers, and other compounds, such as the ethylstyrenes, also is quite satisfactory.
[0043] Other types of multifunctional initiators can be employed such as those prepared by contacting a sec- or tert-organomonolithium compound with 1,3-butadiene, at a ratio of about 2 to 4 moles of the organomonolithium compound per mole of the 1,3-butadiene, in the absence of added polar material in this instance, with the contacting preferably being conducted in an inert hydrocarbon diluent, though contacting without the diluent can be employed if desired.
[0044] Alternatively, specific organolithium compounds can be employed as initiators, if desired, in the preparation of polymers in accordance with the present invention. These can be represented by R(Li)x wherein R represents a hydrocarbyl radical containing from 1 to 20 carbon atoms, and wherein x is an integer of 1 to 4. Exemplary organolithium compounds are methyllithium, isopropyllithium, n-butyllithium, sec-butyllithium, tert-octyllithium, n-decyllithium, phenyllithium, 1-naphthyllithium, 4-butylphenyllithium, p-tolyllithium, 4-phenylbutyllithium, cyclohexyllithium, 4-butylcyclohexyllithium, 4-cyclohexylbutyllithium, dilithiomethane, 1,4-dilithiobutane, 1,10-dilithiodecane, 1,20-dilithioeicosane, 1,4-dilithiocyclohexane, 1,4-dilithio-2-butane, 1,8-dilithio-3-decene, 1,2-dilithio-1,8-diphenyloctane, 1,4-dilithiobenzene, 1,4-dilithionaphthalene, 9,10-dilithioanthracene, 1,2-dilithio-1,2-diphenylethane, 1,3,5-trilithiopentane, 1,5,15-trilithioeicosane, 1,3,5-trilithiocyclohexane, 1,3,5,8-tetralithiodecane, 1,5,10,20-tetralithioeicosane, 1,2,4,6-tetralithiocyclohexane, 4,4′-dilithiobiphenyl and the like.
[0045] The polymerization temperature utilized can vary over a broad range of from about −20° C. to about 180° C. In most cases, a polymerization temperature within the range of about 30° C. to about 125° C. will be utilized. It is typically preferred for the polymerization temperature to be within the range of about 45° C. to about 100° C. It is typically most preferred for the polymerization temperature to be within the range of about 60° C. to about 85° C. The pressure used will normally be sufficient to maintain a substantially liquid phase under the conditions of the polymerization reaction.
[0046] The polymerization is conducted for a length of time sufficient to permit substantially complete polymerization of monomers. In other words, the polymerization is normally carried out until high conversions are attained. The polymerization is then terminated by the addition of a tin halide and/or silicon halide. The tin halide and/or the silicon halide are continuous added in cases where asymmetrical coupling is desired. This continuous addition of tin coupling agent and/or the silicon coupling agent is normally done in a reaction zone separate from the zone where the bulk of the polymerization is occurring. In other words, the coupling will typically be added only after a high degree of conversion has already been attained. For instance, the coupling agent will normally be added only after a monomer conversion of greater than about 90 percent has been realized. It will typically be preferred for the monomer conversion to reach at least about 95 percent before the coupling agent is added. As a general rule, it is most preferred for the monomer conversion to exceed about 98 percent before the coupling agent is added. The coupling agents will normally be added in a separate reaction vessel after the desired degree of conversion has been attained. The coupling agents can be added in a hydrocarbon solution, e.g., in cyclohexane, to the polymerization admixture with suitable mixing for distribution and reaction.
[0047] The coupling agent will typically be a tin halide. The tin halide will normally be a tin tetrahalide, such as tin tetrachloride, tin tetrabromide, tin tetrafluoride or tin tetraiodide. However, tin trihalides can also optionally be used. Polymers coupled with tin trihalides having a maximum of three arms. This is, of course, in contrast to polymers coupled with tin tetrahalides which have a maximum of four arms. To induce a higher level of branching, tin tetrahalides are normally preferred. As a general rule, tin tetrachloride is most preferred.
[0048] The silicon coupling agents that can be used will normally be silicon tetrahalides, such as silicon tetrachloride, silicon tetrabromide, silicon tetrafluoride or silicon tetraiodide. However, silicon trihalides can also optionally be used. Polymers coupled with silicon trihalides having a maximum of three arms. This is, of course, in contrast to polymers coupled with silicon tetrahalides which have a maximum of four arms. To induce a higher level of branching, silicon tetrahalides are normally preferred. As a general rule, silicon tetrachloride is most preferred of the silicon coupling agents.
[0049] A combination of a tin halide and a silicon halide can optionally be used to couple the rubbery polymer. By using such a combination of tin and silicon coupling agents improved properties for tire rubbers, such as lower hysteresis, can be attained. In such cases, the molar ratio of the tin halide to the silicon halide employed in coupling the rubbery polymer will normally be within the range of 20:80 to 95:5. The molar ratio of the tin halide to the silicon halide employed in coupling the rubbery polymer will more typically be within the range of 40:60 to 90:10. The molar ratio of the tin halide to the silicon halide employed in coupling the rubbery polymer will preferably be within the range of 60:40 to 85:15. The molar ratio of the tin halide to the silicon halide employed in coupling the rubbery polymer will most preferably be within the range of 65:35 to 80:20.
[0050] Broadly, and exemplary, a range of about 0.01 to 4.5 milliequivalents of tin coupling agent (tin halide and silicon halide) is employed per 100 grams of the rubbery polymer. It is normally preferred to utilize about 0.01 to about 1.5 milliequivalents of the coupling agent per 100 grams of polymer to obtain the desired Mooney viscosity. The larger quantities tend to result in production of polymers containing terminally reactive groups or insufficient coupling. One equivalent of tin coupling agent per equivalent of lithium is considered an optimum amount for maximum branching. For instance, if a mixture tin tetrahalide and silicon tetrahalide is used as the coupling agent, one mole of the coupling agent would be utilized per four moles of live lithium ends. In cases where a mixture of tin trihalide and silicon trihalide is used as the coupling agent, one mole of the coupling agent will optimally be utilized for every three moles of live lithium ends. The coupling agent can be added in a hydrocarbon solution, e.g., in cyclohexane, to the polymerization admixture in the reactor with suitable mixing for distribution and reaction.
[0051] In the practice of this invention, the coupling reaction is carried out in the presence of a lithium compound selected from the group consisting of lithium salts of a saturated aliphatic alcohol, a lithium halides, and lithium phenoxides. The molar ratio of the lithium compound to the polar modifier will typically be within the range of about 0.01:1 to 100:1. The molar ratio of the lithium compound to the polar modifier will more typically be within the range of about 0.1:1 to 10:1. The molar ratio of the lithium compound to the polar modifier will preferably be within the range of about 0.4:1 to 2:1. The molar ratio of the lithium compound to the polar modifier will most preferably be within the range of about 0.7:1 to 1.4:1.
[0052] The lithium salt of the saturated aliphatic alcohol can be added immediately prior to coupling or it can be present during the polymerization and coupling steps. The lithium compound can be added directly as a salt of an saturated aliphatic alcohol or the salt can be made “in-situ” by the addition of an saturated aliphatic alcohol. For instance, menthol can be added as a part of a lithium initiator system and will react with organolithium compounds therein to form a lithium mentholate. It is generally preferred for the lithium salt of the saturated aliphatic alcohol to be made by such an “in-situ” technique in commercial applications.
[0053] The lithium salt of the aliphatic alcohol can also be blended with the organolithium compound prior to using it as an initiator. This offers a significant advantage because it stabilizes the organolithium compound. Additionally, it makes the lithium salt of the aliphatic alcohol much more soluble in hydrocarbon solvents. For instance, secondary alkyl lithium compounds, such as secondary-butyl lithium, and tertiary alkyl lithium compounds, such as tertiary-butyl lithium, are extremely unstable and typically must be used within 48 hours. However, it has been found that salts of saturated aliphatic alcohols can be used to stabilize such secondary alkyl lithium compounds and tertiary alkyl lithium compounds. For instance, secondary alkyl lithium compounds and tertiary alkyl lithium compounds can be stabilized with about 1 part by weight to about 100 parts by weight of a lithium salt of a saturated aliphatic alcohol per 100 parts by weight of the secondary alkyl lithium compound or the tertiary alkyl lithium compound. Such compositions will typically contain from about 10 parts by weight to about 50 parts by weight of the lithium salt of a saturated aliphatic alcohol per 100 parts by weight of the secondary alkyl lithium compound or the tertiary alkyl lithium compound. Such stabilized lithium initiator systems will typically be dispersed in a hydrocarbon solvent.
[0054] The lithium salt of the saturated aliphatic alcohol will preferably be a lithium alkoxide. Such lithium alkoxides are of the formula LiOR, wherein R is an alkyl group containing from about 2 to about 12 carbon atoms. The lithium alkoxide will typically contain from about 2 to about 12 carbon atoms. It is generally preferred for the lithium alkoxide to contain from about 3 to about 8 carbon atoms. It is generally most preferred for the lithium alkoxide to contain from about 4 to about 6 carbon atoms. Lithium t-amyloxide (lithium t-pentoxide) is a representative example of a preferred lithium alkoxide that can be utilized in the process of this invention.
[0055] It should be noted that even small amounts of sodium alkoxides, potassium alkoxides, cesium alkoxides, or rubidium alkoxides result in undesirable side reactions, such as chain transfer. Thus, the coupling reactions of this invention are carried out in the absence of sodium alkoxides, cesium alkoxides, rubidium alkoxides, and potassium alkoxides. For instance, the presence of sodium salts of saturated aliphatic alcohols, such as sodium alkoxides, causes an undesirable jump in Mooney viscosity and interferes with improved coupling efficiency.
[0056] As has been explained it is preferred to utilize lithium salts of cyclic alcohols. The lithium salts of the cyclic alcohols that can be mono-cyclic, bi-cyclic or tri-cyclic. They can be substituted with 1 to 5 hydrocarbon moieties and can also optionally contain hetero-atoms. For instance, the metal salt of the cyclic alcohol can be a metal salt of a di-alkylated cyclohexanol, such as 2-isopropyl-5-methylcyclohexanol or 2-t-butyl-5-methylcyclohexanol. These salts are preferred because they are soluble in hexane. Metal salts of disubstituted cyclohexanol are highly preferred because they are soluble in hexane. Lithium mentholate is the most highly preferred metal salt of a cyclic alcohol that can be employed in the practice of this invention. The metal salt of the cyclic alcohol can be prepared by reacting the cyclic alcohol directly with the metal or another metal source, such as cesium hydride, in an aliphatic or aromatic solvent.
[0057] After the coupling has been completed, a tertiary chelating alkyl 1,2-ethylene diamine or a metal salt of a cyclic alcohol can optionally be added to the polymer cement to stabilize the coupled rubbery polymer. The tertiary chelating amines that can be used are normally chelating alkyl diamines of the structural formula:
wherein n represents an integer from 1 to about 6, wherein A represents an alkylene group containing from 1 to about 6 carbon atoms and wherein R′, R″, R″′ and R″″ can be the same or different and represent alkyl groups containing from 1 to about 6 carbon atoms. The alkylene group A is the formula —(—CH 2 —) m wherein m is an integer from 1 to about 6. The alkylene group will typically contain from 1 to 4 carbon atoms (m will be 1 to 4) and will preferably contain 2 carbon atoms. In most cases, n will be an integer from 1 to about 3 with it being preferred for n to be 1. It is preferred for R′, R″, R″′ and R″″ to represent alkyl groups which contain from 1 to 3 carbon atoms. In most cases, R′, R′″,R″′ and R″″ will represent methyl groups.
[0059] A sufficient amount of the chelating amine or metal salt of the cyclic alcohol should be added to complex with any residual tin coupling agent remaining after completion of the coupling reaction.
[0060] In most cases, from about 0.01 phr (parts by weight per 100 parts by weight of dry rubber) to about 2 phr of the chelating alkyl 1,2-ethylene diamine or metal salt of the cyclic alcohol will be added to the polymer cement to stabilize the rubbery polymer. Typically, from about 0.05 phr to about 1 phr of the chelating alkyl 1,2-ethylene diamine or metal salt of the cyclic alcohol will be added. More typically, from about 0.1 phr to about 0.6 phr of the chelating alkyl 1,2-ethylene diamine or the metal salt of the cyclic alcohol will be added to the polymer cement to stabilize the rubbery polymer.
[0061] After the polymerization, coupling, and optionally the stabilization step, has been completed, the coupled rubbery polymer can be recovered from the organic solvent. The coupled rubbery polymer can be recovered from the organic solvent and residue by means such as decantation, filtration, centrification and the like. It is often desirable to precipitate the coupled rubbery polymer from the organic solvent by the addition of lower alcohols containing from about 1 to about 4 carbon atoms to the polymer solution. Suitable lower alcohols for precipitation of the rubber from the polymer cement include methanol, ethanol, isopropyl alcohol, normal-propyl alcohol and t-butyl alcohol. The utilization of lower alcohols to precipitate the asymmetrically tin-coupled rubbery polymer from the polymer cement also “kills” any remaining living polymer by inactivating lithium end groups. After the coupled rubbery polymer is recovered from the solution, steam-stripping can be employed to reduce the level of volatile organic compounds in the coupled rubbery polymer.
[0062] The coupled rubbery polymers that can be made by using the technique of this invention are comprised of a tin and/or silicon atoms having at least three polydiene arms covalently bonded. In the case of asymmetrically coupled rubbery polymers made by the technique of this invention at least one of the polydiene arms bonded to the tin atoms and/or the silicon atoms has a number average molecular weight of less than about 40,000, at least one of the polydiene arms bonded to the tin atoms and/or the silicon atoms has a number average molecular weight of at least about 80,000. The ratio of the weight average molecular weight to the number average molecular weight of the asymmetrically coupled rubbery polymer will also normally be within the range of about 2 to about 2.5.
[0063] The asymmetrically coupled rubbery polymers that can be made by the process of this invention contain stars of the structural formula:
wherein M represents silicon or tin, wherein R 1 , R 2 , R 3 and R 4 can be the same or different and are selected from the group consisting of alkyl groups and polydiene arms (polydiene rubber chains), with the proviso that at least three members selected from the group consisting of R 1 , R 2 , R 3 and R 4 are polydiene arms, with the proviso that at least one member selected from the group consisting of R 1 , R 2 , R 3 and R 4 is a low molecular weight polydiene arm having a number average molecular weight of less than about 40,000, with the proviso that at least one member selected from the group consisting of R 1 , R 2 , R 3 and R 4 is a high molecular weight polydiene arm having a number average molecular weight of greater than about 80,000, and with the proviso that the ratio of the weight average molecular weight to the number average molecular weight of the asymmetrical tin-coupled rubbery polymer is within the range of about 2 to about 2.5. It should be noted that R 1 , R 2 , R 3 and R 4 can be alkyl groups because it is possible for the tin halide coupling agent to react directly with alkyl lithium compounds which are used as the polymerization initiator. The ratio of silicon containing stars to tin containing stars will be within the range of about 20:80 to about 80:20 in cases where the rubber is coupled with both a silicon and a tin coupling agent.
[0065] In most cases, four polydiene arms will be covalently bonded to the tin atom or the silicon atom in the asymmetrical tin-coupled rubbery polymer. In such cases, R 1 , R 2 , R 3 and R 4 will all be polydiene arms. The asymmetrical tin-coupled rubbery polymer will often contain a polydiene arm of intermediate molecular weight as well as the low molecular weight arm and the high molecular weight arm. Such intermediate molecular weight arms will have a molecular weight that is within the range of about 45,000 to about 75,000. It is normally preferred for the low molecular polydiene arm to have a molecular weight of less than about 30,000 with it being most preferred for the low molecular weight arm to have a molecular weight of less than about 25,000. It is normally preferred for the high molecular polydiene arm to have a molecular weight of greater than about 90,000 with it being most preferred for the high molecular weight arm to have a molecular weight of greater than about 100,000. The arms of the coupled polymer will typically be either homopolymers or random copolymers. In other words, the arms of the coupled polymers will normally not be block copolymers.
[0066] This invention is illustrated by the following examples which are merely for the purpose of illustration and are not to be regarded as limiting the scope of the invention or the manner in which it can be practiced. Unless specifically indicated otherwise, all parts and percentages are given by weight.
EXAMPLE 1
[0067] In this experiment, a tin coupled styrene-butadiene rubber was prepared at 70° C. In the procedure used, 2300 g of a silica/alumina/molcular sieve dried premix containing 19.5 weight percent styrene/1,3-butadiene mixture in hexanes was charged into a one-gallon (3.8 liters) reactor. The ratio of styrene to 1,3-butadiene was 15:85. After the amount of impurity in the premix was determined, 2.4 ml of 1 M solution of TMEDA (N, N, N′, N′-tetramethylethylene-diamine in hexanes), 1.5 ml of 1 M solution of lithium t-butoxide (in hexanes) and 2.92 ml. of 1.03M solution of n-butyllithium (in hexanes) were added to the reactor. The target Mn (number averaged molecular weight) was 150,000. The polymerization was allowed to proceed at 70° C. for 1.5 hours. The GC analysis of the residual monomers contained in the polymerization mixture indicated that most of the monomers were converted to polymer. After a small aliquot of polymer cement was removed from the reactor (for analysis), 1.2 ml. of a 0.6 M solution of tin tetrachloride (in hexanes) was added to the reactor and the coupling reaction was carried out the same temperature for an hour. At this time, 1.0 phr (parts per 100 perts of rubber by weight) of BHT (2,6-di-tert-butyl-4-methylphenol) and 3.0 ml of 1 M solution of TMEDA were added to the reactor to shortstop the polymerization and to stabilize the polymer. After evaporating the hexanes, the resulting polymer was dried in a vaccum oven at 50° C. The coupled styrene-butadiene rubber (SBR) produced was determined to have a glass transition temperature (Tg) at −45° C. It was also determined to have a microstructure that contained 49 percent 1,2-polybutadiene units, 37 percent 1,4-polybutadiene units and 14 percent random polystyrene units. The Mooney viscosity (ML-4) at 100° C. for this coupled polymer was also determined to be 108.
[0068] The ML-4 for the base polymer (before coupling) was 25. Based on GPC measurement, the coupling efficiency was 80%.
EXAMPLE 2
[0069] The procedure described in Example 1 was utilized in this example except that lithium t-butoxide solution was added to the polymerization mixture when all the monomers were consumed (90 minutes after initiation) and prior to adding the coupling agent. The Tg and microstructure of the resulting coupled SBR are shown in Table 1. The Mooney viscosities of the base and coupled polymers are also shown in Table 1. The coupling efficiency was 81%, based on GPC measurement.
COMPARATIVE EXAMPLE 3
[0070] The procedure described in Example 1 was utilized in this example except that no lithium t-butoxide solution was used. The Tg and microstructure of the resulting coupled SBR are shown in Table 1. The Mooney viscosities of the base and coupled polymers are also shown in Table 1. The coupling efficiency was 55%, based on GPC measurement.
TABLE 1 Ex- Tg ML-4 Microstructure (%) Coupling ample (° C.) Base Coupled 1,2-PBd 1,4-PBd Styrene Efficiency 1 −45 25 108 49 37 14 80 2 −44 28 115 50 36 14 81 3 −45 25 85 49 37 14 55
EXAMPLE 4
[0071] The tin coupled SBR prepared in this experiment was synthesized in a three-reactor (1 gallon, 2 gallon, 2 gallon) continuous system at 80° C. A premix containing styrene and 1,3-butadiene in hexanes was charged into the first polymerization reactor continuously at a rate of 98 grams per minute. The premix monomer solution containing a ratio of styrene to 1,3-butadiene of 18:82 and had a total monomer concentration of 16%. Polymerization was initiated by adding n-butyl lithium (0.6 mmole/100 grams of monomer), TMEDA (1 mmole/100 grams monomer) and lithium mentholate (0.5 mmole/100 grams monomer) to the first reactor continuously. The resulting polymerization medium containing the live ends was continuously pushed to the second rector (for completing the polymerization) and then the third reactor where the coupling agent, tin tetrachloride, (0.15 mmole/100 grams monomer) was added continuously. The residence time for all reactors was set at one hour to achieve complete monomer conversion in the second reactor and complete coupling at the third reactor. The polymerization medium was continuously pushed over to a holding tank containing stabilizer and antioxidant. The resulting polymer cement was then steam stripped and the recovered SBR was dried in a vented oven at 50° C. The polymer was determined to have a glass transition temperature at −43° C. and have a Mooney ML-4 viscosity of 82. The Mooney viscosity of base (uncoupled percurser) was 41. It was also determined to have a microstructure that contained 18% random polystyrene units, 41% 1,2-polybutadiene units, and 41% 1,4-polybutdiene units.
EXAMPLE 5
[0072] The procedure described in Example 4 was utilized in this example except that lithium mentholate solution was formed in-situ by reacting menthol with n-butyllithium in a catalyst mixer loop before entering the first reactor. The glass transition temperature (Tg) and microstructure of the resulting coupled styrene-butadiene rubber (SBR) are shown in Table 2. The Mooney viscosities of the base and coupled polymers are also shown in Table 2.
COMPARATIVE EXAMPLE 6
[0073] The procedure described in Example 4 was utilized in this example except that no lithium alkoxide solution was used. The glass transition temperature and microstructure of the resulting coupled styrene-butadiene rubber are shown in Table 2. The Mooney viscosities of the base and coupled polymers are also shown in Table 2.
TABLE 2 Tg ML-4 Microstructure (%) Example (° C.) Base Coupled 1,2-PBd 1,4-PBd Styrene 4 −43 41 82 41 41 18 5 −43 38 82 40 40 18 6 −42 42 68 42 41 17
[0074] While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. | Rubbery polymers made by anionic polymerization can be coupled with fin halides or silicon halides to improve the characteristics of the rubber for use in some applications, such as fire treads. In cases where the rubbery polymer was synthesized utilizing a polar modifier it is difficult to attain a high level of coupling. This invention is based upon the unexpected finding that coupling efficiency can be significantly improved by conducting the coupling reaction in the presence of a lithium salt of a saturated aliphatic alcohol, such as lithium t-amylate. This invention discloses a process for coupling a living rubbery polymer that comprises reacting the living rubbery polymer with coupling agent selected from the group consisting of tin halides and silicon halides in the presence of a lithium salt of a saturated aliphatic alcohol. The lithium salt of the saturated aliphatic alcohol can be added immediately prior to the coupling reaction or it can be present throughout the polymerization and coupling process. Lithium t-amylate reacts with water to form t-amyl alcohol during steam stripping. Since t-amyl alcohol forms an azeotrope with hexane, it co-distills with hexane and can contaminate recycle feed streams. This problem of recycle stream contamination can be solved by using metal salts of cyclic alcohols that do not co-distill with hexane or form compounds during steam stripping which co-distill with hexane. Thus, the use of metal salts of cyclic alcohols is preferred for this reason and because they are considered to be environmentally safe. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to apparatus for roasting or calcining fine grained material such as cement raw meal, limestone or dolomite and has particular application in a cement producing system utilizing a suspension-type preheater, a stationary calcining furnace and a separate clinkering furnace followed by a cooler.
The present invention is an improvement over U.S. Pat. No. 4,381,916 issued May 3, 1983. In that patent, it is disclosed that it is desirable in an ore roasting apparatus similar to the present invention to recirculate material to be roasted or calcined through the calcining furnace of the apparatus. In that patent there is disclosed a suspension-type preheater followed by a separate calcining furnace followed by a clinkering furnace and a cooler. Cement raw meal or other material to be roasted is preheated in the preheater, then supplied to the calcining furnace. Material discharged from the calcining furnace is supplied to a separate processer such as the clinkering furnace while a portion of it is recirculated back to the calcining furnace for further calcining. The advantage of such a system is that the fine material to be calcined or roasted is exposed to the temperature in the calciner for a greater period of time so that a higher percentage of material is calcined at a given temperature.
According to the present invention, a practical apparatus has been provided for carrying out the process disclosed in the aforementioned U.S. patent.
In cement clinker producing plants and in other thermal processing installations, large pieces of material such as pieces of broken refractory, tramp iron and the like can work its way through a preheater to plug downstream apparatus. These large chunks of material should be separated from the system or they will plug the recirculation system. It is best if these oversized particles can be supplied directly to the kiln.
It is also known that in material roasting systems such as those to which the present invention relates that due to the sticky nature of the intermediate material, plugging of the system can occur and it is necessary to provide a by-pass system around the recirculation system in the event of such plugging.
SUMMARY
It is the principal object of this invention to provide an apparatus for roasting fine grained material such as cement raw meal, lime, or dolomite which will improve the operating characteristics of a recirculating calcining system thereby improving the operation of the roasting apparatus.
The foregoing and other objects will be carried out by providing apparatus for roasting fine grained material such as cement raw meal, lime or dolomite comprising a furnace having an inlet for gas for combustion, an inlet for raw fine grained material to be roasted, an inlet for fuel for combustion in said furnace and an outlet for spent combustion gas and at least partially roasted fine grained material; a gas-solids separator having an inlet for spent combustion gas and at least partially roasted fine grained material flow connected to the outlet of said furnace, an outlet for separated at least partially roasted fine grained material and an outlet for separated spent combustion gas; means for recirculating a portion of the least partially roasted fine grained material from the outlet for separated at least partially roasted fine grained material of said gas-solids separator to said furnace; and for discharging the remainder of the at least partially roasted fine grained material; and means for by-passing material around said means for recirculating a portion of the material for discharging the by-passed material from the system.
According to the present invention, an arrangement has been provided which permits particle size classification so that in the event large chunks of material are discharged from the calcining vessel, they may be discharged from the calcining system without recirculation. This is carried out by the utilization of strategically located grizzly bars. These oversized particles are discharged from the calcining system. In a cement clinker application, they are supplied to the clinkering furnace.
Also according to the present invention, gas locks are provided in the recirculation conduit and in the conduit for oversized material so that the intended gas flow is not short circuited around the calcining system.
A low profile for the system is maintained by using a high temperature fluidizing gravity conveyor in the recirculation system.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be described in connection with the annexed drawing wherein:
FIG. 1 is a diagramatic view of a cement manufacturing facility utilizing the present invention;
FIG. 2 is a view on an enlarged scale of a portion of the recirculation system of the present invention; and
FIG. 3 is a top view of the recirculation system shown in FIG. 2 with parts broken away for clarity.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing, the invention is described in connection with a cement manufacturing facility which includes a preheater generally indicated at 1, a calcining furnace means generally indicated at 2, a clinkering furnace generally indicated at 3 and a cooler generally indicated at 4. Each of these components is generally known in the art and need not be described in detail.
The preheater includes of a plurality of serially connected gas-solids separators of the cyclone type each indicated at 10. Each of these cyclones 10 has an inlet 11 for gas and entrained material, an outlet 12 for separated gas and an outlet 13 for separated solids. The system includes an inlet 15 for raw material to be treated. A gas conduit 16 flow connects the gas outlet 12 of each cyclone with the gas inlet 11 of the next higher cyclone. A material duct 17 connects the material outlet 13 of each cyclone 10 with the conduit 16 of the next lower cyclone. Material supplied from the conduit 17 to the conduit 16 is entrained in hot gas being discharged from the lower cyclone 10 and supplied to the upper cyclone 10 where the gas and solids are separated so that heat from the hot gas is transferred to the material as the material flows downwardly generally countercurrent to the upward gas flow through the preheater in a manner well known in the art.
Generally in the art, the various cyclones are referred to as preheater stages. In the drawing illustrated, a five-stage preheater is utilized with stage I being illustrated as the uppermost cyclone 10 and stage V being the lowermost cyclone with intermediate stages II, III and IV. Spent preheating gas in discharged from the preheater 1 through outlet 19 to a high efficiency dust collector (not shown).
The calcining furnace means 2 includes a stationary calcining furnace 20 and the gas solids separator 10 which forms stage V of the preheater. A duct 21 connects the outlet 22 of furnace 20 with the stage V cyclone 10. The furnace 20 also includes burner means 24 so that combustion takes place in the calcining furnace means 2. Preheated material to be processed is supplied by the material duct 17 from the stage IV cyclone to the material inlet 25 of the calcining furnace means 2 and vessel 20 where it is exposed to the combustion in the furnace 20 for calcining or roasting the material. Spent combustion gas and entrained at least partially calcined material is discharged from the furnace 20 and supplied through the outlet 22 and duct 21 to the stage V cyclone 10. The outlet 13 for at least partially calcined material of the stage V cyclone serves as the material outlet of the calcining furnace means 2. The gas outlet 12 of the stage V cyclone 10 serves as the gas outlet of the calcining means 2 for supplying preheated gas to the preheater 1.
The apparatus also includes a clinkering furnace such as a rotary kiln 30 having an inlet 31 for calcined material to be clinkered and an outlet 32 for clinkered material. The rotary kiln 30 includes a burner means 33 for burning fuel in the clinkering furnace 3 to complete the clinkering process.
The system also includes a clinker cooler generally indicated at 4 which is preferably of the reciprocating grate type generally known in the art. This type of cooler includes a gas permeable grate 41 dividing the cooler into a lower plenum chamber 42 and an upper material chamber 43 and serves as a means for moving the clinker from the inlet 32 to the outlet 45. Cooling air is supplied from a source such as a fan 44 to the undergate compartment 42 for passage through the reciprocating grates 41 and bed of material supported thereon to simultaneously cool the material and heat the air.
Some to the air which is heated by the hot clinker is supplied directly to the rotary kiln to serve as preheated combustion air in the kiln. Other spent cooler gas is supplied through duct 48 and a gas solid separator 49 to the calcining furnace 2 through combustion air inlet 27 of the calcining furnace means 2 to serve as preheated combustion air for the calciner 2. The cooler 4 also includes a vent duct 47 which supplies excess cooling air to a high efficiency dust collector (not shown).
The clinkering furnace 3 includes a riser duct 35 flow connecting the clinkering furnace to the calcining furnace 2 so that exhaust gas from the kiln is supplied to the calcining furnace 2 and then the preheater 1.
Referring now to FIGS. 2 and 3, the recirculation system of the present invention is generally indicated at 7. The recirculation system 7 includes a duct 70 which is connected to the outlet 13 of the stage V cyclone 10 of the calcining means 2. The duct 70 also includes a branch 71 with a particle size classifying means 72 positioned between the duct 70 and the duct 71. This particle size classifying means is preferably in the form of grizzly bars 73 in (FIGS. 2 and 3). The grizzly bars remove oversize material which cannot pass between the bars so that this oversize material may be discharged from the calcining furnace through duct 71. In a practical application, this oversize material and duct 71 are connected directly to the material inlet 31 of the clinkering furnace 3.
The duct 70 is connected at its lower end to a conveyor 75 which may be in the form of a fluidizing gravity conveyer of the type wherein gaseous fluid from a source (not shown) is blown up through a gas permeable bottom to aerate and fluidize material in the conduit so that it flows freely down a conduit having a slight slope. While similar apparatus has been used for conveying cement and cement raw meal which is at ambient temperature, utilization of such apparatus in conveying high temperature such as calcined cement raw meal is not generally utilized; see U.S. Pat. No. 2,527,455 for this type of apparatus, but for this application a high temperature gas permeable material is required to withstand the high temperatures. Use of this type of conveyor permits the system to have a lower overall height in general and specifically permits a reduction in the distance between the outlet of stage V vessel and the inlet 31 of the kiln 3. The conveyor 75 has an outlet end 76 which is flow connected to the riser duct 35 connecting the outlet 31 of the clinkering kiln 3 and the calcining furnace 2. The conveyor 75 has connected thereto another conduit 78 which supplies material from conduit 75 to the lower end of conduit 71 and the inlet 31 of the clinkering furnace 3. Material which is supplied through conveyor 75 to riser duct 35 is entrained in the hot kiln exhaust gases and recirculated to the calcining furnace 20 for further roasting or calcining.
The conduit 75 includes a adjustable gate 80 to control the fraction of material which is supplied through conduit 75 to outlet 76 and riser duct 3 (the recirculated material) and the fraction of material which is supplied through duct 78 to the duct 71 and inlet 31 of the clinkering furnace 3 (the discharged material). By adjusting the position of gate 80, the quantity of material directed to the duct 78 and therefore the quantity of material supplied to riser duct 35 can be controlled. As pointed out in U.S. Pat. No. 4,381,916, this quantity of material being recirculated through the calciner 2 may be as much as four times the quantity of new feed through inlet 25.
The duct 70, and conduit 75 may be referred to as means defining a second conduit flow connecting the material outlet 13 of the calcining furnace 2 with the riser duct 35 and thus the recirculation duct. Material which is supplied through this second conduit is entrained in the hot exhaust gases from the kiln and is recirculated to the calcining furnace 2. The hot exhaust gases from the kiln assist in calcining the material and raising the temperature inside the calciner 20. The conduit 70, 75, 78 and 71 define a first conduit for supplying calcined material from the material outlet 13 of the calcining furnace 2 to the material inlet 31 of the clinkering furnace 3. In the case of a simple calcining system which does not include a clinkering furnace material may be discharged from the system through duct 71.
In order to prevent the hot exhaust gases from the clinkering furnace 3 from being short circuited from riser duct 35 through conduits 71 and 75 to the outlet 13 of the gas solid separator 10 of stage V, a gas lock 90 is positioned in the conduit 75. This gas lock may be a one-way flap valve for permitting solid material to flow from the conduit 70 to the outlet 76 while preventing gas from flowing from 76 towards outlet 13. Similarly, a gas lock 92 is included in conduit 71 for preventing exhaust gas from flowing from inlet 31 through conduit 71 to the outlet 13.
The ducting arrangement of the present invention has the advantage that if there are large chunks of material being discharged from calcining furnace means through outlet 13 such as pieces of refractory tramp iron or agglomerations of calcined material, these large chunks will not pass through the grizzly 72 to the conduit 75, but instead will flow down enlarged conduit 71 to the inlet 31 of the clinkering furnace. This prevents such large pieces of material from blocking the conveying duct 75.
The arrangement of the present invention also has the advantage that in the event there is a plug or blockage in the recirculating duct 75, material may fill ducts 75 and 70 up to the point of the grizzly 72, and thereafter material will flow down through the oversize material duct 71 directly to the clinkering furnace 3. While such a plug would interfere with the advantageous recirculation of at least partially calcined material back to the calciner, the system could still operate producing satisfactory product until a scheduled shut-down and clean out was possible. The duct 71 may thus be referred to as a means for by-passing material around the recirculation means 75 and discharge ducts 71 and 78.
While the invention has been described primarily in connection with the manufacture of cement clinker, it us equally useful in the calcining of fine lime or dolomite or roasting of other ores. It may be practical where there is only utilized the calcining furnace and not the secondary clinkering furnace. In this case, the duct 71 would be connected to a cooling device to remove the calcined material from the system.
From the foregoing, it should be apparent that the objects of this invention have been carried out. It is intended that the present invention be limited solely by that which is within the scope of the appended claims. | An improved apparatus for roasting fine material which includes recirculation of at least partially roasted material through the roasting furnace for further roasting. An adjustable gate is included in the recirculation system for controlling the quantity of material recirculated. A high temperature fluidizing gravity conveyor is used in the recirculation system to maintain a low profile for the system. The invention utilizing a system for classifying large particles so that they may be removed from the recirculation system. Gas locks are included for preventing the short circuiting of hot gases. The system also includes overflow conduit in the event of a plug or blockage in the system. | 5 |
ORIGIN OF THE INVENTION
The invention described herein was made in the performance of work under a NASA contract and is subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958, Public Law 84-568 (72 Stat. 435; 42 U.S.C. S2457).
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of Application Ser. No. 762,363, filed Jan. 25, 1977, which is in turn a division of application Ser. No. 598,969, filed July 24, 1975, now U.S. Pat. No. 4,065,053, for "Low Cost Solar Energy Collection System."
BACKGROUND OF THE INVENTION
The present invention relates generally to improvements in solar energy collection systems and more particularly pertains to new and improved primary reflectors for use in sun-tracking solar energy collection systems that are capable of producing high solar energy concentration ratios.
The overriding problem confronting developers of solar energy power systems has been the problem of producing the required high temperatures at a cost that would make the utilization of solar power competitively attractive. Presently, systems capable of producing the required high temperatures directly from solar energy, utilize tracking devices with large moving primary reflectors. Accurate tracking devices, however, are expensive to construct and costly to maintain if they are to track under conditions of weather extremes and varying high wind forces. The cost of producing large tracking reflectors and the costs of an associated tracking mechanism sturdy enough to withstand expected wind forces make a solar energy heat generating plant that can provide sufficient power to produce electricity in the multi-megawatt range an uneconomical prospect.
Solar energy collection systems that are to be used for producing superheated steam for use by steam-driven generator equipment for generating electric power must be capable of transforming solar energy into thermal energy in the range of 1000° F. or higher. The prior art systems capable of such heat generation involve tracking concentrators such as three-dimensional paraboloidal dishes which can be precisely steered in both altitude and azimuth to follow the sun's movement. In order to generate temperatures in the range of 1000° F. in sufficient quantity for use as energy for the generation of electrical power, literally thousands of 20-foot diameter, three-dimensional parabolic dishes must be utilized. The cost of producing large numbers of such optically finished compound-curve reflecting surfaces that are sturdy enough to hold their figure when tilted and turned in the wind is prohibitive.
OBJECTS AND SUMMARY OF THE INVENTION
An object of this invention is to provide a fixed, linear, ground-based primary reflector for use in a tracking solar energy collection system.
Another object of this invention is to provide a process for relatively inexpensively making a large linear fixed primary reflector for tracking solar energy collection systems.
These objects and the general purpose of this invention are accomplished in the following manner. A large fixed primary reflector is constructed at ground level by slip-forming in concrete or stabilized dirt a trough with a segmented one-dimensional circular cross-section profile. This profile is covered with an inexpensive light-reflective material. The axis of the primary reflector is optimally aligned with respect to the sun path in the area.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and many of the attendant advantages of this invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like-reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 is a perspective, partial section, illustrating a primary reflector according to the present invention used in a solar energy collection system;
FIG. 2 is a diagrammatic illustration, useful in explaining the principle of the large-scale primary reflector of the present invention;
FIG. 3 is a diagrammatic illustration, useful in explaining the desired structure of the large-scale primary reflector of the present invention;
FIG. 4 is a diagrammatic illustration of the daily and seasonal adjustments required by a collector system utilizing the primary reflector of the present invention;
FIG. 5 is a partial perspective illustration of a type of laterally movable collector system that can be utilized with the large-scale primary reflector of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of a tracking solar energy collection system utilizing a primary reflector according to the present invention is illustrated in FIG. 1. The ground-based reflector 11 can be made up of a plurality of identical sections 13, 15, each section having its own fluid-carrying vessel 87, 89, respectively, for collecting the solar energy reflected from the respective modular surfaces of the sections 13, 15. The width of each modular surface is preferably within the capability of present day concrete road laying machinery.
The segments 25, 23, 17, 21, 22, 27 and 29, which make up the module reflector surface for section 13, can be laid by a process that utilizes standard highway construction or airstrip construction methods. The primary reflector modules may be formed as follows. A sifter mechanism mounted on wheels having a width equal to or slightly greater than the width of a primary reflector module is utilized. This sifter mechanism may have the following structure. A sifter body is divided into multiple segments, each segment utilizing a rotary screen-type mechanism for accepting a different particle size. Conveniently, four segments of the following particle grades may be used: rocks, coarse, medium and fine. The aggregate containing all these grades of particles is supplied to the sifter by a conveyor mechanism, the aggregate being inserted at the "fine" end of the sifter. The entire sifter mechanism moves in a direction whereby its coarse segments is always in the front. Consequently, the rocks or very large particles are laid down first, then the coarse particles, then the medium particles and then the fine particles.
This aggregate material may be the in-situ soil. Or, if the in-situ soil is unsuitable, suitable material may be brought in. As the aggregate is being delivered to the sifter, a binder material such as cement is mixed in with it. Consequently, all the various graded particles will be associated with the binder. As each graded particulate is ejected from the sifter, it is sprayed with water.
The moistened particulate of each graded layer is partially shaped to the desired contour of the primary reflector by a screed attached to the moving sifting mechanism for each. A plurality of pipes 62 in FIG. 2, having orifices therein, are preferably laid into the multi-layer substrate thus formed in the medium or fine layers.
The multi-layered substrate having binder material throughout is finished to the desired sawtooth segmented cross-section by a roller mechanism that preferably has the following structure: a roller having the inverse curvature of the desired profile and being the width of a primary reflector module. The roller travels along the graded aggregate substrate in front of a sled having the same contour as the foller. The sled has mounted thereon acoustic vibrators that operate at high frequency to provide a very smooth surface to the sawtooth segmented primary reflector. The depth of the various segmented steps with varying radii of curvatures 25, 23, 17, 21, 22, 27 and 29 is determined mainly by the slump factor of the thus stabilized soil during its curing process.
An aluminized Mylar sheeting material, 0.00025 inches thick, or an equivalent reflective material is laid over the slip-formed profile. The reflecting material is held down by a slight vacuum created at the surface of the reflector profile by drawing a vacuum on the pipes laid therein. Since concrete is a porous substance, drawing a vacuum on the pipes within the concrete will create a low pressure region at the surface of the concrete. This will hold the reflective film material in place without the necessity of glue or some other such fastening means. Holding the reflector covering in place by a vacuum also facilitates rapid replacement of torn or dirty reflector material. A vacuum level which varies in intensity suitable to the prevailing wind velocity is preferred. Any well-known vacuum-producing process may be utilized. However, an inexpensive method of producing the vacuum is preferred. One such method is commonly known as steam ejection, using the steam supplied by the system.
Each reflector module of the section, such as section 13, has a flat portion 31 which can provide access to the curved reflector segments for maintenance and inspection purposes, using a gantry-type vehicle. One type of support structure that may be used for each section to support the fluid-carrying vessel 87 comprises a plurality of stanchions 51, 53, 55, equidistantly spaced along a line parallel to the longitudinal axis of each reflector module of the reflector 11. The stanchions 51, 53, 55, for example, have a four-bar linkage 75, 77, 78, respectively, attached thereto which supports the fluid-bearing pipe 87. A hydraulic or electrical actuating device of well-known construction 63, 65, 67 is respectively located on the stanchions 51, 53, 55 for moving the four-bar linkages 75, 77, 79 in synchronism. This synchronous movement of the linkage causes the fluid-bearing pipe collector 87 to be transversely shifted in an area relative to the reflecting module 13. The movement of the pipe collector can be controlled either by a programmed source correlated to stored data relating to the apparent sun movement in the area, or alternatively, by sun-sensing and following systems similar to that used for attitude control on spacecraft.
Every other section of the reflector 11 is similarly constructed. Each section, such as section 15, for example, has a flat walkway portion 33 in which the plurality of stanchions 57, 59 and 61 are placed. These stanchions support respective four-bar linkages 81, 83 and 85. Each bar linkage supports a portion of the fluid-carrying pipe 89, which is moved transversely in an arc by actuation of motive means 69, 71 and 73, respectively connected to the bar-linkage devices. The cylindrical segments 40, 41, 35, 37, 36, 43 and 45 of the reflector module 15 may have the same radius of curvature as the segments 25, 23, 17, 21, 22, 27 and 29, respectively, of module 13.
These optimum width modules of the reflector surface 11 may be laid side by side in the manner illustrated in FIG. 1 for any desired distance. The length of each reflective module along the longitudinal axis may also be any length desired. It is envisioned that a reflector surface a mile square could be utilized in a solar energy collection system.
The height of the stanchions for each reflector module depends upon the radius of curvature of the troughs, as will be more fully explained hereinafter. The radius of curvature of the troughs depends upon the width of each module. The depth depends on the slump factor limitations of the stabilized soil or concrete used to form the primary reflector profile. This will also be more fully explained hereinafter.
It is well known in the art that a parabolic reflecting trough focuses received parallel light rays (that arrive in a direction such that a plane perpendicular to the directrix sheet contains the light rays in question) into a line focus along a line parallel to the vertex line and passing through the axis. If the received light rays, arriving parallel at a parabolic trough, arrive in such a direction that they make an angle with the above-mentioned plane perpendicular to the directrix sheet, the line focus suffers from coma and the focus becomes diffuse. It is for this reason that parabolic trough reflectors must be guided so that they always face the incoming sunlight squarely.
It is possible to achieve many of the results of the tracking parabolic trough with a non-tracking reflecting trough if the cross-section is made to be circular. Cylindrical reflecting surfaces of circular cross-section approximate the parallel line focusing action of an optimally positioned parabolic cylinder if only small segments of the circular cylinder surfaces are utilized. Incoming parallel light is brought to a substantial line focus for most angles of approach of the sunlight to the circular trough, albeit the location of the line focus varies with the angle of approach of the sunlight.
FIG. 2 illustrates a circular trough 92 receiving a plurality of differently angled parallel light beams. If only a small segment of the circular trough 92 is considered, such a segment 94, for example, parallel light rays 97A, 95A, 93A impinging upon the segment are reflected at the surface of the radius of curvature with an angle of incidence that equals the angle of reflection. As a consequence, rays 93A, 95A and 97A are reflected as rays 93B, 95B and 97B. These rays intersect at a point 105 lying on the focal surface 109. Rays 99A, 101A and 103A of the cylindrical segment 94 are reflected as rays 101B, 103B and 99B that intersect at a point 107 on the focal surface 109. Other skewed light rays, such as rays 116A, for example, would impinge upon the cylindrical surface 92 and be reflected in a direction 116B, and so on. The focal point 105 for parallel lines 95A, 97A and 93A, and the focal point 107 for parallel lines 101A, 103A and 99A turn into focal lines that run parallel to the longitudinal axis of the cylindrical trough when sheets of light rays parallel to 99A, 101A and 103A, but extending into and out of the paper are considered. The focal surface 109, therefore, becomes a cylindrical focal trough.
Because a shallow reflecting surface is desired from the standpoint of economy in construction and maintenance, the maximum height 111 to which any reflecting surface may peak should not exceed approximately 12 inches. This problem can be overcome by segmenting the cylindrical surface 92 into a sawtooth-like reflecting surface. Thus, for example, segment 119 is the segment 117 of the cylindrical surface 92 brought down to lie on a common plane with segment 94. Likewise, segment 115 is segment 113 of the cylindrical surface 92 brought down to lie on the same common plane. These segments all have a common height 111.
This segmented reflecting surface, however, will not function to focus parallel lines into a line focus on the surface of focal trough 109. Although the radius of curvature of the various segments is the same as the radius of curvature of the cylindrical trough 92, the distance from the center of curvature of the cylindrical trough 92 varies for each segment. As a consequence, ray 116A, for example, will be reflected from surface segment 115 along reflected light beam 118B. Light beam 116A travels an extra distance 118A before it strikes a reflecting surface 115. The focal point for all parallel light rays striking reflective surface 115 will lie at point 122, which is on a different focal surface of curvature 120 than the focal surface 109 of cylindrical surface 92. Each segmented radius of curvature such as 119, for example, may well have a different focal surface.
In order to provide a segmented one-dimensional linear reflecting element that is within the range of 4 to 12 inches in height, the radius of curvature of the various segments must be chosen so that no matter which segment of the equivalent flattened reflective surface 119, 94 and 115, for example, is impinged upon by parallel light rays, these light rays will intersect in the surface of a common focal surface. FIG. 3 illustrates how the radii of curvatures for the various segments of the reflector 123 is determined. The largest segment 125 of the reflecting profile 123 is chosen to have a radius of curvature (r a ) 127 that, for example, is 10 to 20 feet, this distance being a practical distance for the height of the stanchions. Conceivably, higher stanchions may be utilized. However, the cost of stanchions higher than 20 feet goes up considerably.
Having determined the radius of curvature for the main segment from the cylindrical center of curvature 145 to be approximately 20 feet, the focal surface 131 is located 10 feet from the surface of segment 125. This focal surface distance is equal to half the radius of curvature (1/2)r a . The radii of curvature of the other segments such as 133 and 139, for example, must then be chosen so that the distance from each surface to the chosen focal surface 131 is equal to half of its radius of curvature. Segments 133, as shown in FIG. 5, can be seen as having a radius of curvature 135, termed r b extending from a center of curvature 147.
The location of point 147 is chosen so that the distance from surface 133 to point 147 is twice the distance from surface 133 to the selected focal surface 131. For this reason, the focal surface of segments 133 will be located on a cylinder with its center at point 147 and having a radius (1/2)r b . From the geometry, the focal surface of segments 133 will be almost exactly coincident with focal surface 131, the focal surface for segment 125. Therefore, an absorber pipe traveling along focal surface 131 and receiving reflected energy from segment 125 will, at the same location, receive energy reflected from segments 133.
In a similar fashion, segments 139 are given a radius of curvature r c , extending from a point 149. The location of point 149 is chosen so that the distance from segment surface 139 to point 149 is twice the distance from segment surface 139 to the earlier-selected focal surface 131. Therefore, the focal surface of segments 139 will be located on a cylinder having its center at point 149 and a radius of (1/2)r c . Thus, the focal surface of segments 139 will be almost exactly coincident with focal surface 131, the focal surface segments 126.
By choosing the radii of curvature of the various segments in the trough reflecting surface 123 in this manner, a reflecting surface that effectively functions like the deep trough 117 of FIG. 2, but is actually shaped as shown at 123 in FIG. 3, is obtained. The reflector-concentrator cross-sectional profile 123 illustrated in FIG. 3 can be slip-formed according to the process above described. Rather than slip-forming the reflector surface to have straight edges 128, sloping edges 130 at an obtuse angle are formed. The reason for interleaving the segments in this manner is that the area 132 within each valley between the imaginary straight edge 128 and the real sloped edge 130 is not effective as a reflecting surface because of shading by the upper corner of edge 128. As will be more fully explained hereinafter, by choosing the slope of edges 130 carefully, light rays striking those edges can be reflected to the line focus of an adajcent collector.
The orientation of the longitudinal axis of the segmented trough reflector surface will determine the extent of movement required by the collector pipe along the focal surface, in order to track the movement of the sun diurnally and seasonally. An east-west longitudinal axis orientation is the preferred orientation for the reason that a minimum of collector movement will be required. FIG. 4 illustrates the various positions that the collector must take during various times of the day and throughout the year, in order to be at the focal line of the solar energy reflected from the surface 151 at all times. The various segments of the reflector 151 have radii of curvature that will cause a substantial part of the parallel light impinging on most parts of the reflector surface to be reflected to a common point on arc 155.
The longitudinal axis of the reflecting surface 151 is assumed to be oriented in the east-west direction so that the troughs of the reflecting surface are parallel with the east-west direction. Broken line 153 represents the local vertical axis, shown here for purposes of reference. For an example relating to a location at latitude 34° N., a light ray 157A, at an angle of 11° to the local vertical, depicts the angle of incidence of solar energy impinging upon the reflector surface 151 at about 12 noon on June 21, i.e., the summer solstice. This light is reflected by surface 151 as a light beam 157B, and intersects the focal arc 155 at point 165. As the afternoon wears on, the angle with the local vertical increases, causing the reflected light beam 157B to move toward point 161 on the focal arc 155. At approximately 3:00 p.m., the reflected rays 157B are intersecting the focal arc 155 at point 161. At 9:00 a.m. that same day, the light rays 157A, impinging on surface 151, were reflected to cross the focal arc 155 at the same point 161. Thus, in the morning, these reflected rays will move from point 161 on the focal arc 155 towards point 165, and back toward point 161 in the afternoon.
The light ray 159A depicts the solar energy from a noontime sun on December 21. This energy is reflected by surface 151 as light rays 159B to intersect the focal arc 155 at point 179. At about 3:00 p.m., the reflected rays 159B are intersecting the focal arc 155 at point 183. At 9:00 a.m. of that same day, the rising sun causes the reflected beam 159B to intersect the focal arc 155 at point 183. Thus, the sun's movement causes the reflected rays to start at point 183, gradually move to point 179, at noon, reverse itself and go back to point 183.
Segment 193 of the focal arc 155 depicts the swing of the reflected sun's rays during the month of January. At about 9:00 a.m., the reflected light rays cross the focal arc at point 181. During the morning, they move toward point 177 where they cross at noontime. In the afternoon, they move back toward 181 where they cross at 3:00 p.m. Segment 191 of focal arc 155 depicts the movement of the reflected sun's rays during the month of February. Intersection 173 is the noontime intersection and intersection 195 being the ±3 hours from noon intersection point. Intersection point 172 of focal arc 155 represents the intersection of the reflected light rays during the month of March. There is minimal movement of the reflected light rays at the equinox date because the sun rises directly in the east and sets directly in the west on this data. The segment 189 of the focal radius 155 represents the movement required during the month of April, intersection point 171 being the noontime intersection point. Intersection point 169 is the ±3 hours from noon intersection point. Segment 187 of focal arc 155 is the movement required during the month of May, intersection point 167 being the noon time intersection point. Intersection point 163 is the ±3 hours from noon intersection point. As already noted, segment 185 of the focal arc 155 is the movement required for the month of June, intersection 165 being the noon intersection point and intersection point 161 being the ±3 hours from noon intersection point.
For the month of July, the reflected sun's rays again move along segment 187 of focal arc 155 as they did in May. In August, the reflected sun's rays move along segment 189 of focal arc 155 as they did in April, In September, the sun again rises directly in the east and sets directly in the west as it did in March. In October, the reflected sun's rays again traverse segment 191 of focal arc 155 as they did in February. In November, the reflected sun's rays again traverse segment 193 of focal arc 155 as they did in January.
In order to track the sun's movement diurnally and seasonally, the collector must traverse the focal arc 155 as the sun moves in the sky. As can be seen from FIG. 3, however, the movement of the collector during each day is quite small. Thus, for example, during December the collector need only move within segment 185. At the equinox dates of March and September, however, the collector pipe is substantially stationary at point 172. By not requiring large transversal movements on a daily basis, the drive mechanism for moving the collector pipe along the focal arc 155 is considerably simplified.
FIG. 5 illustrates one embodiment for suspending the high pressure steel, heat-absorbing, fluid-bearing collector pipes that are moved to always be at the focal line of the reflected sun's rays. The pipes 201, 217 preferably carry water or other fluid that is heated by the reflected solar energy from the reflecting surface 199. As was explained earlier, the fluid-bearing pipes 201 and 217 must move along the focal arcs 215, 233, respectively, in order to track the sun's movements.
There exists for every set of distance and size relationships between the modules that make up the solar reflector an obtuse angle for the edges 130 of the segments of the primary reflector 199 that is most effective in reflecting the incident light rays to an adjacent collector. For example, an incident light ray 206A hitting segment surface 132 is reflected as ray 206B to collector 201. Because of the obtuse angle of slope of edge 130, the entire surface 132 of that segment is an effective reflector. Light rays, such as ray 208A incident on edge surface 130, are reflected as rays 208B to the collector 217 for the adjacent module. Likewise, collector 201 will receive some light rays reflected from the edge surface 130 of its adjacent module.
One parallel line of stanchions would be required for each transversely movable collector pipe. The heat-absorbing pipe 201 is connected to a vertical intake pipe member 205 and a vertical outlet pipe member 203. Water (preferably treated or distilled in liquid, vapor, or steam form) is supplied to vertical pipe member 205 from pipe 209 through a high-pressure slip joint 213. Steam from the vertical pipe member 203 is supplied to pipe 207 through a high-pressure slip joint 211. The assembly, consisting of pipes 205, 201 and 203, can be seen to make up a trapeze that pivots at slip joints 213 and 211 to swing in the focal arc 215. The intake pipe 209 and outlet pipe 207 are, of course, connected to a utilization device (not shown) by standard, well-known valving techniques which includes pressurizing and pressure-relief devices, matched to the system operating pressure. Such systems being well within the purview of a person of skill in the art, they are not further disclosed herein. In order for the pipe 201 to swing along this focal arc 215, the distance from the slip joints to the pipe must be equal to half the focal radius of the basic segment in the reflector surface 199.
As was illustrated in FIG. 1, another parallel line of stanchions may support another fluid-bearing pipe member 217 suspended to swing along the focal arc 233. The vertical inlet pipe 291, the vertical outlet pipe 221 and the heat-absorbing pipe 217 again forms a trapeze that swings about the slip joints 229 and 231 that connect the inlet pipe 225 and the outlet pipe 227 to the trapeze assembly. The length of the heat-absorbing pipe assembly is determined by the length of each modular section of the primary reflection surface. The number of heat-absorbing pipes utilized is determined by the number of modules forming the entire primary reflecting surface.
Many modifications and variations of the present invention are possible in light of the above teachings. It is to be understood, therefore, that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A fixed, linear, ground-based primary reflector having an extended curved sawtooth-contoured surface covered with a metalized polymeric reflecting material, reflects solar energy to a movably supported collector that is kept at the concentrated line focus of the reflector primary. The primary reflector may be constructed by a process utilizing well-known freeway paving machinery. | 5 |
BACKGROUND
[0001] The invention generally relates to a modular retrievable packer.
[0002] A packer is a device that is used in an oilfield well to form a seal for purposes of controlling production, injection or treatment. In this manner, the packer is lowered downhole into the well in an unset state. However, once in the appropriate position downhole, the packer is controlled from the surface of the well to set the packer. As an example, for a mechanically-set packer, a tubular string that extends from the surface to the packer may be moved pursuant to a predefined pattern to set the packer. For a hydraulically-set packer, fluid inside the tubular string may be pressurized from the surface, creating a tubing pressure differential to set the packer.
[0003] In its set state, the packer anchors itself to the casing wall of the well and forms a seal in the annular region between the packer and the interior surface of the casing wall. This seal subdivides the annular region to form an upper annular region above the packer that is sealed off from a lower annular region below the packer. The packer also forms a seal for conduits that are inserted through the packer between the upper and lower annular regions. As examples, one of these conduits may communicate production fluid from a production zone that is located below the packer, one of the conduits may communicate control fluid through the packer, one of the conduits may house electrical wiring for a submersible pump, allow production or injection through two different reservoir zones, etc.
[0004] As a more specific example, FIG. 1 depicts a well that includes a packer 20 . As shown, the packer 20 may be connected to a tubular string 16 that extends downhole into the well. The packer 20 forms an annulus seal with the interior surface of a wall of a casing string 12 that circumscribes the packer 20 . The packer 20 typically includes at least one seal assembly 24 to form the annulus seal and at least one set of slips 22 to anchor the packer 20 to the casing string 12 . In this manner, when run into the well, the seal assembly 24 and the slips 22 are radially retracted to allow passage of the packer 20 through the central passageway of the casing string 12 . However, when the packer 20 is in the appropriate downhole position, the packer 20 is set to place the packer 20 in a state in which the seal assembly 24 and slips 22 are radially expanded. When radially expanded, the slips 22 grip the interior surface of the wall of the casing string 12 to physically anchor the packer 20 in position inside the well. The radial expansion of the seal assembly 24 , in turn, seals off the annular space between the string 16 and the casing string 12 to form a sealed annular region above the seal assembly 24 and a sealed annular region below the seal assembly 24 .
[0005] The packer 20 may be hydraulically actuated for purposes of controlling the packer 20 from the surface of the well to set the packer 20 . This means that pressure may be communicated through fluid inside the string 16 to the packer 20 . In response to this pressure reaching a predefined threshold level, pistons (not shown in FIG. 1) move to radially expand the slips 22 and apply compressive forces on the seal assembly 24 to radially expand the assembly 24 . A retention mechanism of the packer 20 serves to hold the packer 20 in the set state when the pressure that is used to set the packer 20 is released.
[0006] One or more mandrels 21 , or tubular elements, may extend through the packer 20 for purposes of providing communicating paths through the packer 20 . Depending on the particular application of the packer 20 , a particular mandrel 21 may contain one or more communication paths, such as paths to communicate production fluid, electrical lines, or control fluid through the packer 20 . For example, in a particular application, a single mandrel 21 may extend through the packer 20 for purposes of communicating production fluid from a tubular string 22 located below the packer 20 to the string 16 located above the packer 20 . However, in other applications, more than one mandrel 21 may be extended through the packer 20 . Thus, one mandrel 21 may be used for purposes of communicating electrical or hydraulic lines, for example, and another mandrel 21 may be used for purposes of communicating production fluid through the packer 20 .
[0007] The packer 20 may be retrievable, and thus may include a release mechanism that when engaged, releases the retention mechanism of the packer 20 to radially retract the slips 22 and seal assembly 24 to permit retrieval of the packer 20 to the surface of the well.
[0008] The packer 20 establishes two general seals: an interior seal between the interior of the packer 20 and the exterior of the one or more mandrels 21 that are extended through the packer 20 ; and an exterior seal between the exterior of the packer 20 and the interior surface of the wall of the casing string 12 . Because the mandrel configuration may change depending on the particular application of the packer, a given packer design may need to be modified to accommodate the particular application. Thus, for example, the packer 20 may have a first design for an application in which a single mandrel extends through the packer 20 . However, the design of the packer 20 must be redesigned for an application in which two mandrels are extended through the packer 20 . In this manner, the exterior profiles and structure that are presented by two mandrels are significantly different from the exterior profiles and structures that are associated with one mandrel, thereby requiring a substantial redesign of the packer's interior sealing rings and structure that establishes the packer's interior seal. Furthermore, the design of the packer 20 may need to be redesigned to accommodate different size mandrels or additional mandrels that are inserted through the packer 20 .
[0009] Thus, there is a continuing need for an arrangement that addresses one or more of the problems that are set forth above.
SUMMARY
[0010] In an embodiment of the invention, a packer that is usable with a subterranean well includes an assembly to circumscribe one out of multiple tubular arrays that are inserted through the packer. The packer also includes a member that is separable from the assembly to configure the assembly for connection to the tubular array. The member includes a first seal between the member and the tubular array and a second seal that is located between the member and the shell. The first seal is separate from the second seal. The assembly includes a slip to engage a casing of the well and a sealing element to seal an annulus of the well.
[0011] Advantages and other features of the invention will become apparent from the following description, drawing and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a schematic diagram of a packer of the prior art.
[0013] [0013]FIGS. 2 and 3 are schematic diagrams of a packer in accordance with an embodiment of the invention depicting a state of the packer when run into a well.
[0014] [0014]FIGS. 4, 5 and 6 are schematic diagrams depicting the packer in accordance with the invention in a state in which the packer is set.
[0015] [0015]FIGS. 7, 8 and 9 are schematic diagrams depicting the packer in accordance with the invention in a state after the packer has been unset for purposes of retrieval of the packer from the well.
[0016] [0016]FIGS. 10 and 11 are schematic diagrams of a packer in accordance with another embodiment of the invention depicting a different mandrel configuration.
DETAILED DESCRIPTION
[0017] An embodiment of a packer in accordance with the invention is depicted in its run in state in FIGS. 2 and 3. FIG. 2 depicts an upper section 100 A of the packer, and FIG. 3 depicts the lower section 100 B of the packer. In this run in state, the packer is ready to be run into a well to the appropriate position at which the packer may be set, as described further below.
[0018] The packer includes one or more internal tubes, or mandrels, that extend through the packer for purposes of establishing one or more communication paths through the packer. In the embodiment that is depicted in FIGS. 2 and 3, the packer includes an internal tubing, or mandrel 25 , that extends through the packer for purposes of establishing fluid communication between a tubular member 26 that extends above the packer and a tubular member (not shown in FIG. 2 or 3 ) that extends below the packer.
[0019] The packer forms a seal between the packer and the exterior surface(s) of the one or more mandrels. Thus, the different mandrel configurations require different seals. However, the packer has a design that minimizes the number of components that must be changed to reconfigure the packer from a first configuration for use with a particular mandrel configuration (such as the mandrel configuration depicted in FIGS. 2 and 3) to a second mandrel configuration for use with a different mandrel configuration (a two mandrel configuration, for example).
[0020] In some embodiments of the invention, the ability of the packer to be easily reconfigured flows from the modular design of the packer. Referring to FIGS. 2 and 3, in some embodiments of the invention, the packer includes an internal and generally circularly cylindrical shell 34 . The shell 34 has a central passageway through which the internal mandrel 25 extends. Mounted on the exterior of the shell 34 are components that are associated with anchoring the packer to the casing wall and forming a seal between the packer and the casing wall. In this manner, these components may include, for example, a set of slips 70 (one slip being depicted in FIGS. 2 and 3) that are spaced regularly around the periphery of the packer to anchor the packer to the casing string, and these components may also include an elastomer seal assembly 36 (FIG. 2) that circumscribes the shell 34 and is compressed to seal off the well annulus. As further described below, also mounted on the exterior of the shell 34 are various pistons and other devices used to set and unset the elastomer seal assembly 36 and the slips 70 , as described below. Thus, the shell 34 forms a basic structure of a shell assembly that includes the shell 34 and components that are associated with anchoring the packer to the casing wall and forming a seal between the casing wall and the packer.
[0021] For purposes of facilitating the redesign of the packer for different mandrel configurations, unlike conventional packers, sealing rings do not directly bridge the space between the interior surface of the shell 34 and the exterior surface of the mandrel 25 . The inclusion of such sealing rings that form direct seals between the shell 34 and mandrel 25 hinders the reconfiguration of the packer, as specific grooves must be formed in the exterior surface of the mandrel 25 and/or in the interior surface of the shell 34 to accommodate these sealing rings. Thus, for example, the grooves and general design of the shell for a one mandrel design would be different than the design of the shell for a two mandrel design. This means a different shell would have to be used for each configuration. However, unlike conventional packers, the packer has a different design in which seals between the shell 34 and mandrel(s) are established by separate components, called sealing bulkheads with the diversity to change the internal configuration without changing most of the components on the shell.
[0022] In this manner, for the embodiment of the packer 20 depicted in FIGS. 2 and 3, the packer includes an upper sealing bulkhead 32 . This upper sealing bulkhead 32 includes a first sealing ring to form a seal between the bulkhead 32 and the mandrel 25 and a second sealing ring to form a seal between the bulkhead 32 and the shell 34 . Similarly, the packer includes a lower sealing bulkhead 80 (see FIG. 3) that includes a third sealing ring to form a seal between the bulkhead 80 and the mandrel 25 and includes a fourth sealing ring to form a seal between the bulkhead 80 and the shell 34 . Thus, no sealing rings extend directly between the shell 34 and the mandrel 25 , i.e., no seals are formed directly between the shell 34 (and shell assembly) and the mandrel 25 .
[0023] Due to this arrangement, a different mandrel configuration is accommodated by simply changing the sealing bulkheads and sealing rings, as compared to redesigning the packer's shell assembly or another part of the packer associated with the anchoring and annulus sealing functions of the packer. In this manner, a particular set of upper and lower sealing bulkheads are used with one mandrel configuration, another set of upper and lower sealing bulkheads are used with a two mandrel configuration, a third set of upper and lower sealing bulkheads are used with mandrel configurations with mandrels having different diameters, etc. Thus, because only the sealing bulkheads and sealing rings are dependent on the mandrel configuration, design time and costs associated with reconfiguring the packer for different mandrel configurations are minimized.
[0024] Turning now to a more detailed description of the packer and more particularly referring to FIG. 2, in some embodiments of the invention, the upper sealing bulkhead 32 includes an annular groove 32 c that holds a corresponding elastomer sealing ring 33 (an O-ring, for example) to form a seal between the upper sealing bulkhead 32 and the exterior surface of the mandrel 25 . The upper sealing bulkhead 32 also includes an annular groove 32 b that holds an elastomer sealing ring 38 (an O-ring, for example) to form a seal between the upper sealing bulkhead 32 and the shell 34 . Thus, with these two sealing rings 33 and 38 , the upper sealing bulkhead 32 forms a seal between the shell 34 and the mandrel 25 .
[0025] The upper sealing bulkhead 32 has a lower annular inclined surface 32 a that forms a shoulder that, in turn, abuts an upper annular contact surface of the elastomer seal assembly 36 . As described below, when the packer is set, a piston of the packer exerts an upward force on the elastomer seal assembly 36 , forcing the elastomer seal assembly 36 against the surface 32 a and causing the seal assembly 36 to radially expand.
[0026] In some embodiments of the invention, the packer is hydraulically actuated by fluid pressure that is applied through a central passageway 39 of the mandrel 25 . For purposes of establishing fluid communication between pistons of the shell assembly and the central passageway 39 , the mandrel 25 includes radial fluid ports 31 that extend through the sidewall of the mandrel 25 . In this manner, the pressure on the fluid in the central passageway 39 is increased to actuate the pistons to set the packer. Afterwards, the applied pressure is decreased, or bled off. As described below, the packer includes a retention mechanism to hold the packer in its set state, even after the applied fluid pressure is released.
[0027] As also described below, the packer may be retrieved by exerting an upward force of sufficient magnitude on a tubular string that is connected to the mandrel 25 and extends to the surface of the well. In this manner, a sufficient upward force on the mandrel 25 engages a release mechanism of the packer to release the slips 70 (FIG. 3) and elastomer seal assembly 36 to permit radial retraction of these devices and the retrieval of the packer to the surface of the well.
[0028] In some embodiments of the invention, the force to radially expand the elastomer seal assembly 36 is applied by an upper piston assembly 42 that circumscribes the shell 34 . The piston assembly 42 includes an upper sleeve 42 a that circumscribes the shell 34 and has an upper annular inclined surface 42 h to contact a lower annular contact surface of the seal assembly 36 . For purposes of preventing the inadvertent setting of the packer, the upper sleeve 42 a is initially held in place to the shell 34 via one or more shear screws 43 . In this manner, when the packer is set, enough upward force is applied on the piston assembly 42 to shear the shear screws 43 to permit compression of the elastomer seal assembly 36 by the piston assembly 42 .
[0029] In addition to the upper sleeve 42 a , the upper piston assembly 42 includes an intermediate sleeve 42 b that is located below and is connected to the upper sleeve 42 a . The intermediate sleeve 42 b , in turn, circumscribes the shell 34 , and is located above and is connected to a lower sleeve 42 c of the piston assembly 42 . This lower sleeve 42 c also circumscribes the shell 34 . The lower end of the lower sleeve 42 c , in turn, includes a piston head 42 f (FIG. 3) that is in fluid communication with an expandable chamber 54 .
[0030] Referring to FIGS. 2 and 3, an annular region that is defined radially between the exterior surface of the mandrel 25 and the inner surface of the shell 34 and longitudinally between the upper 32 and lower 80 sealing bulkheads communicates fluid between the radial ports 31 of the mandrel 25 and the chamber 54 . Due to this communication, an upward force is exerted on the upper piston assembly 42 in response to the fluid inside the central passageway 39 being pressurized. After the shear pins 43 shear, this upward force causes upward movement of the piston assembly 42 that, in turn, applies a compressive force to radially expand the seal assembly 36 .
[0031] Referring to FIG. 3, in some embodiments of the invention, the packer includes a lower piston assembly 50 that circumscribes the shell 34 and resides below the expandable chamber 54 . In this manner, the piston assembly 50 includes a piston head 50 a that is in fluid communication with the chamber 54 . Because the piston head 50 a is located below the chamber 54 , when sufficient pressure is applied to the fluid inside the central passageway 39 , the piston assembly 50 moves in a downward direction. As described below, this movement of the piston assembly 50 causes the radial expansion of the slips 70 .
[0032] More particularly, the piston assembly 50 is formed from a generally circularly cylindrical sleeve that circumscribes the shell 34 . The piston assembly 50 is initially held in place to the shell 34 by one or more shear screws 51 . However, after sufficient fluid pressure is applied to expand the chamber 54 , the shear screws 51 shear, thereby freeing the piston assembly 50 to move in a downward direction.
[0033] The sleeve that forms the piston assembly 50 is connected to a generally circularly cylindrical upper cone assembly 64 that circumscribes the shell 34 . The upper cone assembly 64 moves downwardly with the piston assembly 50 to apply force to the slips 70 for purposes of causing the slips 70 to radially expand. In this manner, in the depiction of the packer of FIG. 3, the cone assembly 64 includes a lower inclined annular face 64 c that contacts the inclined faces of the slip 70 . Thus, when the lower piston assembly 50 moves in a downward direction, the inclined face 64 c of the cone assembly 64 pushes against the corresponding inclined faces of the slips 70 to force the slips 70 in radially outward directions. Each slip 70 is held in position by a spring-biased connection 70 a that radially retracts the slip 70 when the cone assembly 64 is not pushing against the slip 70 .
[0034] In some embodiments of the invention, a generally circularly cylindrical outer sleeve 67 circumscribes the upper cone assembly 64 . The sleeve 67 has openings through which the slips 70 extend. The sleeve 67 is initially secured to the upper cone assembly 64 via one or more shear screws 65 . In this manner, after the lower piston assembly 50 exerts sufficient force against the cone assembly 64 , the shear screws 65 shear, thereby allowing movement of the upper cone assembly 64 and thus, the extension of the slips 70 .
[0035] A lower cone assembly 76 abuts a lower inclined annular surface of each slip 70 . In this manner, the lower cone assembly 76 is circumscribed by the outer sleeve 67 and includes an inclined annular surface 76 c that mates with corresponding inclined surfaces of the slips 70 to produce a force to radially extend the slips 70 when the lower piston assembly 50 moves in a downward direction. The lower cone assembly 76 is secured to the mandrel 25 via one or more shear screws 89 .
[0036] As described further below, the shear screws 89 shear in response to a sufficient upward force that is exerted on the mandrel 25 to cause the packer to transition from a set state to an unset state for retrieval from the well. In this manner, when the packer is set, the lower cone assembly 76 is fixed in position. Thus, the application of an upward force on the mandrel 25 causes the shear screws 89 to shear, thereby freeing the mandrel 25 to move relative to the lower cone assembly 76 . The release of the packer from its set state is further described below.
[0037] Among the other features of the packer, the packer may include a pin and slot arrangement to permit a limited movement between the upper 64 and lower 76 cone assemblies and the outer sleeve 67 . Such movement permits movement for purposes of setting the slips 70 , but the range of movement is limited for purposes of disengaging the packer from its set state, as described further below. The pin and slot arrangement includes one or more upper slots 90 that are formed in the outer sleeve 67 above the slips 70 and one or more lower slots 94 that are formed in the outer sleeve 67 below the slips 70 . Each upper slot 90 is associated with a pin 91 that radially extends from the upper cone assembly 64 into the associated upper slot 90 . Each lower slot 94 is associated with a pin 95 that radially extends from the lower cone assembly 76 into the associated lower slot 94 .
[0038] The lower sealing bulkhead 80 is generally circularly cylindrical, circumscribes the mandrel and is circumscribed by the shell 34 . The lower sealing bulkhead 80 includes an interior annular groove 80 a that holds an elastomer sealing ring 81 (an O-ring, for example) that forms the seal between the interior surface of the bulkhead 80 and the exterior surface of the mandrel 25 . The lower sealing bulkhead 80 also includes an exterior annular groove 80 b that holds an elastomer sealing ring 83 (an O-ring, for example) that forms the seal between the exterior surface of the bulkhead 80 and the interior surface of the shell 34 . In some embodiments of the invention, the lower sealing bulkhead is secured to the shell 34 via one or more screws 97 .
[0039] Referring to FIGS. 2 and 3, for purposes of maintaining the set state of the packer after the release of the fluid pressure in the central passageway 39 , the packer includes a sleeve 46 that is generally circularly cylindrical and circumscribes the lower portion of the upper piston assembly 42 and the upper portion of the lower piston assembly 50 . The sleeve 46 forms a set retention mechanism by forming a non-retractable extension between the upper 42 and lower 50 piston assemblies; and this extension is increased in response to the upper movement of the upper piston assembly 42 and the lower movement of the lower piston assembly 50 .
[0040] More specifically, a lower end 46 b (FIG. 3) of the sleeve 46 is attached to the lower piston assembly 50 ; and an upper end 46 a (FIG. 2) of the sleeve 46 is connected in a ratchet-type arrangement with the upper piston assembly 50 . The upper portion 46 a of the sleeve 46 includes teeth that engage exterior mating teeth of a ratchet ring 48 (FIG. 2). The ratchet ring 48 is circumscribed by the upper end 46 a of the sleeve 46 and circumscribes the upper piston assembly 42 . More specifically, interior ratchet teeth of the ratchet ring 48 interact with exterior ratchet teeth 42 g of the upper piston assembly 42 . The interior ratchet teeth of the ratchet ring 48 and the ratchet teeth 42 have profiles to permit the ratchet teeth 42 g (and upper piston assembly 42 ) to move in an upward direction relative to the ratchet ring 48 , but these profiles do not permit the ratchet teeth 42 g (and upper piston assembly 42 ) to move in a downward direction relative to the ratchet ring 48 . Due to this arrangement, when pressure is applied to the fluid to drive the piston assembly 42 in an upward direction and drive the lower piston assembly 50 in a downward direction, the sleeve 46 maintains the positions of the upper 42 and lower 50 piston assemblies, while allowing more movement in the upper and lower directions of the upper 42 and lower 50 piston assemblies, respectively. Thus, when pressure is released from the fluid in the central passageway, the piston assemblies 42 and 50 maintain the forces on the elastomer seal assembly 36 and the slips 70 to keep the packer in the set state.
[0041] [0041]FIGS. 4, 5 and 6 depict upper 120 A, intermediate 120 B and lower 120 C sections of the packer in the packer's set state. Referring to these figures, in its set position, the elastomer seal assembly 36 is expanded radially in an outward direction. Furthermore, the teeth 42 g of the lower piston assembly 42 engage the ratchet ring 48 at a lower position so that the piston assemblies 42 and 50 are located by a distance apart that does not change when pressure is released from the fluid inside the central passageway. As depicted in FIG. 5, in the set position, the slip 70 is expanded so that teeth 70 b of the slip 70 may engage the inner surface of the surrounding well casing string. As depicted in FIG. 4, in this position of the upper piston assembly 42 , the shear screws 43 have been sheared, thereby allowing free movement of the upper piston assembly 42 . Furthermore, in the depicted position of the lower piston assembly 50 in FIG. 5, the shear screws 51 have been sheared thereby allowing downward movement of the lower piston assembly 50 .
[0042] Referring to FIG. 6, in the set position of the packer, a collet ring 82 of the packer has a shoulder 85 that engages a corresponding inner shoulder of the lower cone assembly 76 . The collet ring 82 is pressed into this engagement by a retaining ring 84 that is positioned in a corresponding annular groove formed in the outer surface of the mandrel 25 . The collet ring 82 is located below and abuts the shell 34 . Thus, due to this arrangement, the collet ring 82 prevents movement of the shell 34 with respect to the mandrel 25 . The movement of the mandrel 25 with respect to the lower cone assembly 76 , in turn, is prevented via the shear screws.
[0043] [0043]FIGS. 7, 8 and 9 depict upper 140 A (FIG. 7) intermediate 140 B (FIG. 8) and lower 140 C (FIG. 9) sections of the packer after the packer has been released from its set state. In this manner, the release of the packer from its set state occurs in response to the application of a sufficient upward force to the tubing that is connected to the mandrel 25 . This force, in turn, shears screws of the packer, discussed below, to release the actuating mechanisms of the packer to retract the elastomer seal assembly 36 and retract the slips 70 .
[0044] More particularly, in some embodiments of the invention, the upper force on the mandrel 25 shears the shear screws 89 that connect the lower cone assembly 76 to the mandrel 25 . Due to this released connection, the retaining ring 84 slides upwardly with the mandrel 25 , thereby freeing the collet ring 82 to radially retract. This radial retraction of the collet ring 82 , in turn, permits movement of the shell 34 with the mandrel 25 . When the shell 34 moves in an upward direction, the shell contacts an upper shoulder 27 (see FIG. 7) of the upper sealing bulkhead 32 , to cause movement of the upper sealing bulkhead 32 away from the elastomer seal assembly 36 , thereby releasing pressure on the upper seal assembly 36 . Due to the upward motion of the upper sealing bulkhead 32 , the shell 34 further slides in an upward direction until a shoulder 34 a of the shell 34 contacts a corresponding shoulder 42 h (FIG. 7) of the upper piston assembly 42 . This contact pulls the upper piston assembly 42 , the sleeve 46 and the lower piston assembly 50 an upward direction to release the applied pressure on the slips 70 . Furthermore, the pins 91 reach the upper limit of their respective slots 90 to pull the upper cone assembly 64 and the sleeve 65 in an upward direction to release pressure on the slip 70 b.
[0045] Different sealing bulkheads may be used in other embodiments of the invention. For example, FIGS. 10 and 11 depict upper 150 A and lower 150 B sections of a packer in accordance with another embodiment of the invention. In this embodiment, two mandrels pass through the packer: a primary mandrel 173 and a secondary mandrel 174 . As an example, the primary mandrel 173 may be used for purposes of communicating production fluids, and the secondary mandrel 174 may be used as a bypass line or for purposes of providing a path for electrical and/or hydraulic communication lines through the packer. In this embodiment of the invention, the upper sealing bulkhead 32 is replaced with an upper sealing bulkhead 160 (FIG. 10), and the lower sealing bulkhead 80 is replaced by a lower sealing bulkhead 180 .
[0046] Referring to FIG. 10, the upper sealing bulkhead 160 has an opening 178 to receive the primary mandrel 173 and an opening 176 to receive the secondary mandrel 174 . An interior annular groove 162 that circumscribes the opening 178 holds an elastomer sealing ring 164 (an O-ring, for example) that forms a seal between the sealing bulkhead 160 and the primary mandrel 173 . An interior annular groove 170 that circumscribes the opening 176 holds an elastomer sealing ring 172 (an O-ring, for example) that forms a seal between the sealing bulkhead 160 and the secondary mandrel 174 . The sealing bulkhead 160 also includes an interior annular groove 166 that circumscribes the shell 34 and holds an elastomer sealing ring 168 (an O-ring, for example) that forms a seal between the sealing bulkhead 160 and the shell 34 .
[0047] Referring to FIG. 11, the lower sealing bulkhead 180 has an opening 194 to receive the primary mandrel 173 and an opening 192 to receive the secondary mandrel 174 . An interior annular groove 182 that circumscribes the opening 194 holds an elastomer sealing ring 184 (an O-ring, for example) that forms a seal between the sealing bulkhead 180 and the primary mandrel 173 . An interior annular groove 189 that circumscribes the opening 192 holds an elastomer sealing ring 190 (an O-ring, for example) that forms a seal between the sealing bulkhead 180 and the secondary mandrel 174 . The sealing bulkhead 180 also includes an exterior annular groove 186 that is circumscribed by the shell 34 and holds an elastomer sealing ring 188 (an O-ring, for example) that forms a seal between the sealing bulkhead 180 and the shell 34 .
[0048] In the preceding description, directional terms, such as “upward” and “downward,” were used for reasons of convenience to describe the packer and its associated components. However, such orientations are not needed to practice the invention, and thus, other orientations are possible in other embodiments of the invention. For example, in some embodiments of the invention, the packer may be used in a horizontal or lateral well bore.
[0049] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention. | A packer that is usable with a subterranean well includes an assembly to circumscribe one out of multiple tubular arrays that are inserted through the packer. The packer also includes a member that is separable from the assembly to configure the assembly for connection to the tubular array. The member includes a first seal between the member and the tubular array and a second seal that is located between the member and the shell. The first seal is separate from the second seal. The assembly includes a slip to engage a casing of the well and a sealing element to seal an annulus of the well. | 4 |
This application is a continuation-in-part of application Ser. No. 06/709,415 filed Mar. 7, 1985 by Lloyd Berg and An-I Yeh, now U.S. Pat. No. 4,642,167.
FIELD OF THE INVENTION
This invention relates to a method for separating isobutyl acetate from isobutanol using certain higher boiling liquids as the extractive agent in extractive distillation.
DESCRIPTION OF PRIOR ART
Extractive distillation is the method of separating close boiling compounds or azeotropes by carrying out the distillation in a multiplate rectification column in the presence of an added liquid or liquid mixture, said liquid(s) having a boiling point higher than the compounds being separated. The extractive agent is introduced near the top of the column and flows downward until it reaches the stillpot or reboiler. Its presence on each plate of the rectification column alters the relative volatility of the close boiling compounds in a direction to make the separation on each plate greater and thus require either fewer plates to effect the same separation or make possible a greater degree of separation with the same number of plates. When the compounds to be separated normally form an azeotrope, the proper agents will cause them to boil separately during extractive distillation and thus make possible a separation in a rectification column that cannot be done at all when no agent is present. The extractive agent should boil higher than any of the close boiling liquids being separated and not form minimum azeotropes with them. Usually the extractive agent is introduced a few plates from the top of the column to insure that none of the extractive agent is carried over with the most volatile component. This usually requires that the extractive agent boil twenty Centigrade degrees or more higher than the lowest boiling component.
At the bottom of a continous column, the less volatile components of the close boiling mixtures and the extractive agent are continuously removed from the column. The usual methods of separation of these two components are the use of another rectification column, cooling and phase separation or solvent extraction.
One of the commercially important ways to manufacture isobutyl acetate is by the catalytic esterification of isobutanol with acetic acid. Isobutyl acetate (b.p.=118° C.), isobutanol (b.p.=108.1° C.) and water (b.p.=100° C.) form a ternary azeotrope boiling at 86.8° C. containing 46.5 wt.% isobutyl acetate, 23.1 wt.% isobutanol and 30.4 wt.% water.
Isobutyl acetate also forms a binary azeotrope with isobutanol which boils at 107.4° C. and contains 45 wt.% isobutyl acetate, and a binary azeotrope with water boiling at 87.4° C. containing 83.5 wt.% isobutyl acetate. Isobutanol also forms a binary minimum azeotrope with water which boils at 89.8° C. and contains 67 wt.% isobutanol. Thus in the esterification of isobutanol with acetic acid to form isobutyl acetate and water, the rectification of this mixture has three binary and one ternary azeotrope to contend with, and yields the lowest boiling constituent, namely the isobutyl acetate-isobutanol-water ternary azeotrope. It is therefore impossible to produce isobutyl acetate from isobutanol and water mixtures by rectification because the lower boiling ternary azeotrope will always come off overhead as the initial product. Any mixture of isobutyl acetate, isobutanol and water subjected to rectification at one atmosphere pressure will produce an overhead product boiling at 86.8° C. and containing 46.5 wt.% isobutyl acetate, 23.1 wt.% isobutanol and 30.4 wt.% water. Extractive distillation would be an attractive method of effecting the separation of isobutyl acetate from isobutanol if agents can be found that (1) will break the isobutyl acetate-isobutanol-water azeotrope and (2) are easy to recover from the isobutanol, that is, form no azeotrope with isobutanol and boil sufficiently above isobutanol to make the separation by rectification possible with only a few theoretical plates.
Extractive distillation typically requires the addition of an equal amount to twice as much extractive agent as the isobutyl acetate-isobutanol-water on each plate of the rectification column. The extractive agent should be heated to about the same temperature as the plate into which it is introduced. Thus extractive distillation imposes an additional heat requirement on the column as well as somewhat larger plates. However this is less than the increase occasioned by the additional agents required if the separation is to be done by azeotropic distillation.
Another consideration in the selection of the extractive distillation agent is its recovery from the bottoms product. The usual method is by rectification in another column. In order to keep the cost of this operation to a minimum, an appreciable boiling point difference between the compound being separated and the extractive agent is desirable. It is also desirable that the extractive agent be miscible with isobutanol otherwise it will form a two-phase azeotrope with the isobutanol in the recovery column and some other method of separation will have to be employed.
Berg et al investigated the breaking of the acetate-alcohol-water ternary azeotropes for a number of acetates other than isobutyl acetate, the subject of this invention. U.S. Pat. Nos. 4,543,164, 4,549,938 and 4,597,834 described the separation of methyl acetates from methanol; 4,379,028 and 4,569,726 described ethyl acetate from ethanol; 4,592,805, n-propyl acetate from n-propanol and 4,507,175 and 4,525,245, n-butyl acetate from n-butanol.
OBJECTIVE OF THE INVENTION
The object of this invention is to provide a process or method of extractive distillation that will enhance the relative volatility of isobutyl acetate from isobutanol in their separation in a rectification column. It is a further object of this invention to identify suitable extractive distillation agents which will eliminate the isobutyl acetate-isobutyl-water ternary azeotrope and make possible the production of pure isobutyl acetate and isobutanol by rectification. It is a further object of this invention to identify organic compounds which, in addition to the above constraints, are stable, can be separated from isobutanol by rectification with relatively few theoretical plates and can be recycled to the extractive distillation column and reused with little decomposition.
SUMMARY OF THE INVENTION
The objects of the invention are provided by a process for separating isobutyl acetate from isobutanol which entails the use of certain oxygenated, nitrogenous and/or sulfur containing organic compounds as the agent in extractive distillation.
DETAILED DESCRIPTION OF THE INVENTION
We have discovered that certain oxygenated, nitrogenous and/or sulfur containing organic compounds, some individually but principally as mixtures, will effectively negate the isobutyl acetate-isobutanol-water ternary azeotrope and permit the separation of pure isobutyl acetate from isobutanol by rectification when employed as the agent in extractive distillation. Table 1 lists the compounds, mixtures and approximate proportions that we have found to be effective. The data in Table 1 was obtained in a vapor-liquid equilibrium still. In each case, the starting material was the isobutyl acetate-isobutanol-water azeotrope. The ratios are the parts by weight of extractive agent used per part of isobutyl acetate isobutanol-water azeotrope. The relative volatilities are listed for each of the two ratios employed. The compounds which are effective when used alone are dimethylsulfoxide (DMS0) and dimethylformamide (DMFA). The compounds, in addition to the above, which are effective when used in mixtures of two or more components are acetamide, N,N-dimethylacetamide, ethylene carbonate and propylene carbonate.
The two relative volatilities shown in Table 1 correspond to the two different ratios employed. For example, in Table 1, one part of DMSO with one part of isobutyl acetate-isobutanol-water azeotrope gives a relative volatility of 1.71, 6/5 parts of DMSO gives 2.29. One half part of DMSO mixed with one half part of DMFA with one part of isobutyl acetate-isobutanol-water azeotrope gives a relative volatility of 2.05, 3/5 parts of DMSO plus 3/5 parts of DMFA gives 2.32. One third parts of DMSO plus 1/3 parts of DMFA plus 1/3 parts of N,N-dimethylacetamide mixed with one part of isobutyl acetate-isobutanol-water azeotrope gives a relative volatility of 2.18, with 2/5 parts, these three give 2.22. In every example in Table 1, the starting material is the isobutyl acetate-isobutanol-water azeotrope which possesses a relative volatility of 1.0.
Several of the compounds and mixtures listed in Table 1 and whose relative volatility has been determined in the vapor-liquid equilibrium still, were then evaluated in a glass perforated plate rectification column possessing 4.5 theoretical plates. The isobutyl acetate-isobutanol-water mixture studied contained 63.8 wt.% isobutyl acetate, 31.7 wt.% isobutanol, 4.5 wt.% water. The isobutyl acetate-isobutanol-water azeotrope contains 46.5 wt.% isobutyl acetate, 23.1 wt.% isobutanol and 30.4 wt.% water. In every case, the overhead was richer than 46.5 wt.% isobutyl acetate and the results are tabulated in Table 2. Without the extractive agent, the overhead would be the azeotrope, 46.5 wt.%, isobutyl acetate. This proves that the extractive agent is negating the azeotrope and makes rectification proceed as if the azeotrope no longer exists and brings the more volatile components, isobutyl acetate and water, out as the overhead products. It is our belief that this is the first time that this has been accomplished for this azeotrope.
The data in Table 2 was obtained in the following manner. The charge was 63.8 wt.% isobutyl acetate, 31.7 wt.% isobutanol and 4.5 wt.% water and after a half hour of operation in the 4.5 theoretical plate column to establish equilibrium, ethylene glycol at 75° C. and 20 ml/min. was pumped in. The rectification was continued for two hours with sampling of overhead and bottoms after one hour, 1,5 hours and two hours. The average of the three analyses was 96.8 wt.% isobutyl acetate in the overhead and 36 wt.% in the bottoms, both on a water-free basis which gives a relative volatility of 2.61 of isobutyl acetate to isobutanol. This indicates that the ternary azeotrope has been negated ans separation accomplished. The isobutyl acetate comes off in the overhead with the water which on condensation, immediately forms two liquid layers. The solubility of isobutyl acetate in water is only 0.6%.
TABLE 1__________________________________________________________________________Effective Extractive Distillation Agents. RelativeCompounds Ratios Volatilities__________________________________________________________________________Dimethylsulfoxide (DMSO) 1 6/5.sup. 1.71 2.29DMSO, Dimethylformamide (DMFA) (1/2).sup.2 (3/5).sup.2 2.05 2.32DMSO, Acetamide " " 1.86 1.66DMSO, N,N--Dimethylacetamide " " 2.21 2.20DMSO, Ethylene carbonate " " 1.50 1.62DMSO, Propylene carbonate " " 1.31 1.40DMSO, DMFA, Ethylene carbonate (1/3).sup.3 (2/5).sup.3 1.46 1.85DMSO, DMFA, Propylene carbonate " " 1.56 1.57DMSO, DMFA, N,N--Dimethylacetamide " " 2.18 2.22DMFA, Acetamide (1/2).sup.2 (3/5).sup.2 1.57 1.93DMFA, N,N--Dimethylacetamide " " 1.35 1.86DMFA, Ethylene carbonate " " 1.43 1.41DMFA, Propylene carbonate " " 1.19 1.18DMFA, Acetamide, N,N--Dimethylacetamide (1/3).sup.3 (2/5).sup.3 2.00 1.99DMFA, Acetamide, Ethylene carbonate " " 1.57 1.90DMFA, Acetamide, Propylene carbonate " " 1.24 1.21__________________________________________________________________________
TABLE 2______________________________________Data From Runs Made In Rectification Column. RelativeAgent Volatility______________________________________Dimethylsulfoxide (DMSO) 2.61Dimethylformamide (DMFA) 2.26DMSO + DMFA 2.12DMSO + Acetamide (1:1) 1.68______________________________________ Mixture: 255 gm. Isobutyl acetate + 127 gm. Isobutanol + 18 gm. Water Agents: Added at 75° C. and 20 ml/min. Numbers in (--) indicate the weight ratio of the agents.
THE USEFULNESS OF THE INVENTION
The usefulness or utility of this invention can be demonstrated by referring to the data presented in Tables 1-2. All of the successful extractive distillation agents show that isobutyl acetate, isobutanol and water can be separated from their ternary azeotrope by means of distillation in a rectification column and that the case of separation as measured by relative volatility is considerable. Without these extractive distillation agents, no improvement above the azeotrope composition will occur in a rectification column. The data also show that the most attractive agents will operate at a boilup rate low enough to make this a useful and effecient method of recovering high purity isobutyl acetate from any mixture of these three including the ternary minimum azeotrope. The stability of the compounds used and the boiling point difference is such that complete recovery and recycle is obtainable by a simple distillation and the amount required for make-up is small.
WORKING EXAMPLES
Example 1
The isobutyl acetate-isobutanol-water azeotrope is 46.5 wt.% isobutyl acetate, 23.1 wt.% isobutanol, 30.4 wt.% water. Fifty grams of the isobutyl acetate-isobutanol-water azeotrope and fifty grams of DMSO were charged to an Othmer type glass vapor-liquid equilibrium still and refluxed for 15 hours. Analysis of the vapor and liquid by gas chromatography gave vapor of 59.5% isobutyl acetate, 40.5% isobutanol; liquid of 46.2% isobutyl acetate, 53.8% isobutanol. This indicates a relative volatility of 1.71. Ten grams of DMSO were added and refluxing continued for another thirteen hours. Analysis indicated a vapor composition of 65.8% isobutyl acetate, 34.2% isobutanol; a liquid composition of 45.7% isobutyl acetate, 54.3% isobutanol which is a relative volatility of 2.29.
Example 2
Fifty grams of the isobutyl acetate-isobutanol-water azeotrope, 25 grams of DMSO and 25 grams of DMFA were charged to the vapor-liquid equilibrium still and refluxed for eleven hours. Analysis indicated a vapor composition of 66.2% isobutyl acetate, 33.8% isobutanol; a liquid composition of 48.9% isobutyl acetate, 51.1% isobutanol which is a relative volatility of 2.05. Five grams of DMSO and five grams of DMFA were added and refluxing continued for another twelve hours. Analysis indicated a vapor composition of 66.1% isobutyl acetate, 33.9% isobutanol; a liquid composition of 45.7% isobutyl acetate, 54.3% isobutanol which is a relative volatility of 2.32.
Example 3
Fifty grams of the isobutyl acetate-isobutanol-water azeotrope, 17 grams of DMSO 17 grams of DMFA and 17 grams of N,N-dimethylacetamide were charged to the vapor-liquid equilibrium still and refluxed for twelve hours. Analysis indicated a vapor composition of 63.8% isobutyl acetate, 36.2% isobutanol; a liquid composition of 44.7% isobutyl acetate, 55.3% isobutanol which is a relative volatility of 2.18 Three grams each of N,N-dimethyl acetamide, DMSO and DMFA were added and refluxing continued for another seven hours. Analysis indicated a vapor composition of 62.9% isobutyl acetate, 37.1% isobutanol; a liquid composition of 43.3% isobutyl acetate, 56.7% isobutanol which is a relative volatility of 2.22.
Example 4
A glass perforated plate rectification column was calibrated with ethylbenzene and p-xylene which possesses a relative volatility of 1.06 and found to have 4.5 theoretical plates. A solution of 255 grams of isobutyl acetate, 127 grams of isobutanol and 18 grams of water was placed in the stillpot and heated. When refluxing began, an extractive agent comprising ethylene glycol was pumped into the column at a rate of 20 ml/min. The temperature of the extractive agent as it entered the column was 75° C. After establishing the feed rate of the extractive agent, the heat input to the isobutyl acetate, isobutanol and water in the stillpot was adjusted to give a total reflux of 10-20 ml/min. After one hour of operation, the overhead and bottoms samples of approximately two ml. were collected and analysed using gas chromatography. The overhead analysis was 96.2% isobutyl acetate, 3.8% isobutanol. The bottoms analysis was 36% isobutyl acetate, 64% isobutanol. Using these compositions in the Fenske equation, with the number of theoretical plates in the column being 4.5, gave an average relative volatility of 2.52 for each theoretical plate. After 1.5 hours of total operating time, the overhead and bottoms samples were again taken and analysed. The overhead composition was 96.8% acetate, 3.2% isobutanol and the bottoms composition was 36% isobutyl acetate, 64% isobutanol. This gave an average relative volatility of 2.61 for each theoretical plate. After two hours of total operating time, the overhead and bottoms samples were again taken and analysed. The overhead composition was 97% isobutyl acetate, 3% isobutanol and the bottoms composition was 35.6% isobutyl acetate, 64.4% isobutanol. This gave an average relative volatility of 2.7 for each theoretical plate. | Isobutyl acetate cannot be completely removed from isobutyl acetate - isobutanol - water mixtures by distillation because of the presence of the minimum ternary axeotrope. Isobutyl acetate can be readily removed from mixtures containing it, isobutanol and water by using extractive distillation in which the extractive distillation agent is a higher boiling oxygenated, nitrogenous and/or sulfur containing organic compound or a mixture of these. Typical examples of effective agents are dimethylsulfoxide; dimethylsulfoxide and dimethylformamide; dimethylsulfoxide, dimethylformamide and N,N-dimethylacetamide. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a rotary multi-colour printing machine particularly for use in offset printing.
Known rotary multi-colour printing machines generally comprise a number of printing units each associated with a different colour and arranged in spaced relationship, the sheet material to be printed passing through these units in turn. Because of this, these printing machines cover a considerable amount of floor-space. Also, the operation of changing plates before starting a new run is relatively lengthy and has to be carried out successively or in parallel in the various printing units. This represents a major drawback when the printing machine is intended to be used for printing short runs of a few thousand copies at the most.
The aim of the present invention is to eliminate these disadvantages by providing a printing machine of particularly simple and compact design which enables printing plates to be changed easily and rapidly.
SUMMARY OF THE INVENTION
The present invention provides a rotary multi-colour printing machine comprising a frame and a plurality of printing units each of which prints in a different colour on sheet material passing through the machine, the printing units being mounted in the frame one above the other so that sheet material can pass successively through the printing units, each printing unit comprising a counter-pressure roll, a blanket roll, a plate roll and an inking roll, the axes of these rolls being parallel, wherein the plate roll and the blanket roll of each printing unit are rotatably mounted in a support, the counter-pressure roll of each printing unit is rotatably mounted in the frame on one side of the support, and the inking roll of each printing unit being rotatably mounted in the frame on the other side of the support, and wherein the support is slidably mounted in the frame for movement in a direction which is horizontal and axial with respect to the rolls.
In order to effect a considerable reduction in both the vertical and horizontal dimensions of the machine the inking apparatus of each printing unit advantageously consists of an arrangement using a small-diateter rod applied under pressure against the inking roll and turning in the same direction as the latter, the film of ink that passes between the rod and the inking roll being spread by the rod.
Preferably, means are provided for automatically applying pressure to the rolls, separately or for all the printing units simultaneously, after the plate-changing operation.
Because of the close proximity of the printing units, this machine avoids the need for using an electronic system for registering the colours. The various colours are automatically brought precisely into the correct positions in relation to each other by a simple mechanical indexing of the various plate rolls, after the plates have been changed.
BRIEF DESCRIPTION OF THE DRAWINGS
A rotary multi-colour printing machine constructed in accordance with the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic elevational view of the printing machine, part thereof being shown as broken away;
FIG. 2 is a vertical section on the line II--II of FIG. 1;
FIG. 3 is a horizontal section of part of the machine at the level of one of the printing units, this sectional view being drawn along line III--III of FIG. 1;
FIG. 4 is a vertical longitudinal sectional view drawn on a larger scale and along line IV--IV of FIG. 2;
FIG. 5 is an elevational view of part of the indexing means of a plate roll;
FIG. 6 is a partial vertical longitudinal section through a modified form of printing unit of the printing machine; and
FIG. 7 is a diagram showing the pneumatic control circuit of the machine.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, the rotary printing machine comprises a frame constituted by two parallel rear and front uprights 1 and 2 respectively, between which are arranged a plurality (four in the present example) of superposed printing units 3, 4, 5 and 6 for printing several colours on sheet material 7. The rear and front uprights 1 and 2 are suitably braced, and at the bottom of each of them there is fitted a screw-jack 8 for truing them in relation to the floor. The sheet material 7 is offwound from a roll 9 mounted to rotate at the bottom of the frame, and the sheet material passes in turn through the printing units 3, 4, 5 and 6, beginning at the bottom unit 3 and finishing at the top unit 6.
On leaving the printing machine, the sheet material 7 may be treated in any suitable manner, and in particular, cut into lengths by a rotary cutting machine 11 of conventional design, a collecting bin 12 for the cut sheets being provided at the delivery side of the cutting machine.
Since all the printing units 3, 4, 5 and 6 are constructed in the same manner, only one of them will be described in detail, that is the top printing unit 6. This printing unit 6 comprises a counter-pressure roll 13, a blanket roll 14, a plate roll 15, an inking roll 16, a wetting roll 17 and a wiping roll 18. The four counter-pressure rolls 13, blanket rolls 14, plate rolls 15 and inking rolls 16 are aligned horizontally and in contact with each other in the printing position as illustrated in FIG. 1. The counter-pressure rolls 13 and the inking rolls 16 are mounted to rotate on the frame 1, 2 whereas the two intermediate rolls of each unit, that is the blanket roll 14 and the plate roll 15 are mounted to rotate on the sub-frame 19 which can be moved horizontally and transversely in relation to the sheet material 7. In other words, the sub-frame 19 can be displaced horizontally in the direction at right-angles to the uprights 1 and 2 of the main frame. The sub-frame 19 comprises two parallel vertical cheek-plates, namely a rear cheek-plate 21 and a front cheek-plate 22 which are transversely interconnected by upper and lower stays 23 and 24 respectively.
In the printing position, the sub-frame 19 is fully housed within the main frame of the machine, its rear cheek-plate 21 being disposed flat against the rear upright 1 of the main frame, whereas its front cheek-plate 22 is located in a vertical rectangular window 25 formed in the front upright 2 of the main frame to permit the sub-frame 19 to emerge. In FIG. 2 this sub-frame 19 is shown in relatively thick lines in the printing position, and in thinner lines in the position it occupies on emerging from the printing machine.
The lower stays 24 of the sub-frame 19 carry lateral rolls 26 having horizontal spindles, these rollers running on two horizontal transverse rails 27 which extend towards the front of the machine so as to receive the sub-frame 19 in its "out" position. These rails 27 are supported on the ground at their forward ends by way of two vertical columns 28 and two screw-jacks 29.
The sub-frame 19 is laterally guided at its lower part by rollers 31 which have vertical spindles and are mounted below the bottom stays 24 and move between each rail 27 and a horizontal transverse straight-edged element 32 (see FIG. 1). At its top the sub-frame 19 comprises a central cross-member 33 extending between the two cheek-plates 21 and 22 and carrying rollers 34 which have vertical spindles and are displaceable between two parallel horizontal transverse straight-edged elements 35 secured to the uprights 1 and 2 of the main frame. The cross-member 33 and the two straight-edged elements 35 extend towards the rear of the machine beyond the rear upright 1 as can be seen in FIG. 2, so that the sub-frame 19 cannot completely escape from the upper lateral guide means when it is in the front "out" position.
All of the printing units 3 to 6 are caused to rotate by an electric motor 36 arranged to the rear of the machine, and this motor is connected, by way of a variable speed transmission unit 37 and a bevel gear 38, to a vertical main operating shaft 39 extending over the entire height of the machine. At its upper end, the shaft 39 is connected to a hand-wheel 41 by way of a free wheel 42, so as to enable this shaft to be driven manually. The main control shaft 39 is connected to all the printing units and more particularly to the inking rolls 16 of these units. For this purpose it carries, in the zone of each of the various units, endless screws 43 which mesh with screw-threaded wheels 44 solidly connected to the shafts 45 (see FIG. 3) of the inking rolls 16. These rolls 16 are mounted to rotate in front and rear bearings 46 carried by the front and rear uprights 2 and 1 respectively of the main frame.
The inking apparatus of each of the printing units 3 to 6 comprises an ink container 47, the front and rear walls 48 of which bear on the lateral surface of the inking roll 16. The ink container rests on two horizontal strips 49 secured to the uprights 1 and 2 of the main frame and within these uprights. It also comprises a round metallic rod 50 which is caused to rotate by a continuous current electric motor, the speed of which can be varied. This rod 50 is applied under pressure to the inking roll 16 which is faced with rubber, the rod turning in the same direction as this roll and causing the ink to be spread over it. Screws fitted in the uprights 1 and 2 act on the ink container 47 and enable the penetration of the rod 50 into the inking roll 16 to be regulated, and these screws thus effect variation in the thickness of the film of ink.
The wetting rolls 17 and the wiping rolls 18 are the standard parts of wetting systems of conventional design and are mounted between the two uprights 1 and 2 of the main frame.
Referring now to FIGS. 3 to 5, in each printing unit the rotary movement of the various rolls is transmitted to them from the inking roll 16. For this purpose, a helical pinion 51 is keyed on to the shaft 45 of the inking roll 16, and this pinion meshes with another helical pinion 52 keyed on to the shaft 53 of the plate roll 15, in the rear portion of the sub-frame 19. The shaft 53 of the plate roll 15 is itself solidly connected, in the front portion of the sub-frame 19, to an axially-toothed pinion 54 which meshes with another axially-toothed pinion 55 keyed on to the shaft 56 of the blanket roll 14 at the front of the latter.
The shafts 53 and 56 of the plate roll 15 and the blanket roll 14 respectively are mounted to rotate in bearings 57 and 58 respectively at the rear, and in bearings 59 and 61 at the front. These bearings are mounted to slide in pairs of horizontal rails 62 and 63 carried by the inner faces of the rear cheek plates 21 and the front cheek-plate 22 respectively of the sub-frame 19.
The counter-pressure roll 13 is mounted to rotate on the two uprights 1 and 2 of the main frame, in the opposite sense to the inking roll 16. For this purpose the counter-pressure roll 13 is mounted by means of roller bearings on a fixed shaft 64 secured by its ends to two vertical cheek plates 65 and 66 which are mounted to slide horizontally in slideways formed by rear and front pairs of horizontal rails 67 and 68. The two cheek plates 65 and 66 are interconnected by a stay 69 parallel to the counter-pressure roll 13, which stay is connected to the rods 71 and 72 of two diaphragm chambers 73 and 74 respectively secured to a transverse vertical cheek plate 75 extending between the two uprights 1 and 2. The rods 71 and 72 extend horizontally and at right-angles to the counter-pressure roll 13 so as to apply horizontal thrust to this roll in the direction of the other rolls of the printing unit.
Normally the counter-pressure roll 13 is biased away from the blanket roll 14 by the action of springs 76 housed in the uprights 1 and 2 and supported on studs 77 and 78 respectively, extending laterally towards the exterior fo the cheek plates 65 and 66 respectively. This return force of the springs 76 is supplemented by the forces applied by springs forming part of the diaphragm chambers 73 and 74 and biasing the rods 71 and 72 in the return direction.
The cheek plates 65 and 66 are used to press the blanket roll 14 and the plate roll 15 against each other and to apply pressure to the inking roll 16. For this purpose the cheek plates 65 and 66 bear by their vertical front faces on shoes 79 which are carried by the rear and front bearings 58 and 61 respectively of the blanket roll 14. Each shoe 79 is mounted to slide along a screw 81, screwed into and blocked in the corresponding bearing 58 and 61, the head of each screw limiting the movement of the shoe 79 in the outward direction. Between each shoe 79 and its bearing 58 or 61 (or a locking nut) is lodged a compression spring 83 formed for example by a stack of spring washers. Rods 80 (see FIG. 4) of adjustable length are mounted on the left-hand front faces of the bearings 58 and 61 to limit the compression forces between the counter-pressure roll 13 and the blanket roll 14, that is to limit the width of the area of contact at this point.
Shoes 84 are mounted to slide on screws 85 secured respectively to each of the right-hand front faces of the bearings 58 and 61, opposite to the screws 81 carrying the shoes 79. A compression spring, formed for example by a stack of spring washers 86, is again provided here between each shoe 84 and the corresponding bearing 58 or 61 so as to push this shoe outwardly.
The shoes 84 bear against the left-hand front faces of the rear and front bearings 57 and 59 respectively of the plate roll 15. In the same way, compressions springs 87 (see FIG. 4), consisting for example of a stack of spring washers threaded on screws 88, bear against the right-hand front faces of these same bearings. The springs 87 bear against an abutment 90 formed for example by a vertical cross-member extending between the two horizontal rails 62 and at the right-hand ends thereof.
Also, rods 91 are mounted on the right-hand front faces of the bearings 57 and 59, which rods serve to adjust the width of the contact area as described below, and are likewise designed to move into abutment with the left-hand front faces of the bearings 46.
To enable the various plate rolls 15 to be secured in their correct positions after a plate has been changed, the shafts 53 of these rolls carry, at the exterior of the front cheek plate 22, indexing discs 92 (see FIG. 3) which are solidly connected to hand-wheels 93. The indexing discs 92 each have at their periphery a notch 94 in which can engage a ball-ended stud 95 or a member mounted on a spring-biased pivoting lever.
A particularly convenient and rapid method will now be described whereby the operation of changing the plates can be carried out when one printing run has been completed and the machine is to carry out the printing of a fresh run.
On completion of the printing of the first run, the various elements forming the machine are in the printing positions illustrated in the drawings. All the inking rolls 16 are rotated by the main operating shaft 39 and their movements are transmitted first to the plate rolls 15 by way of the helical pinions 51 and 52 meshing with each other, and then to the blanket rolls 14 by way of the interengaging pinions 54 and 55. The counter-pressure rolls 13 are applied under pressure against the blanket rolls 14 under the action of the diaphragm chambers 73 and 74. The force provided by these diaphragm chambers is applied, in each printing unit, by the lateral cheek plates 65 and 66 to the sliding bearings 57, 58, 59 and 61. Consequently, the compression springs 83, 86 and 87 are compressed, and the plate rolls 15 are pressed against the respective inking rolls 16, this causing a certain degree of flattening of their rubber coverings. The extent of this flattening, to which corresponds what is known as the inking width, is determined by the length of the adjusting rods 91 which form stops interposed between the last sliding bearings 57 and 59 of each plate roll 15 and the fixed bearings 46 of the inking roll 16.
When the rotary printing machine has been stopped after the previous printing run has been completed, the supply to the diaphragm chambers 73 and 74 is cut off, and consequently the pressure on the rolls of the various printing units ceases. As a result, each counter-pressure roll 13 is moved to the left (as seen in the drawings) under the action of the return springs 76 mounted in the main frame and by the inner springs in the diaphragm chambers 73 and 74. Consequently, the various compression springs 83, 86 and 87 relax to the extent that each plate roll 15 is moved to the left away from the corresponding plate roll 15 as a result of relaxation of the springs 86. Leftward displacement of each plate roll 15 relatively to its inking roll 16 is greater than the distance between the corresponding blanket roll 14 and the corresponding plate roll 15, so as to prevent the plate roll 15 from moving into contact with the inking roll 16 when the sub-frame 19 finally moves out of the machine. Once the various rolls of the printing unit have been relieved of pressure, the sub-frame 19 can then be moved out of the machine by causing it to move forward on the lower rails 27 into its completely extracted position shown in thin lines in FIG. 2. During this movement, the sub-frame is laterally guided by the rollers 31 and 34.
Once the sub-frame 19 is in the forward "out" position, the plates of the various rolls 15 can be changed very easily and rapidly for the purpose of starting up the next printing run. Before reintroducing the sub-frame 19 into the machine, the other elements, particularly those of the cutting apparatus 11, are secured in the correct position. For this purpose, the printed sheet material 7 passes on to an upper driving roll 96 (see FIG. 1), to which is solidly connected an indexing disc 97 having a notch 96 formed in its periphery. An indexing finger 99, carried for example on a pivoting lever, engages in this notch. The driving roll 96 is connected to a main operating shaft 94 by way of a set of gears 100. Before reintroducing the sub-frame 19, the elements of the machine are secured in the correct position by rotating the hand-wheel 41 manually until the notch 98 is in register with the indexing finger 99. At this moment all the pinions 51 of the inking rolls 16 are accurately positioned for subsequently engaging the pinions 52 of the plate rolls 15, and the other elements of the machine are correctly positioned in relation to the new plates.
Once the new plates have been placed in position, all that is required is to secure all the plate rolls 15 in their correct positions, that is to say in the positions in which the indexing fingers 95 engage in the notches 94 in the indexing discs 92. The various plates are then correctly positioned in relation to each other for printing the various colours.
The sub-frame 19 is then reintroduced into the machine and brought into a position in which its rear cheek plate 21 lies flat against the rear upright 1. At this moment, the diaphragm chambers 73 and 74 are pressurised, and as a result all the counter-pressure rolls 13 are pushed to the right. The lateral cheek plates 65 and 66 in turn push the sliding bearings 57, 58, 59 and 61 to the right thereby compressing springs 83, 86 and 87. The springs 87, provided between the plate rolls 15 and the inking rolls 16, exercise, when completely compressed, a force which is less than the forces produced by the other compression springs 83 and 86. For example, if the diaphragm chambers 73 and 74 apply a force of 10,000 Newtons on each set of bearings, this total force is distributed as a force of 4000 Newtons, absorbed by the compression springs 83 between the counter-pressure roll 13 and the blanket roll 14, a force of 4000 Newtons, absorbed by the springs 86 between the blanket roll 14 and the plate roll 15, and finally a force of 1000 Newtons, absorbed by the springs 87. Consequently, when the diaphragm chambers 73 and 74 are pressurised, the springs 87, which are weaker, are the first to be flattened as the plate roll 15 moves into contact with the inking roll 16 and the helical pinion 52 engages with the other helical pinion 51 solidly connected to the inking roll 16. As has been seen already, flattening of the inking roll 16 is limited by the adjusting rods 91. Then, the other compression springs 83 and 86 become flattened and thus permit contact under pressure between the blanket roll 14 and the plate roll 15, and between the counter-pressure roll 13 and the blanket roll 14.
As will have been seen above, this rotary printing machine enables the use of electronic means for registering the various colours to be avoided because the printing units are very close to each other. However, it is absolutely essential for the plates as well as selected portions of the plates to be in perfectly matching positions on the rolls 15. To ensure perfect postiioning, the various documents used for engraving the plates (films, selections etc) are perforated in a completely identical manner on the same templates so that they can be held in position by means of pins. In the case of four-colour printing, the four films are superposed in a precise manner and are perforated all at the same time. After engraving on a copying machine having registering pins, the selections are then matched in an identical manner on the plates in relation to the perforations. The perforating template is repeated exactly on the means for securing the plates on the rolls 15 by means of pins, and to register the colours all that is then required is to position the rolls mechanically, as described above.
In the foregoing description, it was mentioned that the plates are replaced on the sub-frame 19 after the latter has been moved out of the machine, and that the sub-frame is then reintroduced into the machine with its fresh plates. Obviously, to save time, a second sub-frame 19, provided with plates suitable for printing the next run, can be prepared in advance and introduced immediately into the machine after the previous sub-frame has been extracted.
FIG. 6 illustrates the same elements forming the rotary printing machine of the invention as those appearing in FIG. 4, these elements bearing the same reference numerals as the corresponding elements in FIG. 4. FIG. 6 shows the counter-pressure roll 13, the blanket roll 14, the plate roll 15, and the inking roll 16, with which the inking rod 50 and the wetting roll 17 are in contact.
The counter-pressure roll 13 is mounted to rotate on a fixed shaft 64 which is secured at its ends to two vertical cheek plates such as that shown at 65, these cheek plates being mounted to slide horizontally in slideways formed by pairs of horizontal rails such as that shown at 67. The two cheek-plates 65 are interconnected by a stay 69 which is parallel to the counter-pressure roll 13 and is connected to the rods 71 of diaphragm chambers such as that shown at 73. The connection between the rods 71 and the cross-member 69 is achieved by means of screws or studs 69a.
As in the case of the arrangement shown in FIG. 4, the cheek plates 65 are used to press the blanket roll 14 and the plate roll 15 against each other and towards the inking roll 16. For this purpose, the cheek plates 65 bear by their right-hand vertical front faces against shoes 79a which are secured, by means of screws 81a, to the left-hand vertical faces of bearings such as that shown at 58, of the shaft of the blanket roll 14. It will be seen that in this arrangement the springs 83 which were provided in the FIG. 4 arrangement, have been dispensed with.
On the other hand, the second compression springs 86 (formed for example by stacks of spring washers) are provided between the bearings, such as that shown at 58, of the blanket roll 14 and the bearings, such as that shown at 57, of the plate roll 15. Similarly, the third compression springs 87 are likewise provided between the right-hand faces of bearings, such as that shown at 57, and the abutment 90. It can thus be seen that in accordance with the preceding description, in this form of construction only the springs 86 and 87 are retained but use is made of stacks of spring washers such that the force emanating from the springs 86 is less than that provided by the springs 87.
Consequently, when the printing unit is displaced under pressure, (with the various rolls still rotating) that is when the sliding cheek plates 65 are moved to the left by the diaphragm chambers 73, the springs 87 first cause the plate roll 15 to move away from the inking roll 16, the plate roll 15 however always remaining in contact with the blanket roll 14 which is applied to the counter-pressure roll 13. The sheet of paper 7 continues to pass between these two latter rolls 13 and 14. Consequently, the ink present on the plate roll 15 is pregressively transferred to the blanket roll 14 and to the sheet of paper 7.
Then, when the counter-pressure roll 13 has been moved a sufficient distance away by the diaphragm chambers 73, the bearings 58 of the blanket roll 14 are again pushed against the abutments 96 under the action of the weaker springs 86. When the movable sub-frame 19 is disengaged from the frame of the machine in the transverse direction, the plate roll 15 is then already partially cleaned, and this greatly reduces the time required for this cleaning operation.
In accordance with a further improved feature of this form of construction, the ink-container assembly 47, which comprises a round metallic rod 50 rotated by an electric motor, is applied under pressure to the inking roll 16 by means of two pneumatic piston-and-cylinder units 110 which are arranged vertically at each side of the ink container. Each of these pneumatic piston-and-cylinder units 110 acts, by way of the end of its piston-rod 111, on the end of one arm 112a of a lever 112 which is mounted to pivot about a horizontal transverse axis 113. Each lever 112 has a further arm 112b whereby it is connected to the ink container 47. Consequently, when each pair of pneumatic piston-and-cylinder units 110 is supplied with air through its base, the piston-rods 111 apply to the levers 112 forces which tend to cause the levers to pivot in the clockwise direction about the axis 113, and this has the effect of pressing the ink container 47, and more particularly the rod 50, against the inking roll 16.
With particular reference to FIG. 7, the automisation of the rotary printing machine will now be described.
The assembly comprising the pneumatic components of the machine 13 connected to a compressed-air source 114. It will be seen from FIG. 7 that the four pairs of pneumatic piston-and-cylinder units 110, which apply pressure to the ink containers 47 corresponding to the four colours, are connected to this compressed-air source 114 through an electrically operated valve 115. Similarly, the diaphragm chambers 73 and 74 which control the application of pressure to the various printing units are connected to the compressed-air source 114 by way of separate control devices 116a, 116b, 116c and 116d and separate electrically operated valves 117a, 117b, 117c, and 117d. These four electrically operated valves are in turn connected to the output side of an electrically operated valve 118 which permits the application of pressure.
Finally, two piston-and-cylinder units 119 for driving the sheet material 7 are likewise connected to the compressed-air source 114 and they ensure that the sheet material is gripped between a lower idling roll and the upper driving roll 96, these driving piston-and-cylinder units being connected to the compressed-air source by way of pneumatic distributor 121.
When the printing machine is started up, pressure is first applied to the ink containers; the pneumatic piston-and-cylinder units 110 are in fact supplied through the electrically operated valve 115. Then, after a time-lag which may be varied over the range 0.1 to 30 seconds, the main motor 36 is started up, pressure is admitted to the driving piston-and cylinder units 119 through the pneumatic distributor 121, and the valve 118, permitting the application of the printing pressure, is opened. Pressure can then be applied manually to each printing unit by admitting air to the pair of diaphragm chambers 73 and 74 through the corresponding electrically operated control valve 117a, 117b, 117c and 117d. This manual application of pressure to each printing unit can take place only if the wetting means is turning and is itself under pressure.
The rotary printing machine is normally brought to a stop by means of a push-button on a control desk, depression of this push-button causing the printing units to be depressurised simultaneously (air being cut off from the diaphragm chambers 73 and 74), and after an adjustable time-lag, the drive is stopped (air being cut off from the piston-and-cylinder units 119). At the same time pressurization ceases (the electrically operated valve 118 being closed), the motor 36 is stopped and pressure on the ink container is relaxed (air being cut off from the pneumatic piston-and-cylinder units 110).
The control devices 116a, 116b, 116c and 116d are provided to adjust the time during which the contact between plate and blanket is maintained when changing from one printing unit to another so as to reduce as far as possible the amount of ink on the plate. | A rotary multi-color printing machine comprises a frame and a plurality of printing units each of which prints in a different color on sheet material passing through the machine. The printing units are mounted one above another in the frame so that the sheet material can pass successively through the printing units. Each printing unit comprises a counter-pressure roll, a blanket roll, a plate roll and an inking roll, the axes of the rolls being parallel. The plate roll and the blanket roll of each printing unit are rotatably mounted in a support. The counter pressure roll of each printing unit is rotatably mounted in the frame on one side of the support, and the inking roll of each printing unit is rotatably mounted in the frame on the other side of the support. The support is slidable relative to the frame in a direction which is horizontal and axial relative to the rolls. In this way, the sub-assembly of the support and all the blanket roll and all the plate rolls can be removed from the machine to change the plates. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to computer user interfaces and, more particularly, to a window access and management system utilizing icons and miniature windows.
2. Description of the Related Art
An icon is a pictorial representation of an object, action, property, or some other concept on a computer display screen. Icons can be displayed within control windows to represent entire programs or files in programs. Furthermore, icons can be used to directly manipulate various operations. For example, U.S. Pat. No. 5,140,677 describes a "mini-icon" which enables a user to move or copy a document into a folder by dragging the document to the mini-icon. Similarly, U.S. Pat. No. 5,072,412 describes a displayed object (e.g., icon) which can be moved to a different workspace to regroup its associated files. U.S. Pat. No. 5,140,678 describes icons which replace common user interface symbols, such as the title window bar, command bar, and scroll bars.
U.S. Pat. No. 5,179,655 describes a displayed file window that can be completely hidden by other displayed window(s). To do this, an icon is generated and displayed as a conduit in a superordinate location of the display screen. Such a conduit enables the user to re-access the hidden window. U.S. Pat. No. 4,868,765 addresses the same issue by providing a porthole that allows the user to view portions of windows hidden behind other windows.
Another porthole or miniature window concept is described in U.S. Pat. No. 4,823,303, which provides "viewport" windows for a main file window. While one "miniature" viewport window provides an overview of the file, the other provides a close-up detailed view of a portion of the overview window.
Also, U.S. Pat. No. 5,072,412 describes a window "pictogram" which is displayed with a corresponding icon "pictogram" The window "pictogram" enables the user to view more information about the content of its corresponding displayed object without actually viewing the main window for the object. Finally, U.S. Pat. No. 4,974,173 describes "small-scale representations" or miniature windows that appear on a screen simultaneously with the main file window. The miniature windows provide a record of changes made in the file window.
A locator input device, such as a mouse, enables users to perform the previously described operations on the icons. Also, users may utilize the tab key in active windows to move the curser along a title bar to perform operations. To do this, the user presses the terminal "ENTER" key. Furthermore, the "page up" and "page down" terminal cursor keys, as well as by the mouse cursor itself, enable users to access scroll bars in window frames.
In the related art, icons merely represent pictograms of the file types or windows they denote. As such, the prior art fails to address several important problems. First, often it is desirable to provide, in a single window, a visual representation of all the windows that belong to the same application. The present invention provides a means of not only collecting together both icons and/or miniature windows, but also a means of showing various relations among them.
Second, often it is desirable to provide a convenient means of performing operations on the actual window through its representative icon or miniature window. The present invention not only provides a means for performing operations (e.g., sizing, moving, etc) on the actual window using an icon or miniature window, but these miniature window representations also dynamically maintain the state of the actual window (as opposed to maintaining a static state which must be periodically and explicitly refreshed).
SUMMARY OF THE INVENTION
The present invention is directed to a control window containing icons that permit the user to perform a number of operations on the parameters of product windows, whether or not those windows are actually open at the time the operations are registered on the icons. The present invention also provides miniature windows associated with each icon that can be displayed in the control window through which the various window operations can be performed. The miniature windows presented in this invention are dynamic and reflect the input of both control and parameter changes made directly to the associated product windows.
Accordingly, it is an object of the present invention to provide a control window container for performing window management operations in a computer system having a display, a locator input device associated with the display, and a plurality of product windows adapted for selective display in a multiple window format. The container comprises means for displaying a plurality of icons where each icon represents a separate product window, means for displaying a miniature window in association with each displayed icon, and means for linking each displayed icon to its corresponding product window. The link means permits transmission of window management operations performed by the user through the locator input device on either a displayed icon or its associated miniature window to the corresponding product window.
It is another object of the present invention to provide a method for performing file window management operations in a computer system having a display and locator input means associated with the display. The method includes the computer implemented steps of creating and displaying a control container, displaying an array of icons inside the container, where each icon represents a separate product window within the computer system, and linking the icons with their corresponding product windows to transmit window management operations from the icons to the product windows. In response to user performed operations on the icons through the locator input device, the method also provides for displaying miniature windows for selected icons within the container. In response to user performed operations through the locator input device on either the icons or miniature windows, the method provides for transmitting the window management operations for performance to the corresponding product windows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a window management control window displaying a plurality of icons, in a multiple window format, according to the invention.
FIG. 2 is a view similar to FIG. 1, showing the control window with a pop-up menu selected on one of the icons.
FIG. 3 is a view similar to FIG. 1, showing miniature windows constructed inside the control window, according to the invention.
FIG. 4 is a view similar to FIG. 1, showing icons displayed in a tree hierarchy in the control window, according to another aspect of the invention.
FIG. 5 is a view similar to FIG. 1, of miniature windows displayed in a tree hierarchy in the control window, according to a further aspect of the invention.
FIG. 6 is a flow diagram setting forth the computer implemented steps for display and management of the control window.
FIG. 7 is a flow diagram setting forth the computer implemented steps for effecting window management operations through product windows interacting with icons contained in the control window.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention comprises a single control window container on a computer display containing representations of product windows or related file windows. The generic term "product window" designates both of these types of windows. The control window container enables a user to control each individual product window by using or manipulating the representations and by integrating together the individual windows. These representations include miniature windows and icons. Any suitable locator input device, such as a mouse or touch screen, enables a user to control the product window.
The term "container" refers to a window display object that contains other display objects within its frame or boundary, such as icons and miniature windows. As a window display object, standard user interface techniques (described herein) control its opening, closing, and parameters (e.g., size and location). When the displayed contents of the container overflow its established parameters, standard scrolling is available to increase its usable display area.
Referring to FIG. 1, control window 10 contains multiple icons (generally designated by numerals in the 20's). Each icon represents an open product window that can be displayed on the display screen simultaneously with the icon. Illustratively, "List:1" icon 21 represents the displayed "List:1" window 31, while "Graph:2" icon 25 represents the displayed "Graph:2" window 35. The remaining icons ("Text:1" 22, "Graph:1" 23, "List:2" 24, "Text:2" 26, and "List:3" 27) represent hidden windows. Hidden windows are windows that are not currently displayed on the display screen, but are still "open" windows in the operating system.
A visual indicator enables the user to distinguish icons representing displayed windows from those representing hidden windows. This is especially useful in avoiding user confusion when large numbers of icons are displayed in control window 10. Illustratively, both "List:1" and "Graph:2" icons 21 and 25, respectively, have a distinctive border to designate that their corresponding product windows are displayed. Alternately, other highlighting features known in the art could be utilized to indicate displayed windows.
However, the previously described visual indicator (i.e., a distinctive border) must be distinguished from another visual indicator used to denote an active icon. Active ions are illustrated as a highlighted labels (e.g., see icon 27 in FIG. 1 and icon 26 in FIG. 2). Alternately, other indicator means known in the art might be utilized to indicate active icons.
A focus area is an area which receives subsequent keyboard input. The present invention allows only one focus area in the control window and, as such, only one icon will be active (e.g., subject to the focus area) at a time. Alternately, other possible embodiments could provide for the presence of more than one focus area at a time on the display. However, numerous product windows may be simultaneously displayed in the multiple window format on the display screen. Therefore, more than one icon may be shown with a distinctive border in control window 10.
To simplify the displayed presentation, a user interface technique displays the same type of product window using a common icon symbol. For example, all "Graph" windows are represented by a common icon illustrating one graphic depiction (see icons 23 and 25 and icons 22 and 26, respectively).
In FIG. 1, the icons displayed in control window 10 are arranged horizontally by wrapping at the right hand side of the window. Another alternative shown in FIG. 2 arranges the icons displayed in control window 10a vertically from top to bottom by wrapping at the bottom of the control window. The user can alter the icon arrangement in the control window and, thus, tailor the display to suit individual preference. This can be performed either by menu selections or by drag/drop operations.
FIG. 4 illustrates an advanced application having multiple related files or product windows. Depending on the style of display, the appropriate menu selection commands enable the user to view window 10c. Control window 10c shows the hierarchical relationship between the product windows represented by the icons. Without this feature, these relationships would not be readily apparent to the user. Each icon representing an individual product window (referred to as icon window representation) is arranged in a tree. These icon window representations are displayed as leaf nodes 42 through 47 in the tree. The root node 41 is the icon for the entire product (a browser in this illustration) denoting that all icon window representations are part of the overall product.
Icon window representations of the same type are grouped under an icon denoting that window type. Descriptive text labelling accompanies the icons to differentiate levels in the file hierarchy. Illustratively, icons 42, 44 and 45 denote a generic type of product window, while icons 43, 46 and 47 each denote specific product windows. This hierarchical display is particularly useful in object oriented technology because the hierarchical structure of the class library defines the characteristics (e.g., functions, types) of files (objects).
Referring to FIG. 2, standard user interface techniques indicate what operations can be performed on a product window via its representative icon. Illustratively, pop-up menu 50 can be obtained by locating the mouse cursor directly on "text:2" icon 26 and single-clicking the mouse. Selection of an operation from pop-up window 50 alters the parameters of the product window. For example, pop-up window 50 lists four operations--restore, maximize, hide, and close. However, because the corresponding file window is hidden, the "Hide" operation in pop-up window 50 is "grayed out" to indicate that this operation is not currently available.
File related operations can also be performed through the use of miniature windows which, like the pop-up windows, are displayed in the control window. FIG. 3 illustrates miniature windows 51 and 55 in control window 10b. Miniature window 51 corresponds to product window 31 (e.g., "List:1"), while miniature window 55 corresponds to product window 35 (e.g., "Graph:2").
A miniature window is a dynamic picture of the product window it represents, the contents and parameters of which change to reflect changes made to the product window. The contents of the miniature window cannot be directly manipulated. However, the operations that are performable on the product window's parameters can typically be performed on the miniature window's parameters. When performed on the miniature window's parameters, the same parameters of the product window are directly affected.
Such operations include those usually allowed on the individual product windows themselves, such as re-sizing, moving, minimizing, maximizing and restoring. For example, re-sizing the actual product window automatically re-sizes its corresponding miniature window. Similarly, re-sizing the miniature window automatically re-sizes its corresponding product window. This example could apply equally to other window operations, such as moving and restoring.
Possible features for the miniature windows include: (1) system and pull-down menus; (2) title bars; (3) minimize, hide, and maximize buttons; (4) minimize icons, where the product window is being minimized; (5) a miniature window denoting the product window; and (6) a scaled down version of the contents of the individual product window, which is displayed as the contents of the miniature window.
Window representations are placed in the control window according to their relative position on the entire screen. Windows can be minimized (e.g., replaced by an icon) to the contents of the control window and are represented by an "inactive" icon (i.e., absent the distinctive border). FIG. 3 illustrates an "inactive" icon 28 in control window 10b.
A more specialized application of the miniature window is illustrated in FIG. 5. Control window 10d displays miniature window 60 and miniature windows "Graph:1" 53 (corresponding to icon 23) and "Text:2" 56 (corresponding to icon 26). These miniature windows are derived from the hierarchical format shown in FIG. 4.
Referring again to FIG. 5, these miniature windows are further derived from downwardly directed arrows 62 connecting miniature window 60 to miniature windows 53 and 56. This illustrates the hierarchical relationship between the actual product windows represented by the miniature windows. In other words, miniature window 60 is the miniature window representing browser control icon 41 (the overall product in this example). Therefore, miniature window 60 is the superclass for each of the "Graph:1" and "Text:2" files, which are represented by their icons 43 and 47, respectively, in FIG. 4 and by their miniature windows 53 and 56, respectively, in FIG. 5.
The flow diagram of FIG. 6 illustrates the numerous window management operations that can be performed through icons or miniature windows in the control window. For simplicity, the term "icon" is used throughout the flow diagram, but it should be noted that many of the same operations can be implemented through miniature windows displayed on their corresponding icons and the preferred embodiment covers this extended application.
On starting a control window for a particular product (block 100), links are established with all open product windows (whether displayed or hidden). A control window having linked icons thereon is displayed at block 102.
In using the control window, if the user selects an option to display a pop-up menu for a particular icon "x" at block 104, the computer displays the pop-up menu at block 106. Operations from the pop-up menu include "icon restore" at block 108, "icon maximize" at block 114, and "icon minimize" at block 118.
The "icon restore" operation (block 108) displays the product window represented by the icon at block 110. Further, it implements an "active" visual indicator (e.g. a border) on the icon to show that its product window is displayed (block 112).
The "icon maximize" operation (block 114) either maximizes the size of a displayed product window or displays the product window directly at its maximum size (block 116). If the icon is not already marked as active (i.e. window open border), execution of this operation causes the border to appear (block 112).
The converse operation is "icon minimize" (block 118) that hides the associated file window at block 120, without closing or terminating the link between the control window and the product window. On hiding its associated product window, the icon is marked as inactive at block 122. That is, the indicator border is removed.
The "display system menu" operation (block 124) relates specifically to miniature window use. This operation displays the system menu for the product window (block 126) from the title bar of the associated miniature window. The system menu allow window manipulation operations. This system menu contains the standard window operations shown in the flow diagram of FIG. 7, such as "restore" (block 204), "maximize" (block 208) and "minimize" (block 212) and permits performance of these operations on the product window through implementing the locator input device on the specific operation displayed in the miniature window.
Other operations performable on the miniature window that directly affect the parameters of the corresponding product window include sizing (block 128) and moving (block 132). For example, performing a change of size operation (block 128) directly changes the size of the corresponding product window if displayed, or is recorded in the hidden product window's parameters (block 130). Similarly, performing a "move icon" operation (block 132) moves the corresponding displayed product window on the display screen (block 134). If the product window is hidden, then the miniature window would be an icon and, therefore, move are not possible.
In order to remove the link between the control window and the product window, the "icon close" operation (block 142), which can be implemented through either the icon or miniature window, deletes the icon from the control window (block 144) and removes the product window, if displayed, or simply severs the link between the control window and the product window so that the product window can no longer be accessed (block 146).
The "icon refresh" operation (block 136) causes the miniature window displaying the contents of a product window to be refreshed and, thus, reflects any changes made to those contents (block 138). This operation involves copying a suitably transformed image of the product window's contents into the "contents" of the miniature window (block 140).
Operations that have a direct effect on the control window itself include creating new file windows (block 148), changing the layout of icons in the control window (block 156) and closing the control window (block 160). When adding a new product window, the "control create new window" operation (block 148) establishes a link between control window 10 and the new product window (i.e., creates a new product window in relation to the control window--block 150). Furthermore, it establishes a new icon in the control window that represents the new window (block 152) and provides the visual representation of the link between the control window and the new product window. The new icon is immediately marked as active in the focus area (block 154).
As is known, icons in the control window can be rearranged simply by pressing the mouse button and dragging each icon to the desired location. Either this manual method or pre-programmed arrangements can be effected through an operation for "control change layout" (block 156), which causes computer implementation of the layout change (blocks 158 and 102).
The "control close" (block 160) operation closes the control window, deleting the icons from the display (block 162) and severing links with the various product windows (block 164) to exit the control window program (block 166).
FIG. 7 sets forth computer implemented operations in a product window represented in the control window by either an icon or a miniature window.
The operation to start a product window (block 200) sends a message to establish a link (for passing window management operations) between the control window and the new product window (block 202). Once the link has been established, the following operations can be performed on the product window through its representative icon in the control window:
1. The "restore" operation (block 204) displays the product window and sends an "icon restore" command (block 206) to the control window. In turn, the control window receives and executes the "icon restore" command (blocks 108 and 110 in FIG. 6), thereby marking the icon as "active" (block 112 in FIG. 6);
2. The "maximize" operation (block 208 in FIG. 7) sends an "icon maximize" command to the control window (block 210). In turn, the control window receives and executes the "icon maximize" command (blocks 114 and 116 in FIG. 6) to display, if necessary, and maximize the size of the product window, while also marking the icon as "active" (block 112 in FIG. 6);
3. The "minimize" operation (block 212 in FIG. 7) sends an "icon minimize" command to the control window (block 214). In turn, the control window receives and executes the "icon minimize" command (blocks 118 and 120 in FIG. 6) to hide the product window corresponding to icon "x" and mark icon "x" as "inactive" (block 122); and
4. The "close" operation (block 216 in FIG. 7) sends an "icon close" command (block 218) to close out the product window, delete the icon representing the file, and sever the link between the control window and the product window (blocks 142, 144 and 146 in FIG. 6).
Operations performed directly on the product window parameters alter the parameters of the miniature window in the control window. These operations include changing the size of the product window (blocks 220 and 222 in FIG. 7) and changing the location of the product window (blocks 228 and 230). After these operations, the product window is refreshed (block 224), as well as the corresponding icon (block 226 in FIG. 7 leads to blocks 136, 138 and 140 in FIG. 6). Any changes to the product window generate a "refresh" operation (block 232). The "refresh" operation also updates the corresponding miniature window.
Finally, as previously described, operations performed on a miniature window affect the parameters of its corresponding product window. Illustrations of these operations are shown in FIG. 7. However, other operations would be obvious modifications to one skilled in the art, such as: (1) the "do -- restore" operation (block 236), which opens the product window from the control window (block 238); (2) the "do -- maximize" operation (block 240), which increases the size of the product window from the control window (block 242); and (3) the "do -- minimize" operation (block 244), which closes the product window (block 246).
This "do -- minimize" operation can also be performed directly on the product window as a "do -- close" operation (block 248) to close the product window (block 250) and end (block 252).
Provision of a single control window containing icons and miniature windows representing multiple file windows has been particularly shown and described in relation to the concept of a single product where the multiple file windows are related. However, modifications to the described preferred embodiments will be obvious to one skilled in the art and are intended to be covered by the following claims. | A user interface system is used for accessing and performing window management operations. A control window containing icons linked to product windows. Each icon in the control window is also capable of projecting a miniature window dynamically linked in terms of content and parameters to the actual information represented by the icon. Window management operations, such as moving, sizing, restoring, and closing, performed on either the iconic or miniature window representations in the control window are transmitted directly to the contents of the represented windows and implemented, whether these windows are opened or closed at the time that the operations are performed. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims benefit and priority from U.S. provisional application 61/387,258 entitled “Stand and/or Support for Planar or Tablet Computing Device,” filed on Sep. 28, 2010, the disclosure of which is hereby incorporated by reference herein in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates generally to apparatus and methods for supporting planar or tablet computing devices such as iPads and other tablet computers and iPhones and other smart cellular telephones and the like.
BACKGROUND OF THE INVENTION
[0003] Conventional designs and constructions for supporting planar or tablet computing devices all have drawbacks, especially that they are not very versatile in function. While they may be able to support a tablet computer in one orientation or for one purpose, such as orienting the tablet computer in a comfortable position for typing or word processing, they are limited in such functions.
[0004] Accordingly, it would be desirable to provide a stand or support for a planar or tablet computing device which is multi-functional and portable.
[0005] In addition, it would be desirable to provide a stand or support for a planar or tablet computing device which may be used on a table or other surface, as well as being removably attachable to a user's body.
[0006] Further, it would be desirable to provide a stand or support for a planar or tablet computing device which is specially designed to enhance the gaming capabilities of such computing device.
[0007] In addition, it would be desirable to provide a stand or support which allows for numerous different orientations of a planar or tablet computing device.
[0008] These and other advantages of the invention will be appreciated by reference to the detailed description of the preferred embodiment(s) that follow.
BRIEF SUMMARY OF THE INVENTION
[0009] In a first aspect, the present invention comprises a stand or support for a planar or tablet computing device, comprising: a base; a ball-shaped shaft support removably disposed within a socket defined by the base; a support shaft removably secured to the ball-shaped shaft support; and a support plate for supporting the planar or tablet computing device; wherein the support plate is removably attachable to the support shaft.
[0010] In accordance with another aspect of the stand or support for a planar or tablet computing device, the base has a convex upper surface and a concave underside.
[0011] In yet another aspect of the stand or support, the underside of the base and/or a perimeter of the base comprises a non-slip material, an adhesive material or a temporary fixation material.
[0012] In yet an additional aspect, the stand or support further comprises means for removably attaching the base to a limb of a user or other generally cylindrical object.
[0013] In yet another aspect of the stand or support, the ball-shaped shaft support is rotatably disposed within the socket.
[0014] In another aspect of the stand or support, the ball-shaped shaft support is removably retained within the socket by a threaded retainer ring that can be tightened onto a cylindrical column defined by the base; wherein the cylindrical column defines the socket and has a threaded outer surface on which the threaded retainer ring may be removably secured.
[0015] In yet a further aspect of the stand or support, the retainer ring may be tightened onto the cylindrical column to varying degrees to allow for rotational movement of the ball-shaped shaft support within the socket and also for temporary immobilization of the ball-shaped shaft support within the socket.
[0016] In yet another aspect of the stand or support, the support plate comprises a non-slip upper surface. In another aspect of the stand or support, the support plate comprises a tacky upper surface.
[0017] In yet an additional aspect, the stand or support further comprises a non-slip cover for covering the tacky upper surface.
[0018] In yet another aspect of the stand or support, the support plate comprises an upper surface comprising an adhesive material, a tacky material or a temporary fixation material.
[0019] In yet a further aspect of the stand or support, the support plate comprises an upper surface comprising a polyurethane material.
[0020] In yet another aspect of the stand or support, the support plate comprises an upper surface comprising a thermoplastic elastomer, a silicone, a rubber, an acrylic, an acrylic foam or an acrylic adhesive.
[0021] In yet an additional aspect, the stand or support further comprises a suction cup disposed on the support plate; wherein the suction cup is used for removably attaching the planar or tablet computing device to the support plate.
[0022] In another aspect, the stand or support further comprises a hook and loop fastener for removably fastening the planar or tablet computing device to the support plate.
[0023] In yet another aspect of the stand or support, the base comprises a central body and first and second side members, wherein the central body defines the socket and each of the first and second side members articulates with the central body.
[0024] In another aspect of the stand or support, the each of the first and second side members may be folded underneath the central body.
[0025] In yet a further aspect of the stand or support, the support shaft comprises external threading and the ball-shaped shaft support comprises a generally spherical body and a cylindrical neck portion having a threaded bore for receiving the support shaft.
[0026] In an additional aspect of the stand or support, the base defines a slot; wherein the slot is of sufficient length and width for receiving a side of the planar or tablet computing device for supporting the same in a vertical position or at angle with respect to vertical. In a further aspect of the stand or support, the width of the slot is adjustable.
[0027] In yet another aspect of the stand or support, the base and the first and second side members collectively define a slot.
[0028] In another aspect of the stand or support, the slot is of sufficient length and width for receiving a side of the planar or tablet computing device for supporting the same in a vertical position or at angle with respect to vertical. In a further aspect of the stand or support, the width of the slot is adjustable.
[0029] In another aspect of the stand or support, the slot has an open top, an open bottom and one open side, in-whole or in-part.
[0030] In another aspect, the stand or support further comprises means for removably attaching the planar or tablet computing device to the support plate.
[0031] In another aspect, the present invention comprises a stand or support for a planar or tablet computing device, comprising: a base; a slot defined by the base, wherein the slot is of sufficient length and width for receiving a side of the planar or tablet computing device for supporting the same in a vertical position or at angle with respect to vertical; and a ridge slidably disposed on the base, wherein the planar or tablet computing device may be supported against the ridge when the planar or tablet computing device is disposed in the slot.
[0032] In yet a further aspect, the present invention comprises a stand or support for a planar or tablet computing device, comprising: a base; and means for removably attaching the planar or tablet computing device to the base.
[0033] In yet another aspect, the present invention comprises a method for supporting a planar or tablet computing device, comprising: providing a stand or support for a planar or tablet computing device, comprising a base; a ball-shaped shaft support removably disposed within a socket defined by the base, a support shaft integral with or secured to the ball-shaped shaft support; and a support plate integral with or secured to the support shaft; wherein the base defines a slot and the slot is of sufficient length and width for receiving a side of the planar or tablet computing device; wherein the ball-shaped shaft support is removably retained within the socket by a threaded retainer ring that can be tightened onto a cylindrical column defined by the base; and wherein the retainer ring may be tightened onto the cylindrical column to varying degrees to allow for rotational movement of the ball-shaped shaft support within the socket and also for temporary immobilization of the ball-shaped shaft support within the socket; inserting a side of the planar or tablet computing device into the slot; and adjusting the position of the support plate so that a side or upper surface of the support plate contacts the planar or tablet computing device disposed in the slot.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0034] For the present disclosure to be easily understood and readily practiced, the present disclosure will now be described for purposes of illustration and not limitation in connection with the following figures, wherein:
[0035] FIG. 1 is a perspective view of a stand or support for a planar or tablet computing device according to a preferred embodiment of the present invention;
[0036] FIG. 2 is a perspective view of the stand or support of FIG. 1 showing a planar or tablet computing device supported for use thereon;
[0037] FIG. 3 is a perspective view showing the stand or support of FIG. 1 removably attached to a user of the planar or tablet computing device supported by the stand or support;
[0038] FIG. 4A is a perspective view showing the folding of the stand or support of FIG. 1 for stowage;
[0039] FIG. 4B is a perspective view showing the stand or support of FIG. 1 folded for stowage;
[0040] FIG. 5 is a perspective view of a preferred embodiment of the base of the stand or support of FIG. 1 ;
[0041] FIG. 6 is an exploded, perspective view of the stand or support of FIG. 1 ;
[0042] FIG. 7 is an exploded view of a stand or support for a planar or tablet computing device according to another preferred embodiment of the present invention;
[0043] FIG. 8 is a partial, cross-sectional view of the stand or support of FIG. 7 partially folded for stowage;
[0044] FIG. 9 is a series of elevational views of a preferred embodiment of a support plate having a dual-sided support pad having a non-slip side and a hi-tack or adhesive side for use with the stand or support of the present invention;
[0045] FIG. 10A is a cross-sectional view a preferred embodiment of a dual-sided support pad having a non-slip side and a hi-tack or adhesive side for use with a stand or support of the present invention;
[0046] FIG. 10B is a cross-sectional view another preferred embodiment of a dual-sided support pad having a non-slip side and a hi-tack or adhesive side and an embedded magnet for use with a stand or support of the present invention;
[0047] FIG. 11 is a perspective view of a preferred embodiment of a harness useful as part of a means for removably attaching a planar or tablet computing device to a stand or support of the present invention;
[0048] FIG. 12 is a perspective view of a preferred embodiment of a bracket useful as part of a means for removably attaching a planar or tablet computing device to a stand or support of the present invention;
[0049] FIG. 13 is a perspective view of another preferred embodiment of a bracket useful as part of a means for removably attaching a planar or tablet computing device to a stand or support of the present invention;
[0050] FIG. 14 is a perspective view of another preferred embodiment of a harness useful as part of a means for removably attaching a planar or tablet computing device to a stand or support of the present invention;
[0051] FIG. 15 is a perspective view of a preferred embodiment of a cover with an aperture useful as part of a means for removably attaching a planar or tablet computing device to a stand or support of the present invention;
[0052] FIG. 16 is a front perspective view of a preferred embodiment of a cover or bracket with a support shaft useful as part of a means for removably attaching a planar or tablet computing device to a stand or support of the present invention;
[0053] FIG. 17 is a rear perspective view of the cover or bracket with a support shaft of FIG. 16 ;
[0054] FIG. 18 is a perspective view of another preferred embodiment of a cover or bracket useful as part of a means for removably attaching a planar or tablet computing device to a stand or support of the present invention; and
[0055] FIG. 19 is a perspective view of a stand or support for a planar or tablet computing device according to another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0056] In the following detailed description, reference is made to the accompanying examples and figures that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the inventive subject matter may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that other embodiments may be utilized and that structural or logical changes may be made without departing from the scope of the inventive subject matter. Such embodiments of the inventive subject matter may be referred to, individually and/or collectively, herein by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed.
[0057] The following description is, therefore, not to be taken in a limited sense, and the scope of the inventive subject matter is defined by the appended claims and their equivalents.
[0058] FIG. 1 illustrates a preferred embodiment of a stand or support 10 for a planar or tablet computing device 20 of the present invention comprising a base 12 having an outer perimeter 14 and defining slot 19 . As shown in the figures, base 12 preferably has a convex upper surface 8 and a concave underside 9 . The concave underside 9 preferably conforms to a substantially cylindrical article, such as a user's thigh 32 , as shown in FIG. 3 , to provide added support for the stand 10 and computing device 20 while in use. An optional tether strap 36 hooked onto tether prongs 21 in tether openings 18 defined by base 12 may be used to further secure stand 10 to the leg 32 of a user 30 as also shown in FIG. 3 .
[0059] Preferably, perimeter 14 of base 12 , including the perimeter 14 defining slot 19 , as well as the underside 9 of base 12 , all comprise a layer of non-slip or adhesive material thereon. As shown in the figures, base 12 defines an annular shoulder 11 surrounding a threaded cylindrical column 13 surrounding aperture 31 (see FIG. 5 ). Cylindrical column 13 defines a socket 38 which receives ball shaft support 22 having neck 25 and a bore (not shown) preferably extending completely through ball shaft support 22 and neck 25 . Threaded support shaft 15 may be removably engaged to both the ball shaft support 22 and support plate 16 . Both the perimeter 17 and upper surface of support plate 16 are preferably made from a non-slip, tacky, adhesive or temporary fixation material. A thin dust cover of non-slip sheet material preferably is used to cover the upper surface of support plate 16 when the latter is made from a hi-tack, adhesive or temporary fixation material to keep dust and dirt off of such hi-tack, adhesive or temporary fixation material layer to prolong the effective life thereof. Such dust cover would also provide a non-slip surface on which computing device could be disposed on when a less aggressive gripping surface is desired.
[0060] Threaded retainer ring 24 may be removably secured onto the threaded cylindrical column 13 and over annular shoulder 11 to retain ball shaft support 22 in socket 38 . The degree to which retainer ring 24 is tightened onto the cylindrical column 13 will provide various amounts of rotational freedom of the ball shaft support 22 in socket 38 . If the retainer ring 24 is only loosely tightened on cylindrical column 13 , ball shaft support 22 will be able to rotate freely to position support plate 16 , as well as the computing device 20 disposed thereon or supported thereby, in positions desired by user 30 . Then, retainer ring 24 can be securely tightened onto cylindrical column 13 to temporarily immobilize the support plate 16 , along with the computing device 20 disposed thereon or supported thereby, is such desired positions, such as the positions shown in FIGS. 2 and 3 .
[0061] As used herein, non-slip materials preferably include polyurethane material and thermoplastic elastomer materials, and polyester films. Hi-tack and adhesive materials preferably include Regabond-S non-slip and temporary fixation material and cushion foam, silicone, rubber, acrylic, acrylic foam, micro-suction materials and/or acrylic adhesive materials. Base 12 and other components of stand 10 are preferably made from an acrylonitrile butadiene styrene (ABS) or other suitable material.
[0062] As further illustrated in FIG. 2 , stand 10 may be used to hold a planar computing device 20 , such as an iPad or iPhone, vertically (true 90°) or at an angle from vertical, in slot 19 with support plate 16 positioned such that its upper surface and/or perimeter 17 adds further support to the computing device 20 . As shown in FIG. 2 , the long side of the computing device 20 has been inserted into slot 19 . However, if long enough so that computing device 20 would maintain a level orientation, the short side of computing device 20 may also be inserted into slot 19 .
[0063] FIG. 3 shows stand 10 being used by user 30 wherein the concave underside 9 of stand 10 has been fitted over the leg 32 of user 30 . An optional tether strap 36 hooked onto tether prongs 21 in tether openings 18 defined by base 12 may be used to further secure stand 10 to the leg 32 of user 30 .
[0064] FIGS. 4A and 4B show stand 10 in a partially stowed and fully stowed configurations, respectively. FIG. 4 is a prospective view of the concave underside of base 12 showing hinges 29 that allow each of the right side member 27 and the left side member 28 to articulate or fold with respect to the central body 26 of base 12 . As also shown, support plate 16 has been removed from the convex upper surface 8 of base 12 and has been removably installed against the concave underside 9 of base 12 . This is accomplished by unscrewing support shaft 15 from ball shaft support 22 , loosening retainer ring 24 , and then screwing the threaded support shaft 15 with support plate 16 attached thereto into the central bore in the ball shaft support 22 from the concave underside 9 of base 12 . Retainer ring 24 is then tightened onto cylindrical column 13 to bring support plate 16 as close as possible to the underside of base 12 whereupon side members 27 and 28 may be folded over support plate 16 to configure the stand 10 in its fully stowed position as shown in FIG. 4B . The tether strap 36 may be wrapped around the stowed stand 10 , preferably around the side members 27 and 28 where they define slot 19 .
[0065] FIG. 5 illustrates stand 10 without retainer ring 24 , ball shaft support 22 , support shaft 15 and support plate 16 to clearly show annular shoulder 11 , cylindrical column 13 , central aperture 31 and socket 38 defined by base 12 .
[0066] FIG. 6 provides an exploded, perspective view of stand 10 including base 12 and its three sections, the central body 26 and side members 27 and 28 hingedly connected to central body 26 by hinges 29 . Here, retainer ring 24 is shown disposed below ball shaft support 22 , but the diameter of the opening in retainer ring 24 is preferably smaller than the diameter of the ball portion of ball shaft support 22 which must necessarily be inserted into socket 38 prior to retainer ring 24 being screwed onto cylindrical column 13 .
[0067] FIG. 7 shows an exploded, perspective view of another preferred embodiment of stand 10 of the present invention wherein support shaft supports and is removably connected to connector plate 33 having a suction cup 34 and a Velcro (hook and loop) fastening ring 35 disposed thereon. The complementary component of the Velcro ring preferably would be attached to the computing device 20 to be removably attached to this embodiment of stand 10 via connector plate 33 and suction cup 34 . In this way, both the suction cup 34 and Velcro ring 34 would act as part of the means for removably securing computing device 20 to connector plate 33 and thus also to stand 10 .
[0068] FIG. 8 illustrates in a partial, cross-sectional view of the stand 10 of FIG. 7 partially folded for stowage with side member 28 partially folded under central body 26 . Also shown is how ball shaft support 22 is inverted in socket 38 in the stowage configuration of stand 10 , with connector plate 33 and suction cup 34 disposed adjacent to the concave underside 9 of base 12 . Retainer ring 24 has been tightened onto cylindrical body 13 to bring connector plate 33 as close as possible to the concave underside 9 of base 12 .
[0069] FIG. 9 comprises a series of elevational views of a preferred embodiment of a support plate 40 having a dual-sided support pad 46 having a non-slip side 47 and a hi-tack or adhesive side 49 (shown in FIG. 10A ) for use with the stand 10 of the present invention. Additionally, the support plate 40 comprises an articulating clip or clasp 42 and a fixed catch 44 for removably securing dual-sided pad 46 or dual-sided pad 50 ( FIG. 10B ) to support plate 40 and thus to stand 10 .
[0070] FIG. 10B shows a cross-sectional view another preferred embodiment of a dual-sided support pad 50 having a non-slip side 54 and a hi-tack or adhesive side 53 and an embedded magnet 52 for use with a stand 10 wherein the magnet 52 provides additional attraction forces to keep a computing device 20 having a ferromagnetic case or outer shell removably attached to support plate 16 or 40 of the stand 10 of the present invention.
[0071] FIG. 11 illustrates a perspective view of a preferred embodiment of a harness 56 useful as part of a means for removably attaching a planar or tablet computing device 20 to a stand 10 of the present invention.
[0072] FIG. 12 shows a perspective view of a preferred embodiment of a bracket 58 useful as part of a means for removably attaching a planar or tablet computing device 20 to a stand 10 of the present invention.
[0073] FIG. 13 illustrates perspective view of another preferred embodiment of a bracket 60 useful as part of a means for removably attaching a planar or tablet computing device 20 to a stand 10 of the present invention.
[0074] FIG. 14 shows a perspective view of another preferred embodiment of a harness or bracket 62 useful as part of a means for removably attaching a planar or tablet computing device 20 to a stand 10 of the present invention.
[0075] FIG. 15 displays a perspective view of a preferred embodiment of a cover 64 with an aperture 65 useful as part of a means for removably attaching a planar or tablet computing device 20 to a stand 10 of the present invention.
[0076] FIG. 16 shows a front perspective view of a preferred embodiment of a cover or bracket 66 with a support shaft 68 useful as part of a means for removably attaching a planar or tablet computing device 20 to a stand 10 of the present invention. FIG. 17 illustrates a rear perspective view of the cover or bracket 66 with a support shaft 68 .
[0077] FIG. 18 shows a perspective view of another preferred embodiment of a cover or bracket 70 useful as part of a means for removably attaching a planar or tablet computing device 20 to a stand 10 of the present invention.
[0078] FIG. 19 shows a perspective view of a stand or support 67 for a planar or tablet computing device according to another preferred embodiment of the present invention comprising a base 12 having a non-slip ridge 70 and a protrusion 76 for sliding non-slip ridge 70 to different positions in channels 74 . Base 12 defines slot 19 and may be comprise joints 72 such that left side member 28 and/or right side member 27 may be folded under base 12 for stowage. Base 12 may also comprise a singe joint only for folding base 12 upon itself for stowage as well. Again, base 12 preferably has a convex upper surface 8 and a concave underside 9 . In this preferred embodiment, a computing device (not shown) could be supported in slot 19 and rest against non-slip ridge 70 either vertically (90°) or at various angles from vertical depending upon where non-slip ridge 70 is positioned along channels 74 .
[0079] In the foregoing Detailed Description, various features are grouped together in a single embodiment to streamline the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. | A stand or support for a planar or tablet computing device, comprising: a base, the base may define a slot; wherein the slot is of sufficient length and width, which may be adjustable, for receiving a side of the planar or tablet computing device for supporting the same in a vertical position or at angle with respect to vertical; a ball-shaped shaft support removably disposed within a socket defined by the base; a support shaft removably secured to the ball-shaped shaft support; and a support plate for supporting the planar or tablet computing device; wherein the support plate is removably attachable to the support shaft and the position of the support plate may be adjusted so that a side or upper surface of the support plate contacts the planar or tablet computing device disposed in the slot to provide additional support for the planar or tablet computing device. | 5 |
RELATED APPLICATION
This patent application is related to U.S. Provisional Application No. 61/713,295, filed Oct. 12, 2012 and U.S. Provisional Application No. 61/768,703 filed on Feb. 25, 2013.
FIELD OF THE INVENTION
This invention relates to a low-head hydropower generation, and more specifically to refitting of power generation systems to existing dam structures.
BACKGROUND OF THE INVENTION
The conventional method of adding hydropower generation capability to a non-electrified dam is to remove a portion of the dam and then (1) to build a structure to provide the water conduits to drive conventional turbines, (2) to build a powerhouse to protect the turbines and generators, and (3) to provide a crane to install and service this equipment. It requires drying out the location by means of temporary or cofferdams upstream and downstream of the dam to enable placement of the civil works structure on the bottom of the waterway. A conventional turbine system places an unsightly building on an otherwise low-profile dam structure, and installation is an expensive and time-consuming process.
Other conventional methods involve the use of conventional combined turbine/generators, also called bulb turbines, which are heavy, expensive and less efficient than a newly-developed turbine/generators that weigh much less and install on a bulkhead, thereby avoiding the expense of civil works and cofferdams. This newly-developed turbine is the subject of U.S. Pat. Nos. 7,235,894, 7,385,303, 8,536,723 and U.S. patent application Ser. No. 13/356,288. The system, by virtue of its low weight and small dimensions, allows installation in single or multiple units on a movable gate, thereby allowing for the movable gate to be raised into a maintenance position for the turbine/generator to be serviced or replaced in short order (less than one day), avoiding long-term interruption to power generation.
The mitigation or elimination of some ecological threats created by conventional systems is important in that the present invention makes possible the avoidance of interference with wildlife.
The prior art generally involves systems that are made of steel or bronze and are very heavy. U.S. Pat. No. 5,825,094 discloses a gate structure that is extremely heavy and not practical to build, and using such a gate structure with prior (very heavy) turbines would involve cost which would never be able to be recovered by revenue from electricity generated. Further, such an approach would require an outsized lifting system to raise the gate structure with turbines installed above flood level. Service and maintenance would be extremely difficult since all runners have mechanical drive lines to the generators which use hypoid gear drives. Failure of one of the units stops all other connected turbines, and repair requires the complete unit to be taken out for repair.
Many patents such as U.S. Pat. No. 6,146,096, U.S. Pat. No. 6,281,597 and U.S. Pat. No. 7,372,172 refer to using existing dam gate installations to provide added power generation and the use of multiple self-contained, bulb-type turbine/generators placed in a matrix within a movable gate or pod to provide a low-head hydropower generation system without the need for a powerhouse. Such systems are severely limited by the metallic turbine/generators and fail to address efficiency and variation in flow rate to maintain efficiency. Also, these systems rely on existing crane lifting systems for movement of the turbine matrices. Since heavy metallic turbine/generators require the use of a larger number of smaller units to generate the required level of power, efficiency of the overall system suffers.
U.S. Pat. No. 7,372,172 is characteristic of such an approach whereby a limited number of small metallic turbine/generators are placed in an enclosure, pod or container. This patent discloses a lifting mechanism substantially different for the present invention, and weight of the structures which must be lifted is extremely high.
The present invention incorporates patented and patent-pending low-weight turbine/generators that can be installed in gates and a unique lifting mechanism utilizing rotational movement and capable of spanning the width between piers of a dam agate section. In contrast to the conventional bulb-type matrix turbines, the present invention allows for higher power, larger diameter, low weight turbine/generators to be employed.
In addition, because of the sensitive state (due to age and poor maintenance) of the present dam system in the United States, the modification of an existing non-power-producing dam, however small, creates a concern over the effect of modification such that permission to make changes to add hydropower generation may be denied. The present patent provides a system that does not attach to or alter an existing dam structure in any way while cooperating with the existing dam equipment to provide maximum capacity power generation.
OBJECTS OF THE INVENTION
It is an object of this invention to provide low-cost, highly-efficient power generation for existing and new low-head dams.
Another object is to provide a system which makes use of existing gate construction features to install hydropower generation on a dam.
A further object of this invention is to provide a system which adds power generation capability to an existing dam without modifying or altering the existing dam in any way.
Another object is to provide a system which avoids the building of a powerhouse on a previously non-powered dam.
It is a further object to use the existing structure to provide support for a downstream gate which carries at least one turbine/generator.
Yet another object is to enable the simultaneous use of the hinge support of an existing dam gate structure for a downstream gate carrying at least one turbine/generator without interfering with the original gate structure and its operation.
Another object is to enable the use of dual parallel arms to move at least one gate with a turbine/generator installed in a substantially vertical direction and to allow controlled flow underneath the gate.
Another object is to enable the use of dual gates, whereby an upstream gate operates as a controlled flow device for one or more turbine/generators installed on a downstream gate.
It is a further object of this invention to provide trash and fish passage prevention through a turbine/generator.
Another object is to provide the thrash and fish passage prevention system to be self-cleaning.
Another object is to reduce the lifting load required during the raising of a gate having turbine/generators installed therein.
Another object is to provide a maintenance position, overhaul and replacement of the turbine/generators installed in a retrofit power generation system for a dam.
These and other objects of the invention will be apparent from the following descriptions and from the drawings.
DEFINITIONS
The term “head” as used herein refers to the height differential between the upstream water level and the downstream water level of the dam, typically measured in feet or meters.
The term “low-head dam” as used herein refers to a dam with a head of less than 50 feet or 15 meters.
The term “conventional turbine” as used herein refers to a separate turbine and generator connected by a drive shaft and requiring a foundation with water passages to accommodate the turbine operation.
The term “turbine/generator” as used herein refers to a combination of a turbine and generator in a common housing.
The term “second gate” as used herein refers to a gate placed downstream of a first gate, the first gate being the upstream gate controlling the head of a dam. The second gate carries the turbine/generators and maintains the head while the turbine/generators produce electric power with the first gate open.
SUMMARY OF THE INVENTION
The present invention is apparatus for positioning at least one hydroelectric turbine/generator in a dam having at least two spaced piers. The apparatus comprises (a) at least one first gate each spanning the space between a respective pair of neighboring piers and being movable to closed and open positions and positions therebetween to control flow and maintain head and (2) at least one second gate, each second gate associated with a corresponding first gate upstream thereof and supporting at least one hydroelectric turbine/generator in a maintenance position and a plurality of operating positions such that in operating positions, water flows through each turbine/generator to produce electric power.
In certain embodiments, the apparatus further includes at least one first-gate controller configured to control one or more first gates to control flow rate through the at least one turbine/generator in the corresponding one or more second gates.
In some embodiments, the apparatus further includes at least one second-gate controller configured to control second-gate operating position to control water passage therebelow.
In certain embodiments, the apparatus of claim 1 whereby the at least one first gate is positioned in the closed position, thereby eliminating flow through the at least one turbine/generator and permitting the raising of the corresponding at least one second gate.
Also in some embodiments, at least one of the first and second gates is rotated into position by means of arms fixed to the gate and supported by pivots in pier walls. In some of these embodiments, each of the at least one second gates rotates about the pivots of its corresponding first gate, and in some embodiments, the pivots are above tailwater level.
In certain preferred embodiments of the apparatus, at least one of the first and second gates is raised and lowered by sliding or rolling in a substantially vertical direction by tracks in or on the pier walls.
In certain embodiments, at least one of the first and second gates is moved in a substantially vertical direction supported by parallel control bars pivoted on the pier walls. In some such embodiments, the at least one second has parallel control bars.
In certain preferred embodiments of the apparatus, the top of the at least one second gate in an operating position is at a head level of the dam and the at least one corresponding first gate is in an open position, thereby allowing the head to drive the at least one turbine/generator while allowing flow over the top of the at least one second gate in the operating position.
In certain embodiments of the inventive apparatus, the at least one second gate can be raised to the maintenance position to allow service and replacement access to the at least one turbine/generator. In some of these embodiments, the at least one second gate in the maintenance position places the at least one turbine/generator in a vertical-axis position.
In some preferred embodiments of the apparatus, the at least one second gate has a screen placed such that it prevents trash and fish from passing through the at least one turbine/generator, and in some such embodiments, the screen is cleaned by raising the second gate to rotate the screen to cause debris to fall away. In other such embodiments, the screen is equipped with piping and nozzles to remove debris from the screen with pressurized fluid. Further, in some embodiments, the screen is placed such that flow through the screen diminishes toward the head-water surface, such diminished water flow lowering the force of impingement of debris on the screen and promoting movement of debris over the at least one second gate.
In highly-preferred embodiments of the inventive apparatus, the at least one second gate is supported independently of the two corresponding spaced piers. In some of these embodiments, the at least one second gate is supported by at least two pylons placed adjacent to the two corresponding spaced piers. In some such embodiments, the pylons support a sill to provide shut-off for the at least one corresponding second gate in a closed position. In some embodiments, each pair of spaced piers includes a service platform supported by the pylons. In some embodiments, the apparatus further includes at least one lifting mechanism for movement of a corresponding second gate, the lifting mechanism supported by pylons.
In certain preferred embodiments, the inventive apparatus further includes at least one barrier adjacent to each spaced pier and supported by pylons.
In some preferred embodiments, the apparatus includes at least one barrier placed adjacent to each spaced piers such that all water flowing between two spaced piers flows to the corresponding second gate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation of a dam looking upstream from the downstream side and including an embodiment of the inventive apparatus retrofitted thereto. In FIG. 1 , the inventive apparatus is in an operating position.
FIG. 2 is a section through the dam of FIG. 1 with common pivot Tainter gates and the turbine/generator units in a maintenance position. (Section A-A as shown herein are so labeled even when the position of the apparatus is changed.)
FIG. 3 is a section through the dam of FIG. 1 with common pivot Tainter gates and the units in an operating position.
FIG. 4 is a section of a dam with a roller-gate alternative embodiment of the inventive apparatus in a maintenance position.
FIG. 5 is a section of the dam of FIG. 4 with the inventive apparatus in an operating position.
FIG. 6 is a section of a dam with a sliding-gate alternative embodiment of the inventive apparatus in a maintenance position.
FIG. 7 is a section of the dam of FIG. 6 with the inventive apparatus in an operating position.
FIG. 8 is a section of a dam with a parallel-bar embodiment of the inventive apparatus in a maintenance position.
FIG. 9 is a section of the dam of FIG. 8 with the inventive apparatus in an operating position.
FIG. 10 is a detail section of a second gate in an embodiment of the inventive apparatus having an inventive air- or water-jet screen-cleaning system.
FIG. 11 is a section of a dam with an embodiment of the inventive apparatus placed adjacent to and independent of the existing dam structure.
FIG. 12 is a plan view of the dam section of FIG. 11 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention are depicted in FIGS. 1-12 . The inventive concept centers around using existing dam elements, namely the headwater level control/flood gates present in the major American rivers and rivers worldwide, to generate electric power. These gates double as shut-off gates for turbine/generators placed downstream of such gates and are necessary components in this invention. Such gates are referred to as “first gates.”
Most existing dam systems consist of a combination of a solid concrete or earthen dam and an array of piers stretched across the river. The piers support first gates lowered into the stream that restrict flow downstream and cause higher water levels upstream. These first gates may be raised and lowered to provide control of the restriction, permitting water to rise to a controlled level, allowing flow underneath the first gates and maintaining a head by raising the water level upstream of the dam. This provides flood control and deeper shipping channels. These dams are often provided with locks to allow shipping to bypass the dam.
FIG. 1 depicts such a dam system looking upstream from the downstream side and having an embodiment 100 of the inventive apparatus installed thereon. On the right on FIG. 1 is a solid dam 1 and adjacent to it is a pier 2 . Further to the left are piers 3 , 4 , etc. First gates 5 are suspended between piers 2 and 3 and piers 3 and 4 , etc. and are shown in a raised position. (In the embodiment of FIGS. 1-3 , first gates 5 are Tainter gates.) A set of second gates 14 carry ten turbine/generators 15 (in this embodiment) to maintain the water level P of the dam while allowing water to pass through turbine/generators 15 . Piers 2 , 3 , 4 , etc. are supported by a concrete base 6 set in the river-bottom bedrock 7 .
FIG. 2 shows section A-A of dam 1 in elevation cross-section with second gate 14 in a maintenance position. First gate 5 has controllable elevation and can be lowered to seat on a sill 9 thereby shutting off all water flow. FIG. 2 shows first gate 5 in an almost-closed position. It allows water passage by varying the size of a gap 8 and thus the rate of water flow 11 and so can control water level P of the upstream pool 10 by means of controllers 17 C 2 . The head H is the height difference between water level P and a water level T of tailwater 12 . First gate 5 is raised and lowered by hydraulic cylinders 16 operated by a hydraulic pump and valve system 17 . Multiple first gates 5 may be suspended between piers 3 and 4 and between 4 and subsequent piers providing multiple gate arrangements across the river, as is understood by those versed in the art of dam construction.
Second gates 14 are also raised and lowered by hydraulic cylinders 26 and operate in conjunction with first gates 5 . In order to take turbine/generators 15 out of the water flow and move them to a maintenance position, first gate 5 must be closed to stop water flow through turbine/generators 15 . Then, second gate 14 can be raised to place turbine/generators 15 in the maintenance position as shown in FIG. 2 . First gate 5 is in a raised position allowing headwater 10 to extend to second gate 14 .
As shown in FIG. 3 , second gate 14 is in an operating position (power-generating position) and first gate 5 is in an open position. The lower edge 5 L of gate 5 , in a raised position, is at least the height of the flood level F to ensure the water passage at the flood stage. Second gate 14 is sized to maintain level P of headwater 10 and seats on downstream sill 24 . Power is generated as a result of water flow W caused by head H between headwater 10 and tailwater 12 . The power is transmitted via cables 18 , a junction box 19 and a cable tray 20 to a power conditioner 21 . Power conditioner 21 converts the power generated by turbine/generators 15 to match the power grid 22 and is transported thereto via wires 23 .
First gates 5 , controlled by controllers 17 C 1 , and second gates 14 may advantageously pivot around common pivot 31 advantageously placed above tailwater level T to allow installation of pivot 31 from a barge (not shown) and to avoid water submersion. Pivot 31 is attached to pier wall 3 W of pier 3 .
Second gate 14 is provided with a trash screen 25 to prevent fish and debris from passing through turbine/generators 15 and is shaped to deflect debris. As water flows over trash screen 25 , the water flow will drive debris over the top of second gate 14 and deposit it in tailwater 12 via flow 27 flowing over second gate 14 . Heavier debris deflected downward toward an under portion 25 U of trash screen 25 will accumulate until second gate 14 is raised and then will pass into tailwater 12 across downstream sill 24 . When second gate 14 is in a raised position, it places turbine/generators 15 in a position for maintenance or replacement (as shown in FIG. 2 ) utilizing a platform 29 , a railing 30 and an overhead crane 28 . FIG. 10 later in this document illustrates an alternative embodiment for moving debris from trash screen 25 .
FIGS. 4 and 5 illustrate an alternative embodiment 105 having a roller gate 32 as its first gate. First gate 32 is operated by a mechanical drive 33 . Second gate 14 is identical to that shown in FIGS. 1-3 . FIG. 4 illustrates second gate 14 in a maintenance position while FIG. 5 illustrates second gate 14 in an operating position.
FIGS. 6 and 7 illustrate another alternative embodiment 110 having a sliding gate 34 as a first gate operated by machinery 35 . Second gate 14 is again identical to that shown in FIGS. 1-3 . FIG. 6 illustrates second gate 14 in a maintenance position while FIG. 7 illustrates second gate 14 in an operating position.
FIGS. 8 and 9 illustrate an alternative embodiment 115 having a second gate 36 placed in a dam having sliding gate 34 as a first gate. First gate 34 is operated by machinery 35 . Second gate 36 movement is controlled by a pair of parallel control arms 37 and 38 . The location of the pivots 39 and 40 in pier walls 3 W is above tailwater level T to enable installation without the need for drying out the area around first gate 34 and second gate 36 with the use of a cofferdam.
In the embodiments FIGS. 2 , 4 and 6 , with trash screen 25 in a raised position on second gate 14 debris, will drop off into tailwater 12 . FIG. 10 illustrates an enhanced approach to removing debris from trash screen 25 . FIG. 10 shows a detail of trash screen 25 with a set of nozzles 51 installed, fed by a pump 53 (driven by a motor 53 M) with air or water via a piping system 52 installed behind trash screen 25 . Nozzles 51 direct water to flow in upward direction 54 carrying debris otherwise stuck on trash screen 25 over the top of second gate 14 . This system works also in the raised position of second gate 14 , ejecting debris from trash screen 25 into tailwater 12 .
FIGS. 11 and 12 illustrate another alternative embodiment 120 but one that is not mechanically connected to piers 2 , 3 , 4 etc. Rather, embodiment 120 is placed adjacent to and downstream of piers 2 and 3 of an existing dam and uses first gate 32 of the dam to provide shut-off for second gate 64 . Second gate 64 and other apparatus ( 17 , 21 , 22 , 23 , 25 , 26 , 28 , 29 and 31 as shown) are supported by two or more pylons 56 bored into the bedrock 7 downstream of and in-line with piers 2 , 3 , 4 , etc., and such support is independent of piers 2 , 3 , 4 etc.
Drilling into bedrock 7 to place pylons 56 is done from a barge (not shown) and does not require a cofferdam. Pylons 56 support a structure that contains hinge points 31 for second gate 64 and hydraulic cylinder 26 to raise second gate 64 . Barriers 57 are attached to pylons 56 to maintain the water flow W to second gate 64 by preventing water flow W from by-passing second gate 64 . Pylons 56 also support sill 24 .
Pylons 56 further support service platform 29 that provides access to turbine/generators 15 for maintenance or replacement. Service platform 29 also supports overhead crane 28 to transport components to shore. First gate 32 (roller gate) is shown in its closed position in FIG. 11 . First gate 32 is shown in a raised position 32 A when second gate 64 is in an operating position (down position). FIG. 11 shows second gate 64 in its raised maintenance position 64 A. FIG. 12 shows a plan view of embodiment 120 but shows only piers 2 and 3 without adjacent structure.
While the principles of this invention have been described in connection with specific embodiments, it should be understood clearly that these descriptions are made only by way of example and are not intended to limit the scope of the invention. For example, hydraulic actuators are shown as part of the embodiments herein, but such actuators are in no way intended to be limiting; several other configurations for moving structures within the inventive apparatus, such as cables and drums, are possible. | Apparatus for positioning a hydroelectric turbine/generator in a dam having at least two spaced piers, the apparatus comprising (a) at least one first gate each spanning the space between a respective pair of neighboring piers and being movable to closed and open positions and positions therebetween to control flow and maintain head; and (b) at least one second gate, each second gate associated with a corresponding first gate upstream thereof and supporting at least one hydroelectric turbine/generator in a maintenance position and a plurality of operating positions such that in operating positions, water flows through each turbine/generator to produce electric power. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a control arrangement for influencing individual threads in a thread sheet, in particular, for warp knitting machines comprising a bar extending in the longitudinal direction having provided therein, stroke elements moveable in the stroke direction and a carrier extending in the longitudinal direction driveable to and fro in the stroke direction which is provided with adjacently ordered piezoelectric transducers. One end of said transducers being connected to the carrier and the other, free end, in dependence upon electrical control signals will either take up a first position, or a second position displaced in the longitudinal direction. The arrangement further comprises entrainment means which are connected to the free end of the transducers. The entrainment means (a) in the first position can move appropriate stroke elements in the stroke direction by contacting a counterstop of the stroke element, and (b) in the second position can leave the stroke element uninfluenced.
2. Description of Related Art
In a known stroke control arrangement of this type (DE 195 14 995 A1, FIGS. 8 through 11) the strip-formed piezoelectric transducers are provided as extensions of the corresponding stroke elements. The entrainment means are attached to flanges attached to and extending beyond both sides of the free ends of the transducers which, in the first position work together with a front facing step of the stroke element and in the second position are so bent that they lie next to the appropriate stroke element, wherein the transducer enters into an aperture in the stroke element. Since the transducers are attached to the carrier and are constantly moved backwards and forwards therewith, it is not necessary to provide sensitive pawls controlled by fixed transducers to the stroke elements (DE 195 14 995 A1, FIGS. 1 through 7). However, certain deficiencies in the transducers must be taken into account.
A purpose of the present invention is to provide a stroke control arrangement of the sort described hereinabove which better addresses the requirements of the art.
This task is preferably served thereby that the entrainment means are provided in the transverse direction adjacent to the transducers and at one end thereof are supported in a construction unit rigidly affixed to the carrier and whose other end carries the entrainment means.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a stroke control arrangement for influencing individual threads of a thread sheet for a warp knitting machine. The stroke control arrangement includes a longitudinally extending bar, and a plurality of guided stroke elements. Each of the stroke elements has a counterstop and each is mounted on the longitudinally extending bar in a stroke direction. Also included is a carrier extending longitudinally and adapted to reciprocate in the stroke direction, as well as a plurality of piezoelectric transducers mounted in a row at the carrier. Each of the transducers is responsive to an electrical control signal and each has a restrained end connected to the carrier. Each of the transducers also has a free end moveable, in dependence upon the electrical control signal, between a first position and a longitudinally displaced second position. The stroke control arrangement also has a plurality of entrainment means transversely mounted adjacent to the transducers. Each of the entrainment means has one end with a stop and another end supported on a portion of the carrier. Each of the entrainment means is coupled to the free end of a corresponding one of the transducers and is operable (a) in a first position to affect engagement between the stop of the entrainment means and the counterstop of the stroke element, in order to carry the corresponding one of the stroke elements in the stroke direction, and (b) in a second position to refrain from affecting the stroke elements.
In this construction the entrainment forces may be transmitted to the stroke element via the entrainment means. The transducers remain uninfluenced thereby. This increases their working life and the switch security quite considerably. The entrainment means can have a sufficient stability and can be displaced by small forces by the transducers. Friction can be kept at a minimum by the use of low friction materials and by swing path limiting stops, which again increases the operative life.
It is advantageous generally to make the entrainment means from flat sheet metal. Thus, the entrainment means can be arranged rather close to each other.
It is advantageous to provide that the entrainment means are connected with the free ends of the appropriate transducers via sidewardly extending arms. The entrainment means and the transducers can thus lie in a common plane.
Advantageously, the entrainment means with the sideward arms may interact with the opposed protrusions in the apertures which limit the swing path. Both positions of the entrainment means are thus clearly defined.
It is further advantageous if the transducers are set back in the stroke direction, relative to the entrainment means. Thus, the size of the swing path of the entrainment means is increased with respect to the swing path of the transducers. Rather small deflections of the transducers will then be sufficient to displace a entrainment means from one position to the other.
It is advantageous to provide of one end the entrainment means with an axle on which it is rotatable. The entrainment means thus provide levers which are readily rotatable.
A similarly preferred alternative resides wherein, the stroke elements are supported in a groove whose side walls converge somewhat inwardly. Since the entrainment means, through their combination with the transducers are held in the grooves, even here there is provided an easy rotatability.
It is further advantageous if the supporting area is formed of a material with better support qualities than the carrier. This insert can tolerate relatively high entrainment forces, which again increases the operative life.
It is desirable in some embodiments, that at the free ends of the transducers, carry a front facing end piece provided with a slit which has the same thickness and breadth as the adjacent portion as the transducer, and that sideward arms grip into the slot. Such transducers may be readily mass produced and integrated. The dimensions of the end section thus do not exceed those of the corresponding transducer.
It is advantageous for the entrainment means to be provided with a return stop which, through contact with a return counterstop of the corresponding stroke element, returns it in the stroke direction. Such a return stop forces the stroke element back into the initial position. An operating interference due to the collision of the stroke elements and other knitting elements is therefore excluded.
In a preferred embodiment, it is provided that the entrainment means in the first position are located flat against the appropriate stroke elements and have a stop-forming flange between the front facing edge and an aperture, and that the stroke element carries counterstops extending from both sides of the flange in its plane. This type of coupling permits close grouping of the stroke elements.
In particular, the counterstops can be formed from a tongue pressed out of the stroke element and/or from a plate set thereon.
Further, the plate can overlie the stroke element in the transverse direction and grip into a guide groove. The plate therefore has a double function.
In a similarly preferred embodiment it is provided that the entrainment means in the first setting are provided as extensions of the appropriate stroke elements and that the stops and counterstops are formed by the edges of the entrainment means and the stroke elements. This permits a particularly compact arrangement, wherein 16 stroke elements per inch can be provided.
Herein, it is advantageous that in the first position an extension of one element grasps into an aperture in the other element, wherein the flange segments extending in the transverse direction overlap each other.
In a further embodiment of the invention, guide sheets are connected with a part rigidly affixed to the carrier, which occupy the space between the entrainment means and the stroke element. These guides facilitate exact operation of the system.
Furthermore, it is advantageous to provide that the stroke elements are located between a guide sheet and a guide lamella attached to the adjacent guide sheet. In this way, the stroke elements have a definite positioning.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a partial, cross-sectional, elevational view of the working area of a warp knitting machine.
FIG. 2 is a side, elevational, cross-sectional view of the entire stroke arrangement of FIG. 1.
FIG. 3 is a detailed illustration of a portion of the arrangement of FIG. 3.
FIG. 4 is a plan view of a portion of the stroke control arrangement of FIG. 1.
FIG. 5 is a partial, cross-sectional view showing the interaction between the entrainment means and the stroke element of FIG. 4.
FIG. 6 is a perspective view of the relationship between the transducers, the entrainment means and the stroke element of FIGS. 1-5.
FIG. 7 is a partial cross-sectional, side elevational view of a second embodiment of a stroke control arrangement.
FIG. 8 is a partial cross-sectional, side elevational view of the entrainment means of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A warp knitting machine in accordance with FIGS. 1 through 4 and 6, comprises a working area (1) in which the needle bed (2) is near a knock-over bar (3). There are provided two guides bars (4) and (5) which serve to create ground fabric from threads (6) and (7). A further guide bar (8), equipped with a jacquard arrangement (9), provides pattern threads (10) which, by means of needles (11) of a stroke control arrangement (12) can, in accordance with the pattern, be grasped and held and then be cut-off by means of a cutting knife (13). There is further provided for this purpose a suction jet (14) which removes the cut-off segment of the pattern thread (10).
The stroke control arrangement (12) comprises a longitudinally extending bar (15) in which a carrier (16) is driven to and fro by a rod (17) acting with a cam plate (18). To the carrier (16) are provided piezoelectric transducers (19), entrainment means (20), and stroke elements (21), which will be considered in detail hereinbelow. The transducers (19) are served by an electrical control arrangement (22) via conduit bundle (23) and a 17-poled plug (24).
The to and fro driveable carrier (16) comprises removable segments (25) (see e.g., FIGS. 2 and 3). These carry a comb (26) which takes up one end of the 16 piezoelectric transducers (19). These transducers are constructed, as usual, of a strip of insulating material on each side of which, is provided a working electrode, a piezoelectric layer, and on the outside, a ground electrode. When the working electrode is provided, for a short time, with potential, the free end of transducer (19) takes up a first position. When the other electrode is provided with potential for a short time, the free end of the transducer (19) takes up a second position. The free end carries an end portion (27) which is provided with a slot (28) (FIG. 6) which corresponds to the breadth and thickness of the strip-formed transducer (19).
The entrainment means (20), which are made of sheet metal, are provided at one end with a bearing peg (29) protruding from both sides thereof which is supported in an insert (30) (FIG. 3) in segment (25). This insert is made of a material of better support qualities then segment (25). A lid (31) serving as a guide element, closes off the support area.
The entrainment means (20) comprises a sidewardly extending arm (32) which grips into slot (28) of end piece (27). On the opposite side, a protrusion (33) grips into pocket formed opening (34). The mutually opposite end surfaces of the pocket serve as stops to exactly position the entrainment means (20) in the first or second position. Entrainment means (20) has a rectangular aperture (35) so positioned that a stop member (flange 36) remains, whose outer edge comprises an entrainment means stop (37) and whose opposite edge forms the return stop (38).
The stroke elements (21), which are also made of sheet metal, carry the hook needles (11) and are biased by compression springs (54). By means of the entrainment means stop (37) they move in working position A (FIG. 4) and, by means of the return stop (38) and the compression spring (54) are returned into the at rest position B. On one side they carry a plate (39) whose edge, in the first position C (FIGS. 5 and 6) of the entrainment means (20) works together with the entrainment means stop (37) as an entrainment means counterstop (40), so that at the entrainment of carrier (16) the appropriate stroke element (21) can be carried along into working position A (FIG. 4).
Furthermore, stroke element (21) carries a return counterstop (42) on a pressed out tongue (41), which in the first position C of the entrainment means (20) enters into a connection with the return stop (38) so that stroke element (21) is forced to move out of the working position A when carrier (16) moves itself backward. When, per contra, the entrainment means (20) takes up the second position D, both of the stops (37) and (38) are located outside the travel path of the counterstops (40) and (42). In this case the appropriate stroke element (21) is not transported, but stays in its at rest position B. The plate (39) is located sidewards over the stroke element (21) and grips into a groove (43) which guides the stroke element relative to segment (25).
FIG. 5 is, in the upper half, a plan view and in the lower half a cross-sectional cut through the entrainment means (20). It is illustrated as an embodiment wherein, for the support of the entrainment means (20) there is provided an insert (44) of a material having good supporting qualities, set in a groove (45) having tapered walls with a mild V form relative to each other. In this situation, it is only necessary for end (46) of entrainment means (20) whose pegs (29) protrude somewhat, on both sides, to be set into the groove. The lid (31) prevents the entrainment means (20) from falling out.
In FIGS. 7 and 8 there are illustrated embodiments wherein the corresponding item numbers are raised by 100. The difference is that the group of transducers (119) are displaced rearwardly in the stroke direction relative to the entrainment means (120) thus, the displacement of the entrainment means (120) is approximately twice as large as that of the corresponding transducers (119).
Furthermore, a package of guide sheets (147) rest on lid (131) which, by means of ledge (148) are held in such separation that an entrainment means (120) and a stroke element (121) find adequate moving room between them. The guide walls (147) comprise inwardly bent guide lamellae (149) so that the stroke element (121) is guided from both sides.
On the free ends of entrainment means (120) there is an aperture (150) whereby there are provided a mutually opposing pair of flange segments (151). The stroke element (121) is provided with an extension (152) with mutually extending flange segments (153). There is thus provided on one face edge, an entrainment (137) which equally works with an edge-formed entrainment counterstop (140) on the face side of the stroke element (121) when both elements lie in the same plane (first position (C)). The consequence is that during the stroke movement of the carrier (16) the stroke element (121) is carried along by entrainment means (120). Furthermore, an edge of the flange segment (151) forms a return stop (138) and the edge on flange segment (153) forms a return counterstop (142), when the entrainment means finds itself in the first position C. Thus, stroke element (121) during the return movement of the carrier is brought back into the at rest position. Per contra, if the entrainment means (120) takes up the second position D during the stroke movement of the carrier (16) the appropriate stroke element (121) remains in its previous position.
In toto, there is obtained a reliably operating stroke control arrangement with a long life and, what is particularly important for warp knitting machines, a very small spacing between the individual stroke elements of two millimeters or less.
The suggested stroke control arrangement is suitable not only for the described purpose of clamping a thread. By utilizing this methodology guides can also be displaced. The system is utilizable for all stroke controls in which individual threads from a thread sheet are to be influenced in particular, with knitting machines.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A stroke control arrangement (1) for influencing individual threads of a thread sheet, in particular for a warp knitting machine, comprises entrainment devices (20) controllable by piezoelectric transducers (19). The entrainment devices (20) are provided adjacent to the transducers (19) in the transverse direction and are born at one end thereof in a portion (25) supported by a carrier (16) and carry at the other end thereof a transport stop (37). The transport stop (37) in a first position carries a stroke element, which in a second position of the transport stop (37), to the contrary, is left uninfluenced. In this way there is obtained a reliable system for stroke control. | 3 |
FIELD OF THE INVENTION
The present invention relates generally to safety restraints, and, more particularly, to a safety railing for temporary installation around the edge of a building roof during construction work.
BACKGROUND OF THE INVENTION
A recurring safety problem has been workers falling from the roofs of buildings which are under construction, or on which other work is being performed. Oftentimes, these accidents occur when the workers are moving about and carrying materials back and forth, and it sometimes happens that a worker will simply back over the edge of the roof while not looking.
The magnitude of this hazard has drawn the attention of several regulatory bodies, including the Occupational Safety and Health Administration in the United States, and the Department of Occupational Safety and Health in Canada. As a result, some form of barrier is now required around roof edges where people will be working, and various attempts have been made to comply with this, with very modest success to date. For example, one approach has been to plant a series of posts on the roof and string a cord and warning flags between these; obviously, the actual restraint which is provided by the cord is minimal, and so this must be placed a considerable distance (about 6 feet) inboard from the edge of the roof, which tends to greatly reduce the available working space, and also presents a problem when it becomes necessary to work in the area outside the cord. A somewhat similar approach has involved the use of rails mounted to posts supported by base plates which rest on top of the roof; while this provides a somewhat more positive restraint, the base plates must still be set in a significant distance from the edge of the roof, which restricts the ability of the workers to work near the edge, and this also necessitates a laborious and time consuming effort to move the railings as the work progresses over the surface of the roof.
Attempts have also been made to mount a railing at the very edge of the roof, usually by mounting a plain bracket (such as a conventional leg-and-shield type arrangement) to the outer wall of the building and then mounting the bottom of a stanchion to this so that the stanchion extends up above the edge of the roof and supports railings which are mounted to this. Several problems have been encountered with this approach, and these stem primarily from the inability of this arrangement to withstand any significant loading or impact on the upper railing. Current requirements call for the upper rail to be positioned about 42 inches above the edge of the roof, and OSHA standards require this to be able to withstand the impact of a 200 pound worker, while Canadian standards call for this rail to be able to support a 200 pound static load in either outward or inward directions. When a conventional bracket arrangement is used, these loads translate to a pull-out force on the order of 1000 pounds or more at the wall bracket; for example, if an outwardly directed impact is received by the rail at the upper end of the stanchion, this will tend to force the lower edge of the bracket plate into the wall of the building so that this acts as a pivot point, and this provides a lever arm for pulling out the fasteners which hold the plate to the wall, much in the same manner that a claw hammer provides leverage for removing a nail. Of course, if there is the force at the rail is directed inwardly, the upper edge of the bracket serves as the pivot point, with the same result. Also, because of this pivoting action, essentially the entire pull-out force must be born by whichever fastener is located near the outwardly moving edge of the plate, while the fasteners near the pivot edge bears relatively little of this.
The net result of this situation is that conventional railings of this type are either wholly inadequate in terms of their ability to restrain workers against potential accidents, or they must be constructed so massively as to be very difficult to install and remove, which renders them impractical for many applications. For example, those fasteners which are favored for quick installation and removal from concrete (e.g., those sold under the trade names "Tap-Con" and "Scru-It") simply do not have the load-bearing capacity necessary to withstand the pull-out loads to which they would be subjected in an conventional bracket-mounting arrangement, and so fasteners of a heavier and usually more permanent nature (e.g., lag bolts) must be employed, which simply renders this approach impractical for temporary installations.
Accordingly, there exists a need for a railing system which can be mounted right at the edge of a roof so as to make the maximum space available for work, and also eliminate the need to move this as the work progresses. Furthermore, there exists a need for a railing system of this type which is easily installed and removed, so that this can be efficiently used on a temporary basis during building construction. Still further, there is a need for a railing system of this type which is economical to fabricate, and which takes advantage of readily available railing members, such as standard length 2×4s.
SUMMARY OF THE INVENTION
The present invention has solved the problems cited above, and this is a safety railing for installation about the roof edge of a building, the safety railing comprising vertically elongate stanchion members each having a lower end and an upper end which is configured to extend above the roof edge, the upper end being configured for mounting to a railing member. A bracket member is provided for mounting to an outer wall of the building, and a pivoting link member is provided for interconnecting the bracket member and a middle portion of the stanchion member so that in response to application of an outwardly directed force to the railing member on the upper end of the stanchion, the lower end of the stanchion is pivoted inwardly against the wall of a building, and the pivoting link member is pivoted outwardly at an angle to the bracket member such that the force is transmitted to the bracket member in a combined pull-out and shear direction. The assembly may include a plurality of fasteners for mounting the bracket member to the wall, and for transmitting the force in the combined direction thereto.
Preferably, the safety railing further comprises hinge means for connecting the pivoting link member to the base member so that the link member is pivotable about an axis which extends in a horizontal direction. An attachment member may be mounted to the middle portion of the stanchion member for detachably mounting the stanchion to an outer end of the pivoting link, and this may be a laterally-extending pivot pin. To receive this, the pivoting link member may comprise at least one hook portion which is configured to receive and support the pivot pin so that this pivots about an axis which extends in a horizontal direction, this being parallel to the axis of the hinge on the bracket member.
Preferably, there are first and second stopper assemblies mounted to the stanchion member and extending inwardly from this so as to abut the wall of the building, the first being mounted below the pivot pin and the second being mounted above this. The stopper assemblies are each configured for selective adjustment of the distance which they extend inwardly from a stanchion member, so as to permit adjustment of the stanchion member to a vertical alignment, and also to an outwardly displaced position such that the possibility of accidental dislodgement of the pivot pin from the hook portion of the swinging link as a result of movement of the stanchion member is eliminated.
At the upper end of the stanchion member, there may be a loop member which is configured to receive the overlapped ends of first and second railing members. These railing members may be wooden boards, and the loop member may be provided with an opening for extending a nail through the loop member and into the overlapped ends of the wooden rail member so as to lock these together within the loop member.
Objects and advantages of the invention not clear from the above will be understood by a reading of the detailed description and a review of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the railing system of the present invention, this showing the system mounted at the roof edge of a building, with 2×4 railing members extending between the stanchions;
FIG. 2 is a perspective view of the stanchion and mounting bracket assemblies of the railing system of FIG. 1;
FIG. 3 is a side elevational view of a portion of the railing system of FIG. 1, showing this being installed on the roof edge of the building, the building being shown partly in cross section;
FIG. 4 is a side elevational view similar to that of FIG. 3, showing the railing system having been installed and properly adjusted;
FIG. 5 is a side elevational view similar to that of FIGS. 3-4, showing an outwardly directed force being applied to the upper railing of the system, and how the system responds by the swinging link pivoting outwardly from the wall bracket so that a combined loading is applied to the fasteners which hold this to the building; and
FIG. 6 is a side elevational view of the upper end portion of the stanchion assembly shown above, this showing the ends of 2×4 railing members positioned in this in side-by-side relationship, as opposed to being overlapped on top of one another as shown in FIGS. 4-5.
DETAILED DESCRIPTION
FIG. 1 provides an overview of the railing system 10, this being mounted to the roof edge of a building 12. The railing system comprises a series of spaced-apart support assemblies 14, each of these being made up of a swinging link bracket assembly 16 which is mounted to the vertical outer wall 18, and a stanchion assembly 20 which is mounted to the bracket assembly and extends upwardly from this above the edge of the roof 22. At the upper end of each stanchion assembly there is a square loop portion 24, and there is a second square loop portion 26 positioned a short distance down the stanchion below this. These square loop portions provide receptacles through which the ends of rail members 28 extend; as can be seen in FIG. 1, the end of a first rail member is received in each loop portion, and then the end of the next rail member in the series is also received in this loop so as to overlap against the end of the first member. Thus, those rail members which are received and supported in the upper loop portions 24 form a continuous upper rail 30, while those which are received in the lower loop portions 26 form a continuous lower rail 32. It has been found that standard 10-foot long wooden 2×4s provide eminently suitable rail members for this system, and are well up to bearing the necessary impact loads.
Having provided an overview of the railing system of the present invention, its components and their operation will now be described in greater detail.
FIG. 2 illustrates the two primary support components of the system, the stanchion assembly 20 and the swinging link bracket assembly 16. The primary structural component of the stanchion assembly 20 is an elongate bar member 34, this preferably being a tubular steel member; a 6-foot length of 11/4 inch square steel tubing has been found eminently suitable for this purpose. As was noted above, an upper loop portion 24 is mounted at the upper end of the stanchion, and a lower loop portion 26 is mounted a short way below this. Each of these loop portions is preferably formed of a piece of flat bar stock bent to form a square receiving area 36, 38, and welded to the bar member 34 at the desired locations; it has been found desirable to position the lower loop portion (and hence the lower rail) about 19 inches below the upper.
Each of the square receiving areas 36, 38 is sized so that the ends of two rail members can be received in this, either in side-by-side relationship or overlapped on top of one another: for conventional 2×4s, 3 3/4 inch square receiving areas have been found appropriate. The upper and side legs of each of these square loop portions are pierced by upper and side nail openings 40, 42, the use of which will be discussed below.
Then, generally toward the lower end of the stanchion, there is a pivot pin 44 which is mounted to the bar member 34 so as to extend transversely across this. In order to obtain the desired height of the upper rail above the roof edge (i.e., about 42 inches), it has been found desirable for many applications to mount the pivot pin 44 about 501/2 inches below the upper end of a 72-inch stanchion. The pivot pin may be provided by a 1/2-inch steel pin approximately 4 inches long, and this is preferably mounted to the same, inboard face of the square bar member 34 as the loop portions, so that the rail members are supported against the inboard side of the bar member (i.e., toward the working area) when the assembly is in place.
A first adjustable stopper assembly 46 is mounted a relatively short distance (e.g., about 6 inches) above the horizontally extending pivot pin, and this is made up of a base nut 50 which is welded to the inboard face of the bar member, and a foot portion 52 having a threaded shaft which is engaged by the base nut so that the distance by which the foot portion extends inwardly from the bar member 34 is selectively adjustable. A hole (not shown) is formed in the inboard wall of bar member 34 for the shaft of the foot portion to extend through in order to permit a greater range of adjustment, and an elastomeric friction pad 54 is mounted on the outer end of the foot portion so as to enhance the frictional engagement of the stopper assembly with the outer wall of the building. The lower stopper assembly 48, in turn, is mounted at or near the very lower end of bar member 34 (about 21-22 inches below pivot pin 44 on a 6-foot long stanchion assembly), and this similarly comprises a base nut 56, adjustable foot portion 58, and friction pad 60. As will become apparent from the description provided below, these stopper assemblies serve to provide the correct vertical alignment of the stanchion assembly, and also make it impossible for this to be accidentally dislodged from the bracket assembly once the system has been properly installed and adjusted.
Turning now to the bracket assembly 16, it will be seen in FIG. 2 that this comprises generally a base plate portion 62 and a swinging link portion 64. The swinging link portion is made up of first and second parallel hook portions 66, 68, these having U-shaped enclosed ends which together define an area for receiving the pivot pin 44 of the stanchion assembly, and supporting this in pivoting relationship; hook portions providing a receiving channel about 2 inches long and about 3/8 inch wide have been found suitable for use with a stanchion assembly having the exemplary dimensions described above. The two hook portions 66, 68 are interconnected by the pin of a hinge 70 so that these move together in unison. The central loop 72 of the hinge, in turn, is mounted to the base plate portion of the assembly. This base plate portion is a flat, preferably rectangular member which is configured to abut the outer wall of the building. This is pierced by bores 74 above and below the hinge loop for the fasteners to extend through. A suitable spacing for these fastener bores has been found to be about 3 inches, centered on the horizontal hinge of the assembly, with a lower portion of the base plate extending about 31/2 inches below the lower bore to give an overall plate length of about 7 inches. First and second upstanding, parallel ears 78 are mounted at the lower end of the base plate, and these define a gap for receiving the bar member 34 of the stanchion assembly and fitting closely adjacent the sidewalls of this; these ears 78 serve to steady the stanchion assemblies against side-to-side "tipping" motion before the rail members have been installed therein.
The installation of these assemblies and their adjustment will now be described with reference to FIGS. 3-4. The building structure 12 shown in FIG. 3 represents a typical wooden construction, in which there are wooden wall studs 80, 82 covered by an exterior facia 84, and these provide anchors for the fasteners of the railing system 10. However, it will be understood that the mounting shown here is equally applicable to concrete block structures, in which there is a concrete bond beam at the upper edge of the wall, as well as to those buildings which are constructed with a poured wall which extends all the way to the roof edge.
To install the railing system, the bracket assembly 16 is positioned a sufficient distance below the upper edge 86 of the exterior facia that the upper stopper assembly 46 will be positioned to abut the facia when the stanchion is received in the bracket assembly. The fastener bores are placed in proper vertical alignment, and then fasteners 88 are driven through these into the underlying wall structure. Since the configuration of the railing system of the present invention is such that the fasteners do not have to resist the tremendous pull-out forces which are experienced when using the conventional railing systems discussed above, these can be fasteners of the type which are easily and quickly installed and then removed to provide a temporary installation, such as the Tap-Con™ or Scru-It™ fasteners noted above.
The bracket assembly having been installed, the next step is to set the stanchion assembly in this. This is done by pivoting the swinging link portion 64 of the bracket assembly outwardly so that the gap between the tips of the hook portions 66, 68 and the hinge 70 extends laterally to receive the pivot pin on the stanchion assembly. As may be seen in FIG. 3, the hook portions of the bracket assembly are preferably sized so that this gap is only just large enough to let the pivot pin 44 pass through, so as to further reduce the chances of accidental dislodgment of the stanchion from the bracket assembly.
As the pivot pin is set in the hook portion of the bracket assembly, the lower portion of the bar member 34 is simultaneously received in the gap between the upstanding ear portions 78 these steady the stanchion assembly against side-to-side rocking. The stanchion assembly is then lowered until the pivot pin rests in the closed ends of the hooks 66, 68 and the stanchion is suspended therein, and the foot portions of the stopper assemblies 46, 48 are extended outwardly from bar member 34 until the stanchion is aligned in a vertical direction. Further outward adjustment of the stopper assemblies is made, if necessary, until the pivot pin 44 has pulled the swinging link portion of the bracket assembly outwardly a short distance to the point where the receiving areas in the hook portions no longer extend in a vertical direction, as this is shown in FIG. 4. It will be understood that in this position it is no longer possible for the pivot pin 44 to become accidentally dislodged from the hook portions of the bracket assembly, whether by lifting or pivoting of the stanchion assembly, being that it is not possible to move the pin in a vertical direction within the receiving areas of the hooks.
Having completed the installation and alignment of the bracket and stanchion assemblies, the next step is to install the rail members 28, and this is done by inserting their ends in the receiving areas of the loop portions 24, 26 (24 only shown in FIGS. 3-4). These are overlapped in the manner previously described, and a suitable nail 90 is then inserted through the appropriate nail opening (top opening 40, in the arrangement shown in FIG. 4) and hammered into the overlapped ends of the rail members so as to lock these together and prevent them from sliding out of the loop portion. This is done at each of the spaced-apart support assemblies until the continuous rail is completed, and the same is done for the lower rail as well. The installation is then complete and ready for work to commence.
FIG. 5 illustrates the operation of the railing system 10, as this would prevent a person from moving outwardly over the edge of the roof. As can be seen, the force of the outwardly directed load or impact is represented in FIG. 5 by arrow 96. As this is applied to the upper railing, this force is transmitted through the railing to the upper end of the bar member 34. This outward movement of the upper end of the bar member causes the stanchion assembly to pivot about pivot pin 44, forcing the lower stopper assembly 48 against the exterior facia 84, and lifting the upper stopper assembly 46 away from this. Simultaneously, as the bar member 34 pivots outwardly about the pivot point which is provided by the lower stopper assembly 48, pivot pin 44 pulls outwardly on the swinging link portion of the bracket assembly, causing the hook portions thereof to pivot outwardly.
In this position, with the hook portions of the bracket assembly extending at an angle from the base plate, and the outward force being transmitted from the stanchion assembly to the bracket assembly in this direction, the fasteners 88 are subjected to a "combined" loading. That is, they are not subjected to a pure pull-out force, nor to a pure shear force, but instead they are subjected to a force which combines elements of both pull-out and shear. As a result, because the fasteners' capacity with respect to both of these forces is being employled, the effective load-bearing ability of each fastener is greatly increased (relative to that for pure pull-out or shear), to the point of being nearly doubled. Also, because the pivot point is now provided by the lower stopper assembly 48, instead of the lower edge of the bracket plate, the ratio of the two lever arms is greatly reduced, and the magnitude of the pull-out force is therefore much smaller. Furthermore, because the force is transmitted to the base plate of the bracket assembly at the midpoint between the two fasteners 88, the load is equally shared by these, rather than one or the other of the fasteners having to bear most of this alone. As was noted above, these factors render the mounting of the railing system of the present invention much safer and more secure than conventional railing systems, and also make it possible to use easily installed temporary fasteners which would not be able to withstand the severe loading which would be encountered when using a conventional bracket arrangement.
As was also noted above, the loop portions 24, 26 of the stanchion assemblies are configured so that their receiving areas are able to accommodate the ends of railing members (such as 2×4s) which are laid on top of one another, so that the railing members themselves rest horizontally, or these ends may be positioned in side-by-side relationship so that the railing members stand on edge. FIG. 6 shows this latter arrangement, with the two railing members 28a set on edge in the loop portion 24, and then a nail 98 is inserted through the side nail opening and driven into the boards to hold these in place.
Having described the invention in its preferred embodiments, it will be clear that changes and modifications may be made without departing from the spirit of the invention. It is therefore not intended that the words used to describe the invention or the drawings illustrating the same be limiting on the invention. Rather, it is intended that the invention only be limited by the scope of the appended claims. | A safety railing for installation about a roof edge of a building. Vertically extending stanchion members are mounted to wall brackets by pivoting links. These swing outwardly in response to an impact on the railing at the upper ends of the stanchions, so that a combined pull-out and shear loading is applied to the wall bracket. This effectively increases the load-bearing capacity of the fasteners which attach the bracket to the wall. The swinging link member may be a pivoting hook, and this detachably engages a horizontally-extending pivot pin which is mounted to a middle portion of the stanchion. | 4 |
FIELD OF THE INVENTION
[0001] This application relates to the field of tying knots. In particular, the application relates to the formation of decorative knots for use primarily in artistic designs.
BACKGROUND OF THE INVENTION
[0002] There is a considerable interest in forming knots from lace, line, string, rope, cable, ribbon, fabric, or any other kind of material known in the art of knot tying. While it is well known that knots can be used to bind and secure objects, knots are also often used in the artistic design of decorating clothing, small personal belongings, house interiors, and the like.
[0003] Knots have long been used in the clothing industry, the accessory industry, and decorative design. The kinds of knots used in these applications range from the structural to the ornamental, and in some cases, a knot can be both structural and ornamental (e.g., buttons). Ornamental knots, unlike structural knots, must be pleasing to the eye. There needs to be, therefore, a method of unvaryingly and efficiently tying a sequence of substantially identical knots. Efficiently tying substantially identical knots is particularly useful when the knots are to be arranged in a continuous matter or in close proximity. Using conventional knot-tying methods, however, can make this task quite daunting.
[0004] One advantage of the current invention is using the aforementioned principles in combination with a newly discovered knot-creating technique that enables the user to form a continuous, uniform sequence of knots from a single piece of material, such as fabric.
SUMMARY OF THE INVENTION
[0005] In accordance with one aspect of the present invention, a method is provided for tying a continuous sequence of substantially identical knots. The sequence of knots is useful in the art of clothing design, accessory ornamentation, and decorative design, but may also be used for other aesthetic purposes.
[0006] The term “designer” as used herein refers to a person or persons, as the case may be, who devises and/or executes designs related to knots, clothes, or other works in which knots may be used, whether alone or in one or more groups, whether in the same or various places, and whether at the same time or at various different times.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIGS. 1-3 illustrate a method of folding a piece of material to produce a ribbon-like length of material for use in knot tying;
[0008] FIG. 4 . illustrates an end portion of the ribbon-like length;
[0009] FIGS. 5 and 6 illustrate the method of producing a single overhand knot using the ribbon-like length of FIG. 4 ;
[0010] FIGS. 7 and 8 illustrate the method of producing a continuous sequence of substantially identical knots using the method of FIGS. 5 and 6 ; and
[0011] FIGS. 9A and 9B illustrate both sides of a continuous length of the knots.
DETAILED DESCRIPTION
[0012] In certain embodiments, the knot may be constructed from a ribbon-like length of fabric. The ribbon-like length may be prepared from any type of fabric known in the art (e.g., acetate, acrylic, cotton, linen, nylon, polyester, rayon, silk, satin, velvet, denim, felt, flannel, microfiber, etc.).
[0013] In certain embodiments, the first step in the formation of the ribbon-like length of material is to fold over the end, or edge, of a piece of material as illustrated in FIG. 1 . The end folding width 102 can vary depending on the designer's application, but in the depicted embodiment, the folding width 102 is approximately ¼ inch. In certain embodiments, folding the end of the material may prevent fraying of the material and/or provide the termination point of the ribbon-like length of material with a cleaner, finished look.
[0014] FIG. 2 illustrates the step of folding the sides of the ribbon. The folding width 202 depends on the desired thickness of the final, ribbon-like length of material and the desired shape. In the depicted embodiment, the desired thickness of the ribbon-like length 400 is six material layers, thus the folding width 202 on each side would be approximately ⅙th the overall material width 104 .
[0015] FIG. 3 illustrates the additional step of folding the sides of the material shown in FIG. 2 . In the depicted embodiment, the folding width 302 is substantially equal to the folding width 202 in FIG. 2 .
[0016] FIG. 4 illustrates the final step of folding the sides of the material shown in FIG. 3 . In the depicted embodiment, the folding width 402 is substantially equal to both the folding width 202 in FIG. 2 and the folding width 302 in FIG. 3 .
[0017] In the depicted embodiment of FIG. 4 , the ribbon-like length 400 is six material layers thick; however, the ribbon-like length 400 may be any number of layers in thickness. The number of layers needed is a function of both the individual designer's desired final thickness and the thickness of the material being used. For example, if a very thin material is used, a designer may use many folds to increase the final thickness. Contrarily, if a thick material is used, the designer may use only a few folds, and the final ribbon-like length will be only a couple of layers thick.
[0018] In certain embodiments, an adhesive may be used between the layers or the folds to ensure that the ribbon-like length 400 does not unfold before, during, or after preparation. The adhesive or similar material may also be used to prevent the edges of the material from fraying.
[0019] In certain embodiments, the folding width in FIGS. 2-4 may be intentionally varied, thus giving the ribbon an inconsistent thickness. In some designs, for example, the designer may prefer the appearance of knots if one side of the ribbon-like fabric is thicker than the other.
[0020] FIGS. 5 and 6 illustrates the steps of forming a single overhand knot 408 from a ribbon-like length 400 . A loop 406 to receive the working end 404 is formed in the ribbon-like length 400 . The working end 404 is folded over the intersection point 410 of the working end 404 and the standing part 412 and pulled through the loop 406 . The overhand knot 408 is tightened by pulling or tugging on the working end 404 while securing the standing part 412 .
[0021] Once the first overhand knot 408 is formed, the process, as seen in FIG. 7 and FIG. 8 , is repeated at another point in the fabric length. In the depicted embodiment, the knots are arranged such that each knot in succession is in direct contact with the previous knot. The process of FIGS. 7 and 8 is repeated until the desired length of knots is reached.
[0022] FIGS. 9A and 9B show both sides of a portion of a complete, continuous, uniform sequence of knots from a single piece of fabric.
[0023] In general, the embodiments described herein use fabric in the knot-tying process. However, it is entirely possible to apply the process of tying a continuous, uniform sequence of knots to other applications which involve flexible materials other than fabric. For example, in jewelry making, a designer could choose to use metal ribbon, strips or the like when making the metal equivalent of the ribbon-like fabric length 400 . The final product could be used in a plurality of applications, including the fabrication of necklaces, rings, or bracelets, or it could be used merely as ornamentation.
[0024] Although various embodiments have been described with reference to a particular arrangement of parts, features and the like, these embodiments are not intended to exhaust all possible arrangements or features, and indeed, many other embodiments, modifications, and variations will be ascertainable to those of skill in the art. | A method is provided for tying a continuous sequence of substantially identical overhand knots from a single piece of material. The sequence of knots is useful in the art of clothing design, accessory ornamentation, and decorative design, but may also be used for other aesthetic purposes. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. 119 based upon Provisional Application Ser. No. 61/810,333, filed on Apr. 10, 2013. The entire disclosures of the aforesaid applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a novel decoupage method. In particular, the invention relates to a decoupage method that enables improvements in the applicability of standard printed photographs as a motif, to a material to be decoupaged, and in decorative value.
BACKGROUND OF THE INVENTION
[0003] (Decoupage)
[0004] Decoupage is widely-known as a kind of handicraft.
[0005] As the word “decoupage” is derived from the French word “decouper (cut out),” decoupaging is a decorative technique of cutting out motifs such as pictures and patterns printed on paper, fabric, etc., and after pasting the cutouts on a material such as a box or a plate, smoothly finishing the surface of the material to make the motif become integral part of the surface. Decoupage is highly popular as handicraft for decorating materials, since performing easy, high-level decorating is possible simply by transferring an existing pattern or picture to a material by means of decoupage.
[0006] Conventional decoupage, as a method of using photographs as a material, is roughly divided into two methods.
[0007] (Conventional Method 1: The Method of Pasting Photo Paper without Altering.)
[0008] The first method is a method of pasting a motif printed on paper or fabric without being altered on a material, and then coating a material with a coating solution. This method has the advantage of being extremely simple to carry out. However, because a significant height difference may be formed between the material and the motif, depending on the type of paper or fabric that the motif is printed on, there are cases when the use of relatively thin paper or fabric is necessary. For example, if a hard or thick material such as standard photo paper is used, it is necessary to apply a thicker layer of coating than would be needed otherwise in order to eliminate the height difference between the borders of the photo element and the material.
[0009] Conventional Method 2: The Method of Using a Transfer Solution.
[0010] The second method employs a transfer solution. In this method, the step of applying a transfer solution to a material and allowing the solution to dry is repeated several times until only a pattern or a picture, which constitutes the motif, is transferred from the paper or fabric, producing a thin film (film) that this method utilizes. The problem explained in the above-mentioned first method is non-existent since the film produced by means of this method is thin. However, the step of forming the film is intricate and time-consuming since it is necessary to repeat the step of coating the material with the transfer solution and allowing the transfer solution to dry. Furthermore, since the thickness of the film, to which a pattern from a material is transferred, varies depending on the number of times that the transfer solution is coated and dried, it is difficult to produce a film having uniform thickness optimal for adhesion. In the method of using a transfer solution, after the step of coating and drying the transfer solution, the material which was coated with the transfer solution is scraped off from the back side of the film to separate the film from the material. Thus, if the produced film is too thin, there exists the problem of the film being torn during the step of separating the film. Moreover, if the produced film is too thick, the final finish becomes stiff and appearance is impaired.
[0011] Furthermore, significant disadvantages exist in the method of extracting an image using the transfer solution. For example, the image is reversed and writing, especially, becomes a mirror image. In the case of photographs printed in three colors of ink, the color white becomes transparent such that white color in the photograph is not visible if pasted on a color other than white, and since the transferred image is thin and transparent, the base color shows through the entirety of the image. Moreover, the image quality of the transferred image is reduced in comparison to the original photograph.
SUMMARY OF THE INVENTION
[0012] As described above, in the method of extracting a motif from a material using decoupage, treatment is difficult when using standard photographs due to issues such as thickness. Meanwhile, in the method utilizing a transfer solution, although it is possible to extract a motif in the form of a thin film, there exist the problems of the work being laborious, extraction being difficult such that the quality of the photograph decreases, writing becomes a mirror image, the color white becomes transparent when there are three different colors of ink, and the base color shows through the entirety of the image since the transferred image is thin and transparent.
[0013] Furthermore, the method is not suited for practical use when decoupaging material such as leather or synthetic leather, since the material feels hard and stiff after curing when a standard coating agent is used. Moreover, since soft-curing type coating agents for fabric and paper napkins have weak adhesive power, application is limited to fibrous materials such as fabric and paper napkins. As a result, decoupaging supple leather or synthetic leather had been difficult.
[0014] Accordingly, the purpose of the present invention is to eliminate the deficiencies of the abovementioned prior art, to enable the minimization of height differences, and to provide a highly workable and applicable decoupage.
[0015] In order to resolve the abovementioned issues, the inventor of the present invention conducted diligent research into techniques for relatively easily extracting motifs from materials, in a state which is easy to treat, and as a resulted of the research, they obtained the knowledge associated with the present invention. Then, through using that knowledge on all types of motif materials, and application objects, and repeating experiments, the present invention was accomplished.
[0016] According to a decoupage method of the present invention, a decoupage method of adhering a motif to the surface of an object to decorate the object is provided. The method comprises the steps of: (a) printing a motif using sublimation thermal transfer printing on photographic printing paper having a thin-film image-receiving layer on the surface; (b) separating only the thin-film image-receiving layer on which the motif is printed from the photographic printing paper as a thin-film image-receiving layer sheet; (c) adhering the separated thin-film image-receiving layer sheet to the surface of an object; and (d) finishing the surface of the object to which the thin-film image-receiving layer sheet is adhered.
[0017] According to one embodiment of the present invention, the thin-film image-receiving layer sheet preferably comprises a thermoelastic polyester resin.
[0018] Further, the step (c) preferably comprises applying a glue to the rear surface of the thin-film image-receiving layer sheet and drying the glue; and positioning the thin-film image-receiving layer sheet in relation to the object to apply heat over the surface of the thin-film image-receiving layer sheet whereby the thin-film image-receiving layer sheet is closely pressed along the surface of the object to cause the glue to become viscous and adhere to the object.
[0019] The object may be a felt material, and if it is the case, the step (d) comprises coloring the surface of the object to which the thin-film image-receiving layer sheet is adhered; and forming an irregular texture on the surface of the object to which the thin-film image-receiving layer sheet is adhered, whereby an synthetic leather-like texture is provided to the surface of the object.
[0020] The object may be a leather material or an synthetic leather material, and if it is the case, the step (d) comprises coating the surface of the object to which the thin-film image-receiving layer sheet is adhered with a coating agent; and after the coating agent is dried, placing a Teflon® sheet on the coated surface of the object to apply heat and pressure by a thermo-pressure means to the coated surface through the Teflon® sheet, whereby the coating agent is bonded to the object through thermo-compression bonding. According to this method, it is possible to process leather or a synthetic leather material. Furthermore, the object to which the coating agent is bonded through thermo-compression bonding may be a leather product or a synthetic leather product.
[0021] According to the abovementioned decoupage method, it is possible to obtain the effect of being able to decoupage a printable motif of choice on a desired location, without compromising the appearance.
[0022] Other characteristics of the present invention, which were not mentioned above, will be clear to a person skilled in the art based on the descriptions of embodiments of the present invention which will be discussed below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows the layered structure of the photographic printing paper which has a surface film layer upon which the material to be decoupaged is printed.
[0024] FIG. 2 is a flow chart indicating the decoupage creation process in the method of one embodiment of the present invention.
[0025] FIG. 3 is a flow chart indicating the decoupage creation process in the method of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Below, one embodiment of the present invention is explained with reference to the figures.
[0027] FIG. 1 is a schematic diagram indicating the photographic printing paper ( 1 ) used in the decoupage method of this embodiment. FIG. 2 is a flow chart indicating each step (S 1 -S 5 ) of the decoupage method of the embodiment.
[0028] First, an image to be used for a motif is formed on the photographic printing paper ( 1 ). This step of forming the image is done by printing the image created by image editing software or illustrating software on a computer using a sublimation thermal transfer printer.
[0029] In standard image printing methods, there is an ink recording system and a heat transfer recording system, and the method used in this embodiment is a method in the heat transfer recording system known as a sublimation thermal transfer system. In order to form an image using the sublimation thermal transfer system, a photographic printing paper ( 1 ) wherein an image-receiving layer sheet ( 3 ) is formed on a base sheet ( 2 ) is used in this embodiment. The base sheet ( 2 ) has a configuration wherein, for example, both sides of the paper core are layered with foam polyolefin layers, and the image-receiving layer sheet ( 3 ) comprises a thermoelastic polyester resin which has a high affinity for dispersion dyes. In this embodiment, the image-receiving layer sheet ( 3 ), as is explained hereafter, is separated from the base sheet ( 2 ) after printing, and a supplemental material, such as silicon or fluorine-based resin may be added in order to reduce the possibility of heat-adhesion of the image-receiving layer sheet in the base sheet and increase peeling properties of the image-receiving layer sheet.
[0030] In this step, an image is formed using the abovementioned heat-sensitive sublimation thermal transfer printer, by controlling and transferring the dye of a printer ribbon sublimation dye layer ( 4 ) to a heat-transfer image-receiving sheet ( 5 ). Since the coloring material is dye, transparency is excellent, the formed image is extremely clear, and as the reproducibility of halftones and gradation are excellent, a very high-definition image is obtained, such that high-quality images comparable to full-color, silver-halide photographs can be obtained.
[0031] Next, in step S 2 , the image-receiving layer sheet ( 3 ) (thermoelastic sheet) comprising the printed motif is separated from the base sheet ( 2 ). Although not necessarily limited to the following, the separation of the image-receiving layer sheet in this step is performed by inserting a thin separation tool in between the base sheet ( 2 ) and the image-receiving layer sheet ( 3 ) of the photographic printing paper ( 1 ), and by moving the tool in parallel along the base sheet ( 2 ). In the event that the paper element is sticking and cannot be separated only using the separation tool, it is possible to completely scrape the paper element away using dampened sandpaper of approximately 600 grit. A thin, elastic, film-like sheet having a motif formed thereon is produced as the image-receiving layer sheet ( 3 ) by means of this separation process.
[0032] Next, in step S 3 , the position to decoupage the abovementioned image-receiving layer sheet ( 3 ) on an object to be decorated is determined Any material may be acceptable as the object of the present embodiment for the decoupage method to be carried out thereon. For example, a material of choice, such as paper, leather, synthetic leather, wood, plastic, soap, metal, etc., is possible. Furthermore, the surface of the “object” of the present invention may also be curved.
[0033] Next, in step S 4 , the image-receiving layer sheet ( 3 ) is pasted onto the surface of a object. For pasting, first an aqueous glue of choice which is standardly used in decoupage is applied on the back side of the image-receiving sheet that was separated from the photographic printing paper, and the glue is dried (step S 4 - 1 ). Then, the image-receiving sheet ( 3 ) is placed in a pre-determined position on a object, a Teflon® sheet is placed thereon, and heat is added from above with an iron, such that the glue which was applied on the back of the image-receiving sheet and dried in advance, is caused to soften and become adhesive. According to this method, since the water content of the glue has already been removed, quick adhesion not only to paper, wood, metal, etc. but strong adhesion to fabric is also possible.
[0034] Furthermore, since the image-receiving layer sheet ( 3 ) is relatively resistant to heat, even if heat around 100 degrees is applied, the formed image goes undisturbed. (However, since the ink from the image may burn and melt if a hot iron with a temperature of more than 100 degrees is applied to the surface of the image, setting the iron temperature below 120 degrees may be desirable.)
[0035] Since adhesive methods which utilize irons are superior for adhesion to fabrics, even when a handmade synthetic leather having an embedded photograph therein is created, the result is durable, such that the image portion does not peel off or lift off of the fabric when the fabric is folded.
[0036] Next, in step S 5 , a finish coating is performed. The coating can be done with a finish coating agent of choice that is standardly used in decoupage. However, the finish coating agent must be an aqueous coating agent. There are no particular procedure as to how many times the coating agent must to be applied, rather coating is performed as necessitated for the finished appearance. After coating, and after allowing the finish coating agent to dry, water-resistant paper may be used in order to integrate the decoupaged portion into the peripheral portions, and in order to remove uneven brushstrokes which were created in the application of the finish coating agent.
[0037] FIG. 3 is a flow-chart indicating another embodiment of this invention. This embodiment exemplifies applications for elastic materials other than fibrous materials such as fabric, in particular, using leather and synthetic leather as the object.
[0038] In this example, after the finish coating applied in step S 5 is dried, further in step S 6 , an iron is applied to the coated surface of the image-receiving layer sheet ( 3 ) through a Teflon® sheet thereon so as to soften the coating agent, and carry out thermo-compression bonding on the image-receiving layer sheet ( 3 ).
[0039] In this example, as the finish coating used in step S 5 , it is ideal to use a vinyl acetate resin emulsion adhesive, or an ethylene vinyl acetate resin emulsion adhesive in which water dispersion has been adjusted to a consistency that can be applied to fabric. For example, Mod Podge®, which is manufactured for use on fibrous materials by Plaid Enterprises, Inc. in Norcross, Ga., USA, may be used.
[0040] In step S 6 , after hardening the finish coating agent, a Teflon® sheet is placed on the coated surface of the image-receiving layer sheet ( 3 ) so that direct contact with the iron is avoided. Furthermore, in order to avoid damaging the image-receiving layer sheet ( 3 ) or the object, heat and pressure are added in approximately two to three second intervals by uniformly ironing the entire surface, while observing the appearance. Since shape-conformity and the degree of adhesion between the coating agent, the image-receiving layer sheet ( 3 ) and the object improve through undergoing this process, even if a soft-curing type coating agent for fibrous materials such as fabrics is used, the adhesion and strength of the image-receiving layer sheet ( 3 ) increases dramatically. Accordingly, processing flexible materials other than fabric, such as leather and synthetic leather, is also possible using a soft-curing type coating agent meant for use fabrics.
[0041] Moreover, in the initially explained embodiment, step S 4 has a thermo-compression bonding process which uses an iron, whereas in the embodiment indicated by FIG. 3 , an additional thermo-compression bonding process is carried out in step S 6 . Conducting a similar thermo-compression bonding process in step S 6 , in addition to the thermo-compression bonding process of step S 4 , enables even greater results to be obtained when the object is leather or synthetic leather. It should be understood that even when the object is not leather or synthetic leather, a thermo-compression bonding process can be conducted two times or more, as shown in FIG. 3 .
[0042] The above-explained method allows for obtaining the effect of resolving the problems of conventional decoupage motif photograph transfer methods, and dramatically improving the finished appearance and applicability.
[0043] Namely, although standard transfer methods are employed when extracting an photograph for use in decoupage from a photograph printed on normal photographic printing paper, in the method of this invention, an extremely thin film-like motif is able to be easily extracted without the use of a transfer solution. Accordingly, without using a transfer solution or special printing paper, anybody can easily transform a printed photograph in an album into a form suited for decoupage materials, and use the photograph as a decoupage material.
[0044] Therefore, the present invention is not limited to the above-mentioned embodiments such that, without changing the spirit of the present invention, various modifications are possible.
[0045] For example, after applying and drying glue on the back side of the image-receiving layer sheet ( 2 ), the application and drying of glue two times or more may be carried out. Furthermore, even stronger adhesion is achieved if glue is also applied and dried on the object side.
[0046] Furthermore, the above-mentioned finishing process is not limited only to mere glue coating. For example, in order to draw attention away from the borders of the image-receiving layer sheet ( 2 ) and the surrounding object, coloring such as acrylic paint or ink on the object and the surface of the image-receiving layer sheet ( 3 ) may be used. For example, when using a felt material as the object, a leather-like texture on the surface can be created by applying acrylic paint or ink to the object in accordance with the intended purpose, layering on a coating agent, and by stroking the surface with a brush before the coating agent dries. Moreover, after drying completely, moderate luster and strength can be increased by placing a Teflon® sheet on the surface and ironing with a sliding movement from above at a low temperature for approximately two seconds. After the object has cooled this process may be repeated as necessary.
[0047] Additionally, the material of the photographic printing paper ( 1 ) containing the image-receiving layer sheet ( 3 ) is not limited to the material in one of the above-mentioned embodiments, such that another material may be used so long as the purpose of the invention is achieved. | Treatment is difficult when using standard photographs due to issues such as thickness, and in the method utilizing a transfer solution, although it is possible to extract a motif in the form of a thin film, there exists the problem of the work being laborious. A decoupage method is provided which comprises the steps of (a) printing a motif using sublimation thermal transfer printing on photographic printing paper having a thin-film image-receiving layer on the surface, (b) separating only the thin-film image-receiving layer on which the motif is printed from the photographic printing paper as a thin-film image-receiving layer sheet, (c) adhering the separated thin-film image-receiving layer sheet to the surface of a object, and (d) finishing the surface of the object to which the thin-film image-receiving layer sheet is adhered. | 1 |
[0001] The present application claims priority from U.S. 60/943,708 filed 13 Jun. 2007, the entire contents of which are incorporated herein in their entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to methods of modulating traits, particularly production traits, in avians such as chickens. In particular, the invention relates to the in ovo delivery of a dsRNA molecule, especially siRNAs, to modify production traits in commercially important birds.
BACKGROUND OF THE INVENTION
[0003] Man has modified the phenotypic characteristics of domestic animals through selection of seed stock over many generations ever since animals were domesticated.
[0004] This has led to improvements in quantitative production parameters such as body size and muscle mass. More recent innovations of modifying production traits of poultry and/or improving resistance to pathogens has focussed on transgenic approaches, however, many consumers have concern's about genetically modified organisms. Chicken producers have been searching for an efficient, economical method of determining the sex of day old chicks. Vent sexing and feather sexing have been used by the various producers, but these methods have been found to have substantial economic disadvantages because of the substantial time required and labour costs in separating the male from the female chicks. The use of probes (U.S. Pat. No. 5,508,165) is also an expensive procedure and not practical economically. Light sensing of anal areas of chicks (U.S. Pat. No. 4,417,663) is another way of determining sex of chicks, but it is also expensive and time consuming as each chick must be handled and manipulated. The use of experts who could feather sex the chicks has been used, but such experts are costly and feathering is time consuming.
[0005] There is a need for methods of modifying production traits in poultry that do not result in transformation of the bird's genome, but are amenable to high throughout processing.
SUMMARY OF THE INVENTION
[0006] The present inventors have surprisingly found that administering a suitable nucleic acid molecule comprising a double-stranded region to an egg of an avian can modify the phenotype of the developing embryo.
[0007] Thus, in a first aspect the present invention provides a method of modifying a trait of an avian, the method comprising administering to an avian egg at least one nucleic acid molecule comprising a double-stranded region, wherein the nucleic acid molecule results in a reduction in the level of at least one RNA molecule and/or protein in the egg.
[0008] In a preferred embodiment, the nucleic acid molecule is dsRNA. More preferably, the dsRNA is a siRNA or a shRNA.
[0009] In a further preferred embodiment, the trait is a production trait. Examples of production traits include, but are not limited to, muscle mass or sex.
[0010] In an embodiment, the production trait is sex and the nucleic acid molecule reduces the level of a protein encoded by a DMRT1 gene.
[0011] In an embodiment, the production trait is sex and the nucleic acid molecule reduces the level of a protein encoded by a WPKCl (ASW) gene.
[0012] In another embodiment, the production trait is muscle mass and the nucleic acid molecule reduces the level of a protein encoded by a myostatin gene.
[0013] Preferably, the nucleic acid molecule is administered by injection.
[0014] The avian can be any species of the Class Ayes. Examples include, but are not limited to, chickens, ducks, turkeys, geese, bantams and quails. In a particularly preferred embodiment, the avian is a chicken.
[0015] In a further aspect, the present invention provides an avian produced using a method of the invention.
[0016] In another aspect, the present invention provides a chicken produced using a method of the invention.
[0017] In yet a further aspect, the present invention provides an isolated and/or exogenous nucleic acid molecule comprising a double-stranded region which reduces the level of at least one RNA molecule and/or protein when administered to an avian egg.
[0018] Preferably, the nucleic acid molecule is a dsRNA molecule. More preferably, the dsRNA is a siRNA or a shRNA.
[0019] In an embodiment, the nucleic acid molecule reduces the level of a protein encoded by a DMRT1 gene or a myostatin gene.
[0020] Also provided is a vector encoding a nucleic acid molecule, or a single strand thereof, according to the invention. Such vectors can be used in a host cell or cell-free expression system to produce nucleic acid molecules useful for the method of the invention.
[0021] In another aspect, the present invention provides a host cell comprising an exogenous nucleic acid molecule, or a single strand thereof, of the invention and/or a vector of the invention.
[0022] In another aspect, the present invention provides a composition comprising a nucleic acid molecule, or a single strand thereof, of the invention, a vector of the invention, and/or a host cell of the invention.
[0023] In a further aspect, the present invention provides an avian egg comprising a nucleic acid molecule, or a single strand thereof, of the invention, a vector of the invention, and/or a host cell of the invention.
[0024] In another aspect, the present invention provides a kit comprising a nucleic acid molecule, or a single strand thereof, of the invention, a vector of the invention, a host cell of the invention, and/or a composition of the invention.
[0025] As will be apparent, preferred features and characteristics of one aspect of the invention are applicable to many other aspects of the invention.
[0026] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
[0027] The invention is hereinafter described by way of the following non-limiting Examples and with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0028] FIG. 1 —PCR for shRNA expression cassettes. Schematic representation of the PCR strategy used to produce shRNA expression vectors. PCR used forward primers paired with reverse primers comprising all shRNA components. All final PCR products consisted of a chicken U6 promoter, shRNA sense, loop, shRNA antisense, termination sequence and XhoI site.
[0029] FIG. 2 —Testing selected shRNAs for knockdown of EGFP-Dmrt1 gene fusion expression. Mean fluorescence intensity for each transfection condition expressed relative to pEGFP-Dmrt 1. Error bars indicate standard error calculated on each individual experiment completed in triplicate.
[0030] FIG. 3 —Testing selected shRNAs for knockdown of EGFP-Gdf8 gene fusion expression. DF1 cells were transfected with: Panel 1, pEGFP-C alone; Panel 2, pEGFP-Gdf8 transcriptional fusion alone; Panels 3-6 pEGFP-Gdf8 with either pshEGFP or the specific Gdf8 shRNA expression plasmids pshGdf8-258, pshGdf8-913 and pshGdf8-1002. Microscopy was performed using a Leica DM LB Fluorescence Microscope (Leica Microsystems, Germany) and images were captured at 50× magnification using a Leica DC300F colour digital camera (Leica Microsystems, Germany) and Photoshop 7.0 imaging software (Adobe®).
KEY TO THE SEQUENCE LISTING
[0031] SEQ ID NO:1—Chicken myostatin (Genbank NM — 001001461).
SEQ ID NO:2—Nucleotide sequence encoding chicken myostatin (Genbank NM — 001001461).
SEQ ID NO:3—Partial chicken DMRT1 protein sequence (Genbank AF123456).
SEQ ID NO:4—Partial nucleotide sequence encoding chicken DMRT1 (Genbank AF123456).
SEQ ID NO:5—Chicken WPKCl (ASW) (Genbank AF148455).
[0032] SEQ ID NO:6—Nucleotide sequence encoding chicken WPKCl (ASW) (Genbank AF148455).
SEQ ID NO:7—Nucleotide sequence of chicken U6-1 promoter.
SEQ ID NO:8—Nucleotide sequence of chicken U6-3 promoter.
SEQ ID NO:9—Nucleotide sequence of chicken U6-4 promoter.
SEQ ID NO:10—Nucleotide sequence of chicken 7SK promoter.
SEQ ID NO's 11 to 98 and 113 to 122—RNA sequences useful for the invention.
SEQ ID NO's 99 to 112—Oligonucleotide primers.
DETAILED DESCRIPTION OF THE INVENTION
General Techniques and Definitions
[0033] Unless specifically defined otherwise, all technical and scientific terms used herein shall be taken to have the same meaning as commonly understood by one of ordinary skill in the art (e.g., in cell culture, molecular genetics, avian biology, RNA interference, and biochemistry).
[0034] Unless otherwise indicated, the recombinant protein, cell culture, and immunological techniques utilized in the present invention are standard procedures, well known to those skilled in the art. Such techniques are described and explained throughout the literature in sources such as, J. Perbal, A Practical Guide to Molecular Cloning, John Wiley and Sons (1984), J. Sambrook et al., Molecular Cloning: A Laboratory Manual, Cold Spring Harbour Laboratory Press (1989), T. A. Brown (editor), Essential Molecular Biology: A Practical Approach, Volumes 1 and 2, IRL Press (1991), D. M. Glover and B. D. Hames (editors), DNA Cloning: A Practical Approach, Volumes 1-4, IRL Press (1995 and 1996), and F. M. Ausubel et al. (editors), Current Protocols in Molecular Biology, Greene Pub. Associates and Wiley-Interscience (1988, including all updates until present), Ed Harlow and David Lane (editors).
[0035] The term “avian” as used herein refers to any species, subspecies or race of organism of the taxonomic Class Ayes, such as, but not limited to, such organisms as chicken, turkey, duck, goose, quail, pheasants, parrots, finches, hawks, crows and ratites including ostrich, emu and cassowary. The term includes the various known strains of Gallus gallus (chickens), for example, White Leghorn, Brown Leghorn, Barred-Rock, Sussex, New Hampshire, Rhode Island, Australorp, Cornish, Minorca, Amrox, California Gray, Italian Partidge-coloured, as well as strains of turkeys, pheasants, quails, duck, ostriches and other poultry commonly bred in commercial quantities.
[0036] As used herein, the term “egg” refers to a fertilized ovum that has been laid by a bird. Typically, avian eggs consist of a hard, oval outer eggshell, the “egg white” or albumen, the egg yolk, and various thin membranes. Furthermore, “in ovo” refers to in an egg.
[0037] The terms “reduces”, “reduction” or variations thereof as used herein refers to a measurable decrease in the amount of a target RNA and/or target protein in the egg when compared to an egg from the same species of avian, more preferably strain or breed of avian, and even more preferably the same bird, that has not been administered with a nucleic acid as defined herein. The term also refers to a measurable reduction in the activity of a target protein. Preferably a reduction in the level of a target RNA and/or target protein is at least about 10%. More preferably the reduction is at least about 20%, 30%, 40%, 50%, 60%, 80%, 90% and even more preferably, about 100%.
[0038] As used herein, the phrase “the nucleic acid molecule results in a reduction” or variations thereof refers to the presence of the nucleic acid molecule in the egg inducing degradation of homologous RNAs in the egg by the process known in the art as “RNA interference” or “gene silencing”. Furthermore, the nucleic acid molecule directly results in the reduction, and is not transcribed in ovo produce the desired effect.
[0039] The “at least one RNA molecule” can be any type of RNA present in, and/or produced by, an avian egg. Examples include, but are not limited to, mRNA, snRNA, microRNA and tRNA.
[0040] As used herein, the term “production trait” refers to any phenotype of an avian that has commercial value such as muscle mass, sex and nutritional content.
[0041] As used herein, the term “muscle mass” refers to the weight of muscle tissue. An increase in muscle mass can be determined by weighing the total muscle tissue of a bird which hatches from an egg treated as described herein when compared to a bird from the same species of avian, more preferably strain or breed of avian, and even more preferably the same bird, that has not been administered with a nucleic acid as defined herein. Alternatively, specific muscles such as breast and/or leg muscles can be used to identify an increase in muscle mass. Preferably, the methods of the invention increase muscle mass by at about least 1%, 2.5%, 5%, 7.5%, and even more preferably, about 10%.
[0042] A “variant” of a nucleic acid molecule of the invention includes molecules of varying sizes of, and/or with one or more different nucleotides, but which are still capable of being used to silence the target gene. For example, variants may comprise additional nucleotides (such as 1, 2, 3, 4, or more), or less nucleotides. Furthermore, a few nucleotides may be substituted without influencing the ability of the nucleic acid to silence the target gene. In an embodiment, the variant includes additional 5′ and/or 3′ nucleotides which are homologous to the corresponding target RNA molecule and/or which enhance the stability of the nucleic acid molecule. In another embodiment, the nucleic acid molecules have no more than 4, more preferably no more than 3, more preferably no more than 2, and even more preferably no more than 1, nucleotide differences when compared to the sequences provided herein. In a further embodiment, the nucleic acid molecules have no more than 2, and more preferably no more than 1, internal additional and/or deletional nucleotides when compared to the sequences provided herein.
[0043] By an “isolated nucleic acid molecule”, we mean a nucleic acid molecule which is at least partially separated from the nucleic acid molecule with which it is associated or linked in its native state. Preferably, the isolated nucleic acid molecule is at least 60% free, preferably at least 75% free, and most preferably at least 90% free from other components with which they are naturally associated. Furthermore, the term “polynucleotide” is used interchangeably herein with the term “nucleic acid”.
[0044] The term “exogenous” in the context of a nucleic acid molecule refers to the nucleic acid molecule when present in a cell, or in a cell-free expression system, in an altered amount. Preferably, the cell is a cell that does not naturally comprise the nucleic acid molecule. However, the cell may be a cell which comprises an exogenous nucleic acid molecule resulting in an increased amount of the nucleic acid molecule. An exogenous nucleic acid molecule of the invention includes nucleic acid molecules which have not been separated from other components of the recombinant cell, or cell-free expression system, in which it is present, and nucleic acid molecules produced in such cells or cell-free systems which are subsequently purified away from at least some other components.
Gene Silencing
[0045] The terms “RNA interference”, “RNAi” or “gene silencing” refers generally to a process in which a double-stranded RNA (dsRNA) molecule reduces the expression of a nucleic acid sequence with which the double-stranded RNA molecule shares substantial or total homology. However, it has more recently been shown that gene silencing can be achieved using non-RNA double stranded molecules (see, for example, US 20070004667).
[0046] RNA interference (RNAi) is particularly useful for specifically inhibiting the production of a particular RNA and/or protein. Although not wishing to be limited by theory, Waterhouse et al. (1998) have provided a model for the mechanism by which dsRNA (duplex RNA) can be used to reduce protein production. This technology relies on the presence of dsRNA molecules that contain a sequence that is essentially identical to the mRNA of the gene of interest or part thereof, in this case an mRNA encoding a polypeptide according to the invention. Conveniently, the dsRNA can be produced from a single promoter in a recombinant vector or host cell, where the sense and anti-sense sequences are flanked by an unrelated sequence which enables the sense and anti-sense sequences to hybridize to form the dsRNA molecule with the unrelated sequence forming a loop structure. The design and production of suitable dsRNA molecules for the present invention is well within the capacity of a person skilled in the art, particularly considering Waterhouse et al. (1998), Smith et al. (2000), WO 99/32619, WO 99/53050, WO 99/49029 and WO 01/34815.
[0047] The present invention includes nucleic acid molecules comprising and/or encoding double-stranded regions for gene silencing. The nucleic acid molecules are typically RNA but may comprise DNA, chemically-modified nucleotides and non-nucleotides.
[0048] The double-stranded regions should be at least 19 contiguous nucleotides, for example about 19 to 23 nucleotides, or may be longer, for example 30 or 50 nucleotides, or 100 nucleotides or more. The full-length sequence corresponding to the entire gene transcript may be used. Preferably, they are about 19 to about 23 nucleotides in length.
[0049] The degree of identity of a double-stranded region of a nucleic acid molecule to the targeted transcript should be at least 90% and more preferably 95-100%. The % identity of a nucleic acid molecule is determined by GAP (Needleman and Wunsch, 1970) analysis (GCG program) with a gap creation penalty=5, and a gap extension penalty=0.3. Preferably, the two sequences are aligned over their entire length.
[0050] The nucleic acid molecule may of course comprise unrelated sequences which may function to stabilize the molecule.
[0051] The term “short interfering RNA” or “siRNA” as used herein refers to a nucleic acid molecule which comprises ribonucleotides capable of inhibiting or down regulating gene expression, for example by mediating RNAi in a sequence-specific manner, wherein the double stranded portion is less than 50 nucleotides in length, preferably about 19 to about 23 nucleotides in length. For example the siRNA can be a nucleic acid molecule comprising self-complementary sense and antisense regions, wherein the antisense region comprises nucleotide sequence that is complementary to nucleotide sequence in a target nucleic acid molecule or a portion thereof and the sense region having nucleotide sequence corresponding to the target nucleic acid sequence or a portion thereof. The siRNA can be assembled from two separate oligonucleotides, where one strand is the sense strand and the other is the antisense strand, wherein the antisense and sense strands are self-complementary.
[0052] As used herein, the term siRNA is meant to be equivalent to other terms used to describe nucleic acid molecules that are capable of mediating sequence specific RNAi, for example micro-RNA (miRNA), short hairpin RNA (shRNA), short interfering oligonucleotide, short interfering nucleic acid (siNA), short interfering modified oligonucleotide, chemically-modified siRNA, post-transcriptional gene silencing RNA (ptgsRNA), and others. In addition, as used herein, the term RNAi is meant to be equivalent to other terms used to describe sequence specific RNA interference, such as post transcriptional gene silencing, translational inhibition, or epigenetics. For example, siRNA molecules of the invention can be used to epigenetically silence genes at both the post-transcriptional level or the pre-transcriptional level. In a non-limiting example, epigenetic regulation of gene expression by siRNA molecules of the invention can result from siRNA mediated modification of chromatin structure to alter gene expression.
[0053] Preferred small interfering RNA (“siRNA”) molecules comprise a nucleotide sequence that is identical to about 19 to 23 contiguous nucleotides of the target mRNA. In an embodiment, the target mRNA sequence commences with the dinucleotide AA, comprises a GC-content of about 30-70% (preferably, 30-60%, more preferably 40-60% and more preferably about 45%-55%), and does not have a high percentage identity to any nucleotide sequence other than the target in the genome of the avian (preferably chickens) in which it is to be introduced, e.g., as determined by standard BLAST search.
[0054] By “shRNA” or “short-hairpin RNA” is meant an siRNA molecule where less than about 50 nucleotides, preferably about 19 to about 23 nucleotides, is base paired with a complementary sequence located on the same RNA molecule, and where said sequence and complementary sequence are separated by an unpaired region of at least about 4 to 15 nucleotides which forms a single-stranded loop above the stem structure created by the two regions of base complementarity. Examples of sequences of a single-stranded loops are 5′ UUCAAGAGA 3′ and 5′ UUUGUGUAG 3′.
[0055] Included shRNAs are dual or bi-finger and multi-finger hairpin dsRNAs, in which the RNA molecule comprises two or more of such stem-loop structures separated by single-stranded spacer regions.
[0056] There are well-established criteria for designing siRNAs (see, for example, Elbashire et al., 2001; Amarzguioui et al., 2004; Reynolds et al., 2004). Details can be found in the websites of several commercial vendors such as Ambion, Dharmacon, GenScript, and OligoEngine. Typically, a number of siRNAs have to be generated and screened in order to compare their effectiveness.
[0057] Once designed, the dsRNAs for use in the method of the present invention can be generated by any method known in the art, for example, by in vitro transcription, recombinantly, or by synthetic means. siRNAs can be generated in vitro by using a recombinant enzyme, such as T7 RNA polymerase, and DNA oligonucleotide templates, or can be prepared in vivo, for example, in cultured cells. In a preferred embodiment, the nucleic acid molecule is produced synthetically.
[0058] In addition, strategies have been described for producing a hairpin siRNA from vectors containing, for example, a RNA polymerase III promoter. Various vectors have been constructed for generating hairpin siRNAs in host cells using either an H1-RNA or an snU6 RNA promoter (see SEQ ID NO's 7 to 9). A RNA molecule as described above (e.g., a first portion, a linking sequence, and a second portion) can be operably linked to such a promoter. When transcribed by RNA polymerase III, the first and second portions form a duplexed stem of a hairpin and the linking sequence forms a loop. The pSuper vector (OligoEngines Ltd., Seattle, Wash.) also can be used to generate siRNA.
[0059] Modifications or analogs of nucleotides can be introduced to improve the properties of the nucleic acid molecules of the invention. Improved properties include increased nuclease resistance and/or increased ability to permeate cell membranes. Accordingly, the terms “nucleic acid molecule” and “double-stranded RNA molecule” includes synthetically modified bases such as, but not limited to, inosine, xanthine, hypoxanthine, 2-aminoadenine, 6-methyl-, 2-propyl- and other alkyl-adenines, 5-halo uracil, 5-halo cytosine, 6-aza cytosine and 6-aza thymine, pseudo uracil, 4-thiuracil, 8-halo adenine, 8-aminoadenine, 8-thiol adenine, 8-thiolalkyl adenines, 8-hydroxyl adenine and other 8-substituted adenines, 8-halo guanines, 8-amino guanine, 8-thiol guanine, 8-thioalkyl guanines, 8-hydroxyl guanine and other substituted guanines, other aza and deaza adenines, other aza and deaza guanines, 5-trifluoromethyl uracil and 5-trifluoro cytosine.
Traits, Particularly Production Traits, and Genes Responsible Therefor
[0060] The methods of the invention can be used to modify any trait of an avian species, particularly traits determined or influenced whilst the embryo is developing in the egg. Preferred traits which can be modified include sex and muscle mass.
[0061] In an embodiment, the production trait is sex and the nucleic acid molecule reduces the level of a protein encoded by a DMRT1 gene. DMRT1 was the first molecule implicated in sex determination that shows sequence conservation between phyla. The avian homologue of DMRT1 is found on the Z (sex) chromosome of chickens and is differentially expressed in the genital ridges of male and female chicken embryos (Raymond et al., 1999; Smith et al., 1999). DMRT1 is one of the few genes thus far implicated in mammalian sex determination that appears to have a strictly gonadal pattern of expression (Raymond et al., 1999).
[0062] Examples of nucleic acid molecules that can be used to reduce the level of chicken DMRT1 protein include, but are not limited to, those which comprise at least one of the following nucleotide sequences:
[0000] CCAGUUGUCAAGAAGAGCA (SEQ ID NO: 11) GGAUGCUCAUUCAGGACAU (SEQ ID NO: 12) CCCUGUAUCCUUACUAUAA (SEQ ID NO: 13) GCCACUGAGUCUUCCUCAA (SEQ ID NO: 14) CCAGCAACAUACAUGUCAA (SEQ ID NO: 15) CCUGCGUCACACAGAUACU (SEQ ID NO: 16) GGAGUAGUUGUACAGGUUG (SEQ ID NO: 17) GACUGGCUUGACAUGUAUG (SEQ ID NO: 18) AUGGCGGUUCUCCAUCCCU, (SEQ ID NO: 19)
or a variant of any one thereof.
[0063] In a particularly preferred embodiment, the nucleic acid molecules that can be used to reduce the level of chicken DMRT1 protein comprises the sequence GCCACUGAGUCUUCCUCAA (SEQ ID NO:14), or a variant thereof.
[0064] A further example of a gene that can be targeted to modify sex as a production trait is the WPKCl gene. The avian gene WPKCl has been shown to be conserved widely on the avian W chromosome and expressed actively in the female chicken embryo before the onset of gonadal differentiation. It is suggested that WPKCl may play a role in the differentiation of the female gonad by interfering with the function of PKCI or by exhibiting its unique function in the nucleus (Hori et al., 2000). This gene has also been identified as ASW (avian sex-specific W-linked) (O'Neill et al., 2000).
[0065] In another embodiment, the production trait is muscle mass and the nucleic acid molecule reduces the level of a protein encoded by a myostatin gene. Myostatin, also termed “Growth and Differentiation Factor-8” (GDF8), is a recently discovered member of the TGFβ super-family. Myostatin mRNA and protein have been shown to be expressed in skeletal muscle, heart and mammary gland. Targeted disruption of the myostatin gene in mice and a mutation in the third exon of myostatin gene in double-muscled Belgian Blue cattle, where a nonfunctional myostatin protein is expressed, leads to increased muscle mass. Hence, myostatin is a negative regulator of skeletal muscle growth.
[0066] Examples of nucleic acid molecules that can be used to reduce the level of chicken myostatin protein include, but are not limited to, those which comprise at least one of the following nucleotide sequences:
[0000] AAGCUAGCAGUCUAUGUUU (SEQ ID NO: 20) GCUAGCAGUCUAUGUUUAU (SEQ ID NO: 21) CGCUGAAAAAGACGGACUG (SEQ ID NO: 22) AAAGACGGACUGUGCAAUG (SEQ ID NO: 23) AGACGGACUGUGCAAUGCU (SEQ ID NO: 24) UGCUUGUACGUGGAGACAG (SEQ ID NO: 25) UACAAAAUCCUCCAGAAUA (SEQ ID NO: 26) AAUCCUCCAGAAUAGAAGC (SEQ ID NO: 27) UCCUCCAGAAUAGAAGCCA (SEQ ID NO: 28) UAGAAGCCAUAAAAAUUCA (SEQ ID NO: 29) GCCAUAAAAAUUCAAAUCC (SEQ ID NO: 30) AAAUUCAAAUCCUCAGCAA (SEQ ID NO: 31) AUUCAAAUCCUCAGCAAAC (SEQ ID NO: 32) AUCCUCAGCAAACUGCGCC (SEQ ID NO: 33) ACUGCGCCUGGAACAAGCA (SEQ ID NO: 34) CAAGCACCUAACAUUAGCA (SEQ ID NO: 35) GCACCUAACAUUAGCAGGG (SEQ ID NO: 36) CAUUAGCAGGGACGUUAUU (SEQ ID NO: 37) GCAGCUUUUACCCAAAGCU (SEQ ID NO: 38) UUCCUGCAGUGGAGGAGCU (SEQ ID NO: 39) CUGAUUGAUCAGUAUGAUG (SEQ ID NO: 40) GACGAUGACUAUCAUGCCA (SEQ ID NO: 41) CCGAGACGAUUAUCACAAU (SEQ ID NO: 42) UGCCUACGGAGUCUGAUUU (SEQ ID NO: 43) AUGGAGGGAAAACCAAAAU (SEQ ID NO: 44) AACCAAAAUGUUGCUUCUU (SEQ ID NO: 45) CCAAAAUGUUGCUUCUUUA (SEQ ID NO: 46) AAUGUUGCUUCUUUAAGUU (SEQ ID NO: 47) UGUUGCUUCUUUAAGUUUA (SEQ ID NO: 48) GUUUAGCUCUAAAAUACAA (SEQ ID NO: 49) AAUACAAUAUAACAAAGUA (SEQ ID NO: 50) UACAAUAUAACAAAGUAGU (SEQ ID NO: 51) UAUAACAAAGUAGUAAAGG (SEQ ID NO: 52) CAAAGUAGUAAAGGCACAA (SEQ ID NO: 53) AGUAGUAAAGGCACAAUUA (SEQ ID NO: 54) AGGCACAAUUAUGGAUAUA (SEQ ID NO: 55) UUAUGGAUAUACUUGAGGC (SEQ ID NO: 56) GUCCAAAAACCUACAACGG (SEQ ID NO: 57) AAACCUACAACGGUGUUUG (SEQ ID NO: 58) ACCUACAACGGUGUUUGUG (SEQ ID NO: 59) CGGUGUUUGUGCAGAUCCU (SEQ ID NO: 60) GCCCAUGAAAGACGGUACA (SEQ ID NO: 61) AGACGGUACAAGAUAUACU (SEQ ID NO: 62) GAUAUACUGGAAUUCGAUC (SEQ ID NO: 63) UUCGAUCUUUGAAACUUGA (SEQ ID NO: 64) ACUUGACAUGAACCCAGGC (SEQ ID NO: 65) CCCAGGCACUGGUAUCUGG (SEQ ID NO: 66) GACAGUGCUGCAAAAUUGG (SEQ ID NO: 67) AAUUGGCUCAAACAGCCUG (SEQ ID NO: 68) UUGGCUCAAACAGCCUGAA (SEQ ID NO: 69) ACAGCCUGAAUCCAAUUUA (SEQ ID NO: 70) UCCAAUUUAGGCAUCGAAA (SEQ ID NO: 71) UUUAGGCAUCGAAAUAAAA (SEQ ID NO: 72) AUAAAAGCUUUUGAUGAGA (SEQ ID NO: 73) AAGCUUUUGAUGAGACUGG (SEQ ID NO: 74) GCUUUUGAUGAGACUGGAC (SEQ ID NO: 75) GAUGGAUUGAACCCAUUUU (SEQ ID NO: 76) CCCAUUUUUAGAGGUCAGA (SEQ ID NO: 77) ACGGUCCCGCAGAGAUUUU (SEQ ID NO: 78) CGGAAUCCCGAUGUUGUCG (SEQ ID NO: 79) UCCAGUCCCAUCCAAAAGC (SEQ ID NO: 80) GCUUUUGGAUGGGACUGGA (SEQ ID NO: 81) AAGAUACAAAGCCAAUUAC (SEQ ID NO: 82) GAUACAAAGCCAAUUACUG (SEQ ID NO: 83) AGCCAAUUACUGCUCCGGA (SEQ ID NO: 84) UUACUGCUCCGGAGAAUGC (SEQ ID NO: 85) UGCGAAUUUGUGUUUCUAC (SEQ ID NO: 86) CAGGUGAGUGUGCGGGUAU (SEQ ID NO: 87) AUACCCGCACACUCACCUG (SEQ ID NO: 88) GCAAAUCCCAGAGGUCCAG (SEQ ID NO: 89) AUCCCAGAGGUCCAGCAGG (SEQ ID NO: 90) GAUGUCCCCUAUAAACAUG (SEQ ID NO: 91) ACAUGCUGUAUUUCAAUGG (SEQ ID NO: 92) UGGAAAAGAACAAAUAAUA (SEQ ID NO: 93) AAGAACAAAUAAUAUAUGG (SEQ ID NO: 94) GAACAAAUAAUAUAUGGAA (SEQ ID NO: 95) CAAAUAAUAUAUGGAAAGA (SEQ ID NO: 96) AUAAUAUAUGGAAAGAUAC (SEQ ID NO: 97) UAUAUGGAAAGAUACCAGC (SEQ ID NO: 98) CCAGAAUAGAAGCCAUAAA (SEQ ID NO: 113) GCACAAUUAUGGAUAUACU (SEQ ID NO: 114) GUACAAGAUAUACUGGAAU (SEQ ID NO: 115) CCUAUAAACAUGCUGUAUU (SEQ ID NO: 116) GCGAAUUUGUGUUUCUACA (SEQ ID NO: 117) GAGUAUUGAUGUGAAGACA (SEQ ID NO: 118) CCUCCAGAAUAGAAGCCAU (SEQ ID NO: 119) GGUCAGAGUUACAGACACA (SEQ ID NO: 120) CAGUGGAUUUCGAAGCUUU (SEQ ID NO: 121) CAACGGUGUUUGUGCAGAU, (SEQ ID NO: 122)
or a variant of any one thereof.
[0067] In a particularly preferred embodiment, the nucleic acid molecules that can be used to reduce the level of chicken myostatin protein comprises the sequence CAGGUGAGUGUGCGGGUAU (SEQ ID NO:87), or a variant thereof.
Vectors and Host Cells
[0068] The present invention also provides a vector encoding a nucleic acid molecule comprising a double-stranded region, or single strand thereof, of the present invention. Preferably, the vector is an expression vector capable of expressing the open reading frame(s) encoding a dsRNA in a host cell and/or cell free system. The host cell can be any cell type such as, not limited to, bacterial, fungal, plant or animal cells.
[0069] Typically, a vector of the invention will comprise a promoter operably linked to an open reading frame encoding a nucleic acid molecule of the invention, or a strand thereof.
[0070] As used herein, the term “promoter” refers to a nucleic acid sequence which is able to direct transcription of an operably linked nucleic acid molecule and includes, for example, RNA polymerase II and RNA polymerase III promoters. Also included in this definition are those transcriptional regulatory elements (e.g., enhancers) that are sufficient to render promoter-dependent gene expression controllable in a cell type-specific, tissue-specific, or temporal-specific manner, or that are inducible by external agents or signals.
[0071] “Operably linked” as used herein refers to a functional relationship between two or more nucleic acid (e.g., DNA) segments. Typically, it refers to the functional relationship of a transcriptional regulatory element to a transcribed sequence. For example, a promoter is operably linked to a coding sequence, such as an open reading frame encoding a double-stranded RNA molecule defined herein, if it stimulates or modulates the transcription of the coding sequence in an appropriate cell. Generally, promoter transcriptional regulatory elements that are operably linked to a transcribed sequence are physically contiguous to the transcribed sequence, i.e., they are cis-acting. However, some transcriptional regulatory elements, such as enhancers, need not be physically contiguous or located in close proximity to the coding sequences whose transcription they enhance.
[0072] By “RNA polymerase III promoter” or “RNA pol III promoter” or “polymerase III promoter” or “pol III promoter” is meant any invertebrate, vertebrate, or mammalian promoter, e.g., chicken, human, murine, porcine, bovine, primate, simian, etc. that, in its native context in a cell, associates or interacts with RNA polymerase III to transcribe its operably linked gene, or any variant thereof, natural or engineered, that will interact in a selected host cell with an RNA polymerase III to transcribe an operably linked nucleic acid sequence. By U6 promoter (e.g., chicken U6, human U6, murine U6), H1 promoter, or 7SK promoter is meant any invertebrate, vertebrate, or mammalian promoter or polymorphic variant or mutant found in nature to interact with RNA polymerase III to transcribe its cognate RNA product, i.e., U6 RNA, H1 RNA, or 7SK RNA, respectively. Examples of suitable promoters include cU6-1 (SEQ ID NO:7), cU6-3 (SEQ ID NO:8), cU6-4 (SEQ ID NO:9) and c7SK (SEQ ID NO:10).
[0073] When E. coli is used as a host cell, there is no limitation other than that the vector should have an “ori” to amplify and mass-produce the vector in E. coli (e.g., JM109. DH5α, HB101, or XL1 Blue), and a marker gene for selecting the transformed E. coli (e.g., a drug-resistance gene selected by a drug such as ampicillin, tetracycline, kanamycin, or chloramphenicol). For example, M13-series vectors, pUC-series vectors, pBR322, pBluescript, pCR-Script, and such can be used. pGEM-T, pDIRECT, pT7, and so on can also be used for subcloning and excision of the gene encoding the dsRNA as well as the vectors described above.
[0074] With regard to expression vectors for use in E. coli , such vectors include JM109, DH5α, HB101, or XL1 Blue, the vector should have a promoter such as lacZ promoter, araB promoter, or T7 promoter that can efficiently promote the expression of the desired gene in E. coli . Other examples of the vectors are “QIAexpress system” (Qiagen), pEGFP, and pET (for this vector, BL21, a strain expressing T7 RNA polymerase, is preferably used as the host).
[0075] In addition to the vectors for E. coli , for example, the vector may be a mammal-derived expression vector (e.g., pcDNA3 (Invitrogen), pEGF-BOS, pEF, and pCDM8), an insect cell-derived expression vector (e.g., “Bac-to-BAC baculovairus expression system” (GibcoBRL) and pBacPAK8), a plant-derived expression vector (e.g., pMH1 and pMH2), an animal virus-derived expression vector (e.g., pHSV, pMV, and pAdexLcw), a retrovirus-derived expression vector (e.g., pZIPneo), a yeast-derived expression vector (e.g., “Pichia Expression Kit” (Invitrogen), pNV11, and SP-Q01), a Bacillus subtilis -derived expression vector (e.g., pPL608 and pKTH50).
[0076] In order to express nucleic acid molecules in animal cells, such as CHO, COS, Vero and NIH3T3 cells, the vector should have a promoter necessary for expression in such cells, e.g., SV40 promoter, MMLV-LTR promoter, EF1α promoter, CMV promoter, etc., and more preferably it has a marker gene for selecting transformants (for example, a drug resistance gene selected by a drug (e.g., neomycin. G418, etc.)). Examples of vectors with these characteristics include pMAM, pDR2, pBK-RSV, pBK-CMV, pOPRSV and pOP13.
[0077] Nucleic acid molecules comprising a double-stranded region of the present invention can be expressed in animals by, for example, inserting an open reading frame(s) encoding the nucleic acid into an appropriate vector and introducing the vector by the retrovirus method, liposome method, cationic liposome method, adenovirus method, and so on. The vectors used include, but are not limited to, adenoviral vectors (e.g., pAdexlcw) and retroviral vectors (e.g., pZIPneo). General techniques for gene manipulation, such as insertion of nucleic acids of the invention into a vector, can be performed according to conventional methods.
[0078] The present invention also provides a host cell into which an exogenous nucleic acid molecule, typically in a vector of the present invention, has been introduced. The host cell of this invention can be used as, for example, a production system for producing or expressing the nucleic acid molecule. For in vitro production, eukaryotic cells or prokaryotic cells can be used.
[0079] Useful eukaryotic host cells may be animal, plant, or fungi cells. As animal cells, mammalian cells such as CHO, COS, 3T3, myeloma, baby hamster kidney (BHK), HeLa, or Vero cells MDCK cells, DF1 cells, amphibian cells such as Xenopus oocytes, or insect cells such as Sf9, Sf21, or Tn5 cells can be used. CHO cells lacking DHFR gene (dhfr-CHO) or CHO K-1 may also be used. The vector can be introduced into the host cell by, for example, the calcium phosphate method, the DEAE-dextran method, cationic liposome DOTAP (Boehringer Mannheim) method, electroporation, lipofection, etc.
[0080] Useful prokaryotic cells include bacterial cells, such as E. coli , for example, JM109, DH5a, and HB101, or Bacillus subtilis.
[0081] Culture medium such as DMEM, MEM, RPMI-1640, or IMDM may be used for animal cells. The culture medium can be used with or without serum supplement such as fetal calf serum (FCS). The pH of the culture medium is preferably between about 6 and 8. Cells are typically cultured at about 30 to 40° C. for about 15 to 200 hr, and the culture medium may be replaced, aerated, or stirred if necessary.
Compositions
[0082] The present invention also provides compositions comprising a nucleic acid molecule comprising a double-stranded region that can be administered to an avian egg. A composition comprising a nucleic acid molecule comprising a double-stranded region may contain a pharmaceutically acceptable carrier to render the composition suitable for administration.
[0083] Suitable pharmaceutical carriers, excipients and/or diluents include, but are not limited to, lactose, sucrose, starch powder, talc powder, cellulose esters of alkonoic acids, magnesium stearate, magnesium oxide, crystalline cellulose, methyl cellulose, carboxymethyl cellulose, gelatin, glycerin, sodium alginate, antibacterial agents, antifungal agents, gum arabic, acacia gum, sodium and calcium salts of phosphoric and sulfuric acids, polyvinylpyrrolidone and/or polyvinyl alcohol, saline, and water. In an embodiment, the carrier, excipient and/or diluent is phosphate buffered saline or water.
[0084] The composition may also comprise a transfection promoting agent. Transfection promoting agents used to facilitate the uptake of nucleic acids into a living cell are well known within the art. Reagents enhancing transfection include chemical families of the types; polycations, dendrimers, DEAE Dextran, block copolymers and cationic lipids. Preferably, the transfection-promoting agent is a lipid-containing compound (or formulation), providing a positively charged hydrophilic region and a fatty acyl hydrophobic region enabling self-assembly in aqueous solution into vesicles generally known as micelles or liposomes, as well as lipopolyamines.
[0085] It is understood that any conventional media or agent may be used so long as it is not incompatible with the compositions or methods of the invention.
Administration
[0086] Administration of a nucleic acid molecule comprising a double-stranded region (including a composition comprising a nucleic acid molecule comprising a double-stranded region) is conveniently achieved by injection into the egg, and generally injection into the air sac. Notwithstanding that the air sac is the preferred route of in ovo administration, other regions such as the yolk sac or chorion allantoic fluid may also be inoculated by injection. The hatchability rate might decrease slightly when the air sac is not the target for the administration although not necessarily at commercially unacceptable levels. The mechanism of injection is not critical to the practice of the present invention, although it is preferred that the needle does not cause undue damage to the egg or to the tissues and organs of the developing embryo or the extra-embryonic membranes surrounding the embryo.
[0087] When the production trait is sex, it is preferred that the nucleic acid molecule is administered within four days of the egg having been laid.
[0088] Generally, a hypodermic syringe fitted with an approximately 22 gauge needle is suitable. The method of the present invention is particularly well adapted for use with an automated injection system, such as those described in U.S. Pat. No. 4,903,635, U.S. Pat. No. 5,056,464, U.S. Pat. No. 5,136,979 and US 20060075973.
[0089] The nucleic acid molecule is administered in an effective amount sufficient to at least some degree modify the target trait. With regard to sex, the modification can be detected comparing a suitable number of samples subjected to the method of the invention to a similar number that have not. Statistically significant variation in the sex of the birds between to the two groups will be indicative that an effective amount has been administered. Other means of determining an effective amount for sex or other traits is well within the capacity of those skilled in the art.
[0090] Preferably, about 1 ng to 100 μg, more preferably about 100 ng to 1 μg, of nucleic acid is administered to the egg. Furthermore, it is preferred that the nucleic acid to be administered is in a volume of about 1 μl to 1 ml, more preferably about 10 μl to 500 μl.
EXAMPLES
Example 1
Identification of shRNA Molecules for Down-Regulating DMRT1 Protein Production in Chickens
[0091] Selection of shRNA Sequences Targeting DMRT1
[0092] The present inventors selected 30 predicted siRNA sequences for Dmrt1 using the Ambion designed siRNA target finder (www.ambion.com/techlib/misc/siRNA_finder.html). The 30 siRNA sequences were then screened for selection of shRNAs (Table 1). There are several algorithms available to select potential siRNA sequences for specific target genes. It has been shown, however that many of these predicted siRNAs do not function effectively when processed from expressed shRNAs. Taxman et al. (2006) have specifically designed an algorithm to predict effective shRNA molecules and the inventors made their own modification to the algorithm to improve shRNA prediction. The inventors applied the modified Taxman algorithm to the 30 selected siRNAs so as to choose sequences for testing as shRNAs for the specific knockdown of Dmrt1 gene expression.
[0093] There are four criteria for shRNA selection using the Taxman algorithm. Three of the criteria are scored for out of a maximum number of 4 points. These criteria are: 1) C or G on the 5′ end of the sequence=1 point, A or T on 5′ end=−1 point; 2) A or T on the 3′ end=1 point, C or G on the 3′ end=−1 point; 3) 5 or more A or T in the seven 3′ bases=2 points, 4 A or T in the seven 3′ bases=1 point. shRNA sequences with the highest scores are preferred. The fourth criteria is based on a calculation for the free-energy of the 6 central bases of the shRNA sequence (bases 6-11 of the sense strand hybridised to bases 9-14 of the antisense strand). shRNAs with a central duplex ΔG>−12.9 kcal/mol are preferred. The modification to the Taxman algorithm the use different free-energy parameters for predictions of RNA duplex stability as published by Freier et al. (1986). Based on the algorithm, the inventors chose 6 of the siRNA target finder siRNA sequences as potentially effective shRNAs to test for their ability to knockdown Dmrt1 gene expression. The selected sequences are highlighted in bold in Table 1 and their 5′-3′ sequence is shown in Table 2. These 6 sequences were used to construct ddRNAi plasmids for the expression of the 6 shRNAs.
[0000] Construction of ddRNAi Plasmids for Expression of Selected shRNAs
[0094] Chicken polymerase III promoters cU6-1 (GenBank accession number DQ531567) and cU6-4 (DQ531570) were used as templates to construct ddRNAi expression plasmids for the selected dmrt1 and control (EGFP and irrelevant) shRNAs, via a one-step PCR ( FIG. 1 ). PCR for the construction of the shRNA plasmids used primer TD175 paired with TH346 (for shDmrt1-346), TH461 (shDmrt1-461), TH566 (shDmrt1-566), TH622 (shDmrt1-622), TH697 (shDmrt1-697), TH839 (shDmrt1-839) or TD195 (shEGFP) (see Table 3 for primer sequence and details of the specific shRNA amplified). The reverse primers in each PCR were designed to comprise the last 20 nt of each promoter sequence, shRNA sense, loop, and shRNA antisense sequence and were HPLC purified. Full-length amplified expression cassette products were ligated into pGEM-T Easy and then sequenced. The final shRNA expression plasmids used in gene knockdown assays were named pshDmrt1-346, pshDmrt1-461, pshDmrt1-566, pshDmrt1-622, pshDmrt1-697, pshDmrt1-839, and pshEGFP. A cU6-1 irrelevant control plasmid was also constructed and used for mock comparison in the gene expression assays (see below). For this mock plasmid, forward primer TD135 was paired with reverse primer TD 149 comprising the last 20 nt of the chU6-1 promoter and all other irrelevant shRNA components. The PCR product was ligated into pGEM-T Easy and sequenced.
[0000]
TABLE 1
Algorithm selection of shRNA sequences targeting Dmrt1.
5′ end
3′ end
shRNA
score
ΔG central
score
A + T in 3′
Score
Dmrt1-346
1
−11.2
1
1
3
Dmrt1-461
1
−13.3
1
1
3
Dmrt1-566
1
−11.6
1
2
4
Dmrt1-622
1
−13.6
1
1
3
Dmrt1-697
1
−10.7
1
2
4
Dmrt1-839
1
−14.2
1
2
4
Dmrt1-581
1
−13.2
−1
2
2
Dmrt1-341
1
−15.8
1
2
4
Dmrt1-578
−1
−10.9
1
2
2
Dmrt1-563
1
−12.8
1
2
4
Dmrt1-779
−1
−14
1
1
1
Dmrt1-837
1
−15.5
1
2
4
Dmrt1-593
1
−14.7
−1
1
1
Dmrt1-778
1
−15.2
−1
1
1
Dmrt1-577
−1
−9.8
1
1
1
Dmrt1-583
1
−13.8
1
0
2
Dmrt1-839
1
−14.2
1
2
4
Dmrt1-691
1
−16.8
−1
2
2
Dmrt1-455
1
−15.4
−1
1
1
Dmrt1-705
−1
−11.5
−1
2
0
Dmrt1-532
1
−14.6
1
1
3
Dmrt1-184
1
−15.3
1
1
3
Dmrt1-761
−1
−13.6
1
0
0
Dmrt1-505
−1
−15
1
2
2
Dmrt1-208
1
−17.1
1
2
4
Dmrt1-219
1
−13.4
−1
0
0
Dmrt1-458
1
−14.2
1
1
3
Dmrt1-837
1
−15.2
1
2
4
Dmrt1-701
1
−10.7
1
0
2
Dmrt1-628
1
−13.6
1
1
3
[0000]
TABLE 2
Sequence of Dmrt1 shRNAs.
shRNA
5′-3′ Sequence
Dmrt1-346
CCAGUUGUCAAGAAGAGCA (SEQ ID NO: 11)
Dmrt1-461
GGAUGCUCAUUCAGGACAU (SEQ ID NO: 12)
Dmrt1-566
CCCUGUAUCCUUACUAUAA (SEQ ID NO: 13)
Dmrt1-622
GCCACUGAGUCUUCCUCAA (SEQ ID NO: 14)
Dmrt1-697
CCAGCAACAUACAUGUCAA (SEQ ID NO: 15)
Dmrt1-839
CCUGCGUCACACAGAUACU (SEQ ID NO: 16)
[0000]
TABLE 3
Sequence and details of primers used.
Name
Sequence 5′-3′
Location/Feature
TD135
CGAAGAACCGAGCGCTGC (SEQ ID NO: 99)
cU6-1
TD149
GGGCTCGAGTTCCAAAAAAGCGCAGTGTTACTCCACTT
cU6-1 shIrr
CTCTTGAAAGTGGAGTAACACTGCGCTGAATACCGCTT
CCTCCTGAG (SEQ ID NO: 100)
TD175
GAATTGTGGGACGGCGGAAG (SEQ ID NO: 101)
cU6-4
TD195
CTCGAGTTCCAAAAAAGCTGACCCTGAAGTTCATCTCT
cU6-4 shEGFP
CTTGAAGATGAACTTCAGGGTCAGCAAACCCCAGTGTC
TCTCGGA (SEQ ID NO: 102)
TH346
CTCGAGTTCCAAAAAACCAGTTGTCAAGAAGAGCATCT
cU6-4 shDmrt1-346
CTTGAATGCTCTTCTTGACAACTGGAAACCCCAGTGTC
TCTCGGA (SEQ ID NO: 103)
TH461
CTCGAGTTCCAAAAAAGGATGCTCATTCAGGACATTCT
cU6-4 shDmrt1-461
CTTGAAATGTCCTGAATGAGCATCCAAACCCCAGTGTC
TCTCGGA (SEQ ID NO: 104)
TH566
CTCGAGTTCCAAAAAACCCTGTATCCTTACTATAATCT
cU6-4 shDmrt1-566
CTTGAATTATAGTAAGGATACAGGGAAACCCCAGTGTC
TCTCGGA (SEQ ID NO: 105)
TH622
CTCGAGTTCCAAAAAAGCCACTGAGTCTTCCTCAATCT
cU6-4 shDmrt1-622
CTTGAATTGAGGAAGACTCAGTGGCAAACCCCAGTGTC
TCTCGGA (SEQ ID NO: 106)
TH697
CTCGAGTTCCAAAAAACCAGCAACATACATGTCAATCT
cU6-4 shDmrt1-697
CTTGAATTGACATGTATGTTGCTGGAAACCCCAGTGTC
TCTCGGA (SEQ ID NO: 107)
TH839
CTCGAGTTCCAAAAAACCTGCGTCACACAGATACTTCT
cU6-4 shDmrt1-839
CTTGAAAGTATCTGTGTGACGCAGGAAACCCCAGTGTC
TCTCGGA (SEQ ID NO: 108)
[0095] Each ddRNAi plasmid was constructed so that the start of each shRNA sequence was at the +1 position of the native U6 snRNA transcripts. A XhoI restriction enzyme site was engineered downstream of the termination signal to allow screening for full-length shRNA products inserted into pGEM-T Easy. All final shRNA expression vectors consisted of either one of the full length chicken U6 promoters, a shRNA sense sequence, a loop sequence, a shRNA antisense sequence, a termination sequence and a XhoI site. The loop sequence used in all shRNAs was 5′ UUCAAGAGA 3′.
[0000] Testing Selected shRNAs for Knockdown of Dmrt1 Gene Expression
[0096] A reporter gene expression assay was used to test. shRNAs for silencing of Dmrt1. The reporter gene was a transcriptional gene fusion of Dmrt1 inserted downstream of the 3′ end of the Enhanced Green Fluorescent Protein (EGFP) gene in pEGFP-C (Clontech). The reporter plasmid was constructed as follows: cDNA of Dmrt1 was reverse transcribed from total RNA isolated from 4 day old embryo's and cloned into the multiple cloning site of pCMV-Script (Stratagene). The Dmrt1 insert was removed from the cloning vector as a NotI-EcoRI fragment and cloned downstream of the EGFP gene in pEGFP-C (Clontech). The resulting plasmid was named pEGFP-Dmrt1. This plasmid was transfected into chicken DF-1 cells and expression of the transcriptional gene fusion was confirmed by measuring EGFP fluorescence using flow cytometry as described below. DF-1 cells are a continuous line of chicken embryo fibroblasts, derived from an EV-0 embryo (ATCC, CRL-12203), and hence are a model system for studying the in ovo effects of the RNAi molecules.
[0097] Dmrt1 gene silencing assays were conducted by co-transfecting DF-1 cells with the pEGFP-Dmrt1 reporter plasmid and each of the ddRNAi plasmids expressing the Dmrt1 specific and control shRNAs. The co-transfection experiments were performed as follows: DF-1 cells (ATCC CRL-12203, chicken fibroblast) were maintained in a humidified atmosphere containing 5% CO 2 at 37° C. in Dulbecco's Modified Eagle's Medium (DMEM) containing 4.5 g/l glucose, 1.5 g/l sodium bicarbonate, 10% foetal calf serum (FCS), 2 mM L-glutamine supplemented with penicillin (100 U/ml) and streptomycin (100 μg/ml). DF1 cells were passaged as required using 0.25% (w/v) trypsin-ethylenediaminetetraacetic acid (EDTA).
[0098] Co-transfection of pEGFP-Dmrt1 and ddRNAi plasmids for EGFP-Dmrt1 fusion silencing assays was conducted in DF-1 cells grown to 80-90% confluence, in 24 well culture plates (Nunc) for flow cytometry analysis. Cells were transfected with a total of 1 μg of plasmid DNA, per well, using Lipofectamine™2000 transfection reagent (Invitrogen). EGFP expression was analysed in transfected DF-1 cells at 60 hours post-transfection using flow cytometry analysis of transfections performed in triplicate. Cells were trypsinised using 100 μl of 0.25% trypsin-EDTA, pelleted at 2000 rpm for 5 minutes, washed once in 1 ml of cold phosphate buffered saline-A (PBSA) (Oxoid), twice in 1 ml of FACS-wash solution (PBSA+1% FCS) and resuspended in 250 μl of FACS-wash solution. Flow cytometry sampling was performed using a FACScalibur (Becton Dickinson) fluorescence activated cell sorter. Data acquisition and calculation of mean fluorescence intensity (MFI) values for triplicate co-transfection samples, was performed using CELLQuest software (Becton Dickinson). The results of the gene silencing assay are shown in FIG. 2 . pshEGFP was used as a positive control. The shRNA expressed from this plasmid is known to effectively target the EGFP region of the fusion transcript and was shown to reduce reporter fluorescence by approximately 50%. Compared to the negative control irrelevant shRNA expressed from pshIrr, the Dmrt1 specific shRNAs were observed to knockdown expression of the reporter gene to varying levels. shDmrt1-622 induced the greatest level of gene silencing of approximately 60%.
Example 2
Identification of shRNA Molecules for Down-Regulating Myostatin Protein Production in Chickens
[0099] Selection of shRNA Sequences Targeting Myostatin (Gdf8)
[0100] 79 predicted siRNA sequences for Gdf8 were identified using the Ambion designed siRNA target finder (www.ambion.com/techlib/misc/siRNA_finder.html) (Table 4). Additional siRNA sequences optimized using the Taxman algorithm are provided in Table 5. The inventors selected 3 of these sequences (Gdf8-258, Gdf8-913 and Gdf8-1002) for the construction of ddRNAi plasmids for expression of shRNAs (shown in bold in Table 4).
[0000] Construction of ddRNAi Plasmids for Expression of Selected shRNAs
[0101] The chicken polymerase III promoter cU6-1 (GenBank accession number DQ531567) was used as template to construct ddRNAi expression plasmids for the selected Gdf8 and cEGFP shRNAs, via a one-step PCR ( FIG. 1 ). PCR for the construction of the shRNA plasmids used primer TD135 paired with DS304 (for shGdf8-253), DS305 (shGdf8-913), DS306 (shGdf8-1002) or TD148 (shEGFP) (see Table 6 for primer sequence and details of the specific shRNA amplified). The reverse primers in each PCR were designed to comprise the last 20 nt of each promoter sequence, shRNA sense, loop, and shRNA antisense sequence and were HPLC purified. Full-length amplified expression cassette products were ligated into pGEM-T Easy and then sequenced. The final shRNA expression plasmids used in gene knockdown assays were named pshGdf8-253, pshGdf8-913, pshGdf8-1002 and pshEGFP.
[0000]
TABLE 4
Sequence of Gdf8 shRNAs.
shRNA
5′-3′ Sequence
Gdf8-5
AAGCUAGCAGUCUAUGUUU
(SEQ ID NO: 20)
Gdf8-7
GCUAGCAGUCUAUGUUUAU
(SEQ ID NO: 21)
Gdf8-96
CGCUGAAAAAGACGGACUG
(SEQ ID NO: 22)
Gdf8-103
AAAGACGGACUGUGCAAUG
(SEQ ID NO: 23)
Gdf8-105
AGACGGACUGUGCAAUGCU
(SEQ ID NO: 24)
Gdf8-120
UGCUUGUACGUGGAGACAG
(SEQ ID NO: 25)
Gdf8-144
UACAAAAUCCUCCAGAAUA
(SEQ ID NO: 26)
Gdf8-149
AAUCCUCCAGAAUAGAAGC
(SEQ ID NO: 27)
Gdf8-151
UCCUCCAGAAUAGAAGCCA
(SEQ ID NO: 28)
Gdf8-161
UAGAAGCCAUAAAAAUUCA
(SEQ ID NO: 29)
Gdf8-166
GCCAUAAAAAUUCAAAUCC
(SEQ ID NO: 30)
Gdf8-173
AAAUUCAAAUCCUCAGCAA
(SEQ ID NO: 31)
Gdf8-175
AUUCAAAUCCUCAGCAAAC
(SEQ ID NO: 32)
Gdf8-181
AUCCUCAGCAAACUGCGCC
(SEQ ID NO: 33)
Gdf8-195
ACUGCGCCUGGAACAAGCA
(SEQ ID NO: 34)
Gdf8-208
CAAGCACCUAACAUUAGCA
(SEQ ID NO: 35)
Gdf8-211
GCACCUAACAUUAGCAGGG
(SEQ ID NO: 36)
Gdf8-219
CAUUAGCAGGGACGUUAUU
(SEQ ID NO: 37)
Gdf8-240
GCAGCUUUUACCCAAAGCU
(SEQ ID NO: 38)
Gdf8-258
UUCCUGCAGUGGAGGAGC
U (SEQ ID NO: 39)
Gdf8-277
CUGAUUGAUCAGUAUGAU
G (SEQ ID NO: 40)
Gdf8-334
GACGAUGACUAUCAUGCCA
(SEQ ID NO: 41)
Gdf8-356
CCGAGACGAUUAUCACAAU
(SEQ ID NO: 42)
Gdf8-406
UGCCUACGGAGUCUGAUUU
(SEQ ID NO: 43)
Gdf8-416
AUGGAGGGAAAACCAAAA
U (SEQ ID NO: 44)
Gdf8-418
AACCAAAAUGUUGCUUCUU
(SEQ ID NO: 45)
Gdf8-422
CCAAAAUGUUGCUUCUUUA
(SEQ ID NO: 46)
Gdf8-424
AAUGUUGCUUCUUUAAGU
U (SEQ ID NO: 47)
Gdf8-441
UGUUGCUUCUUUAAGUUU
A (SEQ ID NO: 48)
Gdf8-453
GUUUAGCUCUAAAAUACAA
(SEQ ID NO: 49)
Gdf8-455
AAUACAAUAUAACAAAGU
A (SEQ ID NO: 50)
Gdf8-460
UACAAUAUAACAAAGUAG
U (SEQ ID NO: 51)
Gdf8-465
UAUAACAAAGUAGUAAAG
G (SEQ ID NO: 52)
Gdf8-468
CAAAGUAGUAAAGGCACAA
(SEQ ID NO: 53)
Gdf8-476
AGUAGUAAAGGCACAAUU
A (SEQ ID NO: 54)
Gdf8-484
AGGCACAAUUAUGGAUAU
A (SEQ ID NO: 55)
Gdf8-508
UUAUGGAUAUACUUGAGG
C (SEQ ID NO: 56)
Gdf8-514
GUCCAAAAACCUACAACGG
(SEQ ID NO: 57)
Gdf8-516
AAACCUACAACGGUGUUUG
(SEQ ID NO: 58)
Gdf8-524
ACCUACAACGGUGUUUGUG
(SEQ ID NO: 59)
Gdf8-555
CGGUGUUUGUGCAGAUCCU
(SEQ ID NO: 60)
Gdf8-567
GCCCAUGAAAGACGGUACA
(SEQ ID NO: 61)
Gdf8-578
AGACGGUACAAGAUAUACU
(SEQ ID NO: 62)
Gdf8-590
GAUAUACUGGAAUUCGAUC
(SEQ ID NO: 63)
Gdf8-603
UUCGAUCUUUGAAACUUGA
(SEQ ID NO: 64)
Gdf8-615
ACUUGACAUGAACCCAGGC
(SEQ ID NO: 65)
Gdf8-654
CCCAGGCACUGGUAUCUGG
(SEQ ID NO: 66)
Gdf8-667
GACAGUGCUGCAAAAUUGG
(SEQ ID NO: 67)
Gdf8-669
AAUUGGCUCAAACAGCCUG
(SEQ ID NO: 68)
Gdf8-678
UUGGCUCAAACAGCCUGAA
(SEQ ID NO: 69)
Gdf8-688
ACAGCCUGAAUCCAAUUUA
(SEQ ID NO: 70)
Gdf8-696
UCCAAUUUAGGCAUCGAAA
(SEQ ID NO: 71)
Gdf8-709
UUUAGGCAUCGAAAUAAA$$
(SEQ ID NO: 72)
Gdf8-713
AUAAAAGCUUUUGAUGAG$$
(SEQ ID NO: 73)
Gdf8-715
AAGCUUUUGAUGAGACUG$$
(SEQ ID NO: 74)
Gdf8-772
GCUUUUGAUGAGACUGGAC
(SEQ ID NO: 75)
Gdf8-783
GAUGGAUUGAACCCAUUUU
(SEQ ID NO: 76)
Gdf8-822
CCCAUUUUUAGAGGUCAGA
(SEQ ID NO: 77)
Gdf8-866
ACGGUCCCGCAGAGAUUUU
(SEQ ID NO: 78)
Gdf8-871
CGGAAUCCCGAUGUUGUCG
(SEQ ID NO: 79)
Gdf8-913
UCCAGUCCCAUCCAAAAG$$
(SEQ ID NO: 80)
Gdf8-948
GCUUUUGGAUGGGACUGGA
(SEQ ID NO: 81)
Gdf8-950
AAGAUACAAAGCCAAUUAC
(SEQ ID NO: 82)
Gdf8-957
GAUACAAAGCCAAUUACUG
(SEQ ID NO: 83)
Gdf8-963
AGCCAAUUACUGCUCCGGA
(SEQ ID NO: 84)
Gdf8-979
UUACUGCUCCGGAGAAUGC
(SEQ ID NO: 85)
Gdf8-985
UGCGAAUUUGUGUUUCUAC
(SEQ ID NO: 86)
Gdf8-
CAGGUGAGUGUGCGGGUAU
1002
(SEQ ID NO: 87)
Gdf8-
AUACCCGCACACUCACCUG
1033
(SEQ ID NO: 88)
Gdf8-
GCAAAUCCCAGAGGUCCAG
1037
(SEQ ID NO: 89)
Gdf8-
AUCCCAGAGGUCCAGCAGG
1081
(SEQ ID NO: 90)
Gdf8-
GAUGUCCCCUAUAAACAUG
1095
(SEQ ID NO: 91)
Gdf8-
ACAUGCUGUAUUUCAAUGG
1111
(SEQ ID NO: 92)
Gdf8-
UGGAAAAGAACAAAUAAUA
1116
(SEQ ID NO: 93)
Gdf8-
AAGAACAAAUAAUAUAUGG
1118
(SEQ ID NO: 94)
Gdf8-
GAACAAAUAAUAUAUGGAA
1121
(SEQ ID NO: 95)
Gdf8-
CAAAUAAUAUAUGGAAAGA
1124
(SEQ ID NO: 96)
Gdf8-
AUAAUAUAUGGAAAGAUAC
1128
(SEQ ID NO: 97)
Gdf8-
UAUAUGGAAAGAUACCAGC
1141
(SEQ ID NO: 98)
[0000]
TABLE 5
Sequence of myostatin siRNAs optimized
using the Taxman algorithm.
Name
5′-3′ Sequnce
152
CCAGAAUAGAAGCCAUAAA (SEQ ID NO: 113)
460
GCACAAUUAUGGAUAUACU (SEQ ID NO: 114)
548
GUACAAGAUAUACUGGAAU (SEQ ID NO: 115)
1039
CCUAUAAACAUGCUGUAUU (SEQ ID NO: 116)
938
GCGAAUUUGUGUUUCUACA (SEQ ID NO: 117)
612
GAGUAUUGAUGUGAAGACA (SEQ ID NO: 118)
149
CCUCCAGAAUAGAAGCCAU (SEQ ID NO: 119)
762
GGUCAGAGUUACAGACACA (SEQ ID NO: 120)
860
CAGUGGAUUUCGAAGCUUU (SEQ ID NO: 121)
500
CAACGGUGUUUGUGCAGAU (SEQ ID NO: 122)
[0102] Each ddRNAi plasmid was constructed so that the start of each shRNA sequence was at the +1 position of the native U6 snRNA transcripts. A XhoI restriction enzyme site was engineered downstream of the termination signal to allow screening for full-length shRNA products inserted into pGEM-T Easy. All final shRNA expression vectors consisted of the full length chicken U6 promoter, a shRNA sense sequence, a loop sequence, a shRNA antisense sequence, a termination sequence and a XhoI site. The loop sequence used in all shRNAs was 5′ UUCAAGAGA 3′.
[0000] TABLE 6 Sequence and details of primers used. Name Sequence 5′-3′ Location/Feature TD135 CGAAGAACCGAGCGCTGC (SEQ ID NO: 99) cU6-1 TD148 CTCGAGTTCCAAAAAAGCTGACCCTGAAGTTCATCTCTC cU6-1 shEGFP TTGAAGATGAACTTCAGGGTCAGCGAATATCTCTACCTC CTAGG (SEQ ID NO: 109) DS304 CTCGAGTTCCAAAAAATTCCTGCAGTGGAGGAGCTTCTC cU6-1 shGdf8-258 TTGAAAGCTCCTCCACTGCAGGAAGAATATCTCTACCTC CTAGG (SEQ ID NO: 110) DS305 CTCGAGTTCCAAAAAATCCAGTCCCATCCAAAAGCTCTC cU6-1 shGdf8-913 TTGAAGCTTTTGGATGGGACTGGAGAATATCTCTACCTC CTAGG (SEQ ID NO: 111) DS306 CTCGAGTTCCAAAAAACAGGTGAGTGTGCGGGTATTCTC cU6-1 shGdf8-1002 TTGAAATACCCGCACACTCACCTGGAATATCTCTACCTCC TAGG (SEQ ID NO: 112)
Testing Selected shRNAs for Knockdown of Gdf8 Gene Expression
[0103] A reporter gene expression assay was used to test the three selected shRNAs for silencing of Gdf8. The reporter gene was a transcriptional gene fusion of Gdf8 inserted downstream of the 3′ end of the Enhanced Green Fluorescent Protein (EGFP) gene in pEGFP-C (Clontech). The reporter plasmid was constructed as follows: cDNA of Gdf8 was reverse transcribed from total RNA isolated from 7 day old embryo's and cloned into the multiple cloning site of pGEM-T Easy (Promega). The Gdf8 insert was removed from the cloning vector as a NotI fragment and cloned downstream of the EGFP gene in pEGFP-C (Clontech). The resulting plasmid was named pEGFP-Gdf8. This plasmid was transfected into chicken DF-1 cells and expression of the transcriptional gene fusion was confirmed by measuring EGFP fluorescence using flow cytometry as described below.
[0104] Gdf8 gene silencing assays were conducted by co-transfecting DF-1 cells with the pEGFP-Gdf8 reporter plasmid and each of the ddRNAi plasmids expressing the Gdf8 specific or EGFP control shRNAs. The co-transfection experiments were performed as follows: DF-1 cells (ATCC CRL-12203, chicken fibroblast) were maintained in a humidified atmosphere containing 5% CO 2 at 37° C. in Dulbecco's Modified Eagle's Medium (DMEM) containing 4.5 g/l glucose, 1.5 g/l sodium bicarbonate, 10% foetal calf serum (FCS), 2 mM L-glutamine supplemented with penicillin (100 U/ml) and streptomycin (100 μg/ml). DF1 cells were passaged as required using 0.25% (w/v) trypsin-ethylenediaminetetraacetic acid (EDTA).
[0105] Co-transfection of pEGFP-Gdf8 and ddRNAi plasmids for EGFP-Gdf8 fusion silencing assays was conducted in DF-1 cells grown to 80-90% confluence, in 8 well chamber slides (Nunc) for fluorescence microscopy analysis. Cells were transfected with a total of 1 μg of plasmid DNA, per well, using Lipofectamine™2000 transfection reagent (Invitrogen). EGFP expression was analysed in transfected DF-1 cells at 60 hours post-transfection as follows: Co-transfected cells in 8-well chamber slides were washed with PBSA, chamber slide housings were removed and coverslips mounted over cell monolayers. Microscopy was performed using a Leica DM LB Fluorescence Microscope (Leica Microsystems, Germany) and images were captured at 50× magnification using a Leica DC300F colour digital camera (Leica Microsystems, Germany) and Photoshop 7.0 imaging software (Adobe®). The results are shown in FIG. 3 . shGdf8-1002 was very effectively silenced expression of the fusion transcript and would therefore be an excellent candidate for silencing of the native Gdf8 transcript.
[0106] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
[0107] All publications discussed and/or referenced herein are incorporated herein in their entirety.
[0108] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.
REFERENCES
[0000]
Amarzguioui et al. (2004) Biochem Biophys Res Commun 316:1050-1058
Elbashire et al. (2001) Nature 411:494-498
Hori et al. (2000) Mol Biol Cell 11:3645-3660
Freier et al. (1986) Proc Natl Acad Sci USA 83:9373-9377
Needleman and Wunsch (1970) J Mol Biol 48: 443-453
O'Neill et al. (2000) Dev Genes Evol 210:243-249
Raymond et al. (1999) Dev Biol. 215:208-220
Reynolds et al. (2004) Nat. Biotech., 22:326-330
Smith et al. (1999) Nature 402:601-602
[0118] Smith et al. (2000) Nature 407: 319-320.
Taxman et al. (2006) BMC Biotechnol, January 24, 6:7 Waterhouse et al. (1998) Proc Natl Acad Sci USA 95:13959-13964 | The present invention relates to methods of modulating traits, particularly production traits, in avians such as chickens. In particular, the invention relates to the in ovo delivery of a dsRNA molecule, especially siRNAs, to modify production traits in commercially important birds. | 0 |
BACKGROUND OF INVENTION
[0001] The present invention relates generally to charging systems for electric and hybrid electric types of vehicles, and more particularly to selectively retaining a charging plug in the vehicle while the vehicle's batteries are being charged.
[0002] Some recent automotive vehicles employ on-board battery packs that can be charged while the vehicle is parked. For these vehicles, one end of a plug may be inserted into an electrical outlet in a garage, for example, and the other end is plugged into a receptacle in the vehicle. While plugged in, the vehicle batteries charge, thus providing the driver with maximum operating range on battery when the vehicle is next used.
SUMMARY OF INVENTION
[0003] An embodiment contemplates a charge cord lock system for a vehicle having a rechargeable battery. The charge cord lock system may comprise a vehicle structure defining a charging receptacle; and a charge cord assembly having a charge plug slidably received in the charging receptacle, with the charge plug including a retention recess recessed into a side of the charge plug to define a retention flange. The charge cord lock system also may comprise a cord lock including a catch resiliently mounted to a plunger, with the plunger mounted to an actuator that selectively moves the plunger toward and away from the charging receptacle, the catch engageable with the retention flange when the plunger is in an extended position to prevent removal of the charge plug from the charging receptacle and not engageable with the retention flange when the plunger is in a retracted position; and a controller in communication with a vehicle door lock/unlock request mechanism and the actuator to cause the actuator to move the plunger to the retracted position when a door unlock signal is received from the lock/unlock request mechanism and to cause the actuator to move the plunger to the extended position when a door lock signal is received from the lock/unlock request mechanism.
[0004] An embodiment contemplates a method of selectively retaining a charge plug of a charge cord assembly in a charging receptacle of vehicle structure for a vehicle having a rechargeable battery, the method comprising the steps of: receiving a vehicle door lock signal; after receiving the vehicle door lock signal, moving a plunger of a cord lock to an extended position, causing a catch mounted on the plunger to move into engagement with a retention flange on the charge plug when the charge plug is installed in the charging receptacle; receiving a vehicle door unlock signal; and after receiving the vehicle door unlock signal, moving the plunger of the cord lock to a retracted position, causing the catch to remain out of engagement with the retention flange on the charge plug when the charge plug is installed in the charging receptacle.
[0005] An advantage of an embodiment is that the charge cord assembly can be easily locked into the charging receptacle on the vehicle so that it is not accidentally pulled out while charging. In addition, the charge cord assembly can be easily unlocked and removed when the vehicle is going to be driven. The locking and unlocking of the charge cord is accomplished in an intuitive manner, making it easy for a new vehicle owner to operate the cord lock. Moreover, the charge plug can be inserted in the receptacle whether the charge cord assembly is locked or unlocked.
[0006] Another advantage of an embodiment is that only one additional electrical actuator assembly needs to be packaged in the vehicle, without additional vehicle switches or controls required, thus minimizing cost and complexity of the assembly.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 is a schematic drawing of a charge cord assembly and cord lock, with the cord lock in an unlocked position.
[0008] FIG. 2 is a schematic drawing similar to FIG. 1 , but with the cord lock in a locked position.
[0009] FIG. 3 is a schematic drawing of a charge cord assembly and a cord lock according to a second embodiment.
DETAILED DESCRIPTION
[0010] Referring to FIGS. 1 and 2 , a vehicle with plug-in electrical charging, indicated generally at 20 , is shown. The vehicle 20 includes vehicle structure 22 that forms a vehicle charging receptacle (charging socket) 24 that is sized and shaped to receive a charge plug 26 of a charge cord assembly 28 . The charge plug 26 connects to electronic hardware (not shown) on the vehicle for charging vehicle batteries (not shown). The charge cord assembly 28 also includes a charge cord 30 , the other end of which connects to a source of electricity (not shown).
[0011] The charge plug 26 includes a main body 32 that telescopically slides into the receptacle 24 and has a sloped insertion surface 34 adjacent to a terminal end 36 of the plug 26 . A retention recess 38 is recessed into a side of the plug 26 and forms a retention flange 40 adjacent to the sloped surface 34 . The sloped surface 34 , recess 38 and retention flange 40 all include at least a portion that faces a cord lock 42 .
[0012] The cord lock 42 is mounted to the vehicle structure 22 and includes a catch 44 that is pivotally mounted on a plunger 46 . A catch spring 47 is secured between the catch 44 and plunger 46 to bias the catch 44 into a position where it extends toward the retention recess 38 . The spring 47 may be a coil spring or may be something else, such as an elastically flexible material that can be relatively easily flexed and when released will return the catch 44 to its original position. The plunger 46 is mounted to and telescopically slidable by a motor and gear assembly (actuator) 48 . The motor and gear assembly 48 may be, for example, much like a conventional power door lock actuator as is used on common automotive vehicles. When actuated, the motor and gear assembly 48 can selectively push the plunger 46 outward toward the retention recess 38 or retract the plunger 46 inward away from the retention recess 38 .
[0013] The motor and gear assembly 48 may be controlled by a controller 50 , such as, for example, a body controller. Although, it may be a separate controller or another type of vehicle controller, if so desired. This controller 50 may also be in communication with a door lock/unlock switch 52 for a vehicle door (not shown) or a wirelessly transmitting key fob 54 or both. The controller 50 door lock switch 52 and key fob 54 are part of a power door lock system of the vehicle.
[0014] In addition, a manual release assembly 64 may be included as a backup cable release, if so desired. The manual release assembly 64 may include a Bowden cable 58 . A first end 56 of the Bowden cable 58 may be attached to the catch 44 , with a second end 60 attached to a manual release handle 62 that is accessible to a vehicle operator. The release handle 62 can be located anywhere in the vehicle where it is generally out of the way of vehicle occupants but still accessible should one need to manually release the cord lock 42 from the charge plug 26 .
[0015] The operation of the charge cord assembly 28 and cord lock 42 will now be discussed. When the controller 50 receives a signal from the key fob 54 or the door lock switch 52 to unlock the vehicle doors (not shown), not only does the controller 50 cause the vehicle doors to unlock, but it also activates the motor and gear assembly 48 to move the plunger 46 to the retracted position (shown in FIG. 1 ). In this position, the charge plug 26 can be easily slid into and out of the charging receptacle 24 without engagement with the catch 44 of the cord lock 42 .
[0016] When the controller receives a signal from the key fob 54 or the door lock switch 52 to lock the vehicle doors, not only does the controller 50 cause the vehicle doors to lock, but it also activates the motor and gear assembly 48 to move the plunger 46 to the extended position (shown in FIG. 2 ). In this position, the charge plug 26 can still be easily slid into the receptacle 24 because, as one holds the main body 32 and pushes the charge plug 26 into the receptacle 24 , the sloped insertion surface 34 will cause the catch 44 to pivot outward against the bias of the catch spring 47 until the catch 44 aligns with the retention recess 38 . At this point, the catch spring 47 will pivot the catch 44 into the retention recess 38 . Once in this position, the charge plug 26 cannot be removed while the vehicle doors are still locked. If one tries to pull the charge plug 26 out, the catch 44 will engage the retention flange 40 , preventing removal.
[0017] Thus, the cord lock 42 is able to selectively lock the charge plug 26 into the charging receptacle 24 without the need for additional controllers, vehicle switches or key fob switches. The charge plug 26 can always be slid into the receptacle 24 , but the charge plug can be prevented from being inadvertently removed when one wishes to charge the vehicle batteries.
[0018] Additionally, should the motor and gear assembly 48 or other component malfunction or the vehicle lose power while the charge plug 26 is plugged in and the doors locked, removal of the charge plug 26 is still possible. One only needs to pull on the manual release handle 62 , which will cause the catch 44 to pivot away from the retention recess 38 against the bias of the catch spring 47 . The charge plug 26 can then be slid out of the receptacle 24 without the catch 44 engaging the retention flange 40 .
[0019] FIG. 3 illustrates a second embodiment. This embodiment is similar to the first and so similar elements will have similar numbers but in the 100-series. The vehicle 120 includes vehicle structure 122 that forms a vehicle charging receptacle 124 that is sized and shaped to receive a charge plug 126 of a charge cord assembly 128 . The charge cord assembly 128 includes a charge cord 130 , the other end of which connects to a source of electricity (not shown).
[0020] The charge plug 126 includes a main body 132 that telescopically slides into the receptacle 124 and has a sloped insertion surface 134 adjacent to a terminal end 136 of the plug 126 . A retention recess 138 is recessed into a side of the plug 126 and forms a retention flange 140 below the sloped surface 134 . The sloped surface 134 , recess 138 and retention flange 140 all include at least a portion that faces a cord lock 142 .
[0021] The cord lock 142 is mounted to the vehicle structure 122 and includes a catch 144 that is telescopically mounted on a plunger 146 . A catch spring 147 is located between the catch 144 and plunger 146 to bias the catch 144 into a position where it extends toward the retention recess 138 . The spring 147 may be a coil spring or may be something else, such as an elastically flexible material that can be relatively easily compressed and when released will return the catch 144 to its original position. The plunger 146 is mounted to and telescopically slidable by a motor and gear assembly 148 . The motor and gear assembly 148 may include a motor 168 that drives a driving spur gear 170 , which, in turn, drives a driven spur gear 172 . The driven spur gear 172 rotationally drives a jack screw 174 , which engages the plunger 146 to cause the plunger to extend and retract as the jack screw 174 is rotated in one direction or the other. When actuated, the motor and gear assembly 148 can selectively push the plunger 146 outward toward the retention recess 138 or retract the plunger 146 inward away from the retention recess 138 .
[0022] An over center spring 176 may have one end mounted to a flange 178 that extends from the plunger 146 and another end 180 that is mounted in a fixed position relative to vehicle structure. The over center spring 176 and a portion of the plunger 146 are shown in phantom in the retracted position. The solid lines show the components of the second embodiment in the extended position. The over center spring 176 helps to bias the plunger 146 into the fully retracted or fully extended positions.
[0023] The motor and gear assembly 148 may be controlled by a controller 150 . This controller 150 may also be in communication with a door lock/unlock switch 152 for a vehicle door (not shown) or a wirelessly transmitting key fob 154 or both. The controller 150 , door lock switch 152 and key fob 154 are part of a power door lock system of the vehicle.
[0024] In addition, a manual release assembly 164 may be included as a backup cable release, if so desired. The manual release assembly 164 may include a Bowden cable 158 . A first end of the Bowden cable 158 may be attached to the catch 144 , with a second end attached to a manual release handle 162 that is accessible to a vehicle operator.
[0025] The operation of the charge cord assembly 128 and cord lock 142 are similar to the first embodiment. Again, the vehicle door lock and unlock function controls the when the motor and gear assembly 148 extends and retracts the plunger 146 . The difference being that the spur gears 170 , 172 , jack screw 174 and over center spring 176 are now employed for the extension and retraction of the plunger 146 .
[0026] And again, the charge plug 126 can be inserted into the receptacle 124 , even when the plunger 146 is extended. In this case, as the charge plug 126 is inserted, the sloped insertion surface 134 pushes on the catch angled surface 184 , causing the catch 144 to telescopically retract against the bias of the catch spring 147 until the catch 144 reaches the retention recess 138 , at which point the spring 147 will push the catch 144 into the retention recess 138 . The charge plug 126 cannot be pulled out until the vehicle doors are unlocked, at which time the plunger 146 is retracted.
[0027] A backup manual release may also be employed with this embodiment. One only needs to pull on the manual release handle 162 , which will cause the catch 144 to slide away from the retention recess 138 against the bias of the catch spring 147 . The charge plug 126 can then be slid out of the receptacle 124 without the catch 144 engaging the retention flange 140 .
[0028] While the spur gears and jack screw are shown in the second embodiment, such an arrangement may also be employed in the first embodiment to extend and retract the plunger. Also, the shape of the insertion surface on the second embodiment may be employed with the first embodiment and vice versa. Additionally, for either embodiment, the motor and gear assembly that extends and retracts the plunger could be a motor engaging a rack and pinion type of gear arrangement. And, additionally, the over center spring shown in the second embodiment may be employed with the first embodiment as well, if so desired.
[0029] While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. | A charge cord lock system for a vehicle having rechargeable batteries. The system includes a charging receptacle; and a charge cord assembly having a charge plug slidably received in the charging receptacle and including a recess defining a retention flange. The system also includes a cord lock including a catch mounted to a plunger, with the plunger mounted to an actuator that moves the plunger toward and away from the charging receptacle, the catch engaged with the retention flange when the plunger is in an extended position and not engaged with the retention flange when the plunger is in a retracted position; and a controller in communication with a door lock mechanism and the actuator to cause the plunger to move to the retracted position when a door unlock signal is received and to cause the plunger to move to the extended position when a door lock signal is received. | 8 |
BACKGROUND OF THE INVENTION
Plastic shutters that are used to decorate the exterior of a house are normally formed in a single mold. Because of this molding process, standard sizes are manufactured at a reasonable cost. Occasionally, non-standard-sized shutters are required.
It is too expensive to have molds for every possible size. Therefore, manufacturers have developed customizable shutters. These products require cutting portions of the shutter parts and various assembly techniques.
In many of these customizable shutters, separate stiles are employed which connect to slats. Caps are positioned on the top and bottom. An example of this is disclosed in Vagedes U.S. Pat. No. 5,924,255. Others simply cut off the portions of the top and bottom of a preformed shutter and add an end cap. Such shutters are disclosed in Gandy U.S. Pat. No. 5,617,688 and Vagedes U.S. Pat. Nos. 5,530,986 and 5,347,782.
It is very important that customized shutters have the appearance of a standard molded shutter. In other words, it is important not to be able to detect cut edges. It is also important that the assembly process not be labor intensive and, of course, the overall product must be aesthetically appealing.
SUMMARY OF THE INVENTION
The present invention is premised on the realization that a customizable shutter can be formed wherein only straight cuts at 90 degree angels are made at the top and bottom of a preformed shutter body that includes both stiles. Such cuts are easily made with available equipment. A special end cap is formed that includes legs that fit into the hollow interior of the stiles with an end cap body portion that has a generally stepped configuration allowing the ends of the stiles to butt up against the end cap, giving the appearance of a finished shutter. Provision is also made to allow the inside wall of the stile to be concealed by the end cap. This can be used for both slatted shutters as well as raised panel shutters.
The objects and advantages of the present invention will be further appreciated in light of the following detailed description and drawings in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the present invention;
FIG. 2 is an exploded view of the present invention;
FIG. 3 is an exploded perspective view of the present invention with portions cut away;
FIG. 4 is a plan view of the present invention;
FIG. 5 is a cross sectional view taken at lines 5 - 5 of FIG. 4 ;
FIG. 6 is a cross sectional view taken at lines 6 - 6 of FIG. 4 ;
FIG. 7 is a perspective view of an alternate embodiment of the present invention;
FIG. 8 is an exploded view of the embodiment in FIG. 6 ;
FIG. 9 is an exploded view of the embodiment shown in FIG. 6 with portions cut away;
FIG. 10 is a plan view of the embodiment shown in FIG. 6 ;
FIG. 11 is a cross sectional view taken at lines 11 - 11 of FIG. 10 ; and
FIG. 12 is a cross sectional view taken at lines 12 - 12 of FIG. 10 .
DETAILED DESCRIPTION
As shown in FIG. 1 , a customizable shutter 10 includes a body portion 12 , a first end cap 14 and a second end cap 16 . The body portion 12 includes first and second stiles 20 and 22 , each with hollow interior portions 24 and 26 . The body portion 12 further includes a central portion 28 which is formed integrally with the first and second stiles 20 and 22 . As shown in FIG. 1 , shutter 10 is a raised panel shutter, which also includes first and second panels 30 and 32 with peripheral inner bevel portion 36 and side bevel portions 38 . Separating the panels 30 and 32 is a cross member 40 which extends from stile 20 to stile 22 .
The body portion 12 has a top edge 42 and a bottom edge 44 . As can be seen, these edges are simply straight cuts that extend at a 90 degree angle from either of the two parallel stiles.
The end caps 14 and 16 both include first and second legs 52 and 54 and a body portion 56 , which is perpendicular to legs 52 and 54 and has a narrow portion or width approximately equal to the width of stiles 22 and 20 . The body portion 56 includes a front surface 58 , an outer surface 60 and an inner surface 62 . The inner surface 62 is designed to mate with the profile of the raised panels 30 or 32 , and conceal the cut edge 42 or 44 , respectively. As such, each of these inner surfaces 62 include a first and second wing portion 64 and 66 which are adapted to mate with the beveled side portions 38 . Extended between the two winged portions is a narrow strip 68 which is adapted to contact and rest on the central panels 30 or 32 . The wings 64 and 66 each have an outer edge 69 which is adapted to butt against an inner side wall 71 of the stiles 20 and 22 . Thus, small channels 70 and 72 are provided between the legs 52 and 54 and the outer edges 69 of the wings 64 and 68 .
As is shown in FIG. 2 , the legs 52 and 54 have a cross sectional configuration adapted to mate with the interior surface of stiles 20 and 22 with the outer edges 73 of the stiles butted against stepped portions 75 in the end caps 14 and 16 at the juncture of the legs with the body portion 56 . Inner edges 77 of the inner walls 71 of the stiles rest in channels 70 and 72 respectively.
To assemble these shutters, the body portion 12 is simply cut at 90 degree angles relative to the stiles 20 and 22 at the top and bottom to achieve a desired length. The legs 52 and 54 of the end caps are then inserted into the hollow interior of the stiles so that the outer edges of the stiles abut the stepped portions 75 of the end caps 14 and 16 with the inner walls 71 of the stiles located in channels 70 and 72 respectively. The interior wall 68 of the body 56 of the end caps cover the outer cut edges of the raised panel with the wing portions 64 and 66 resting immediately on the beveled portions and the edge 68 resting on the panel surface 28 . Thus, the entire cut edges 42 and 44 on the top and bottom of the body portion 12 either abut stepped portions on the end cap or are concealed by the interior wall 68 of the end cap. The legs 52 and 54 can then be welded, adhered, or fastened to the stile surface to provide a unitary custom-sized shutter.
FIG. 7 to 12 show an alternate embodiment of the present invention and specifically a customizable slatted shutter 80 .
As shown in FIG. 8 , shutter 80 includes a body portion 82 with first and second integral stiles 84 and 86 and a central slatted portion 88 and first and second end caps 90 and 92 . Top and bottom edges 96 and 98 of the body portion 82 are cut edges, which extend 90 degrees relative to the two stiles to provide the desired size.
The end caps 90 and 92 include first and second legs 100 and 102 with a central body portion 104 that extends 90 degrees from the legs. The body portion includes a front surface 106 , an outer surface 108 and an inner surface 110 which faces the slatted portion. The inner wall 110 is a very thin rectangular panel which extends from side to side and includes side edges spaced from legs 100 and 102 providing side channels 122 and 124 . The legs 100 and 102 are sized to mate with the interior surface of the stiles 84 and 86 which, as shown, each includes an outer wall 116 , an inner wall 118 and a top wall 120 . The edges 134 and 136 of the top and outer walls 120 and 116 of the stiles abut against the stepped portions 112 and 114 between the legs 100 , 102 and the body portion 104 of end caps 90 , 92 . Edges 138 of the inner wall 118 of stiles 84 and 86 rest in channels 122 and 124 .
As with the raised panel shutter, the slatted shutter is formed by simply cutting body portion 82 and inserting the end caps 90 and 92 . The legs 100 and 102 can then be welded, adhered, or fastened to the body portion at the interior surfaces of the stiles. The inner wall 110 of the caps will cover the edges 96 , 98 of the body portion 82 . The edges of the stiles will butt against the stepped portions 112 and 114 of the end caps 90 and 92 to provide a neat, clean appearance which will basically be identical to the pre-molded unitary shutters.
The present invention can, of course, be modified without departing from the scope of the invention. As an example, the leg portions of the end caps can be modified so that they do not take the exact configuration of the interior surface of the stiles, but can simply be a single tab or two tabs, as opposed to the three-walled structure shown in the present invention. As long as they can mate along one or more surfaces of the stiles, they can provide the needed stability for the assembled product.
This has been a description of the present invention along with the preferred method of practicing the present invention. However, the invention itself should only be defined by the appended claims, | A custom shutter includes a central body portion and first and second end caps. The central body portion includes two stiles and a central portion all of which are formed integrally as one piece. The top and bottom end caps include first and second legs and a central connecting body portion. The legs are designed to be inserted within the hollow interior of the stiles with the top edges of the stiles resting against the stepped portions of said end cap and wherein an inner surface of said end cap covers any exposed edge of the central portion of the shutter body. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims priority from U.S. Provisional Application No. 60/716,950 filed on Sep. 15, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method for producing menatetrenone, which is a quinone compound.
[0004] 2. Description of the Related Art
[0005] Menatetrenone is a compound represented by the following formula (1),
and vitamin K 2 formulations, which contain this compound as an active ingredient, are used for the prevention and treatment of vitamin K deficiency diseases and are also used as preventive and therapeutic agents for osteoporosis.
[0006] Menatetrenone is also present in, for example, fermented soybeans (natto), which is a fermented food, but the industrial methods of menatetrenone production are mainly based on chemical synthesis.
[0007] It is known that there are several methods for producing menatetrenone by chemical synthesis. As one example of several methods, it is known that a hydroquinone precursor is oxidized to give menatetrenone, the target quinone (Kozlov, E. I., Meditsinskaya Promyshlennost SSSR (1965), 19(4), 16-21).
[0008] The method disclosed in Kozlov uses silver oxide, it is known that there are methods that similarly use metal oxides such as manganese dioxide, lead peroxide (Japanese Patent Application Laid-open No. 49-55650), and so forth.
[0009] However, there were drawbacks to the use of metal oxides; for example, the reaction was difficult to control and there was a risk that side reactions would occur. Moreover, the use of metal oxides made it necessary to carry out a post-reaction treatment in order to prevent adverse effects on the environment.
[0010] In view the above, it has been developed that a method uses hydrogen peroxide (Japanese Patent Application Laid-open No. 48-49733).
[0011] Hydrogen peroxide is, however, a powerful oxidizing agent, and the handling of hydrogen peroxide in large amounts requires special handling with a particular emphasis on safety.
[0012] On the other hand, with regard to the production of ubiquinones, which are structurally similar to menatetrenone, it is known that methods use molecular oxygen, which is a milder oxidizing agent (Japanese Patent Publication No. 39-17514 and Japanese Patent Application Laid-open Nos. 52-72884, 54-151932, and 62-81347).
[0013] However, it was recognized that when using molecular oxygen in the method for the production of ubiquinones, the reaction rate with oxygen alone was very low and complete oxidation was not to be expected (Japanese Patent Application Laid-open Nos. 54-151932 and 62-81347). In order to overcome this problem, it is known that it is essential to add a base (Japanese Patent Application Laid-open No. 52-72884), silica gel (Japanese Patent Application Laid-open No. 54-151932), or copper or copper ion and ammonia or ammonium ion (Japanese Patent Application Laid-open No. 62-81347) to the reaction solution. These methods that use an additive in addition to the oxidizing agent have the problems encountered for the aforementioned use of the metal oxide to produce quinone, i.e., a risk of side reactions in the presence of the additive and complexity in post-reaction treatment.
[0014] In addition, as methods for producing menatetrenone, a specific method that uses molecular oxygen has heretofore been entirely unknown.
SUMMARY OF THE INVENTION
[0015] An object of the present invention, therefore, is to provide a method for producing menatetrenone that does not have a deleterious influence on the environment, that is safe even when applied to large-scale production, and that is also simple to operate.
[0016] As mentioned above, there were problems with the prior art methods for producing menatetrenone. The present inventors carried out focused investigations into methods for oxidizing the hydroquinone (2), which is a precursor for menatetrenone, and as a result, surprisingly discovered that, using molecular oxygen, a satisfactory reaction rate can be obtained and the oxidation reaction will run to completion, entirely without the use of additives and without the occurrence of significant side reactions. This was completely unforeseen given that it was a long-running matter of common knowledge in the art that the use of molecular oxygen alone as the oxidizing agent would give a very low reaction rate and could not be expected to give complete oxidation.
[0017] Moreover, it was additionally discovered that, by also having water be present in the reaction solution, the safety could be improved, although this has no influence on the oxidation reaction itself. Based on this finding, it was discovered that menatetrenone can be produced by a method that does not have a deleterious influence on the environment, that is safe even when applied to large-scale production, and that is also simple to operate, thereby reaching at the present invention.
[0018] That is, in a first aspect, the present invention provides a method for producing a compound represented by the following formula (1):
wherein a reaction solution consisting essentially of a solution of a compound represented by the following formula (2) dissolved in a solvent is treated with an oxygen source.
[0019] In a second embodiment aspect, the present invention provides a method for producing a compound represented by the following formula (1),
wherein a reaction solution consisting essentially of
i) a solution of a compound represented by the following formula (2) dissolved in a water-immiscible organic solvent and
ii) water or aqueous sodium chloride solution is treated with an oxygen source.
[0022] The oxygen source in the first and second aspects is preferably air, and treatment with the oxygen source is preferably carried out by blowing the oxygen source into the reaction solution.
[0023] The present invention enables the production of menatetrenone by a method that does not have a deleterious influence on the environment, that is safe even when applied to large-scale production, and that is also simple to operate.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Hydroquinone (2) used in the present invention as a precursor for menatetrenone is a known substance and several methods are known for its synthesis. For example, it can be synthesized by the following route, which is disclosed in Kozlov.
[0025] As set out above, the hydroquinone (2) can be synthesized by condensing menadiol monoacetate (4) and all-trans-geranyllinalool (5), followed by treatment with Claisen's alkaline solution.
[0026] The condensation reaction between menadiol monoacetate (4) and all-trans-geranyllinalool (5) can be carried out, as disclosed in Koziov, by heating menadiol monoacetate (4), zinc chloride, and boron trifluoride in dioxane to 50° C.; adding a dioxane solution of all-trans-geranyllinalool (5) to the reaction mixture dropwise over 30 minutes; and thereafter holding the reaction mixture at 50° C. for 30 minutes.
[0027] Besides dioxane, any solvent that does not inhibit the reaction can be employed as the solvent used in this condensation reaction. Examples of the solvent used in this condensation reaction include carbon tetrachloride, dichloromethane, chloroform, n-pentane, n-hexane, N,N-dimethylformamide, N-methylpyrrolidone, acetonitrile, dimethyl sulfoxide, benzene, toluene, xylene, methanol, ethanol, n-propanol, isopropanol, tert-butyl alcohol, methyl acetate, ethyl acetate and the like. Such solvent can be used singly, or in combination of two or more thereof in any proportion.
[0028] Acid catalysts other than the above zinc chloride and BF 3 -OEt 2 can also be used. Examples of acid catalysts include oxalic acid; metal salts such as potassium sulfate, potassium persulfate, zinc(II) triflate, and copper(I) sulfate; and sulfonic acid derivatives such as p-toluenesulfonic acid, methanesulfonic acid, sulfophthalic acid, hydroxybenzenesulfonic acid, nitrobenzenesulfonic acid, benzenesulfonic acid, chlorobenzenesulfonic acid, naphthylsulfonic acid, dodecylbenzenesulfonic acid, 4,4′-biphenyidisulfonic acid and flavianic acid.
[0029] As disclosed in Kozlov, Claisen's alkaline (prepared by the dissolution of 35 g KOH in 25 mL water followed by dilution to 100 mL with CH 3 OH) is added to the monoacetyl form (3) obtained by the condensation reaction; 3% aqueous hydrosulfite solution and ether are added thereto; the mixture is stirred; and the layers are then separated to obtain the hydroquinone (2) as the ether solution. Extraction solvents other than ether can be used after the Claisen treatment, and examples of extraction solvents include carbon tetrachloride, dichloromethane, chloroform, n-pentane, n-hexane, N-methylpyrrolidone, benzene, toluene, xylene, tert-butyl alcohol, methyl acetate, ethyl acetate and the like. Such solvent can be used singly, or in combination of two or more thereof in any proportion.
[0030] The next step is the oxidation reaction of the production method according to the present invention. Hydroquinone (2) extract obtained in the preceding step may be directly used in the present invention, or the solvent may be changed by removing the extraction solvent by, for example, distillation under reduced pressure. In any event, it is simply sufficient to prepare a solution in which hydroquinone (2) is dissolved in a solvent, and, except for the addition of water or aqueous sodium chloride solution as described below, the addition of any other additive is unnecessary. There are no particular limitations on the solvent as long as the solvent can dissolve hydroquinone (2) and does not inhibit the oxidation reaction. Examples of the solvent include carbon tetrachloride, dichloromethane, chloroform, n-pentane, n-hexane, N,N-dimethylformamide, N-methylpyrrolidone, acetonitrile, dimethyl sulfoxide, benzene, toluene, xylene, methanol, ethanol, n-propanol, isopropanol, tert-butyl alcohol, methyl acetate, ethyl acetate and the like. Such solvent can be used singly, or in combination of two or more thereof in any proportion. A water-containing solvent can also be used.
[0031] The method according to the present invention can be carried out using only a solution in which hydroquinone (2) is dissolved in the solvent. That is, it is not necessary to add any other additive in order for the oxidation reaction to proceed to completion. However, based on safety considerations, it is preferable that the reaction used in the present invention be carried out in a two-layer system obtained by the addition of water or aqueous sodium chloride solution. In the case of the reaction in a two-layer system, it is preferable to use a water-immiscible organic solvent as the solvent. Examples of the water-immiscible organic solvent include carbon tetrachloride, dichloromethane, chloroform, n-pentane, n-hexane, N-methylpyrrolidone, benzene, toluene, xylene, tert-butyl alcohol, methyl acetate, ethyl acetate, or a mixed solvent of at least two of the foregoing. As to whether water or aqueous sodium chloride solution is to be used, the appropriate selection may be made based on the solvent used. For example, the one that provides the better separation between the organic and water layers during post-reaction layer separation can be selected.
[0032] The term “oxygen source” used in the present invention refers to an oxygen source that can introduce molecular oxygen into the reaction system, for example, oxygen gas or air. When oxygen gas or air is used as the oxygen source, it can be used in the form of a mixed gas with another gas that does not impair the present invention, for example, nitrogen, helium, or argon.
[0033] Effective contact between the reaction substrate in the reaction solution and the molecular oxygen that is introduced into the reaction system is preferably induced by blowing the oxygen source into the reaction solution. When, for example, air is blown into the reaction solution, it can be blown through a nozzle; it can be blown into the reaction solution into bubbles through a porous element provided at the end of a nozzle; it can be blown out from numeraous holes on a ring-shaped pipe provided in the reaction vessel into bubbles of an appropriate size; or various other mechanical means can be implemented.
[0034] The temperature conditions of the oxidation reaction according to the present invention can be suitably selected from the view points of efficiency of reaction, that is, the temperature conditions can vary depending on types of the solvent used, efficiencies of contact with the oxygen source and the like. The reaction can be carried out at from 0° C. up to the boiling point of the solvent, however, taking into account of such factors as the reaction time and the energy efficiency, the reaction temperature is preferably room temperature to 60° C., more preferably 20 to 50° C., most preferably 30 to 40° C. The reaction time can be selected as appropriate by monitoring the completion of the reaction by TLC or HPLC and is preferably from 3 hours to 20 hours; there is no reduction in yield due to side reactions even after reaction overnight for about 15 hours.
[0035] After completion of the oxidation reaction, menatetrenone is obtained by conventional work up and purification. Specifically, the reaction solution may be concentrated, for example, under reduced pressure, to obtain a crude product, which may then be purified by column chromatography and/or recrystallization. From the standpoint of safety, the reaction solution is preferably concentrated after it has been washed with water, and in this context again the solvent used in the oxidation reaction is preferably a water-immiscible organic solvent.
EXAMPLE
[0036] The present invention is explained in terms of specific examples by the examples provided hereinbelow, but the present invention is not limited to these examples.
Example 1
First Step (Condensation Reaction)
[0037] Menadiol monoacetate (4) (28.8 g) was dissolved in a mixed solvent of ethyl acetate (67 mL) and n-hexane (67 mL) and BF 3 -Et 2 O (2.4 g) was added thereto. While stirring this solution, all-trans-geranyllinalool (5) (28.3 g) was added dropwise at 45° C. over about 1 hour and 30 minutes to 2 hours, the reaction was then carried out for 5 hours at the same temperature. The reaction solution was then washed four times with aqueous sodium chloride solution (20 mL, 5%). The organic layer was subsequently washed four times with a solution prepared by the addition of sodium hydrosulfite (2 g) to aqueous potassium hydroxide solution (40 mL, 10%). The organic layer was also washed an additional four times with aqueous sodium chloride solution (20 mL, 5%). The organic layer was concentrated under reduced pressure.
Second Step (Treatment with Claisen's Alkaline)
[0038] The concentrated residue was dissolved in toluene (150 mL), and sodium hydrosulfite (4 g), potassium hydroxide (23 g), water (17 mL), and methanol (40 mL) were added thereto and stirred. The toluene layer was removed by layer separation; the aqueous layer was washed with toluene (90 mL); ethyl acetate (100 mL), n-hexane (100 mL), and water (220 mL) were added to the aqueous layer and the aqueous layer was extracted; and the organic layer was washed twice with aqueous sodium chloride solution (20 mL, 5%) followed by layer separation.
Third Step Three (Oxidation Reaction)
[0039] Aqueous sodium chloride solution (prepared from 14 g NaCl and 80 mL water) and n-hexane (200 mL) were added to the organic layer and the reaction mixture was then stirred while bubbling air into it. The layers were separated after the completion of the reaction and the organic layer was washed three times with water (30 mL) and was concentrated. The concentrated residue was subjected to column chromatography (n-hexane) and the fraction containing the target material was concentrated, yielding crude menatetrenone as an oil. The crude menatetrenone was crystallized from ethanol to give crude crystals. Menatetrenone (1) was obtained (22% yield from (5)) by recrystallizing the crude crystals from ethanol.
Example 2
First Step (Condensation Reaction)
[0040] Menadiol monoacetate (4) (26 g) was dissolved in toluene (130 mL), and, while stirring at 50° C., a solution of all-trans-geranyllinalool (5) (29 g) dissolved in toluene (10 mL) and a solution of BF 3 -Et 2 O (3.6 g) dissolved in toluene (20 mL) were both added dropwise at the same time over 30 minutes. The reaction was then carried out for 30 minutes at the same temperature. The reaction solution was washed with aqueous sodium chloride solution (40 mL, 5%) twice. The organic layer was washed twice with a solution prepared by the addition of sodium hydrosulfite (2 g) to aqueous potassium hydroxide solution (60 mL, 10%).
Second Step (Treatment with Claisen's Alkaline)
[0041] To the organic layer were added sodium hydrosulfite (3 g), potassium hydroxide (23 g), water (17 mL), and methanol (40 mL) and the reaction mixture was stirred. The toluene layer was removed by layer separation; the aqueous layer was washed with toluene (140 mL); toluene (200 mL), acetic acid (30 mL), and water (220 mL) were added to the aqueous layer and the aqueous layer was extracted. The organic layer was washed with aqueous sodium chloride solution (40 mL, 5%) twice, followed by layer separation.
Third Step (Oxidation Reaction)
[0042] Water (80 mL) was added to the organic layer and the mixture was stirred while blowing air into the mixture. After completion of the reaction, the layers were separated and the organic layer was washed with water (30 mL) three times and was then concentrated to give crude menatetrenone.
Example 3
First Step (Condensation Reaction)
[0043] Menadiol monoacetate (4) (30.5 g) and all-trans-geranyllinalool (5) (28.3 g) were dissolved in toluene (130 mL), and, while stirring at 45° C., a solution of BF 3 -Et 2 O (2.1 g) dissolved in toluene (20 mL) was added dropwise over 30 minutes. The reaction was then continued for 60 minutes at the same temperature. The reaction solution was washed with aqueous sodium chloride solution (40 mL, 5%). The organic layer was washed twice with a solution prepared by addition of sodium hydrosulfite (2 g) to aqueous potassium hydroxide solution (60 mL, 10%).
Second Step (Treatment with Claisen's Alkaline)
[0044] To the organic layer were added sodium hydrosulfite (4 g), potassium hydroxide (23 g), water (17 mL), and methanol (40 mL) and the reaction mixture was stirred. The toluene layer was removed by layer separation; the aqueous layer was washed with toluene (100 mL); n-hexane (100 mL), ethyl acetate (100 mL), and water (220 mL) were added to the aqueous layer and the aqueous layer was extracted, and the organic layer was washed twice with aqueous sodium chloride solution (40 mL, 5%), followed by layer separation.
Third Step (Oxidation Reaction)
[0045] n-Hexane (100 mL) and aqueous sodium chloride (14 g NaCl and 80 mL water) were added to the organic layer and the reaction mixture was then stirred while bubbling air into it at 30 to 35° C. The layers were separated after the completion of the reaction and the organic layer was washed twice with aqueous sodium chloride solution (40 mL, 5%) and was then concentrated to give crude menatetrenone.
Example 4
First Step (Condensation Reaction)
[0046] Menadiol monoacetate (4) (30.5 g) was dissolved in toluene (150 mL) and methanesulfonic acid (2 mL) was added. While this solution was being stirred, all-trans-geranyllinalool (5) (27.7 g) was added dropwise over 45 minutes at 49 to 51° C., the reaction was then continued for 2 hours and 55 minutes at the same temperature. The reaction solution was washed with aqueous sodium chloride solution (40 mL, 5%) twice. The organic layer was washed three times with a solution prepared by the addition of sodium hydrosulfite (2 g) to aqueous potassium hydroxide solution (40 mL, 10%).
Second Step (Treatment with Claisen's Alkaline)
[0047] To the organic layer were added sodium hydrosulfite (4 g), potassium hydroxide (23 g), water (17 mL), and methanol (40 mL) and the mixture was stirred. The toluene layer was removed by layer separation; the aqueous layer was washed with toluene (75 mL); ethyl acetate (100 mL), n-hexane (100 mL), and water (220 mL) were added to the aqueous layer and the aqueous layer was extracted; and the organic layer was washed with aqueous sodium chloride solution (40 mL, 5%) twice, followed by layer separation.
Third Step (Oxidation Reaction)
[0048] To the organic layer were added aqueous sodium chloride (prepared from 14 g NaCl and 80 mL water) and n-hexane (200 mL) and the reaction mixture was then stirred for 3 hours while bubbling air into it at 25 to 40° C. The layers were separated after the completion of the reaction and the organic layer was washed with water (40 mL) twice and was concentrated to give crude menatetrenone.
Example 5
First Step (Condensation Reaction)
[0049] Menadiol monoacetate (4) (260.2 kg) and toluene (1300 L) were introduced into a reactor; dodecylbenzenesulfonic acid (3.5 kg) and all-trans-geranyllinalool (5) (290.5 kg) dissolved in toluene (100 L) were introduced; and hot water at 55° C. was thereafter injected through the jacket and the reaction mixture was stirred for 8 hours at an internal temperature of at least 50° C. After cooling with cold water and then reheating with 50° C. hot water, and at an internal temperature of 31.9° C., an aqueous potassium hydroxide/hydrosulfite solution (412 L) prepared from potassium hydroxide (70 kg), hydrosulfite (40 kg), and water (800 L) was added and the mixture was stirred for 20 minutes. The aqueous layer was then separated and discarded. The remaining of the aqueous potassium hydroxide/hydrosulfite solution (508 L) and water (400 L) were added to the organic layer; the mixture was stirred for 20 minutes; and the aqueous layer was then separated and discarded.
Second Step (Treatment with Claisen's Alkaline)
[0050] Hydrosulfite (30 kg) was added and the mixture was heated under a nitrogen atmosphere with 60° C. hot water. The hot water was stopped at the point at which the internal temperature had risen to 30° C.; a solution prepared from potassium hydroxide (205 kg), water (185 L), and methanol (389 L) was added; the reaction mixture was stirred for 30 minutes; and stirring was then stopped and the reaction mixture was stand for 2 hours. The organic layer was separated off; toluene (1300 L) was then added to the aqueous layer; the mixture was stirred for 5 minutes; and the organic layer was separated off and discarded. The aqueous layer was added to a stirred tank containing toluene (2000 L) and water (2200 L), the mixture was stirred for 30 minutes, glacial acetic acid (300 kg) was then added and the mixture was stirred for another 30 minutes. The aqueous layer was separated off and the organic Layer was then washed with aqueous sodium chloride solution prepared from aqueous sodium chloride solution (113 L, 10%) and water (100 L) and was additionally washed with aqueous sodium chloride solution prepared from aqueous sodium chloride solution (97 L, 10%) and water (100 L).
Third Step (Oxidation Reaction)
[0051] Water (800 L) was added to the organic layer; hot water at 60° C. was then injected through the jacket; and the reaction mixture was stirred for 15 hours under a nitrogen stream (20 Nm 3 /hour) at an internal temperature of 30° C. while blowing air into the reaction liquid at 20 Nm 3 /hour. The aqueous layer was separated off; water (300 L) was then added to the organic layer. After stirring for 10 minutes, the aqueous layer was separated off. The organic layer was washed 2 more times with water (300 L). The toluene was distilled off under reduced pressure; the residue was purified by silica gel column chromatography; and the eluting solvent was distilled off to give crude menatetrenone (219 kg).
[0052] The crude menatetrenone was dissolved with heat in 20% acetone-ethanol (2367 L). After then cooling the solution, seed crystals (25 g) were introduced at 11° C., cooling was continued down to −26.3° C. The precipitated crystals were collected by filtration and washed with 20% acetone-ethanol (704 L). The solvent was then eliminated by blowing nitrogen gas over the precipitate at 3.8 Nm 3 /hour for 20 hours while heating with 60° C. hot water, giving menatetrenone (1) (121.71 kg). | A method for producing menatetrenone that does not have a deleterious influence on the environment, that is safe even when applied to large-scale production, and that is also simple to operate, wherein a compound represented by the following formula (1)
is produced by treating with an oxygen source, and without the addition of an additive other than water or aqueous sodium chloride solution, a reaction solution consisting essentially of a solution of a compound represented by the following formula (2) dissolved in a solvent: | 2 |
FIELD OF THE INVENTION
The present invention relates generally to a manually-operated device for scooping and dispensing ice cream. More particularly, the invention concerns an improved ice-cream scoop designed to alleviate strain on the operator's wrist, reduce the fatigue and discomfort associated with frequent and extended periods of use, and lessen the potential for carpal tunnel syndrome. The scoop includes a hemispherical hollow bowl, handle and forearm appendage.
BACKGROUND OF THE INVENTION
Frozen edible substances, including ice cream, sherbet, sorbet, frozen yogurt and the like, are typically dispensed from bulk containers into dishes or cones. The ice cream or yogurt is scooped from the containers by means of traditional ice-cream scooping devices. Most such devices are simple in design, consisting of a hemispherical bowl attached to an elongated handle. "Improved" designs are more complex, featuring moveable or motorized parts. All existing designs, both simple and modified, tend to concentrate the entire force generated by the scooping action on the operator's wrist. None of these designs provide adequate support or stability for the user's wrist, nor do they provide a means for mitigating the strain caused by scooping. This strain and repetitive motion tends to fatigue the operator, especially after long time periods, and can have more serious medical consequences, including carpal tunnel syndrome. Carpal tunnel syndrome, caused by pressure on the median nerve, can have debilitating effects for the commercial operator, including sensory loss, atrophy, and weakness of the thumb. Cecil Textbook of Medicine (1992), J. Wyngaarden, L. Smith and J. Bennett eds. (W. B. Sanders Co.), p. 1563.
Certain prior art scoops purportedly reduce the friction between the scoop and frozen substance, but fail to obviate or relieve the aforementioned problems. Examples include U.S. Pat. No. Des. 305,852 (Clement et al.), disclosing a battery-heated ice-cream scoop, and U.S. Patent No. 5,000,672 (Halimi), disclosing a scoop with a heated forming edge. While these designs may facilitate slicing by partially melting or softening the ice cream, the pressure remains localized on the wrist. Neither device offers wrist support, stability, or relief from the strain caused by scooping. These mechanized devices are also impractical to operate and maintain, especially for the large volume retailer. Cords prove cumbersome and potentially dangerous, and batteries take time and resources to replace. Heated devices also raise the temperature of the ice cream, thereby altering the texture and flavor of the ice cream.
U.S. Pat. No. 4,758,150 (Fanini et al.) discloses an improved "semiautomatic" ice-cream scoop, the improvement comprising a motorized blade which slices and separates the ice cream from the scoop. Like other mechanized devices, however, this device requires an external energy source and is therefore impractical, particularly for the large volume retailer. Supply and return ducts are both cumbersome and potentially dangerous, blades need sharpening, and the motor requires maintenance.
Other "improved" scooping devices employ ejecting mechanisms which assist in releasing the ice cream from the scoop. Examples include U.S. Pat. No. 4,721,449 (Alberts), which discloses an ice cream scoop with a spring biased ejection mechanism, and U.S. Pat. No. 4,392,806 (Houle) which discloses a manually operated ejector mechanism, wherein the ejector comprises a moveable arcuate tongue with an attached lever arm. As with other prior art devices, however, these devices lack wrist support, stability, or relief from the strain caused by scooping.
Other major drawbacks of the mechanized scooping devices include the relatively high manufacturing costs, and the number of moving parts which must be cleaned and maintained. Moreover, while the handle and scoop are virtually indestructible, the moving parts are not. Metal fatigue and corrosion of the moving parts often requires that the entire device be discarded and replaced. The replacement costs, particularly for the large volume retailer, can be significant.
Despite the variety of designs currently available, a need remains for a practical, ergonomic and efficient ice-cream scoop. In particular, no scoop design to date includes a mechanism for diverting pressure away from the user's wrist, provides support or stability for the wrist, or in any way mitigates the strain caused by the repetitive scooping action. While mechanized devices assist in slicing and dispensing, they are impractical and expensive to operate, and lack a means for diverting pressure away from the user's wrist.
SUMMARY OF THE INVENTION
The present invention provides an improved ice-cream scoop designed to divert pressure away from the operator's wrist, and to provide support and stability for the wrist. This novel design significantly reduces the fatigue and discomfort associated with frequent or extended periods of use, and lessens the potential for carpal tunnel syndrome.
Another principal object of this invention is to provide an improved scoop for dispensing ice cream, which is practical and efficient in operation, and which lacks moving parts. The present invention provides a simple, solid piece device which can be easily and quickly cleaned.
Another object of this invention is to provide an improved scoop for dispensing ice-cream, which is of reliable operation, of relatively low manufacturing cost, and requires little or no maintenance.
A further object of this invention is to provide an improved ice-cream scoop which facilitates slicing and dispensing without the use of heat, which affects the texture and flavor of the ice cream.
Yet another object of this invention is to provide an attachable forearm appendage which can be mounted on existing ice-cream scoops as a means to divert pressure away from the operator's wrist, and to provide support and stability for the wrist.
A preferred embodiment of this invention provides an improved ice-cream scoop, comprising a hemispherical hollow bowl, forearm appendage, and handle, wherein said handle has a dimpled, pimpled or knurled surface and a knobbed end so as to ensure a secure grip.
Another preferred embodiment of this invention provides an improved ice-cream scoop, comprising a hemispherical hollow bowl, forearm appendage and handle, wherein said handle is reinforced with an internal brace and affixed to both ends of said forearm appendage so as to strengthen the forearm appendage.
Still another preferred embodiment of this invention provides an improved ice-cream scoop, comprising a hemispherical hollow bowl, handle and forearm appendage, wherein the scoop is coated with a non-stick resin or polymer.
A further embodiment of this invention provides an improved ice-cream scoop, comprising a hemispherical hollow bowl, handle and forearm appendage, wherein the forearm appendage has an adjustable connection with the scoop and handle.
Yet another embodiment of this invention provides an attachable forearm appendage, wherein the forearm appendage has a clamping means for affixing to existing ice-cream scoops.
The exact nature of this invention as well as other objects and advantages thereof will be readily apparent from consideration of the specification, including the drawings. Those of skill in the art will appreciate that the invention described herein is susceptible to many modifications and variations without departing from its scope as defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate a preferred embodiment of the invention, wherein:
FIG. 1 shows a perspective view of the improved ice-cream scoop of the present invention.
FIG. 2 shows a top view of the scoop body, including the handle and forearm appendage.
FIG. 3 shows a side view of the scoop body, including the handle and forearm appendage.
FIG. 4 shows a side view of an improved ice-cream scoop having an adjustable forearm appendage.
FIG. 5 shows a perspective view of an attachable forearm appendage.
FIG. 6 shows a perspective view of an improved ice-cream scoop having a reinforced handle and forearm appendage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings and particularly to FIGS. 1-3, the improved ice-cream scoop of the present invention 1 comprises a hemispherical hollow bowl 2 connected to one end of an elongated handle 3 and the first or proximal end of a forearm appendage 5, the purpose of which will presently be described.
To assist in the scooping of ice cream into the hollow interior of the bowl 2 and, more importantly, to serve as a mechanism for diverting pressure away from the user's wrist during scooping, is a forearm appendage 5 which is formed near the top of the bowl 2 above the handle 3. The forearm appendage functions as a lever means by transmitting force applied at the forearm directly to the bowl 2. This appendage also provides support and stability for the wrist, thereby mitigating the strain caused by the repetitive scooping action.
As used herein, "top" refers to portions of the scoop when the device of the invention is in a position such as is shown in FIGS. 1 and 3, open bowl 2 facing downward relative to the ice cream.
In the present form of the invention, the forearm appendage 5 comprises an elongated arm structure having a first or proximal end 6 connected to the top of the bowl 2 positioned above the handle 3. The forearm appendage 5 which, in the form of the invention shown in the drawings, comprises an elongated, slightly arcuate or bent arm, also includes a second or distal end portion designated by the numeral 7. Distal end portion 7 is transversely arcuate to conform to the rounded shape of the operator's forearm. It is apparent from the drawings that the forearm appendage 5 is longer than the handle 3, preferably extending one to five inches beyond the distal portion of said handle.
Also in the present form of the invention, the handle 3 comprises an elongated, generally cylindrical-shaped handle portion having a first or proximal end connected to the side of the bowl. The handle 3 which, in the form of the invention shown in the drawings, has a dimpled or pimpled surface, also includes a second or distal end portion designated by the numeral 4. Distal end portion 4 ends in a knob so as to prevent the operator's hand from slipping.
A scoop 8 of FIG. 4 could be regarded as a modification of the scoop 1 shown in FIGS. 1-3. In the scoop 8 the connection between the bowl 2 and forearm appendage 5 comprises an adjusting means for extending and/or pivoting said forearm appendage relative to the bowl and handle in order to enable adjustment of the device to various arm sizes. The adjusting means, in the form of the invention shown in the drawing, has a flattened arm portion designated by the numeral 9 and a flattened tubular structure 10 to mate with the flattened arm 9. Both the flattened arm 9 and the flattened tubular structure 10 have holes for inserting pins, screws or other suitable fastening means. Said holes are positioned so as to accommodate various forearm lengths and to allow rotation of the second or distal end portion 7 relative to the first or proximal end 6 of the forearm appendage.
To improve the efficiency and ergonomic value of existing ice-cream scoops, there is an attachable forearm appendage 11 which functions in a manner comparable to the forearm appendage of the scoop 1 shown in FIGS. 1-3. Thus, the attachable forearm appendage, when affixed to an existing scoop, acts as a lever means by transmitting force applied at the operator's forearm directly to the hollow bowl portion of the existing scoop. In the present form of the invention, the attachable forearm appendage comprises an elongated arm structure having a first or proximal end 6 and a second or distal end portion designated by the numeral 7. First or proximal end 6 culminates in a clamping means 12 for affixing to the handle of an exiting scoop, preferably at the portion of the handle connected to the hollow bowl. The clamping means 12, in the form of the invention shown in the drawing, comprises two identical halves having holes on either side for the insertion of screws or other suitable fastening means.
A scoop 13 of FIG. 6 could be regarded as another modification of the scoop 1 shown in FIGS. 1-3. In scoop 13 the handle 3 comprises an internal brace 14 within a casing or outer surface portion. The internal brace 14, in the form of the invention shown in the drawing, comprises a first or proximal end connected to the side of the bowl and a second or distal end 15 which extends beyond the distal portion of the outer surface of the handle and connects with the closed cuff portion of the forearm appendage, designated by the numeral 16. Closed cuff portion 16, in the form of the invention shown in the drawing, is circular in design to conform to the rounded shape of the operator's forearm. The closed cuff portion 16 can be modified as appropriate, for example, to be transversely elliptical or to comprise an upper arcuate portion and a lower flattened portion.
The improved ice-cream scoop of this invention can be fabricated as one piece having the configuration shown in the figures, or as several pieces attached by suitable attachment means to form the depicted configuration.
Obviously, many modifications and variations of the present invention are possible and will be evident to those of ordinary skill in the art. For example, the improved ice-cream scoop is preferably constructed from a strong, durable metallic material; however, any suitable starting material or combination of materials can be used, including, for example, a variety of synthetic plastics widely available in commerce. While the embodiment shown in the drawings hereof comprises a transversely oblong, slightly arcuate or bent forearm appendage, said appendage can also be straight, or transversely flat or cylindrical. Moreover, while the exemplified embodiments comprise forearm appendages positioned directly above and parallel to the handle, said appendage can be positioned to one side of, or at an angle with, the handle. Further, although the exemplified handle surface is dimpled or pimpled, the present invention contemplates all surface textures, including knurled, corrugated, notched, serrated, grooved and smooth. Finally, while the distal end portion of the forearm appendage 7 shown in the drawings is a circular or transversely arcuate structure designed to conform to the shape of the operator's forearm, said distal end portion can be any suitable structure capable of embracing the operator's forearm, including ties, buckles, clamps and other bracing means.
It is therefore to be understood that within the scope of the appended claims, the invention may be practiced in ways other than as specifically described herein. | The invention relates to an improved ice-cream scoop designed to alleviate strain on the operator's wrist, and to provide support and stability to the wrist. This improved scoop design significantly reduces the fatigue and discomfort associated with frequent and extended periods of use and lessens the potential for carpal tunnel syndrome. The scoop includes a hemispherical hollow bowl, handle, and forearm appendage connected to said bowl wherein said forearm appendage extends above the handle and conforms to the shape of an operator's forearm. | 0 |
FIELD AND BACKGROUND OF THE INVENTION
[0001] The present invention relates in a first aspect to a fabric for use as a lining material and more particularly but not exclusively to fabrics and lining materials for use as window coverings.
[0002] The window shade industry has developed many methods and apparatus for covering windows that provide privacy and thermal insulation while being aesthetically pleasing. Such window coverings should be capable of being raised and lowered as access to the window and other factors dictate. It would be advantageous to provide a window covering fabric that can be assembled into a blind or shade with little additional processing.
[0003] One attempt to provide such a window covering is disclosed in U.S. Pat. No. Re. 30,254 to Rasmussen. Rasmussen shows a honeycomb curtain structure that operates as a venetian-type window cover. Rasmussen accomplished this by forming a curtain structure from a series of foldable cells adhered together. Each cell has opposed side portions and a connected part. Thus, when the cells are connected, the top and bottom connected portions of each cell form the lamellae or slats of the venetian type structure. The features of the slat structure are limited by all the other requirements of the cell construction.
[0004] Another attempt to provide such a venetian-type window covering is disclosed in U.S. Pat. No. 3,384,591 to Froget. Froget shows a composite cloth, which may be used as a blind. When the cloth is used as a blind, it is comprised of two transparent sheets connected by movable and opaque blades, which are, parallel to one another and are regularly separated and welded to the sheets. Welding or bonding the edges of these blades or slats is difficult to accomplish and the features of the slats are compromised to that end.
[0005] Colson in U.S. Pat. No. 5,490,553 and Moser in his German Patent No. DE 3525515 A1 show slats inserted into pockets formed by portions of the front and back layers. Although this allows for a different selection of materials for the slat than in Froget and Rasmussen, it is still limited by the necessity or difficulty of sliding a slat into a long narrow pocket.
[0006] Judkins in U.S. Pat. No. 6,033,504 provides a honeycomb window covering structure that operates as a venetian. Judkins' window covering structure has two sheets of material. The sheets are spaced apart and are oriented so as to be generally parallel to one another. A series of elongated slats or threads connects the first and second sheets of material. Judkins' material requires significant processing to the two sheets of material in order to form them into a honeycomb structure.
[0007] Fernandez Lopez in U.S. Pat. No. 5,791,392 describes a woven fabric for use as a shade in a roller blind which is rolled and unrolled, the woven fabric including a continuous flexible woven sheet. The sheet includes a plurality of bands extending across the sheet in a transverse direction and integrally woven therewith. Each band includes a front ply having an inner surface and an outer surface which forms part of the front surface of the sheet, and a rear ply having an inner surface and an outer surface which forms part of the rear surface of the sheet, the outer surface of the rear ply being provided with at least one opening disposed proximate at least one of the side edges and adapted to allow the insertion of a rod therethrough. The front and rear plies are spaced apart from each other to form a pocket between their respective inner surfaces, the pocket being adapted to accommodate the rod. A pair of transverse cords, integrally woven with the rear ply, are disposed in the center of the outer surface of the rear ply. The pair of cords are spaced apart from the rear ply in at least one location to form at least one eyelet having an opening adapted to allow the passage of a thread therethrough. The fabric may also include a wide lower band for holding a weight. An upper portion of the sheet may have a hook and/or loop member that is integrally woven in the sheet.
SUMMARY OF THE INVENTION
[0008] According to a first aspect of the present invention there is thus provided a woven fabric for use as a lining material, wherein the fabric is woven from warp and weft strands, comprising:
at least one regular section in which the warp strands are woven together; and, at least one pocket section in which the warp strands are divided into at least two groups, wherein each group of warp strands is woven separately.
One embodiment further comprises at least one stiffener located within the pocket section. Another embodiment comprises the fabric in use as a lining material. An additional embodiment further comprises at least one loop woven on the pocket section, having drawstrings associated with the loops. In an additional embodiment the stiffener is removably located within the pocket section.
[0011] According to a second aspect of the present invention there is thus provided a fabric for use as a lining material, comprising fibers in a first direction woven between fibers in a second perpendicular direction wherein for a section of the fabric, some of the fibers in the first direction are separated from others of the fibers in the first direction and separately woven with different fibers in the second perpendicular direction, thereby to form a doubled section of the woven fabric. One embodiment further comprises at least one stiffener located within the doubled section. Another embodiment comprises the fabric in use as a lining material. An additional embodiment further comprises at least one loop woven on the doubled section, having drawstrings associated with the loops. In an additional embodiment the stiffener is removably located within the doubled section.
[0012] According to a third aspect of the present invention there is thus provided a woven fabric having warp strands, comprising:
at least one regular section in which the warp strands are woven together; at least one pocket section in which the warp strands are divided into at least two groups, wherein each group of warp strands is woven separately; and, at least one closed shape defined by stitching on one layer of the pocket section, such that the closed shape is cuttable without degrading the integrity of the fabric.
One embodiment further comprises at least one loop woven on the pocket section, having drawstrings associated with the loops. In another embodiment the closed shape is operable to define a place of insertion of a stiffener into the pocket section. Another embodiment further comprises at least one stiffener, wherein the stiffeners are insertable into the pocket through an opening cuttable within the closed shape. In an embodiment the pocket is sealed on both edges of the woven fabric. A further embodiment is for the fabric in use as a window covering. Another embodiment further comprises more than one closed shape defined by stitching on at least one layer of the pocket section, wherein the closed shapes are operable to provide places of insertion of stiffeners into the pocket section.
[0016] In an additional embodiment, the woven fabric further comprises more than one stiffener, insertable into the pocket through openings cut in the closed shapes. In an additional embodiment the fabric is bendable at least one of the intersections between adjacent stiffeners. One embodiment of this fabric is in use as a window covering. In a further embodiment the fabric has two lengthwise edges, wherein the pocket is sealed on both lengthwise edges of the woven fabric.
[0017] According to a fourth aspect of the present invention there is thus provided a woven fabric having warp strands, comprising:
at least one regular section in which the warp strands are woven together; and, at least one pocket section in which the warp strands are divided into at least two groups, wherein each group of warp strands is woven separately, wherein the warp strands of at least one region continuous with the pocket section are woven together without being divided into groups.
One embodiment further comprises at least one loop woven on the pocket section, having drawstrings associated with the loops. Another embodiment further comprises a stiffener insertable into the at least one pocket section. An additional embodiment is for the fabric in use as a window covering.
[0020] According to a fifth aspect of the present invention there is thus provided a woven fabric comprising fibers in a first direction woven between fibers in a second perpendicular direction wherein for a section of the fabric, some of the fibers in the first direction are separated from others of the fibers in the first direction and separately woven with different fibers in the second perpendicular direction, thereby to form a doubled section of the woven fabric, and wherein for at least one segment continuous with the doubled section in the second direction the fibers of the first direction are woven so as to form a single layer of fabric. An embodiment further comprises at least one loop woven on the doubled section, and having drawstrings associated with the loops. An embodiment further comprises a stiffener insertable into the at least one doubled section. An additional embodiment is for the fabric in use as a window covering.
[0021] According to a sixth aspect of the present invention there is thus provided a woven fabric comprising fibers in a first direction woven between fibers in a second perpendicular direction wherein for a section of the fabric, some of the fibers in the first direction are separated from others of the fibers in the first direction and separately woven with different fibers in the second perpendicular direction, thereby to form a doubled section of the woven fabric, and wherein at least one closed shape is defined by stitching on one layer of the pocket section, such that the closed shape is cuttable without degrading the integrity of the fabric. An embodiment further comprises at least one loop woven on the doubled section, and having drawstrings associated with the loops. In an embodiment the closed shape is operable to define a place for insertion of a stiffener into the doubled section. An embodiment further comprises at least one stiffener insertable into the at least one doubled section through an opening cuttable within the closed shape. In another embodiment the doubled section is sealed on both edges of the woven fabric. An additional embodiment is for the fabric in use as a window covering.
[0022] Another embodiment further comprises more than one closed shape stitched onto one layer of the doubled section, wherein the closed shapes are operable to provide places of insertion of stiffeners into the pocket section. Another embodiment further comprises more than one stiffener, insertable into the doubled section through openings cut in the closed shapes. An additional embodiment is for a woven fabric that is bendable at least one of the intersections between adjacent stiffeners. Another embodiment is for such a fabric in use as a window covering. In another embodiment the doubled section is sealed on both lengthwise edges of the woven fabric.
[0023] According to a seventh aspect of the present invention there is thus provided a woven fabric comprising at least one stiffening member attached thereto by hook and loop fastener, the fastener having a first element associated with the fabric and a second element associated with the stiffening member. In one embodiment the stiffening members are attached to the fabric in a transversal direction. In another embodiment the second hook and loop fastener element is an integral part of the stiffening members. In a different embodiment the second hook and loop fastener element is attached to the stiffening member. In one embodiment the first hook and loop fastener element is an integral part of the fabric. In another embodiment first hook and loop fastener element is attached to the fabric. In a further embodiment the length of the stiffening member is substantially larger than the radial dimension of the stiffening member.
[0024] One embodiment is for such a fabric in use as a window covering. In one embodiment the fabric is mounted on a window such that the stiffening members are aligned substantially horizontally. In another embodiment, the fabric has two lengthwise edges, wherein a hem is formed on at least one of the lengthwise edges of the fabric, and wherein at least one end of the stiffening member is located within an opening in the hem, thereby attaching the member more firmly to the fabric. Another embodiment is for such a fabric with hems in use as a window covering. In one embodiment the fabric is mounted on a window such that the stiffening members are aligned substantially horizontally.
[0025] In one embodiment a fabric has the stiffening element is located on a front of the fabric. Another embodiment further comprises at least one loop woven on a back of the fabric, and having drawstrings associated with the loops. In one embodiment a fabric has the stiffening element is located on a back of the fabric. Another embodiment further comprises at least one hook attached to the stiffening element, wherein the hooks are operable to have drawstrings passed through them.
[0026] In another embodiment, the fabric comprises a plurality of stiffening members aligned to form a stiffened axis with at least one break across the fabric. An additional embodiment is for a fabric that is bendable at least one break between adjacent stiffening members. Another embodiment is for such a fabric in use as a window covering.
[0027] According to an eighth aspect of the present invention there is thus provided a method of forming a lining material, comprising the steps of:
weaving a fabric from warp and weft strands; separating a segment of the warp into at least two groups of warp strands; continuing the fabric by weaving each group of warp strands separately for a predetermined length; recombining the groups of warp strands into a single warp; and, continuing to weave the fabric, thereby forming a pocket in the fabric.
[0033] According to a ninth aspect of the present invention there is thus provided a method of forming a stiffened fabric, comprising the steps of:
weaving a fabric from warp and weft strands; separating a segment of the warp into at least two groups of warp strands; continuing the fabric by weaving each group of warp strands separately for a predetermined length; recombining the groups of warp strands into a single warp; and, continuing to weave the fabric, thereby forming a pocket in the fabric; stitching at least one closed shape onto one layer of the pocket section; cutting within the stitched shape to create an opening in the fabric; and, inserting a stiffener through the opening.
One embodiment further comprises the steps of:
stitching more than one closed shape onto one layer of the pocket section; cutting within the stitched shapes to create openings in the fabric; and, inserting more than one stiffener through the opening.
Another embodiment further comprises the step of:
bending the fabric between adjacent stiffeners to form an angled fabric.
[0046] According to a tenth aspect of the present invention there is thus provided a method of forming a stiffened fabric, comprising the steps of:
aligning a stiffening member, which stiffening member has a hook and loop fastener element thereon, across a fabric, which fabric has at least one segment of a second side of a hook and loop fastener element thereon; and, pressing the stiffening member to the fabric so that the hook and loop fasteners adhere, thereby attaching the stiffening member to the fabric.
In one embodiment the second hook and loop fastener element is an integral part of the fabric, created as part of the fabric when the fabric is formed. In another embodiment the second hook and loop fastener element is attached to the fabric. In one embodiment the hook and loop fastener element is an integral part of the stiffening member, created as part of the stiffening member when the stiffening member is formed. In another embodiment the hook and loop fastener element is attached to the stiffening member.
[0049] An additional embodiment further comprises the steps of:
aligning a plurality of stiffening members, which stiffening members have at least one hook and loop fastener element thereon, transversally across a fabric, which fabric has at least one segment of the second side of a hook and loop fastener element thereon; and, pressing the aligned stiffening members to the fabric so that the hook and loop fastener elements adhere, thereby attaching the stiffening members across the fabric.
An additional embodiment further comprises the step of:
bending the fabric at least one of the intersections between adjacent stiffening members to form an angled fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings, in which:
[0054] FIGS. 1 a and 1 b illustrate back and side views respectively of a prior art material consisting of a backing and attached strips forming transversal channels or pockets.
[0055] FIG. 2 illustrates a woven fabric in which a section of the fabric is divided and woven separately.
[0056] FIG. 3 illustrates a material in which a section of divided fabric is both preceded and succeeded by a section of unified fabric.
[0057] FIG. 4 illustrates a side view of a single piece of woven fabric containing a channel or pocket.
[0058] FIG. 5 is a simplified illustration of a fabric with woven channels, in which the channel does not extend for the entire width of the fabric.
[0059] FIG. 6 illustrates a woven fabric with pockets with closed areas of stitching on the pocket.
[0060] FIG. 7 illustrates a woven fabric with pockets in which the pocket stitching is cut open in order to insert a stiffener into the pocket.
[0061] FIG. 8 illustrates a woven fabric with pocket stitching in which the edges of the fabric are closed.
[0062] FIG. 9 illustrates a woven fabric with pockets in which the pocket stitching is cut open in several locations in order to insert several stiffeners into the pocket.
[0063] FIGS. 10 a and 10 b illustrate an above view of an angled window covering formed from a material containing several stiffeners.
[0064] FIG. 11 is a simplified illustration of a cross-section of a fabric with stiffeners attached to it by hook and loop fastener.
[0065] FIG. 12 is a simplified illustration of a stiffening member with a hook attached.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] Reference is now made to FIGS. 1 a and 1 b , which illustrate back and side views respectively of a prior art window covering material. Transversal channels 3 a , 3 b , and 3 c allow stiffening members to be inserted. As shown in FIG. 1 a , the channels are created by attaching strips 2 a , 2 b , and 2 c to a backing material 1 . The strips are attached to the backing by, for example, stitching them together or gluing them together with an adhesive. The strips are not an inherent part of the backing material, and some process must be used to connect them together to form the channels.
[0067] Reference is now made to FIG. 2 , which shows a preferred embodiment for a fabric according to this invention. A fabric 10 is formed by interweaving warp 4 and weft 7 strands as above. The warp 4 is formed of numerous strands, where the number of strands depicted is by way of example only. The weft 7 is woven through these strands, thereby forming a fabric. The fabric is woven in this manner for a predetermined length, and then the warp strands are separated into groups 5 and 6 of alternate strands. The number of groups and the manner of dividing the warp strands shown are for example only, although in practice two groups would generally be used, which two groups extend over the entire width of the fabric. Each group of warp strands is woven separately. For example, warp 5 is woven with weft 8 whereas warp 6 is woven with weft 9 , thereby forming a doubled section of the woven fabric. The number of layers formed depends on the manner in which the warp strands are divided.
[0068] Reference is now made to FIG. 3 , which illustrates the formation of a pocket section within the fabric. The warp strands are woven together for a predetermined length 11 , divided and woven separately for a predetermined length 12 , and then united and woven together for a predetermined length 13 , thereby forming a channel 14 within the woven fabric, where the number of channels and the manner of dividing the warp strands shown in the drawing are for example only and in practice the channel may extend for the width of the fabric.
[0069] Reference is now made to FIG. 4 , which shows a side view of a woven fabric 16 with integral channels 15 a and 15 b , as described above. This fabric may be used as a lining material for any fabric, and is particularly suitable for use as a window covering such as a roman shade that requires transversal stiffeners. Generally the lining material is attached to a decorative fabric, but it can be attached to any fabric. In one embodiment the lining material is glued to the fabric. In another embodiment the lining material is sewn on to the fabric.
[0070] The stiffeners can be inserted into the integral channels formed during the weaving process, without requiring further processing to attach external strips to the fabric. The stiffening element can be made from a variety of materials, for example, metal, plastic or wood.
[0071] When the fabric of this embodiment is used for a blind requiring drawstrings, such as a roman blind, loops may be integrally woven onto the pocket section of the fabric for the drawstring to go through.
[0072] Reference is now made to FIG. 5 , which is a simplified illustration of another embodiment of a fabric 15 with woven channels 16 , in which the channel 16 does not extend for the entire width of the fabric. In this embodiment, a section of the warp strands continuous with the channel is not divided prior to weaving with the weft strands. In this section a single layer is woven. This single layer section provides another point of access 17 for insertion of the stiffening elements into the channel. This point of access 17 is useful in cases in which the lengthwise edges of the fabric are hemmed or otherwise sealed. In these cases the stiffeners cannot be inserted through the openings at the edge of the fabric and an alternate opening must be created to enable stiffener insertion.
[0073] Reference is now made to FIG. 6 , which is a simplified illustration of a woven fabric 20 with pocket 22 . The pocket 22 comprises a closed area 24 , which is defined by stitching 26 on the periphery thereof, the stitching preferably being integrally made onto one layer of pocket 22 . Area 24 is shaped rectangularly, for purposes of example, but can be in any closed shape. In this embodiment, the closed area within the stitching is cut open, thereby enabling the insertion of the stiffener through the hole that is thereby formed. The type of stitch used to form the closed shape is selected so that cutting an opening within the shape does not lead to tearing or unraveling of the woven fabric. Preferably the stitching 26 is introduced during the weaving stage, and may be an integral part of the weave.
[0074] Reference is now made to FIG. 7 , which is a simplified illustration of a woven fabric 30 with lateral pockets 34 with stitching 36 on these pockets. As described above, some of the pockets 34 have been opened 38 , and a stiffener 40 is inserted via such an opening.
[0075] Reference is now made to FIG. 8 , which is a simplified illustration of a woven material 50 with pocket stitching 52 in which the edges of the material 54 56 are hemmed or otherwise sealed. In this embodiment, the pockets 58 in the material are sealed from the edges. In this embodiment, stiffeners cannot be inserted from the edges of the fabric. Stiffener access into the pockets is through openings in the stitched area.
[0076] Reference is now made to FIG. 9 , which is a simplified illustration of a woven material 60 with pocket stitching 62 . Several stitched areas 64 . 1 64 . 2 have been opened in a single pocket, and stiffeners 66 . 1 66 . 2 have been inserted into the openings. In this embodiment, more than one stiffener, where the number of stiffeners is for example only, is inserted into each pocket, thereby forming a supported fabric that can be angled or bent. This embodiment is suited for use as a window covering for angled, curved, or bay windows.
[0077] FIGS. 10 a and 10 b show a simplified view from above of a fabric according to the above embodiment. The fabrics have been angled into several sections, where the number of sections is for example only. In practice, the number of sections is determined by the number of stiffeners inserted into each pocket.
[0078] Reference is now made to FIG. 11 , which is a simplified illustration of a cross-section of another embodiment of a stiffened fabric, in which the stiffeners are attached to the fabric with hook and loop fastener. Stiffener 72 has a hook and loop fastener element 70 on at least one surface of the stiffener 72 . Such a stiffening element 72 is generally elongated. A hook and loop fastener element of the opposite type 74 is attached in the desired direction to fabric 76 . The stiffener 72 is attached to the fabric 76 by pressing it to the fabric 76 , so that the hook and loop fastener elements 70 and 74 connect.
[0079] In the preferred embodiment the hook and loop fastener element 70 is an integral part of the stiffener 72 , and is created during the stiffener 72 manufacturing process. In another embodiment the hook and loop fastener element 70 is not an integral part of the stiffener, but is attached to the stiffener 72 by some other means, such as gluing or stapling.
[0080] The hook and loop fastener element on the fabric has similar embodiments. In the preferred embodiment the hook and loop fastener element 74 is an integral part of the fabric 76 , and is created during the weaving process. In another embodiment the hook and loop fastener element 74 is not an integral part of the fabric 76 , but is attached to the fabric 76 by some other means, such as gluing or sewing.
[0081] When the stiffener is attached to the fabric using hook and loop fastener, the stiffeners may be easily removed for cleaning the fabric. The fabric may be used as the body of a blind or as a lining material for any fabric requiring stiffening members.
[0082] In an additional embodiment a hem is sewn along the length of fabric, and the stiffening element inserted into pockets in the hem. This strengthens the attachment of the fabric to the stiffener.
[0083] In one preferred embodiment the stiffening members are attached to the front of the fabric. The stiffening members serve as decorative elements, and may be made from a variety of materials, for example polyurethane or wood, and in a variety of colors and patterns. When the fabric of this embodiment is used for a blind requiring drawstrings, such as a roman blind, loops may be integrally woven into the rear of the fabric for the drawstring to go through.
[0084] In another embodiment, the stiffeners are attached to the rear of the fabric. The fabric of this embodiment can be used independently, or as a lining material for another fabric.
[0085] Reference is now made to FIG. 12 , which is a simplified illustration of a stiffening member 90 with hooks 92 . 1 and 92 . 2 attached. When the fabric of the embodiment with rear stiffeners is used for a blind requiring drawstrings, a series of hooks 92 may be attached to the stiffener 90 for the drawstring to go through, where the number of hooks varies according to the design of the blind.
[0086] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.
[0087] 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 is defined by the appended claims and includes both combinations and subcombinations of the various features described hereinabove as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description. | A fabric for use as a lining material woven from warp and weft strands contains at least one segment in which all the warp strands are woven together, and at least one other segment in which the warp strands are divided into groups and woven separately. If the divided segment of the fabric is both preceded and followed by a unified section, the divided section intrinsically forms a transversal channel in the fabric. This fabric is well suited for use as a window covering. Window coverings often require transversal stiffening members to ensure that the fabric folds correctly upon opening and closing. Stiffeners can be inserted into the channels formed during the weaving process, without any additional processing of the fabric. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The general field to which this invention pertains is remotely-controlled valves. Specifically this invention relates to foot-operated valves for faucets useful in homes, hospitals, laboratories and the like.
2. Description of the Prior Art
Foot-operated valves are known for use in medical and laboratory sink applications where the hands must be free while controlling faucet water flow. Inexpensive remotely-controlled valves for domestic use in bathroom and kitchen sinks have not been widely accepted primarily due to their lack of inexpensive, yet reliable valve mechanism. U.S. Pat. No. 3,536,294 discloses a foot-operated control valve attachment to a faucet where the valve mechanism uses a flexible diaphragm as the controlled element in the valve to open or close a water passage.
U.S. Pat. No. 2,839,264 discloses a foot-operated control valve where the control valve mechanism is a spring loaded plug.
U.S. Pat. No. 3,638,680 discloses a foot-operated electrical control means for controlling the flow and mix proportions of hot and cold water. Electrically controlled valves control water flow in the hot and cold supply lines.
U.S. Pat. No. 3,786,995 discloses a spray device for attachment to a faucet in which a ball valve member is used to direct water from a supply line to one of two outlet ports, one of which exits through an aerating device and the other of which discharges through spray forming passages.
U.S. Pat. No. 2,608,205 discloses a safety valve in which a ball valve member for a butane tank is opened by means of water pressure created by the activation of a solenoid. If the supply were to be ruptured, the water pressure is released thereby automatically closing the valve.
U.S. Pat. No. 2,849,208 discloses the use of a valve ball as a control valve member in a garden sprayer. A manual actuator forces the valve ball from its seat to allow water to flow through the sprayer.
In overcoming the disadvantages of the prior art, the remotely-controlled valve described hereinafter has a primary advantage in that it provides an inexpensive extremely reliable control element.
A feature of the invention is that it is provided with a reliable manual means to override the remote-control feature.
Another feature is that it is provided with means to control the direction of water flowing from that faucet.
Another feature is that it is provided with means to produce a spray or direct flow of water.
SUMMARY OF THE INVENTION
These and other objects, advantages and features are embodied in a novel remotely-controlled valve attachable to the spout of a faucet for the control of water flowing therethrough. A control valve member is provided with adapting means for attaching it to a faucet. The valve member has a first chamber for accepting water from the faucet via a water inlet passage. A second chamber is provided having an exit passage for directing water out of the control valve member. The first and second chambers are connected by means of an aperture which may be sealed by means of a valve ball within the first chamber. The force of water entering the first chamber from the faucet forces the valve ball against the aperture thereby sealing it and preventing water flow from the first chamber into the second chamber. A foot-operated control member is provided to generate air or water pressure in a flexible conduit which is attached to the control valve member. The air or water pressure is used to urge a piston, and a rigidly attached actuating rod, within the control valve member, against the valve ball. By such action the valve ball is moved away from the aperture in opposition to the force on the valve ball from the water in the first chamber. Water is then free to pass the aperture into the second chamber and out of the control valve member.
An assistance spring is provided between the piston and the body of the control valve member to provide a restraining force against the piston when the foot-operated member is no longer generating air or water pressure applied to force the piston and the actuating rod against the valve ball. This restraining force allows the valve ball to close the aperture opening between the first and second chambers when water pressure in straining force allows the valve ball to close the aperture open-- the first chamber is insufficient to force the valve ball and piston back to a closed position.
A spray head is provided to accept water exiting through the exit passage and force it through small holes or alternatively through a direct flow outlet which may be stoppered by means of a built-in stopper. The valve control member is provided with a threaded adapter to connect it to the faucet and with a swivel ball-bushing mechanism for directing the exiting water in various directions with respect to the faucet.
A mechanism is provided for manual override of the remote control force such that the control-valve member may be locked to an open flow position.
The remote-control force is provided by a foot-operated control member having a bellows placed between a foot pedal and a base. Depression of the foot pedal causes the bellows to force air or water under pressure via a flexible conduit to the control valve member.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention, as well as its objects, advantages and features, will be better understood by reference to the following detailed description of the preferred embodiment of this invention taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective drawing of the remotely-controlled valve according to the invention attached to a faucet for a kitchen sink,
FIG. 2 is a larger perspective drawing of the control valve member according to the invention,
FIG. 3 shows by means of a cross section taken through the internal parts of the control valve member according to the invention,
FIG. 4 shows the control valve member forced in an open position by air or water pressure from a foot-operated control member according to the invention,
FIG. 5 shows the control valve member forced in an open position by a manual override system according to the invention,
FIG. 6 shows a lateral cross section through control valve member illustrating the mechanical construction of the manual override feature according to the invention, and
FIG. 7 shows a foot-operated control member according to the invention.
FIG. 8 shows a threaded cylindrical member used to secure a flexible conduit to the control valve member.
DESCRIPTION OF THE INVENTION
FIG. 1 shows the invention in place attached to a kitchen sink faucet. A control valve member 100 is attached to the faucet. Water flow is controlled by a force generated by foot-operated control member 300 which transmits air or water under pressure to control valve member 100 via flexible conduit 13.
FIG. 2 shows a larger view of the control valve member 100.
FIG. 3 shows a longitudinal cross section through the control valve member. The control valve member 100 is connected to a faucet by means of adapter 1 which has male threads 2a outside and female threads 2b inside so that the control valve member 100 may be attached to threaded faucets of both types. Knurled flange 3 of the adapter provides a means for turning the threads into place on the faucet. A filter washer 4a is provided to remove particles from the water supply at the entrance of inlet passage 4.
The body 5 of control valve member 100 is connected to adapter 1 by means of a swivel ball 50, which allows control valve member 100 to be turned with respect to the faucet to which it is attached. The swivel ball 50 is rotatable and is held by a swivel bushing 51 which can be attached to valve body 5 by means of an ultrasonic weld 52. A swivel collar 53 retains swivel ball 50. An "O" ring 54 prevents water from leaking from the valve member 100 past the swivel ball 50.
The body 5 of control valve member 100, formed of metal or a suitable synthetic plastic, encloses an inlet chamber 6 for incoming water and an outlet chamber 7 for exiting water. Inlet chamber 6 and outlet chamber 7 are connected by means of an aperture 9. A valve ball 10 is provided within inlet chamber 6 which is forced by the pressure of the water in inlet chamber 6 against aperture 9, thereby sealing outlet chamber 7 from the flow of water.
Valve ball 10 is urged away from aperture 9, allowing water to flow therethrough by means of rod 11 rigidly attached to piston 12. In the remote control mode, piston 12 moves in the direction of the valve ball when force is applied to it by means of fluid or air pressure conducted by flexible conduit or tube 13. A manual control mode for moving the piston is described below.
When air or water pressure is transmitted via conduit 13 through pressure inlet 14 of piston guide 15, the pressure is applied to the end of piston 12 throughout valve open chamber 16. The pressure applied to piston 12 urges it and its rigidly attached rod 11 against valve ball 10 allowing water to flow from inlet chamber 6 through aperture 9 and into chamber 7 as shown in FIG. 4. Water then is expelled through outlet passage 17.
A low water pressure assistance spring 18 (FIG. 3), attached between control valve member body 5 and the piston 12 assists in returning the piston 12 to a closed position when air or water pressure via passage 14 is no longer applied. Low water pressure assistance spring 18 assures that valve ball 10 closes, even if the water pressure in inlet chamber 6 is not sufficient to move valve ball 6 against rod 11, thereby pushing piston 12 back to normal position.
Piston 12 moves within cylinder bore 19 which is open to outlet water chamber 7. The walls of cylinder bore 19 cut in valve body 5 are smooth, allowing piston 12 to move easily in both directions. After valve ball 10 is open, cylinder bore 19 is filled with water. The pressure of this water acts on piston 12 and assists in returning it to a normal or closed position when pressure is no longer applied via conduit 13. A piston "O" ring 20 in piston 12 assures that water from bore 19 does not pass to the other side of piston 12.
The piston guide 15 has an annular shape which provides a guide-way for piston 12, thereby preventing piston 12 from rocking in cylinder bore 19. Attached to the piston guide 15 is an inlet member 21 about which conduit 13 is snugly attached by means of a threaded tubing clamp 22. Inlet member 21 is hollow, forming passage 14 which enables a flow of water or air under pressure from conduit 13 to impinge on piston 12. Piston guide 15 is retained within the control valve member 100 by means of cylindrical cap 23. Cylindrical cap 23 can be sealed to valve body 5 by means of an ultrasonic seal 24.
Threaded tubing clamp 22 is part of an override thumb ring 29 which contains thread 22a on the inside of the clamp. When clamp 22 is screwed over the tubing clockwise to secure the tubing to inlet 14 of guide 15, onto tubing clamp 22, clamp 22 butts and becomes secured against piston guide 15 creating a jam nut effect. Thus, piston guide 15 can be rotated within cylinder cap 23 by rotating clamp 22 by ring 29. Rotation of guide 15 causes it to be translated linearly to and fro in the direction of piston 12 by the clockwise-counterclockwise rotation of override thumb ring 29. Three rider guide pins 27, shown in FIG. 6, which is a lateral cross section through cylinder cap 23, slide along the three separate rider slopes 26 in cap 23 with a cam-like action. When the pins hit stops 25 which are part of cylindrical cap 23, the rotation of the guide is terminated. The override thumb ring 29 can be rotated approximately one hundred degrees clockwise, during opening of the valve. The resulting translation of piston 12 and its rigidly attached rod opens valve ball 10 as shown in FIG. 5. Turning override thumb ring 29 in a counterclockwise direction translates piston guide 15 away from piston 12 allowing piston 12 to be urged by spring 18 away from valve ball 10. An "O" ring 30 is provided in piston guide 15 to prevent water or air pressure from valve open chamber 16.
A spray head 35 is attached to valve body 5 for conditioning water exiting from exit passage 17 (FIGS. 4 and 5). Spray head 35 is a curved or arched plate through which spray holes 36 are formed. Between spray head 35 and body 5, a spray head pressure chamber 37 is formed. This chamber 37 will produce water pressure therein because the volume of water entering it through exit passage 7 is greater than that passing through holes 36. Spray head pressure behind spray head is desirable in two respects. Water pressure will prevent residue from collecting in holes 36 and it will assist, via the water in cylinder base 19, piston 12 to return to the closed position when air or water pressure in the conduit 13 is released.
Spray head 35 has a direct flow outlet 38 allowing water from pressure chamber 37 to pass directly out in a solid stream for filling bottles, irons, etc. A stopper 39, connected to stopper handle 40 is provided as a manual means for closing off the direct flow outlet 38 as shown in FIG. 4.
Foot-operated control member 300 is shown in FIG. 7. A foot pedal base 320 is provided as a foundation for foot pedal 330. The pedal and base are of sufficient strength to withstand the weight typically applied by the foot of a human being. Pivot 340 is provided to allow the foot pedal 330 to arch downward upon bellows 310. Bellows 310, when compressed between foot pedal 330 and bellows support 350, compresses air or water forcing it along flexible conduit 13 connected to control valve member 100. When bellows 310 is no longer being compessed, as when a user lifts his toe, a vacuum created by the reverse action of bellows 310 causes the presence of air or water pressure in flexible conduit 13 to be terminated, thereby enabling closure of ball valve 10 in control valve member 100. In a preferred embodiment of foot control member 300, foot pedal 330 and bellows 310 are molded in one piece from a material such as synthetic rubber or plastic.
Various changes and modifications may be made in the details of construction and design of the above specifically described embodiment of this invention without departing from the spirit thereof, such changes and modifications being restricted only by the scope of the following claims. | A remotely-controlled valve is disclosed having a faucet-attachable control valve member and a foot-control member for generating air or water pressure which is communicated to the control valve member by means of a flexible tube or conduit. The air or water pressure urges a piston and a rigidly attached rod within the control valve member against a control ball valve away from an aperture connecting a first water chamber connected to the water supply from the faucet and a second water chamber connected via an exit passage to a spray head. Manual override means are provided to force the control ball valve in an open position regardless of the operation of the foot-control member. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 08/343,297, filed Nov. 22, 1994, now abandoned, which is a continuation of application U.S. Ser. No. 08/132,679, filed Oct. 6, 1993, now abandoned which is a continuation of application Ser. No. 08/016,175, filed Jan. 19, 1993, now abandoned, which is a continuation of application Ser. No. 07/830,763, filed Feb. 4, 1992, now abandoned, which is a continuation of application Ser. No. 07/453,931, filed Dec. 20, 1989, now abandoned.
FIELD OF THE INVENTION
The invention relates generally to methods and compositions for treating diseases associated with excessive interferon-γ (IFN-γ) production, and more particularly, to methods and compositions employing the Epstein-Barr virus (EBV) protein BCRF1 for effectively reducing levels of IFN-γ.
BACKGROUND
The immune system comprises a highly interactive complex of tissues, cell types, and soluble factors. Recently, it has been suggested that several diseases and immune disorders may be associated with imbalances among certain components of the immune system, particularly cytokines, e.g. Mosmann et al, Ann. Rev. Immunol., Vol. 7, pgs. 145-173 (1989); Cher et al, J. Immunol., Vol. 138, pgs. 3688-3694 (1987); Mosmann et al, Immunol. Today, Vol. 8, pgs. 223-227 (1987); and Heinzel et al, J. Exp. Med., Vol. 169, pgs. 59-72 (1989).
For example, a large body of evidence suggests that excessive production of gamma interferon (IFN-γ) is responsible for major histocompatibility complex (MHC) associated autoimmune diseases, Hooks et al, New England J. Med., Vol. 301, pgs. 5-8 (1979) (elevated serum levels of IFN-γ correlated with autoimmunity); Basham et al, J. Immunol., Vol. 130, pgs. 1492-1494 (1983) (IFN-γ can increase MHC gene product expression); Battazzo et al, Lancet, pgs. 1115-1119 (Nov. 12, 1983) (aberrant MHC gene product expression correlated with some forms of autoimmunity); Hooks et al, Ann. N.Y. Acad. Sci., Vol., pgs. 21-32 (1980) (higher IFN-γ levels correlated to greater severity of disease in SLE patients, and histamine-release enhancing activity of interferon can be inhibited by anti-interferon sera); Jacob et al, J. Exp. Med., Vol. 166, pgs. 798-803 (1987) (amelioration and delay of onset of disease conditions in mouse models of systemic lupus erythematosus by blocking anti-IFN-γ monoclonal antibodies); and Iwatani et al, J. Clin. Endocrin. and Metabol., Vol. 63, pgs. 695-708 (1986) (anti-IFN-γ monoclonal antibody eliminated the ability of leucoagglutinin-stimulated T cells to induce HLA-DR expression). It has been hypothesized that excess IFN-γ causes the inappropriate expression of MHC gene products which, in turn, causes autoimmune reactions against the tissues whose cells are inappropriately expressing the MHC products and displaying autoantigens in the context of the products. Thus, it has been suggested that reducing IFN-γ levels in autoimmune patients, e.g. by administering IFN-γ antagonists, could have beneficial effects, e.g. McDevitt, Clin. Res., Vol. 34, pgs. 163-175 (1985).
In addition to the above evidence, IFN-γ may also play a role in allergy by its ability to increase the number and density of Fcε receptors on monocytes, it has been implicated in the pathogenesis of sarcoidosis and psoriasis, and it is believed to augment cell-mediated immunity, which plays a major role in tissue rejection in allogenic transplant patients.
In view of the above, the availability of compounds capable of reducing IFN-γ levels would be highly advantageous for treatment of diseases associated with inappropriate immune responses, such as some parasitic diseases, allergy, and MHC associated immune disorders, including rheumatoid arthritis, systemic lupus erythematosus (SLE), myasthenia gravis, insulin-dependent diabetes mellitus, thyroiditis, and the like.
SUMMARY OF THE INVENTION
The invention relates to methods and compositions for treating diseases associated with high levels of IFN-γ production. The method of the invention comprises the step of administering a disease-controlling amount of a BCRF1, a protein derived from the Epstein-Barr virus. The invention further includes expression vectors for producing recombinant BCRF1, purified BCRF1, and pharmaceutical compositions for use with the method. Preferably, the BCRF1 used with the invention is selected from the group of mature polypeptides of the open reading frame defined by the following amino acid sequence:
______________________________________Formula I______________________________________Met--Glu--Arg--Arg--Leu--Val--Val--Thr--Leu--Gln--Cys--Leu--Val--Leu--Leu--Tyr--Leu--Ala--Pro--Glu--Cys--Gly--Gly--Thr--Asp--Gln--Cys--Asp--Asn--Phe--Pro--Gln--Met--Leu--Arg--Asp--Leu--Arg--Asp--Ala--Phe--Ser--Ara--Val--Lys--Thr--Phe--Phe--Gln--Thr--Lys--Asp--Glu--Val--Asp--Asn--Leu--Leu--Leu--Lys--Glu--Ser--Leu--Leu--Glu--Asp--Phe--Lys--Gly--Tyr--Leu--Gly--Cys--Gln--Ala--Leu--Ser--Glu--Met--Ile--Gln--Phe--Tyr--Leu--Glu--Glu--Val--Met--Pro--Gln--Ala--Glu--Asn--Gln--Asp--Pro--Glu--Ala--Lys--Asp--His--Val--Asn--Ser--Leu--Gly--Glu--Asn--Leu--Lys--Thr--Leu--Arg--Leu--Arg--Leu--Arg--Arg--Cys--His--Arg--Phe--Leu--Pro--Cys--Glu--Asn--Lys--Ser--Lys--Ala--Val--Glu--Gln--Ile--Lys--Asn--Ala--Phe--Asn--Lys--Leu--Gln--Glu--Lys--Gly--Ile--Tyr--Lys--Ala--Met--Ser--Glu--Phe--Asp--Ile--Phe--Ile--Asn--Tyr--Ile--Glu--Ala--Tyr--Met--Thr--Ile--Lys--Ala--Arg______________________________________
Formula I
wherein the above abbreviations indicate the L forms of the amino acids, and the amino acids are listed starting from the N-terminus.
BRIEF DESCRIPTION OF THE FIGURE
FIG. 1 is a diagrammatic illustration of a mammalian expression vector useful in the production of BCRF1.
FIG. 2 is a diagrammatic illustration of a bacterial expression vector useful in the production of BCRF1.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to methods and compositions for treating diseases associated with excessive IFN-γ production. The invention is based in part on the discovery that the nucleic acid sequence encoding a recently discovered protein, designated cytokine synthesis inhibitory factor, possesses a high degree of homology with the EBV BCRF1 open reading frame. EBV is a human herpesvirus endemic in all human populations, and has been associated with several diseases, e.g. Dillner et al, Adv. Cancer Res., Vol 50, pgs. 95-158 (1988); Thorley-Lawson, Biochim. Biophys. Acta, Vol. 948, pgs. 263-286 (1988); and Tasato, Adv. Cancer Res., Vol. 49, pgs. 75-125 (1987). EBV has a double-stranded DNA genome of about 172 kilobases, Baer et al, Nature, Vol. 310, pgs. 207-211 (1984). The genome contains many open reading frames apparently corresponding to proteins produced by EBV, one of which is BCRF1.
The invention includes mature polypeptides, or proteins, of the BCRF1 open reading frame. For secreted proteins, an open reading frame usually encodes a polypeptide that consists of a mature or secreted product covalently linked at its N-terminus to a signal peptide. The signal peptide is cleaved prior to secretion of the mature, or active, polypeptide. The cleavage site can be predicted with a high degree of accuracy from empirical rules, e.g. von Heijne, Nucleic Acids Research, Vol. 14, pgs. 4683-4690 (1986), and the precise amino acid composition of the signal peptide does not appear to be critical to its function, e.g. Randall et al, Science, Vol. 243, pgs. 1156-1159 (1989); Kaiser et al, Science, Vol. 235, pgs. 312-317 (1987). Consequently, mature proteins are readily expressed by vectors encoding signal peptides quite different than that encoded by the open reading frame defined by Formula I.
A wide range of expression systems (i.e. host-expression vector combinations) can be used to produce the proteins of the invention. Possible types of host cells include, but are not limited to, bacterial, yeast, insect, mammalian, and the like. Many reviews are available which provide guidance for making choices and/or modifications of specific expression systems, e.g. to name a few, de Boer and Shepard, "Strategies for Optimizing Foreign Gene Expression in Escherichia coli," pgs. 205-247, in Kroon, ed. Genes: Structure and Expression (John Wiley & Sons, New York, 1983), review several E. coli expression systems; Kucherlapati et al., Critical Reviews in Biochemistry, Vol. 16, Issue 4, pgs. 349-379 (1984), and Banerji et al., Genetic Engineering, Vol. 5, pgs. 19-31 (1983) review methods for transfecting and transforming mammalian cells; Reznikoff and Gold, eds., Maximizing Gene Expression (Butterworths, Boston, 1986) review selected topics in gene expression in E. coli, yeast, and mammalian cells; and Thilly, Mammalian Cell Technology (Butterworths, Boston, 1986) reviews mammalian expression systems. Likewise, many reviews are available which describe techniques and conditions for linking and/or manipulating specific cDNAs and expression control sequences to create and/or modify expression vectors suitable for use with the present invention, e.g. Sambrook et al., Molecular Cloning: A Laboratory Manual, 2nd Ed. (Cold Spring Harbor Laboratory, N.Y., 1989).
An E. coli expression system is disclosed by Riggs in U.S. Pat. No. 4,431,739, which is incorporated by reference. Particularly useful prokaryotic promoters for high expression in E. coli are the tac promoter, disclosed by de Boer in U.S. Pat. No. 4,551,433, which is incorporated herein by reference, and the p L promoter, disclosed by Remaut et al, Gene, Vol 15, pgs. 81-93 (1981), which is incorporated by reference. Secretion expression vectors are also available for E. coli hosts. Particularly useful are the pIN-III-ompA vectors, disclosed by Ghrayeb et al., in EMBO J., Vol. 3, pgs. 2437-2442 (I984), in which the cDNA to be transcribed is fused to the portion of the E. coli OmpA gene encoding the signal peptide of the ompA protein which, in turn, causes the mature protein to be secreted into the periplasmic space of the bacteria. U.S. Pat. Nos. 4,336,336; 4,411,994; 4,332,892; and 4,338,397 also disclose secretion expression vectors for prokaryotes. Accordingly, these references are incorporated by reference. Numerous stains of bacteria are suitable hosts for prokaryotic expression vectors including strains of E. coli, such as W3110 (ATCC No. 27325), JA221, C600, ED767, DH1, LE392, HB101, X1776 (ATCC No. 31244), X2282, RR1 (ATCC No. 31343) MRCI; strains of Bacillus subtilus; and other enterobacteriaceae such as Salmonella typhimurium or Serratia marcescens, and various species of Pseudomonas. General methods for deriving bacterial strains, such as E. coli K12 X1776, useful in the expression of eukaryotic proteins is disclosed by Curtis III in U.S. Pat. No. 4,190,495. Accordingly this patent is incorporated by reference. In addition to prokaryotic and eukaryotic microorganisms, expression systems comprising cells derived from multicellular organism may also be used to produce proteins of the invention. Of particular interest are mammalian expression systems because their posttranslational processing machinery is more likely to produce biologically active mammalian proteins. Several DNA tumor viruses have been used as vectors for mammalian hosts. Particularly important are the numerous vectors which comprise SV40 replication, transcription, and/or translation control sequences coupled to bacterial replication control sequences, e.g. the pcD vectors developed by Okayama and Berg, disclosed in Mol. Cell. Biol., Vol. 2, pgs. 161-170 (1982) and Mol. Cell. Biol., Vol. 3, pgs. 280-289 (1983), and improved by Takebe et al, Mol. Cell. Biol., Vol. 8, pgs. 466-472 (1988). Accordingly, these references are incorporated herein by reference. Other SV40-based mammalian expression vectors include those containing adenovirus regulatory elements, disclosed by Kaufman and Sharp, in Mol. Cell. Biol., Vol. 2, pgs. 1304-1319 (1982), and Clark et al., in U.S. Pat. No. 4,675,285, both of which are incorporated herein by reference. Monkey cells are usually the preferred hosts for the above vectors. Such vectors containing the SV40 ori sequences and an intact A gene can replicate autonomously in monkey cells (to give higher copy numbers and/or more stable copy numbers than nonautonomously replicating plasmids). Moreover, vectors containing the SV40 ori sequences without an intact A gene can replicate autonomously to high copy numbers (but not stably) in COS7 monkey cells, described by Gluzman, Cell, Vol. 23, pgs. 175-182 (1981) and available from the ATCC (accession no. CRL 1651). The above SV40-based vectors are also capable of transforming other mammalian cells, such as mouse L cells, by integration into the host cell DNA.
The biological activity of the BCRF1s of the invention are readily determined in IFN-γ inhibition assays. Such assays require a cell line or cell population that synthesizes IFN-γ. Conveniently, peripheral blood lymphocytes (PBLs) that have been stimulated with a mitogen such as phytohemagglutinin (PHA) can serve as such a cell population. Roughly, the assay works as follows: The PHA-stimulated PBLs are divided into two equal parts. To one part, a sample containing a BCRF1 is added. The other part serves as a control. After several days the supernatants of both cultures are tested for IFN-γ. This is conveniently done with a standard ELISA assay using commercially available monoclonal and polyclonal antibodies for IFN-γ, e.g. Genzyme, Inc., (Boston, Mass.). Alternatively, the readout of the assay can be the amount of IFN-γ mRNA transcribed, for example, as measured by RNA blotting, PCR, or like methodology. PBLs are obtained using standard techniques, e.g. Mishell et al, eds., Selected Methods in Cellular Immunology (Freeman, N.Y., 1980).
When polypeptides of the present invention are expressed in soluble form, for example as a secreted product of transformed yeast or mammalian cells, they can be purified according to standard procedures of the art, including steps of ammonium sulfate precipitation, ion exchange chromatography, gel filtration, electrophoresis, affinity chromatography, and/or the like, e.g. "Enzyme Purification and Related Techniques," Methods in Enzymology, 22:233-577 (1977), and Scopes, Protein Purification: Principles and Practice (Springer-Verlag, New York, 1982) provide guidance in such purifications. Likewise, when polypeptides of the invention are expressed in insoluble form, for example as aggregates, inclusion bodies or the like, they can be purified by standard procedures in the art, including separating the inclusion bodies from disrupted host cells by centrifugation, solubilizing the inclusion bodies with chaotropic and reducing agents diluting the solubilized mixture, and lowering the concentration of chaotropic agent and reducing agent so that the polypeptide takes on a biologically active conformation. The latter procedures are disclosed in the following references, which are incorporated by reference: Winkler et al, Biochemistry, 25: 4041-4045 (1986); Winkler et al, Biotechnology, 3: 992-998 (1985); Koths et al, U.S. Pat. No. 4,569,790; and European patent applications 86306917.5 and 86306353.3.
As used herein "effective amount" means an amount sufficient to ameliorate a symptom of an disease condition mediated by excessive IFN-γ. The effective amount for a particular patient may vary depending on such factors as the state of the disease condition being treated, the overall health of the patient, method of administration, the severity of side-effects, and the like. Generally, BCRF1 is administered as a pharmaceutical composition comprising an effective amount of BCRF1 and a pharmaceutical carrier. A pharmaceutical carrier can be any compatible, non-toxic substance suitable for delivering the compositions of the invention to a patient. Generally, compositions useful for parenteral administration of such drugs are well known, e.g. Remington's Pharmaceutical Science, 151h Ed. (Mack Publishing Company, Easton, Pa. 1980). Alternatively, compositions of the invention may be introduced into a patient's body by implantable drug delivery system, e.g. Urquhart et at., Ann. Rev. Pharmacol. Toxicol., Vol. 24, pgs. 199-236 (1984); Lewis, ed. Controlled Release of Pesticides and Pharmaceuticals (Plenum Press, New York, 1981); U.S. Pat. No. 3,773,919; U.S. Pat. No. 3,270,960; and the like.
When administered parenterally, the BCRF1 is formulated in a unit dosage injectable form (solution, suspension, emulsion) in association with a pharmaceutical carrier. Such carriers are inherently nontoxic and nontherapeutic. Examples of such carriers are normal saline, Ringer's solution, dextrose solution, and Hank's solution. Nonaqueous carriers such as fixed oils and ethyl oleate may also be used. A preferred carrier is 5% dextrose/saline. The carrier may contain minor amounts of additives such as substances that enhance isotonicity and chemical stability, e.g., buffers and preservatives. BCRF1 is preferably formulated in purified form substantially free of aggregates and other proteins at a concentration in the range of about 5 to 20 μg/ml. Preferably, BCRF1 is administered by continuous infusion so that an amount in the range of about 50-800 μg is delivered per day (i.e. about 1-16 μg/kg/day). The daily infusion rate may be varied based on monitoring of side effects, blood cell counts, and the like.
EXAMPLES
Example 1
Expression of BCRF1 in COS 7 Monkey Cells
A gene encoding the open reading frame for BCRF1 was amplified by polymerase chain reaction using primers that allowed later insertion of the amplified fragment into an Eco RI-digested pcD(SRα) vector (FIG. 1). The coding strand of the inserted fragment is shown below (the open reading frame being given in capital letters).
__________________________________________________________________________aattcATGGA GCGAAGGTTA GTGGTCACTC TGCAGTGCCT GGTGCTGCTTTACCTGGCAC CTGAGTGTGG AGGTACAGAC CAATGTGACA ATTTTCCCCAGACCTAAGAG ATGCCTTCAG TCGTGTTAAA ACCTTTTTCC AGACAAAGGACGAGGTAGAT AACCTTTTGC TCAAGGAGTC TCTGCTAGAG GACTTTAAGGATGCCAGGCC CTGTCAGAAA TGATCCAATT CTACCTGGAG GAAGTCATGCCACAGGCTGA AACCAGGAC CCTGAAGCCA AAGACCATGT CAATTCTTTGGGTGAAAATC TAAAGACCCT ACGGCTCCGC CTGCGCAGGT GCCACAGGTTCCTGCCGTGT GAGAACAAGA GTAAAGCTGT GGAACAGATA AAAAATGCCTTTAACAAGCT GCAGGAAAAA GGAATTTACA AAGCCATGAG TGAATTTGACATTTTTATTA ACTACATAGA AGCATACATG ACAATTAAAG CCAGGTGAg__________________________________________________________________________
Clones carrying the insert in the proper orientation were identified by expression of BCRF1 and/or the electrophoretic pattern of restriction digests. One such vector carrying the BCRF1 gene was designated pBCRFI(SRcα) and was deposited with the ATCC under accession number 68193. pBCRFI(SRcα) was amplified in E. coli MC1061, isolated by standard techniques, and used to transfect COS 7 monkey cells as follows: One day prior to transfection, approximately 1.5×10 6 COS 7 monkey cells were seeded onto individual 100 mm plates in Dulbecco's modified Eagle medium (DME) containing 5% fetal calf serum (FCS) and 2 mM glutamine. To perform the transfection, COS 7 cells were removed from the dishes by incubation with trypsin, washed twice in serum-free DME, and suspended to 10 7 cells/ml in serum-free DME. A 0.75 ml aliquot was mixed with 20 μg DNA and transferred to a sterile 0.4 cm electroporation cuvette. After 10 minutes, the cells were pulsed at 200 volts, 960 μF in a BioRad Gene Pulser unit. After another 10 minutes, the cells were removed from the cuvette and added to 20 ml of DME containing 5% FCS, 2 mM glutamine, penicillin, streptomycin, and gentamycin. The mixture was aliquoted to four 100 mm tissue culture dishes. After 12-24 hours at 37° C., 5% CO 2 , the medium was replaced with similar medium containing only 1% FCS and the incubation continued for an additional 72 hours at 37° C., 5% CO 2 , after which the medium was collected and assayed for its ability to inhibit IFN-γ synthesis.
10 ml aliquots of freshly isolated PBLs (about 2×10 6 cells/ml) were incubated at 37° C. with PHA (100 ng/ml) in medium consisting of (i) 90% DME supplemented with 5% FCS and 2 mM glutamine, and (ii) 10% supernatant from COS 7 cells previously transfected with pBCRF1(SRα). After 24 hours the cells and supernatants were harvested to assay for the presence of either IFN-γ mRNA or IFN-γ protein, respectively. Controls were treated identically, except that the 10% supernatant was from COS 7 cultures previously transfected with a plasmid carrying an unrelated cDNA insert. The BCRF1-treated samples exhibited about a 50% inhibition of IFN-γ synthesis relative to the controls.
Example 2
Expression of BCRF1 in Escherichia coli
A gene encoding a mature BCRF1 of the sequence given below may be expressed in E. coli.
______________________________________Thr--Asp--Gln--Cys--Asp--Asn--Phe--Pro--Gln--Met--Leu--Arg--Asp--Leu--Arg--Asp--Ala--Phe--Ser--Arg--Val--Lys--Thr--Phe--Phe--Gln--Thr--Lys--Asp--Glu--Val--Asp--Asn--Leu--Leu--Leu--Lys--Glu--Ser--Leu--Leu--Glu--Asp--Phe--Lys--Gly--Tyr--Leu--Gly--Cys--Gln--Ala--Leu--Ser--Glu--Met--Ile--Gln--Phe--Tyr--Leu--Glu--Glu--Val--Met--Pro--Gln--Ala--Glu--Asn--Gln--Asp--Pro--Glu--Ala--Lys--Asp--His--Val--Asn--Ser--Leu--Gly--Glu--Asn--Leu--Lys--Thr--Leu--Arg--Leu--Arg--Leu--Arg--Arg--Cys--His--Arg--Phe--Leu--Pro--Cys--Glu--Asn--Lys--Ser--Lys--Ala--Val--Glu--Gln--Ile--Lys--Asn--Ala--Phe--Asn--Lys--Leu--Gln--Glu--Lys--Gly--Ile--Tyr--Lys--Ala--Met--Ser--Glu--Phe--Asp--Ile--Phe--Ile--Asn--Tyr--Ile--Glu--Ala--Tyr--Met--Thr--Ile--Lys--Ala--Arg.______________________________________
The cDNA insert of pBCRF1(SRα) is recloned into an M13 plasmid where it is altered twice by site-directed mutagenesis: first to form a Cla I site at the 5' end of the coding region for the mature BCRF1 polypeptide, and second to form a Barn HI site at the 3' end of the coding region for the mature BCRF1 polypeptide. The mutated sequence is then readily inserted into the TRPC11 expression vector described below.
The TRPC11 vector was constructed by ligating a synthetic consensus RBS fragment to ClaI linkers (ATGCAT) and by cloning the resulting fragments into ClaI restricted pMT11hc (which had been previously modified to contain the ClaI site). pMT11hc is a small (2.3 kilobase) high copy, AMP R , TET S derivative of pBR322 that bears the πVX plasmid EcoRI-HindIII polylinker region. (πVX is described by Maniatis et al., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory, 1982). This was modified to contain the ClaI site by restricting pMT11hc with EcoRI and BamHI, filling in the 5 resulting sticky ends and ligating with ClaI linker (CATCGATG), thereby restoring the EcoRI and BamHI sites and replacing the Sinai site with a ClaI site. One transformant from the TRPC11 construction had a tandem RBS sequence flanked by ClaI sites. One of the ClaI sites and part of the second copy of the RBS sequence were removed by digesting this plasmid with PstI, treating with Bal31 nuclease, restricting with EcoRI and treating with T4 DNA polymerase in the presence of all four deoxynucleotide triphosphates. The resulting 30-40 bp fragments were recovered via PAGE and cloned into SmaI restricted pUC12. A 248 bp E. coli trpP-bearing EcoRI fragment derived from pKC101 (described by Nichols et al. in Methods in Enzymology, Vol. 101, pg. 155 (Academic Press, N.Y. 1983)) was then cloned into the EcoRI site to complete the TRPC11 construction, which is illustrated in FIG. 2. TRPC11 is employed as a vector for BCRF1 by first digesting it with ClaI and Bam HI, purifying it, and then mixing it in a standard ligation solution with the ClaI-Bam HI fragment of the M13 containing the nucleotide sequence coding for the mature BCRF1. The insert-containing TRPC11, referred to as TRPC11-BCRF1, is propagated in E. coli K12 strain JM101, e.g. available from the ATCC under accession number 33876.
The descriptions of the foregoing embodiments of the invention have been presented for purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended, hereto.
Applicants have deposited E. coli MC1061 carrying pBCRF1(SRα) with the American Type Culture Collection, Rockville, Md., USA (ATCC), under accession number 68193. This deposit was made under conditions as provided under ATCC's agreement for Culture Deposit for Patent Purposes, which assures that the deposit will be made available to the US Commissioner of Patents and Trademarks pursuant to 35 USC 122 and 37 CFR 1.14, and will be made available to the public upon issue of a U.S. patent, which requires that the deposit be maintained. Availability of the deposited strain is not to be construed as a license to practice the invention in contravention of the rights granted under the authority of any government in accordance with its patent laws. | BCRF1 proteins are provided for treating conditions associated with excessive production of IFN-γ. Also provided are expression vectors for producing BCRF1 proteins. Compositions of the invention are useful in treating a variety of disorders, including allergy, psoriasis, tissue rejection, and MHC-linked autoimmune diseases. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of International Application PCT/EP2008/010402 filed Dec. 8, 2008 and claims priority benefit of German Patent Application DE 10 2007 058 829.3 filed Dec. 6, 2007, the entireties of which are incorporated by reference herein.
FIELD OF THE INVENTION
The invention relates to a liquid agent for the surface treatment of monocrystalline wafers, which contains an alkaline etching agent and also at least one low-volatile organic compound. Systems of this type can be used both for the cleaning, damage etch and texturing of wafer surfaces in a single etching step and exclusively for the texturing of silicon wafers with different surface quality, whether it now be wire-sawn wafers with high surface damage or chemically polished surfaces with minimum damage density.
BACKGROUND
In prior production methods, the wafer cleaning of the slurry residues after the wire-sawing and the wafer texturing are completed in two different process chains. Both processes are implemented operationally by wafer producers and solar cell producers. Slurry wafer cleaning is effected immediately after the wire-sawing by the wafer producers. It essentially comprises removing contamination applied on the wafer surface by the wire-sawing. There is included therein above all the abrasion of silicon and also of the components of the wire and the grinding agent and adhesive used (slurry). The cleaned wafers, after leaving the cleaning unit, have a more or less intensive crystalline damage to the surface which must be removed in a further process step.
The texturing of the wafer surface, if it has been implemented at all, falls within the remit of solar cell producers. Preceding this, during production of highly efficient solar cells, is a complex three-part subsequent cleaning step which follows the wafer subsequent cleaning in the chip industry. This RCA cleaning (D. C. Burkman, D. Deal, D. C. Grant, C. A. Peterson: “Aqueous Cleaning Processes in Handbook of Semiconductor Wafer Cleaning Technology, Science”, Technology and Applications, East Windsor, N.J., USA (1993) pp. 111-129) comprises:
1.) Oxide etching with HF/HNO 3 ; 2.) SC-1 cleaning with H 2 O/NH 4 OH/H 2 O 2 with subsequent HF dip; 3.) SC-2 cleaning with (H 2 O/HCl/H 2 O 2 ) which removes the contamination and residual metallic and organic contaminants, which are applied on the wafer surface by the transport, after the pre-cleaning by the wafer producers (Figure 1a).
After each chemical treatment, the wafers pass through another rinsing step with highly pure, deionised water before moving to the next etching solution. In this way, a total number of tanks of approx. 8 is the rule solely for the RCA cleaning (O. Doll: “Komplexbildner für alkalische Reinigungslösungen von Halbleitersilicium-Oberflächen: Aspekte ihrer Wirksamkeit and ihrer chemischen Stabilität”, (Complex formers for alkaline cleaning solutions of semiconductor silicon surfaces: aspects of their efficacy and their chemical stability), PhD Thesis, Frankfurt/Main (2005)) with small deviations by the various producers.
In the case of commercial solar cells, the wafers cleaned by the wafer producers of the slurry move directly into the texturing process which, in the case of basic texturing according to the prior state of production of commercial solar cells, is implemented on an industrial scale in a batch unit and serves simultaneously also as damage etch. However, it is also possible that the damage etch is implemented as a separate process step before the texturing. After applying the texturing, the wafers are subjected to an HCl and HF dip for respectively up to one minute before the emitter diffusion is implemented (Figure 1b). The HCl dip is intended to neutralise the residues of KOH solution remaining on the wafer surfaces and to stop their further chemical attack on the wafer surface. Likewise, the metallic impurities deposited by the alkaline etching solution in addition on the silicon surface, above all the poorly soluble hydroxides, precipitated from the basic solution, of the trivalent metal ions Fe 3+ and Al 3+ , are intended to be brought again into solution. The HF dip is intended to ensure removal of the native oxide present on the wafers after the texturing step.
The wafer cleaning has been performed to date by two method routes: either in a batch or in an inline process, respectively two units, one for the slurry cleaning and one for the texturing, being used. To date a batch process has been the industrial standard for wafer texturing. Also different chemical systems are thereby used for cleaning and texturing: only weakly basic agents (pH 8-9) which contain cleaning surfactants for the cleaning, and strongly basic agents (pH>13) which contain texture surfactants for the texturing. Cleaning surfactants and texturing surfactants are not identical in the case of previous solar cell processing. In both cases, the pH of the agents is regulated via the addition of alkali hydroxides (generally NaOH in the cleaning and KOH in the texturing).
In the case of the batch cleaning process, the contaminated wafers pass through chemical tanks of a different composition in defined portions. Generally, aqueous alkaline agents based on potassium- or sodium hydroxide with different surfactant additives serve as cleaning agents. Chemical and ultrapure water cascades make use of the dilution effect as an essentially physical principle during cleaning, which dilution effect results when the wafers move through a large number of tanks. The process time for a batch, comprising all those partial steps from wafer separation after the wire-sawing up to the finished cleaned wafer, is generally more than one hour here.
Inline cleaning ensures a tighter temporal course in which the wafers are conveyed over a roller system in the manner of a conveyor belt, said wafers being subjected in the various portions of the cleaning bank, which are not delimited from each other strictly, to variable chemical and physical conditions. Inline cleaning, unlike batch cleaning, is a continuous process. It enables continuous exchange of the cleaning agents in parallel for cleaning without interruption of the process and improved agent control. From a chemical point of view, similar cleaning agents are used here as in batch cleaning.
For texturing of the surface of monocrystalline silicon wafers, generally an alkaline agent comprising potassium hydroxide and 2-propanol is used in the case of solar cell production. In order to ensure sufficient etching removal for removing the sawing damage, etching times in the range between 15 and 25 minutes are normal, for which reason production plants are used exclusively in the batch process. In the case of texturing, the anisotropy of alkaline etching agents is used in the etching behaviour of different crystal directions in the silicon in order to produce so-called “randomly distributed pyramids”, “random pyramids”. As further alkaline etching agents in addition to KOH, furthermore sodium hydroxide, tetramethylammoniumhydroxide and ethylenediaminepyrocatechol are mentioned, the organic etching agents mentioned here differing above all from both inorganic ones in a longer processing time, however the trade-off is they have no metallic cations. Potassium hydroxide is preferred relative to sodium hydroxide in the case of the inorganic etching agents, because the sodium ions remaining on the surface after the texturing can act, because of their higher diffusion rate relative to the larger potassium ions, as mobile charge carriers in the surface oxide of the silicon wafers. This has a negative effect on the electrical properties of above all oxide-passivated silicon substrates.
SUMMARY OF THE INVENTION
Starting herefrom, it was the object of the present invention to provide an aqueous chemical system which allows simpler processing (cleaning, damage etch and texturing) in solar cell production. This likewise includes technical simplification and cost reduction associated therewith in the production process.
This object is achieved by the liquid texturing and cleaning medium having the features disclosed and described herein. The further disclosures reveal advantageous developments. Uses according to the invention are disclosed and described herein.
Texturing solutions normally comprise a hydroxide ion supplier (OH − ions), which concerns an organic or inorganic base and a surface-active substance, a so-called surfactant, which is normally an organic solvent, predominantly 2-propanol, in the case of the solar cell production process.
The chemical attack on the silicon in a basic aqueous medium, shown here in the example of potassium hydroxide solution, follows the reaction equation:
2K + ( aq )+2OH − ( aq )+2H 2 O(1)+Si( s )
2K + ( aq )+Si(OH) 2 O 2 2− ( aq )+2H 2 ( g )
Water soluble salts of silicic acid are produced as reaction products here: potassium silicate and elementary hydrogen which, after exceeding the saturation limit in the solution, escapes from the latter as a gas.
The surfactant has available at least one hydrophilic and at least one hydrophobic group. In the case purely of the texturing process, it has two essential tasks:
1. Because of its double character as water-soluble hydrophilic and hydrophobic substance, it is able both to wet completely hydrophilic and hydrophobic silicon substrates. If the silicon surface is subjected for example, before the texturing step, to a polishing etch with agents containing hydrofluoric acid, then the surface is terminated with hydrogen atoms, i.e. those valences of the surface atoms on which no further silicon atoms abut, are saturated with hydrogen. Because of the low electronegativity difference between silicon and hydrogen, these bonds are non-polar; such a surface is correspondingly hydrophobic. In contrast, if the surface has available a thin layer of native oxide, as is formed for example in the case of newly sawn wafers, whilst the latter are subjected to moist slurry during the wire-sawing process, then the surface is predominantly hydrophilic because of the strong polarity of the Si—O bond which originates from the high electronegativity difference between silicon and oxygen.
Complete and uniform wetting of the surface is indispensable for the formation of a uniform texture of the silicon substrate. If uniform wetting of the surface is not provided, then different regions of the substrate surface are subjected to the chemical attack of the etching agent to greatly differing degrees, which results in the formation of etching pyramids of greatly varying size. In addition to a higher reflection degree, these surfaces also have the disadvantage of more difficult processibility and therefore are undesired in the solar cell production process.
2. Organic liquids generally have available a higher solubility, by a multiple, of non-polar gas molecules than the polar solvent water. This results in turn in the hydrogen, which is formed during the etching process with hydroxide ions, dissolving better also in the absorbed surface film comprising organic solvent and hence being retained longer on the surface than in a purely aqueous solution. The result is high covering of the silicon surface with ultrafine gas bubbles which act as nuclei for the formation of textured pyramids.
One theory for surface texturing of silicon substrates implies that ultrafine gas bubbles which are adsorbed on the surface block locally and temporarily the etching attack of hydroxide ions on the substrate. At the places where gas bubbles adhere, the attack accordingly takes place with a delay, whilst the surroundings around the gas bubbles are already removed. The blocked places later form the peaks of the forming etching pyramids. Although this theory about the course of the etching process is not supported unanimously, very extensive agreement prevails nevertheless in the literature about the necessity for strong and uniform absorption of the formed hydrogen on the substrate surface as a prerequisite for the formation of a qualitatively high-value texture.
For example various alkyl groups, vinyl groups or aromatic systems, e.g. phenyl radicals, serve as hydrophobic groups in surfactants. Also combinations of these groups are possible, such as for instance in the case of toluenesulphonic acid which has a benzene ring with a methyl side chain.
Hydrophilic groups are for example hydroxy groups (—OH), such as in the case of the standard texturing agents, isopropanol, SO 3 H groups, as in the case of toluenesulphonic acid, nitro groups (—NO 2 ), carboxyl groups (—COOH), phosphate radicals (—O—PO 3 H) or ammonium radicals (—NH 4 + ), to mention but a few possibilities.
The type and length of the hydrophobic and hydrophilic radicals determine the wetting and gas solubility properties of the surfactants, just as their boiling point.
The longer for example the hydrophobic radical of the surfactant, the stronger are the van der Waals forces which act between the molecules of the surfactant and the higher is its boiling point. Isopropanol which has available only two short-chain (methyl) groups has therefore a relatively low boiling point of 82° C., whilst p-toluenesulphonic acid with its longer hydrophobic radical only boils at 140° C.
The higher the non-polar, hydrophobic proportion in the surfactant molecules, the higher is also its solubility capacity for non-polar (hydrogen) gas molecules.
In addition to uniform wetting of the surface of the wafer to be textured and its assistance in the gas absorption on the wafer surface, surfactants also make a further important contribution in the processing of the solar cell wafers: they act as effective cleaning agents for the wafers in that they bond organic impurities, for example floating particles or organic residues, from the slurry, such as for instance polyethylene glycol, epoxy resins, or adhesive residues, in the aqueous solution and consequently prevent deposition thereof on the substrate surface.
Inorganic, metallic impurities can likewise be bonded very effectively by some organic reagents which are used here as texturing agent.
The isolation of the organic contaminants in solution is effected via micelle formation. Micelles are spherical agglomerates of surfactant molecules, in the centre of which the generally non-polar organic impurity is situated, surrounded by the non-polar radicals of the surfactant molecules. The polar radicals of the surfactant molecules which form the surface of the micelles ensure the solubility of the micelles in the polar solvent water.
The capacity for micelle formation is not equally pronounced in all surface-active substances. It is dependent inter alia upon the constitution of the hydrophobic radical, above all its spatial extension. For this reason, for example isopropanol with its two very short hydrophobic radicals is a very poor micelle former, whilst long-chain carboxylic acids or the anions thereof, the standard components of many cleaning agents, are very good micelle formers.
With increasing chain length of the hydrophobic radical, the water solubility of the surfactant drops. Long-chain carboxylic acids (with chain lengths of more than 6 C-atoms) are therefore increasingly more poorly water-soluble. They are in fact good micelle formers but poor texturing agents, the latter inter alia also for the reason that they are frequently no longer able to wet the silicon surface completely and uniformly. The reasons for this are, on the one hand, their poor adhesion to hydrophilic regions of the substrate surface relative to the molecule size thereof just as much as the greatly reducing solubility in the polar medium water, as a result of which the concentration of dissolved surfactant molecules become so low with larger hydrophobic chain lengths that it no longer suffices for complete covering of the substrate surface. With respect to the wetting properties, long- and short-chain surfactants, ionic and non-ionic, act in a complementary manner. For this reason, it is presented as sensible to use different types of surfactants in parallel when aiming for as high and homogeneous substrate coverings as possible.
The mixture ratio between surfactants with long-chain and short-chain hydrophobic radicals, just as the mixture ratio between ionic and non-ionic surfactants determines the pyramid growth and also the texture quality.
Toluenesulphonic acid for example hereby represents in contrast a good compromise between texturing effectiveness and cleaning effect. Unlike the long-chain carboxylic acids, it is soluble in water in a high concentration and therefore can be used in a wide concentration range. The same applies to some short-chain (hydroxy-)carboxylic acids and -dicarboxylic acids with and without supplements of a more volatile organic component, for instance a short-chain alcohol.
Aromatic alcohols, such as for example catechol (1,2-dihydroxybenzene), some dicarboxylic acids, e.g. oxalic acid and hydroxycarboxylic acids, e.g. tartaric acid, just as numerous aminocarboxylic acids, such as for example EDTA (ethylenediaminetetraacetic acid, TITRIPLEX III) and CDTA (trans-1,2-cyclohexanediaminetetracetic acid, TITRIPLEX IV), DTPA (diethylenediaminepentaacetic acid, TITRIPLEX V), are able in addition to form chelate complexes with some metal ions in a basic aqueous solution, which chelate complexes contribute to the fact that these metal ions are no longer absorbed on the wafer surface or are deposited as poorly soluble salts, but remain in solution.
Tartaric acid forms for example, with the metal ions Fe 3+ , Al 3+ , Cr 3+ , Pb 2+ , Cu 2+ , very stable chelate complexes and consequently increases the solubility thereof in basic solutions from which these are precipitated in the absence of the chelate former as poorly soluble hydroxides.
The cleaning effect of these organic compounds both on the solution and silicon substrate surfaces is known in semiconductor technology.
Toluenesulphonic acid is a surfactant main component of the wafer cleaning agent PURATRON® 67 by the company ICB GmbH & Co. KG. Alkylsulphonic acids in general and also their alkyl- and (poly-)alkoxyl-substituted derivatives are known as cleaning surfactants and not as substances effective for texturing.
According to the invention, a texturing agent for the surface treatment of monocrystalline wafers is likewise provided. This texturing agent contains at least one alkaline etching agent for monocrystalline silicon and at least one low-volatile organic compound with a boiling temperature of more than 110° C., preferably more than 120° C. and particularly preferred more than 150° C. The texturing agent according to the invention has the advantage that higher process temperatures tend to be able to be used here, e.g. temperatures above 110° C., in comparison with those methods in which exclusively volatile texturing agents are used since here temperatures of approx. 80° C., the approximate boiling point of isopropanol (82° C.) and ethanol (78° C.), are standard. Higher process temperatures thereby ensure a faster etching attack of the cleaning and texturing agent without the danger of rapid outgassing of the components and consequently reduce the process times.
On the other hand, high process temperatures also promote however the undesired diffusion of some metallic impurities from the solution into the silicon substrate if the latter are not bonded already in the solution, e.g. by complex formation. Furthermore, some of the low-volatile texturing agents are relatively cheap to purchase and at the same time are biodegradable since many of these compounds concern natural substances, which likewise reduces the process costs.
DETAILED DESCRIPTION OF THE INVENTION
Preferably, the low-volatile organic compound has a boiling temperature of ≧120° C., particularly preferred ≧150° C.
The at least one low-volatile organic compound is preferably selected from the group comprising saturated or unsaturated aliphatic or aromatic carboxylic acids, dicarboxylic acids, polycarboxylic acids, hydroxy(poly-)carboxylic acids, aminocarboxylic acids (of the general formulae as presented in I.1-I.3), the esters thereof and also mixtures hereof. There are hereby used in particular compounds from the group comprising oxalic acid, malonic acid, maleic acid, succinic acid, adipinic acid, malic acid, tartaric acid, lactic acid, citric acid, phthalic acid, teraphthalic acid, salicylic acid, nitrotriacetic acid (NTA), ethylenediaminetetraacetic acid (EDTA), diethylenetriaminepentaacetic acid (DTPA), trans-1,2-cyclohexanediaminetetraacetic acid (CDTA) and also mixtures hereof.
I.1: Chain-Like Aminocarboxylic Acids
I.2: Ring-Like, Heterocyclic Aminocarboxylic Acids
I.3: Aminocarboxyl Radicals Substituted on Cyclohexane
It is preferred that the low-volatile organic compound is a linear, branched or cyclic alcohol or an ester thereof.
The low-volatile organic compound can be an isomer of pentanol or hexanol, preferably 1-pentanol, 2-pentanol, 3-pentanol, 1-hexanol, 2-hexanol or 3-hexanol, or an ester thereof.
The low-volatile organic compound can be comprised in an amount of 0.01 to 5 wt-%, preferably 0.1 to 1 wt-%, more preferably 0.15 to 0.25 wt-%.
It is possible to combine the low-volatile alcohol or ester with other low-volatile compounds.
There are preferably in the texturing and cleaning agent as low-volatile organic compound, saturated or unsaturated aliphatic (poly)alcohols, in particular selected from the group comprising straight-chain, branched or cyclic C 4 -C 8 diols or C 6 -C 12 triols or mixture hereof. Particularly preferred are 1,5-pentanediol, 1,6-hexanediol, cis/trans-1,X-cyclopentanediol (X=2, 3), cis/trans-1,X-cyclohexanediol (X=2, 3, 4), cis/trans-1,X-cycloheptanediol (X=2, 3, 4), cyclohexanetriols, cycloheptanetriols, cyclononanetriols, in particular 1,4,7-cyclononanetriol, cis/trans-1,4-cyclohexanediol or mixtures hereof.
Cis/trans-1,4-cyclohexanediol may be stressed as a particularly preferred representative from the series of low-volatile alcohols. Because of its extremely rapid texturing effect on silicon substrates, inline texturing is made possible at all for the first time, which is not possible with the previous standard texturing agent 2-propanol, in particular because of the high volatility of 2-propanol and the instability of the bath composition resulting therefrom.
The cleaning effect of the (poly)alcohols is based, on the one hand, on the fact that polyalcohols are good solvents for organic impurities. On the other hand, hydroxy groups can complex, in cis position relative to each other, metal ions as -ligands and, in this way, prevent their redeposition on the wafer surface. The metal-oxygen bond in the case of (poly)alcohols is stabilised, in contrast to simple alcohols, in addition by an intropy effect.
The at least one low-volatile organic compound is thereby used preferably in a concentration of 1 to 20% by weight, particularly preferred 2 to 10% by weight, respectively relative to the total texturing agent.
A further preferred variant provides that there are used as low-volatile organic compounds, those from the group of aromatic sulphonic acids or aromatic (poly-)alcohols, e.g. resorcin or catechol, or aromatic ethers which can be substituted possibly either by non-polar side chains, for instance one or more alkyl- (e.g. ethyl-, propyl-, octyl-, isopropyl-, ter-butyl, etc.), alkyleneoxide- (e.g. ethyleneoxide- or polyethyleneglycoloxide-), alkylvinyl groups, or by polar side chains, for instance hydroxyl groups, —SO 3 H groups, carboxyl groups, —SH groups, amino groups. Particularly preferred from the group of aromatic sulphonic acids with an alkyl side chain is toluenesulphonic acid, whilst a preferred representative from the group of alkoxyl-substituted aromatic alcohols is 1,3-dihydroxy-4-ethoxybenzene. As preferred representatives from the series of aromatic, alkyl-substituted (poly-)ethers, there may be mentioned here Triton X-100® (polyethyleneglycol-tert-octylphenylether), Tergitol NP-9 (various alkyl-phenylethyleneglycols) (both by Union Carbide Corporation) and also nonylphenylethoxylate with the trade name Triton N-57® (manufacturer: Rohm & Haas) (see II.1 to II.2). It was able to be verified experimentally that toluenesulphonic acid itself in a higher concentration (above 3% relative to the entire texturing agent) shows, in texturing agents with a somewhat increased alkalihydroxide content, e.g. between 5 to 10% by weight, a strong texturing effect which is not observed in systems with low contents of alkalihydroxide and toluenesulphonic acid.
p-toluenesulphonic acid
component of PURATRON 67.
1,2-dihydroxy-4-ethoxybenzene
polyethyleneglycol-tert-octylphenylether
component of TRITON X-100
P=0−12; Q=0−12
II.2: Substituted Aromatic Sulphonic Acids, Alcohols and Ethers with Respectively One Preferred Representative
The treatment solution thereby contains preferably 0.1 to 10% by weight of the sulphonic acid.
A further preferred variant provides that there are used as low-volatile organic compounds, those from the group of sulphuric acid alkyl esters and also the salts thereof. Particularly preferred here are laurylsulphates, myristylsulphates, stearylsulphates, caprylsulphates, e.g. sodium laurylsulphate, potassiumlaurylsulphate, ammoniumlaurylsulphate, ammoniumcaprylsulphate (cf.: III).
General Formula of Alkylsulphates
ammoniumlaurylsulphate
laurylsulphates are components of the surfactant SDS
III: Alkylsulphates with Ammoniumlaurylsulphate as a Preferred Representative
In a further preferred embodiment, polysorbates are used as low-volatile organic compounds (cf.: IV). A particularly preferred representative of this substance group is polyoxyethylenesorbitanmonolaurate, commercially available under the trade name TWEEN® 20 (Uniqema, ICI Americas. Inc.) with high purity.
Polysorbate 20: w+x+y+z=16
polyethylenesorbitanmonolaurate
TWEEN 20
IV: Polysorbates with Polysorbate 20 (TWEEN® 20) as Preferred Representative
As etching agent, the texturing agent according to the invention preferably contains a compound selected from the group comprising sodium hydroxide, potassium hydroxide, tetramethylammoniumhydroxide, ethylenediaminepyrocatechol and mixtures hereof.
Preferably, the etching agent, the hydroxide-ion supplier, is contained in a concentration of 4 to 15% by weight, relative to the total texturing agent, in particular 5 to 7% by weight.
In addition the texturing agent can contain at least one high-volatile organic component, in particular a high-volatile, linear or branched alcohol with a boiling temperature of at most 120° C. The high-volatile alcohol is preferably selected from the group comprising methanol, ethanol, n-propanol, isopropanol, n-butanol, sec-butanol, isobutanol, tert-butanol and mixtures hereof. The high-volatile alcohol is preferably in a concentration of 2 to 20% by weight, in particular 2 to 10% by weight, relative to the total texturing agent.
Furthermore, the treatment solution can preferably contain a further surfactant. This is used according to the invention in order to achieve a further, this time large-area homogenisation of the chemical attack of the wafer surface and consequently an improvement in the optical quality of the wafer. This optical homogeneity, with respect to the aesthetics of the wafers, is of particular importance, which is a crucial price factor for industrial solar cells in commercial solar cell production.
The surfactant is preferably selected from the group comprising sodium laurylsulphate, polyethyleneglycol, polyethyleneglycoloctylphenylether and mixtures hereof. The surfactant can thereby be contained in a concentration of 1 to 20% by weight, in particular 2 to 10% by weight, relative to the total treatment solution.
The texturing agent can be used preferably in the immersion etching process which can be implemented as a continuous or batch method.
The texturing agent preferably has a viscosity in the range of 0.3 to 1000 mPa·s, preferably of 0.5 to 100 mPa·s and particularly preferred of 0.6 to 10 mPa·s.
The method according to the invention is intended to be explained in more detail with reference to the subsequent example without wishing to restrict said method to the special embodiments shown here.
Example 1
Cleaning, Damage Etch and Texturing in One Step During the Batch Process
An example according to the invention for cleaning, damage etch and texturing in one etching step relates to a batch cleaning process in which a unit comprises four modules which are separated from each other spatially via respectively an air lock. Each module comprises an externally sealed chamber of variable length, according to the number of wafers to be processed at the same time. The chambers are opened briefly for loading and unloading, which takes at most 10 seconds per module, and have a minimum gas space, in order that the thermal and chemical equilibrium adjustment between liquid phase and gas phase can be effected rapidly.
In the individual chambers there are situated process tanks in which rails can be immersed, on which rails the wafers are fixed at the beginning of the cleaning process and on which they change from process chamber to process chamber.
In the individual modules, the following partial processes take place:
Module 1: Pre-Cleaning of the Wafers Contaminated with Slurry, with the Help of DI Water
A tank is situated in the module and is emptied after each rinsing step. Cleaning agent is warm DI water at 40-80° C. The wafers are irradiated acoustically optionally during the rinsing with a megaacoustic source. Acoustic irradiation frequency is 1 MHz. The process duration is preferably 6½ min.
Module 2: Damage Etch Associated with Removal of Contamination which is Situated in the Damaged Layer+Texturing of the Wafer Surface
In module 2 there is situated, analogously to module 1, at least one basin in which the wafers to be processed are fixed horizontally.
A preferred embodiment has as etching agent in module 2, a 5 percent by weight of KOH solution with 7% by weight of toluenesulphonic acid, relative to the total solution. The etching time is 20 min; the bath temperature is 110° C. The flow rate of the etching agent at the wafer surface is approx. 5 cm/min with a film thickness of 3 mm.
In contrast to the other modules in which the dwell time is approx. 6.5 min, the dwell time of the wafers in module 2 is approx. 3 times higher. In order to ensure a continuous process flow, at least three wafer rails (carriers) are processed simultaneously in module 2 and are introduced temporally offset at an interval of approx. 6 to 6.5 min into the chamber or removed therefrom.
A further embodiment provides, as etching agent for module 2, an aqueous sodium hydroxide solution with adipinic acid as texturing surfactant, the NaOH content of the solution being 6% by weight and the adipinic acid content 4% by weight, relative to the total solution. The etching time here is also 20 min; the bath temperature is 110° C. The flow rate of the etching agent at the wafer surface is approx. 4 cm/min with a film thickness of 4 mm.
Module 3: Subsequent Rinsing of the Finished Textured Wafers with DI water
The object of this process step is the removal of any remaining etching solution residues on the wafers from module 2.
A preferred embodiment of the invention provides the same constructional configuration of module 3, as is present in module 1. The process parameters (process time, process temperature, acoustic irradiation of the tanks) are thereby likewise identical to those of module 1.
In a further embodiment of the invention, the wafers are cleaned of the etching solution residues by means of a spray device. The process duration then is however only 3-3½ min.
Module 4: Shortened RCA Cleaning
The object of this cleaning step is the removal of any entrained residues of metallic and organic contaminants on the wafer surface.
In a preferred embodiment of the invention, module 4 comprises two tanks. The first tank is filled with an aqueous ammonium hydroxide (NH 4 OH)/hydrogen peroxide (H 2 O 2 ) solution in the concentrations which are normal for RCA cleaning. The process temperature here is preferably 80-90° C., the process time 6½ to 7 min.
In a further preferred embodiment, the first tank of module 4 is filled with a semi-concentrated HCl solution. The process time for the HCl dip implemented therein is approx. 2 min, the process temperature 50° C.
The second tank contains aqueous, diluted to semi-concentrated HF solution. The process temperature is 25° C. (room temperature), process duration 10-15 seconds. After leaving the tank, the wafers are subjected in module 3 to a spray process with DI water lasting 3-3½ min.
In this state, they can be further processed immediately without further cleaning steps.
Wafers treated with the present method tend to have, in a practical test, better optical properties (reduced reflection) and comparable electrical (surface charge carrier combination speed) and significantly better mechanical properties (higher resistance to breakage) than wafers processed with the standard cleaning and texturing concept.
Example 2
Cleaning and Texturing of Wire-Sawn Wafers
A further example according to the invention for texturing wire-sawn wafers with simultaneous cleaning relates to a batch process in which an etching agent is used in module 2 and, relative to the total solution, comprises up to 3.5% by weight of potassium tosylate (potassium salt of p-toluenesulphonic acid), 1% by weight of potassium tartrate (potassium salt of tartaric acid), 4% by weight of potassium hydroxide and 2% by weight of 2-propanol. The process time in module 2 is 21 to 25 minutes at approx. 80 to 85° C. bath temperature.
Example 3
Cleaning and Texturing of Wire-Sawn Wafers
A further example according to the invention for cleaning and texturing wire-sawn wafers relates to a batch process in which an etching medium is used in module 2 and comprises, relative to the total solution, up to 3.5% by weight of potassium tosylate, 1% by weight of ammonium citrate, 5% by weight of potassium hydroxide, 3.5% by weight of 2-propanol and 0.5% by weight of Triton® X-100. The process time in module 2 is 21 to 25 minutes with a bath temperature of 82 to 85° C.
In module 4, the first tank is filled with 5% by weight of HCl solution. Bath temperature is 35° C. The immersion time is 2 minutes.
The remaining test parameters are analogous to those in embodiment 1.
Example 4
Cleaning and Texturing of Wire-Sawn Wafers
A further example according to the invention for cleaning and texturing wire-sawn wafers relates to a batch process in which an etching/cleaning solution is used in module 2 and, relative to the mass of the total solution, comprises 4% by weight of potassium hydroxide, 3.5% by weight of potassium tosylate, 2.5% by weight of 2-propanol, 0.5% by weight of sodium laurylsulphate and 0.25% by weight of EDTA (ethylenediaminetetraacetate).
In module 4, the first tank is filled with 5% by weight of HCl solution. Bath temperature is 35° C. The immersion time is 2 minutes.
The remaining test parameters are analogous to those in embodiment 1.
The remaining process parameters for the other modules correspond to those of embodiment 1.
Example 5
Cleaning and Texturing of Wire-Sawn Wafers
A further preferred example for texturing wire-sawn wafers with simultaneous cleaning relates to a batch process in which an etching agent is used in module 2 and, relative to the entire solution, comprises 1% by weight catechol, 4% by weight potassium tosylate, 5% by weight potassium hydroxide. The process time in module 2 is 21 to 25 minutes at approx. 100 to 110° C. bath temperature (varying).
Example 6
Texturing of Polished Wafers
An example according to the invention for texturing polished wafers relates to a batch process in which the system required for the processing comprises four tanks.
In tank 1, the polished (already very clean) wafers are immersed in pure alcohol, preferably isopropanol. The temperature of the alcohol is between 20 and 25° C. This step serves exclusively for uniform wetting of the surface even before the first chemical attack by the etching solution in tank 2. The wafers change from bath 1 to bath 2 in the dripping state.
Tank 2 contains the actual texturing solution comprising 5% by weight of KOH, 3.5% by weight of p-toluenesulphonic acid and 3.5% by weight of 2-propanol, relative to the total solution. The bath temperature during the etching process varies between 80 and 85° C. The etching time is between 40 and 50 minutes, according to the tank temperature (at etching temperatures around constantly 85° C., it is approx. 40 min).
Tank 3 contains an approx. 5 to 6% by weight of hydrochloric acid solution with a temperature of approx. 20 to 25° C. After leaving tank 2, the wafers are sprayed briefly with deionised water before they change to bath 3 where they remain for approx. 1 to 2 minutes.
Process step 3 in tank 3 serves for neutralisation of any remaining KOH residues on the wafer surface and hence for stopping the etching.
After leaving tank 3, the wafers change to a fourth tank with pure, deionised water where they are rinsed up to the conductance of the deionised water.
A wafer surface textured in this way, in the practical experiment, reached a reflection degree of approx. 10.8% (weighted reflection).
Example 7
Texturing of Polished Wafers
A further example according to the invention for texturing polished wafers provides, with otherwise identical parameters to the preceding example as etching constituents for tank 2, an aqueous solution with 5% by weight of potassium hydroxide and 7% by weight of potassium tosylate (potassium salt of toluenesulphonic acid). The bath temperature here is approx. 95 to 100° C., the etching time 30 to 40 minutes.
Example 8
Texturing of Polished Wafers
A further example according to the invention for texturing polished wafers provides as etching formulation for tank 2, an aqueous solution of, relative to the total solution, 5% by weight of KOH and 2% by weight of adipinic acid diethylester. The bath temperature is approx. 80° C., the etching time at most 50 minutes. The test parameters for the baths 1, 3 and 4 are analogous to those of example 1.
The formulations represented in example 2 and 3 and reaction conditions for tank 2 are suitable also as etching agents for module 2 with a cleaning/texturing process for wire-sawn wafers contaminated with grinding agent.
Example 9
Texturing of Polished Wafers
In a further example according to the invention, the use of 2-propanol in the texturing process is dispensed with entirely. Tank 1 contains here, instead of pure 2-propanol, a warm p-toluenesulphonic acid solution at approx. 40° C. with 20 to 30% by weight of toluenesulphonic acid.
A wafer surface textured in this way, in the practical experiment, achieved a reflection degree of approx. 11.3% (weighted reflection). | A liquid agent for the surface treatment of monocrystalline wafers, which contains an alkaline etching agent and also at least one low-volatile organic compound. Systems of this type can be used both for the cleaning, damage etch and texturing of wafer surfaces in a single etching step and exclusively for the texturing of silicon wafers with different surface quality, whether it now be wire-sawn wafers with high surface damage or chemically polished surfaces with minimum damage density. | 2 |
CLAIM TO PRIORITY
[0001] This application claims priority to U.S. Provisional Patent Application serial No. 60/365,492 filed on Mar. 18, 2002 entitled FULLY DRAINABLE WEIR VALVE which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to valves, and more particularly, to plastic diaphragm valves having a weir-type seating surface.
BACKGROUND OF THE INVENTION
[0003] Diaphragm valves provide excellent sealing and isolation characteristics to contain fluid being controlled and prevent migration of the controlled fluid. into the valve mechanisms or out of the valve. Diaphragm valves utilize a resilient diaphragm and a valve shoulder to engage a valve seat and prevent the flow of fluid past the valve seat. A weir-type diaphragm valve is a valve utilizing a resilient diaphragm that engages a weir to control flow of fluid over the weir. The diaphragm may be controllably lifted and sealed against the weir to selectively permit flow though the valve.
[0004] Weir-type diaphragm valves are often employed in the biotechnological, pharmaceutical, chemical, food processing, beverage, cosmetic, and semiconductor industries. These industries require valves that protect against product contamination and leakage within the valve, workplace and atmosphere. Weir-type diaphragm valves are well suited to meet these requirements because the mechanical valve parts are isolated from fluid flowing through the valve.
[0005] Weir-type diaphragm valves are commonly used to control the flow through a branch in a fluid distribution system or to deliver a sample of a fluid from a process. Each of U.S. Pat. No's 5,065,980, 5,227,401, 5,222,523, 5,327,937 and 6,289,933 disclose diaphragm valves suitable for branch control and sampling. Often, it is desirable to mount such valves in a horizontal position, wherein the weir extends in a horizontal direction.
[0006] These prior art valve design do not allow for complete draining of the fluid passageways due to surfaces that are not configured for drainage. U.S. Pat. No. 6,289,933, for example, has a plurality of horizontal surfaces that may retain fluids. Such stagnant or retained fluids may be a source for contamination in a process. For fluids used in industrial processes, such as the pharmaceutical, sanitary, and semiconductor industries, the process fluids generally must be kept ultra. pure. Contamination of these processes may represent significant monetary losses. Therefore, separate cleaning steps must be employed to cleanse any stagnant or trapped fluids from the prior art valve designs. This extra step increases processing time and cost.
[0007] Traditionally, diaphragm valves were made of metal alloys. Such metal valves provide good durability and service life in basic fluid control applications. However, metal alloys are not well suited to some process environments, such as pharmaceutical and semiconductor manufacturing. In those applications, the fluids often used are highly corrosive or caustic and also must be kept ultra pure. These corrosive fluids can erode the metal from the valve body and contaminate the ultra pure process fluids. Also, some metal alloys may act as catalysts causing the process fluids to undergo chemical reactions, thereby compromising end products, and potentially, worker safety.
[0008] Specialized high strength alloys and stainless steels have been developed to minimize reactivity and erosion in the valve bodies. However, such specialized alloys are very difficult to cast or machine into valve components. The resulting valves are very costly to purchase relative to traditional metal valves. Moreover, stainless steel is not suitable in particular applications such as the semiconductor processing industry.
[0009] Plastic lined metal valves were developed to allow traditional metal valve bodies to handle caustic fluids in specialized process applications. The metal valve body is first formed by casting or machining. Then, a plastic or fluoropolymer is molded in the interior of the valve body where process fluids contact the body. U.S. Pat. No. 4,538,638 discloses a plastic lined metal bodied diaphragm valve.
[0010] Although, the plastic lined metal valves and plastic lined plastic valves may provide the desired resistance to degradation by-process fluids, manufacturing costs are high. High costs are attributable to the complicated multi-step manufacturing process of molding a plastic lining in a support body. The plastic lining may be subject to creep with respect to its surface underneath. Creep reduces the useful life of the expensive plastic lined valve.
[0011] Through advances in plastics and manufacturing technologies, valves made entirely or almost entirely of fluoropolymers have become commercially viable. Such plastic valves are capable of providing a cost effective valve having desirable non-reactive and corrosive resistant properties ideally suited for use in pharmaceutical and semiconductor manufacturing applications. U.S. Pat. Nos. 5,279,328 and 4,977,929 disclose plastic diaphragm valves. In certain applications, plastic bodied valves may also be provided with a plastic lining. U.S. Pat. No. 4,538,638 discloses a plastic lined diaphragm valve. These three patents are incorporated by reference herein.
[0012] While fluoropolymer valves and plastic valves having fluoropolymer liners are well suited to withstanding caustic fluids, they are susceptible to dimensional degradation such as warpage and creep. Fluids used in industrial processes, such as the pharmaceutical, sanitary, and semiconductor industries, generally require the process fluids to be kept ultra pure. Components used in fluid delivery systems, such as valves, are routinely cleansed to ensure that contaminants do not become trapped in such components and thereby introduced into the process system.
[0013] The cleansing processes may involve exposure to high temperature steam for a sufficient amount of time to sterilize the component. Particularly when repeated numerous times, this sterilization process can cause the plastic in the valve to change dimension slightly, resulting in warpage. Creeping results when plastic is subject to stress over a period of time. The plastic component's dimensions can change from the stress. Due to such warpage and creep, tolerances, especially at the weir, are affected and leakage may result.
[0014] Therefore, a need exists to provide a plastic lined weir-type diaphragm valve that has improved dimensional stability when exposed to repeated cleansing operations or exposure. to conditions normally conducive to warpage or creep. Further, there is a continuing need to provide for a fully drainable valve suitable to branch control and sampling applications.
SUMMARY OF THE INVENTION
[0015] A fully draining valve apparatus in a preferred embodiment comprises an upper valve portion and a lower valve portion. The upper valve portion preferably includes an upper valve housing or body, a resilient diaphragm and a valve actuator. The lower valve portion comprises a lower valve housing or body that is preferably configured to mate with the upper valve housing to define a valve interior. The lower valve body preferably has an integral weir, which in conjunction with the resilient diaphragm, defines a fluid passage. The diaphragm is configured to sealingly engage and disengage with the weir as effected by the valve actuator. The weir defines an upper surface that is angled slightly with respect to the horizon to provide an interior passage slope. Said slope causes fluid to flow back into passage instead of remaining in the passage. Additionally, a slope is also formed on a lower portion of the flow passage defined by the valve body to cause fluid to drain into the third duct of the valve. The invention also includes the method of manufacturing a valve, preferably including the step of angling the horizontal surfaces within the fluid passages of the valve to promote full drainage of fluids that may otherwise accumulate.
[0016] A weir support member is disposable within the lower housing to support the weir. In preferred embodiments, an exoskeletal framework configured as the support collar extends circumferentially around the valve and supports the weir support member. In. particular embodiments, the valve body components may also comprise a plastic fluoropolymer lining for contacting fluids. The invention also includes the method of manufacturing a reinforced plastic valve preferably including the step of providing a rigid support member to the weir of a lower valve housing.
[0017] An object and advantage of particular embodiments of the present invention is to provide for a fully drainable weir-type diaphragm valve.
[0018] An object and advantage of particular embodiments of the present invention is to provide a diaphragm valve wherein the weir is angled slightly above the horizontal to create a sloping surface.
[0019] An object and advantage of particular embodiments of the present invention is to provide a valve design that reduces the occurrence of retained fluids.
[0020] An object and advantage of particular embodiments of the present invention is to provide a valve design that reduces contamination of sterile or aseptic processes.
[0021] Another object, and advantage of particular embodiments of the present invention is to provide for a fluoropolymer diaphragm valve that is dimensionally tolerant to repeated sterilization processes.
[0022] Another object and advantage of particular embodiments of the present invention is to provide for a valve that is able to withstand repeated sterilization processes and that is also suitable to use in the pharmaceutical, biotechnological, chemical, and/or semiconductor industries.
[0023] Another object and advantage of particular embodiments of the present invention is to provide a means for reinforcing a plastic valve.
[0024] Another object and advantage of particular embodiments of the present invention is to provide for a method of reinforcing a plastic valve, thereby having improved resistance to warpage and creapage.
[0025] Another object and advantage of particular embodiments of the present invention is to provide a support for the weir of a plastic valve.
[0026] Further features, objects and advantages of the present invention will become apparent to those skilled in the art in the detailed description below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 is an exploded parts view of a diaphragm valve according to an embodiment of the present invention.
[0028] [0028]FIG. 2 is a perspective view of the assembled diaphragm valve of FIG. 1.
[0029] [0029]FIG. 3 is another perspective view of the assembled diaphragm valve of FIG. 1.
[0030] [0030]FIG. 4 is a side view of the lower portion of a diaphragm valve according to an embodiment of the present invention.
[0031] [0031]FIG. 5 is a side view of an assembled diaphragm valve according to an embodiment of the present invention.
[0032] [0032]FIG. 6 is an end view of an assembled diaphragm valve according to an embodiment of the present invention.
[0033] [0033]FIG. 7 is a partial cross sectional view of an assembled diaphragm valve according to an embodiment of the present invention taken along line A-A of FIG. 6.
[0034] [0034]FIG. 8 is an exploded perspective view of a diaphragm valve according to an embodiment of the present invention.
[0035] [0035]FIG. 9 is a cross sectional view of a reinforced weir in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] A weir-type diaphragm valve 20 in accordance with the invention is illustrated in FIGS. 1, 2 and 3 . Such valve generally includes an upper valve portion 22 , a lower valve portion 24 , a bracket support framework 26 and a mounting bracket 28 . A plurality of fasteners 30 are used to fasten the upper portion 12 , lower portion 14 bracket 28 and bracket mount 26 as shown in the assembly drawing of FIG. 1. Additionally, an endoskeletal support member 32 may be used to add rigidity to the valve, which is often comprised of plastic. It should be understood that the terms upper valve portion 22 and lower valve portion 24 are used for convenience of description and that the valve of the present invention is not limited to the valve 20 being positioned such that the upper valve portion 22 must be vertically above lower valve portion 24 relative to the earth. In fact, a preferred operating position for the valve may include the upper valve portion 22 being positioned substantially to the side of the lower valve portion 24 .
[0037] The upper portion 22 includes a resilient diaphragm 38 and an actuator for controllably sealing against the valve seat 42 provided in the lower housing 24 . The lower housing 24 , shown in FIGS. 1 and 4, comprises a central flow passage 44 , a first flow duct 46 , a second flow duct 48 , a third flow duct 50 and a valve seat 42 therein. The valve seat 42 includes a weir 52 for isolating the third duct 50 from the first 46 and second 48 ducts when mated with the diaphragm 38 .
[0038] Referring to FIG. 5, the valve 20 is shown assembled and in position for mounting to an overhead surface with the attached bracket 28 . An axis 56 is shown to indicate the normal horizontal H and vertical V orientation of the valve 20 . A centerline C 1 drawn through the third duct 50 is parallel to the vertical axis V. The horizontal axis H is normal to the vertical V. A centerline C 2 through the upper valve portion 22 is not parallel to the horizontal H; rather, it is parallel to the line indicated as H′. V′ is defined as normal to H′. H′ is tilted at angle X to the horizontal H. Angle X is preferably 5 degrees. However, those skilled in the art will recognize that X could include the following range 0°<×<90° without departing from the spirit and scope of the present invention.
[0039] [0039]FIG. 7 indicates a partial sectional view of valve 20 taken along line A-A of FIG. 6. The central passage 44 includes a first inwardly facing surface 58 defined by the weir 52 . The centerline C 2 of the weir 52 (which, in some embodiments, may also be the same as centerline C 2 of the upper housing 22 ) is offset from the horizontal H by X degrees. This produces a slope on the first surface 58 . The first sloped surface 58 ensures that all fluids drain into the central passage 44 between the first 46 and second 48 ducts.
[0040] A second inwardly facing surface 60 is provided to the inside of the passage 44 defined by the lower housing 24 . This slope X may be the same as for the first surface 58 , although it may be more of less depending on the application. Second sloped surface 60 causes fluids in the central passage 44 to drain into the third duct 50 . The presence of these two sloped surfaces 58 and 60 allows all fluids to be fully drained from the valve 20 , thereby addressing the retained fluid problems of the prior art.
[0041] The valve may be reinforced, or supported, by the provision of the endoskeletal support member 32 as depicted in FIG. 8. Endoskeletal support member 32 is configured as a weir support member 62 and exoskeletal framework 64 configured as support collar 66 . The weir support member 62 , as shown in FIG. 8, is preferably rod shaped having a first end 68 , a second end 70 , a longitudinal surface 72 and notches 74 in the longitudinal surface 72 at both first end 68 and second end 70 . As shown in FIG. 9, the weir support member 62 may also be any suitably shaped elongated member. Those skilled in the art will recognize that many alternative embodiments of weir support member shape, such as polygonal, will provide the envisioned support without departing from the scope of the present invention.
[0042] The support collar 66 , shown in FIG. 8 includes an upper bracket 76 and a lower bracket 78 . The upper bracket 76 and lower bracket 78 are preferably approximately U-shaped and overlap when placed on the valve housing. There are a plurality of collar mounting holes 80 and slotted mount holes 82 in the upper bracket 76 that correspond to respective upper mounting holes 84 , lower mounting holes 86 and mounting slots 88 . The slotted mount holes 82 aide in joining the upper bracket 76 to the lower bracket 78 and the valve upper portion 22 and lower portion 24 during assembly.
[0043] The lower bracket 78 may be provided with two mounting posts 90 that cooperate with the mounting slots 88 and upper mounting holes 84 of the valve upper portion 22 and lower portion 24 and slotted mount holes 97 of the upper bracket 76 for enabling the joining of the valve upper portion 22 and lower portion 24 . The mounting posts 90 have a threaded portion 92 and a smooth portion 94 to provide a means for fastening the valve upper portion 22 and lower portion 24 together. The lower bracket 78 also has two collar mounting holes 80 that communicate with respective collar mount holes 80 of the upper bracket 76 , the upper mounting holes 84 of the valve upper portion 22 and the lower mounting holes 64 of the valve lower portion 24 .
[0044] When assembled upper bracket 76 supports weir support member 62 at notches 74 thereby transferring force from weir 52 to weir support member 62 and thence to upper bracket 76 and lower bracket 78 . This support prevents or reduces creep induced by pressure on weir 52 and other valve components. Thus, warpage and creep of the weir, the flanges and generally the valve body is inhibited.
[0045] The valve upper portion 22 and lower portion 24 are preferably formed of fluoropolymers, including but not limited to perfluoroalkoxy resin (PFA), polyvinylidene fluoride (PVDF) or other fluoropolymers. In certain applications, other plastics may be suitable, such as polyvinyl chloride (PVC), or polypropylene (PP). The body components are preferably injection molded, although they may be machined. The wetted portion of the diaphragm 38 may be formed of polytetrafluoroethylene (PTFE). The diaphragm may be composite with a layer adjacent the PTFE layer formed of EPDM. The weir support member 62 and the support collar 66 are preferably constructed of stainless steel. Stainless steel provides the desirable amount of rigidity and durability to provide the plastic valve with the desired amount of dimensional integrity. In certain instances, other rigid materials such as carbon fiber filled PEEK or other polymers may be utilized. Those skilled in the art will recognize that the above structures may be constructed from other materials without departing from the scope of the invention.
[0046] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize changes may be made in form and detail without departing from the spirit and scope of the invention. | A fully draining valve including an upper valve portion and a lower valve portion. The lower valve body has an integral weir, which in conjunction with a resilient diaphragm, defines a fluid passage. The weir axis is sloped from a horizontal plane. A first duct axis is sloped downwardly away from the weir and sloped from the horizontal plane. A second duct axis is sloped downwardly away from the weir and sloped from the horizontal plane. A third duct axis is oriented downwardly away from the weir and substantially parallel to a vertical axis such that substantially all liquid from within the fluid passage drains from the valve by gravity. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to a co-pending application, filed on the same day, with the same inventor and assignee, titled Method, System, and Kit Package for Balloon Weights and Balloon Stompers.
BACKGROUND OF THE INVENTION
[0002] There are a large number of patents that claim a variety of tethers. However, none of these inventions claim a tether as a part of a balloon game kit or a system for balloon weights or balloon stomp (or stompers), as described in the current invention, given below.
[0003] Some examples for those patents are: (US patent numbers)
U.S. Pat. No. 3,227,398, Balloon tether cable, by Struble. U.S. Pat. No. 3,900,989, Balloon clamp, by Weisenthal. U.S. Pat. No. 4,826,161, Balloon game, by Rookmaaker. U.S. Pat. No. 5,011,447, Balloon holder, by Watanabe. U.S. Pat. No. 5,074,510, Balloon holders, by Metz. U.S. Pat. No. 5,104,160, Balloon tying device and method, by Cheng. U.S. Pat. No. 5,188,314, Balloon holding device, by Peters. U.S. Pat. No. 5,301,392, Multi-purpose balloon closure device, by Richman. U.S. Pat. No. 5,482,492, Balloons and balloon valves, by Becker. U.S. Pat. No. 5,595,521, Balloons and balloon valves, by Becker. U.S. Pat. No. 5,638,581, Balloon mooring system, by Burke. U.S. Pat. No. 5,769,683, Attachment for balloon tether, by Park. U.S. Pat. No. 6,076,752, Method and apparatus for inert gas purging/temperature control for pulverizing/grinding system, by Paradowski et al. U.S. Pat. No. 6,352,484, Apparatus for soccer training, by Killion. U.S. Pat. No. 6,422,914, Dual-function balloon weight, by Nelson et al. U.S. Pat. No. 6,582,272, Balloon weight and ribbon assembly, by Nelson et al. U.S. Pat. No. 6,666,405, Adjustable weight ballasts for weighing down differently sized lighter-than-air balloons, by Isaacs. U.S. Pat. No. 6,716,083, Balloon weight, by Castro. U.S. Pat. No. 6,899,538, Identification type instrument assembly, by Matoba. Des. 350314, Retainer for fastening balloon string to clothing, by Schweitzer. D 520078S, Weighted balloon tether, by Pollack. Appl. 2003/0148701 A1, Method and device for fastening a balloon, by Turjanmaa. Appl. 2006/0081665 A1, Balloon keeper bracelet, by Nguyen et al. U.S. Pat. No. 3,783,551, Balloon and sealing means therefore, by Allison et al. U.S. Pat. No. 3,940,133, Ball retrieving apparatus, by Civita. U.S. Pat. No. 4,976,649, Decorative balloon structure, by Mandell. U.S. Pat. No. 5,035,391, Balloon anchor, by Steele et al. U.S. Pat. No. 5,094,462, Soccer training device, by Boyle et al. U.S. Pat. No. 5,154,430, Ring toss apparatus, by Cozzolino. U.S. Pat. No. 5,240,199, Balloon holding device, by Peters. U.S. Pat. No. 5,411,427, Balloon weight and latch assembly, by Nelson et al. U.S. Pat. No. 5,547,413, Heat-staked tether for toy balloons, by Murray. U.S. Pat. No. 5,628,091, Balloon closure device, by Mueller. U.S. Pat. No. 5,765,831, Tethering system for novelty balloon, by Huffhines. U.S. Pat. No. 5,853,339, Football practice aid, by Scerbo. U.S. Pat. No. 6,152,838, Apparatus for soccer training, by Killion. U.S. Pat. No. 6,358,110, weight for toy or decorative balloons, by Apsner. U.S. Pat. No. 6,540,578, Toy balloon, by Billon. U.S. Pat. No. 6,663,460, Balloon weight with selectable ballast, by Nelson. U.S. Pat. No. 6,685,582, Wrist toy, by Abel. U.S. Pat. No. 6,790,120, Balloon valve adapter, by Murray. U.S. Pat. No. 6,938,275, Wrist band construction for balloons, by Fried. Des. 401255, Balloon weight, by Burns. Appl. 2001/0034176 A1, Novelty apparatus, by Deliu. Appl. 2003/0173457 A1, Adjustable weight ballasts for weighing down differently sized lighter-than-air balloons, by Isaacs. Or U.S. Pat. Nos. 4,042,241, 6,540,576, 6,932,125, 6,364,733, 6,375,534, 4,943,225, 4,380,103, 5,666,709, 6,352,484, 6,277,452, 6,152,838, 5,886,839, 5,135,440, 4,003,572, 3,941,384, and 3517934.
[0050] One example of punch balloons is the one by Unique Industries Inc., from Philadelphia, Pa., 19148.
[0051] Other prior art can be found at: (for Professional Resources Catalog)
http://www.qualatex.compages/pro_resrce_cat.php
[0053] Other examples are: balloontime.com, Conwin Inc./conwinonline.com, balloonplace.com, partypro.com, Klip N'Seal, Balloon Barb, and Quickie Clips.
[0054] However, they are all different from the current invention.
SUMMARY OF THE INVENTION
[0055] The invention covers a game kit, system, method, and device for the balloon games. A preferred embodiment is a game kit for the Balloon Stomper/popping game (or kicking, hitting, or bursting). The kit consists of a balloon, a tether for the balloon, and a means of attaching the balloon to a player. The game can be played many different ways: attaching to humans or objects, using different tools (such as broom or shoe) to hit or burst different objects, such as balloons or balls, using team or individual players, using different scoring systems or goals in the game. For example, in one embodiment, the game involves tying a balloon to the ankle of each player. Then the players try to stomp on each other's balloons, while protecting their own balloon. The winner is the last person or team with a balloon that has not been popped. One problem with the game is that preparing a large number of game set-ups is time consuming and labor intensive. Since this game is meant for children, the players cannot be relied upon to complete the preparation. Young children and people with disabilities may not be able to tie their own balloon knots. This invention is intended to make both set-up and clean-up of the balloon stomper game simpler.
[0056] A preferred embodiment uses a rubber band as the means to attach the tether to the player's limb. The preferred embodiment uses a ribbon as the tether because the ribbon is light enough to not interfere with the movement of the balloon. Rubber bands can be stretched to fit the limb of any sized player. This allows a player to easily put on and remove a balloon game device. Furthermore, both rubber bands and ribbon are both disposable and reusable. Thus a single game set-up can be refitted with a new balloon and the game played again or continued, until the player no longer wishes to play and the set-up is thrown out, or stored for the future.
[0057] Another preferred embodiment uses a loop as the means to attach the tether to the player's limb. In this embodiment, one end of the tether is tied so that it creates a loop. The knot used is a slip knot that can be tightened and loosened, when needed. The loop is fitted around a limb of the player and tightened so that it is attached to the player's limb. This allows a player to easily put on and remove a balloon game device. This preferred embodiment also uses a ribbon as the tether because the ribbon is light enough to not interfere with the movement of the balloon. Furthermore, the ribbon is disposable and reusable. Thus, a single game set-up can be refitted with a new balloon, and the game can be played again or continued, until the player no longer wishes to play and the set-up is thrown out, or stored for the future.
[0058] In one embodiment, the tether is tied to the balloon and to the attachment means. Other embodiments can include a tether with a balloon that has not been attached to the tether. The balloon can be pre-filled. Alternatively, the tether is lightly tied to the balloon so that the balloon can be filled and once the balloon is filled, the tether is tightened.
[0059] A preferred embodiment of the invention is a balloon attached to a tether by a slipknot, and the tether is attached to the limb of the person by a rubber band. This embodiment is the simplest to produce and package. This embodiment also has the advantage that the balloon can be packed deflated, but still attached to the tether. The preferred rubber band is a size #32 or #64 rubber band.
[0060] Another embodiment of the invention is a balloon attached to a tether by a slipknot and the tether is attached to the limb of the person by a slipknot. This embodiment is also simple to produce and package. This embodiment also has the advantage that the balloon can be packed deflated, but still attached to the tether. The slipknot is made by tying one end of the tether to itself.
[0061] Another embodiment of the invention is a tether with a net attached. The net can hold a balloon. Thus, the net attaches a balloon to the tether.
[0062] Other embodiments could include a tether with a balloon disc, clip, or cup attached. Any balloon disc, clip, or cup could be used. The tether could also be integral and continuous with the balloon itself, so that the balloon and the tether are manufactured together.
[0063] The invention includes the use of any type of balloon. This includes latex balloons, water balloons, punch balloons, helium balloons, foil balloon, nylon balloons and Mylar balloons. This invention could also be used with balls, such as a punch ball or other objects, such as toys.
[0064] Another embodiment includes balloons manufactured with an attachment point for the tether. The attachment point could be a balloon disk manufactured around the neck of the balloon. Alternatively, the balloon could have a knob or loop manufactured into the balloon, creating an attachment point.
[0065] A preferred embodiment of the invention includes printed rules for balloon games and all equipment needed for each game. Other embodiments could include filled and unfilled balloons. Still other embodiments include storage bags for prepared balloon devices to be stored. Still other embodiment could include balloon pumps or balloon inflators.
[0066] Another embodiment of the invention is the balloon weight setup and system, as described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0067] FIG. 1 shows the balloon device, to be attached to a person's ankle or a body part, for example, for the balloon stomper game.
[0068] FIG. 2 shows another variation of FIG. 1 .
[0069] FIG. 3 shows other variations of the components of FIG. 1 .
[0070] FIG. 4 shows some examples for connecting two parts/components of FIG. 1 .
[0071] FIG. 5 shows an example of the balloon weight setup.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0072] FIG. 1 shows the balloon device, to be attached to a person's ankle or a body part, for example, for the balloon stomper game. Item 101 is a balloon (or a toy). Item 102 is a tether or other means to tie the balloon, so that air stays in the balloon. Item 103 is a tether (e.g. string) to connect the balloon to the ankle of the user. Item 105 is the loop going around the ankle of the user. Item 104 connects item 105 and item 103 together.
[0073] The connection means 102 and 104 can be by any method, such as tied rope, ribbon, string, glued, hinge, metal joint, welded, sewed, solid, rigid, or flexible, and made of any material, such as rubber band, silk string, wool, metal chain, plastic chain, rigid, flexible, or soft material.
[0074] Note that tether's equivalent terms (or other connecting methods/devices) can also be used here, such as cord, chain, fastening device, rope, thread, fibrous material, confining device, string (cotton, nylon, or any other material), belt, tape, tie, attaching device, lace, Velcro fastener, hook-and-loop fastener, band, strap, snap, wire, cable, elastic, glued material, holder, disk, cup, clip, pull tabs, knot, adhesive, and connector. The tether can have multiple components, made of many parts, in series or in parallel configuration, such as chain of cotton and nylon strings tied together.
[0075] The balloons 101 can be of any kind of balloons in the market, such as water balloons, Helium balloons, or air balloons, made of any type of material, and closed off by any method, at the factory or by the user.
[0076] Tether 103 and loop 105 can also be made of any material, such as rubber band, string, wool, silk, solid, plastic, elastic, soft, rigid, flexible, adjustable size, fixed size, or multi-threaded material. For example, (flexible) rubber band 105 is useful for fitting the loop 105 for users of different sizes (e.g. fit a large ankle).
[0077] Item 102 can be a hook or a tie. The tie can be closed up by the user to close off the balloon, to keep air or water inside the balloon. In one embodiment, the loose tie is pre-manufactured at the factory to make it easier for the user to fill up, tie up (e.g. pull tabs of a slipknot), and set up the balloons. Item 102 can have multiple pieces, and can be made of any fastening method or technology. Item 102 can be an integral part of item 103 , such as a slipknot configuration.
[0078] Items 103 - 105 can be 1-piece, 2-piece, or 3-piece setup. Some of those examples are shown in FIG. 3 .
[0079] The rubber band (or loop 105 ) can be connected to a weight or a wine bottle, instead of a user's ankle.
[0080] FIG. 2 shows another variation of FIG. 1 . Here, the balloon is tied up by a balloon tying device 201 , which is connected to tether 103 , using the connection means 202 .
[0081] Item 201 can be of any shape and material, as long as it can keep or hold the water or air inside the balloon. Examples of material for item 201 are plastic, rubber, and metal pieces.
[0082] The connection means 202 can be of any shape and material, as well, such as the ones described above for item 104 or item 102 .
[0083] FIG. 3 shows other variations of the components of FIG. 1 , replacing components/items 103 - 105 of FIG. 1 . Any other logical combinations or variations of these are also meant to be covered under this patent disclosure.
[0084] Item 303 is a solid ring, for example, made of plastic. Item 307 and item 308 are made of magnetic material (magnets), coupled to each other, to connect loop 309 and tether 306 .
[0085] Item 312 is a small loop with a strap (to hold the small loop closed), in order to attach tether 311 to item 313 (the big loop).
[0086] Item 305 is just an extension/tip of item 304 (tether). This is a flexible arrangement to adjust the size of loop (by sliding item 305 along tether 304 ). Note that using rubber band as the loop 105 serves the same purpose (adjusting the size of the loop).
[0087] Item 315 is a knot, which can be of any shape (or any type of knot).
[0088] Item 318 can be of any form, shape, or material, such as those described for items 312 and 315 , above.
[0089] Item 320 closes the loop, or adjusts the size of the loop, and can be similar to item 312 , described above.
[0090] FIG. 4 shows some examples for connecting two parts/components of FIG. 1 . This is very generic, and can be applied to any situation and setup. Items 401 - 402 signify the chain connection. Items 406 - 409 show the connection by screwing one part into another (item 409 into item 408 ). Items 410 - 413 describe a belt-type connection, in which a hook into an opposite hole connects the two pieces (items 410 and 411 ). Items 440 - 442 show a snap-in connection, in which item 441 is pushed into item 440 , and the flexible part 442 snaps/expands inside item 440 , attaching the two parts 440 and 441 . Any other variation of FIG. 4 (any fastening technology or method) can also be used here.
[0091] FIG. 5 shows an example of the balloon weight setup. Items 101 - 103 are similar to the counterparts in FIG. 1 . Item 505 is an object/weight, connected to the tether 103 (and eventually to balloon 101 ) at the connection point 504 . Item 504 is structured similar to item 104 , or any combinations shown in FIG. 3 .
[0092] The balloon may or may not be included in the setup described in FIG. 5 , above. The loose tie (item 102 ) can be pre-fabricated at the factory, and the user can close it off (e.g. pull tabs of a slipknot) (after filling the balloon, using air or water). This makes it easier for the user to fill up and tie up many balloons in a short period of time.
[0093] Currently, people use balloon tying devices/cups at position 102 in FIG. 5 , instead of our item 102 (tie, shown in FIG. 5 ). Balloon tying devices/cups are very awkward. Thus, our configuration (our item 102 (tie, shown in FIG. 5 )) is advantageous over the prior art.
[0094] In one embodiment, one puts a string (or hook, ribbon, or any fastening tool or device) inside the lip (tip) of the balloon (at position 102 in FIG. 5 ) so that the user has an easier time to close off the balloon. This can be pre-manufactured at the factory.
[0095] In one embodiment, the balloon device with the balloon manufactured in such a way that it has an attachment point for ease of attachment or closing the balloon.
[0096] The weight 505 can be used as/for/together with/instead of an anchor, display, balloon bar, set-in-the-ground, attached-to-a-bag, pin, tent peg, spike, spike with a base (for sandy areas, to bury the flat base, for support of the spike), balloon barb, or decoration purposes.
[0097] Any parts of the setup explained above can be sold or packaged as a kit, so that the user can put them together, using an instruction manual. They can be all or partially in one package, with the adhesive material included, as an option.
[0098] The kits can also include (or not include) software, CD-ROM, DVD, VCR, tapes, or tape cassettes, in addition to (or not including) the booklets and other accessories. This system can be included in a retail packaging and/or retail displays (counter, floor, shelf, etc.). The kit or packaging includes various parts or components which can be put together by the user, which can be sold separately or altogether. It can include balloon markers and other accessories.
[0099] This software can offer setup, management, and cleanup tips, as well as multiple game and activity listings. Additionally, it can offer printable and/or E-mail versions, as well as a database to add user developed ideas and notes. It can also provide tools to manage events and setup crews, as well as tools and templates to design event layouts. It can even be integrated with existing recreation program, sports management, facilities management, or tournament scheduling programs. The software can also describe how to incorporate ideas into clowning or twisting businesses for profit or not-for-profit.
[0100] In one embodiment, the balloon is held using a net. The net can be any type net. The net can be made out of cloth, fabric, string, plastic, wire, or any type of material suitable for net. The size of net is any size that can hold a balloon. The net needs to be only as large as the desired balloon.
[0101] The balloon fastener can be any kind of balloon fastener. Possible balloon fasteners include slipknots, knots, a net, a balloon disc, a balloon clip, a balloon cup, or an attachment point on a balloon. Alternatively, balloon fastener could be integral and continuous with the balloon and tether, for example, when balloon and tether are manufactured together. Possible attachment point versions of balloon fastener include a projection or loop that is integral and continuous with the balloon, that the tether can be tied to. These projections or loop would be manufactured as part of balloon. The slipknot version of balloon fastener could include zero, one, or two (or even more than 2) pull tabs.
[0102] In one embodiment/example, the distal fastener could be a rubber band. The tether is tied to the rubber band distal fastener. The rubber band is fitted around a player's limb. The rubber band can be fitted around any size limb (or object) by threading the rubber band through itself and looping it around the limb (or object) enough times to create a tight fit. This process is easy to do and can be done by players of any age. Furthermore, the rubber band is durable and can be reused, so that the same rubber band can be used to play multiple rounds of a balloon game. The preferred rubber band size is #32 or #64.
[0103] In one embodiment/example, the distal fastener could be a loop. The loop distal fastener is created by tying the distal end of the tether to itself. The player then fits a limb through the loop to attach the balloon game kit to the player. The preferred loop distal fastener is made using a slipknot. The slipknot can be tightened to fit the player's limb. Alternatively, the loop could be threaded through itself and looped around the limb until the loop fits the limb. In this version, the loop would be formed by threading the distal end of the tether through a hole in the tether. The loop is durable and can be reused for multiple rounds of a balloon game.
[0104] The distal fastener can be adjustable. The distal fastener can be attached to tether by a knot or a grommet (or metal eyelet or rope). The tether can be made of any flexible material. The preferred embodiment teaches a tether made of ribbon. Other embodiments could use string, cord, elastic, fabric, or wire.
[0105] The balloon can be attached or separate from the tether. The balloon can be filled or unfilled. In one embodiment, the balloon is unfilled and not attached to the tether. A person using the device would fill the balloon and then attach the balloon to the tether using the balloon fastener. The balloon fastener can also seal the balloon. In another embodiment, the balloon is filled and is not attached to the tether. The person using the balloon game kit would attach the balloon to the tether using the balloon fastener. In another embodiment, the balloon is unfilled, but is attached to the tether. In this case, the person using the balloon game device would fill the balloon and then seal the balloon using the balloon fastener. In one embodiment, the balloon is both filled and attached to the tether.
[0106] The disk and cup can be used for attaching a string (or ribbon or similar connecting or attaching means) to a balloon. In one embodiment, the balloon has a hole prefabricated in its elastic enclosure, through which a string or rope can go, for the purpose of attaching another object to a balloon. The strap for the attachment to the balloon may be adjustable. Multiple balloons (sometimes, with different material/content (different gas/liquid contents) or different shapes) may be attached to one or both ankles (or other body parts, or still/moving objects), through one or more connections or strings.
[0107] The weight/closure/an object can be connected to a balloon/second object, for example, using tape, ribbon, staples, or clip (with (or through) a hole, for example). The objects can be inflatable toys, stuffed animal toys, dolls, or objects-glowing-in-dark.
[0108] The balloon stomping or bursting can be done by any other object or parts of human body, such as broom, tooth pick, or finger nail. The attachment can be done to the wrist of a human or to the leg(s) of a table, as well, for example. The balloons can be full of water, Helium, or any other mixture of gas, liquid, and/or powder/solid, with balloons being made of any fabric or material, such as latex or Aluminum.
[0109] The system can be used for decoration or display. In one embodiment, one or more components of the system can be stored in a cavity inside the weight object, or stored/attached on the weight/anchor object.
[0110] Any other variations of the teachings above are also meant to be covered and be protected under this patent disclosure. | This covers a game kit, system, method, and device for the balloon games. A game kit for the Balloon Stomper/popping/hitting/kicking/bursting game. The kit consists of a balloon, a tether for the balloon, and a device for attaching the balloon to a player, as an example. As one example, the game involves tying a balloon to the ankle of each player. Then the players try to stomp on each other's balloons, while protecting their own balloon. The winner is the last person or team with a balloon that has not been popped. There are many other variations for the game/rules as explained here in more details. One problem with the game is that preparing a large number of game set-ups is time consuming and labor intensive. This is intended to make both set-up and clean-up of the balloon stomper game simpler. It also deals with the balloon weight setup and system. | 0 |
DESCRIPTION
1. Technical Field
The invention is in the manufacture of very small devices of the order of 3 to 100 micrometers which may be used for some examples, as cooling tunnels, in transistor semiconductor devices as light emission devices, for various optical purposes, as ink jet nozzles, as charge electrodes, as channel electronic multipliers and as cathodes for cathode ray tubes. The tunnel structures are triangular and are surrounded by monocrystalline material.
2. Background Art
The formation of epitaxial semiconductor structures wherein preferential growth planes and employed have been known in the field for same time. Two illustrative examples are U.S. Pat. Nos. 3,884,733 and 3,855,690 wherein arrays of devices having particular shapes useful for optical purposes are formed by growing epitaxial material on a substrate using a crystallographic plane that exhibits preferential growth and which provides an optically desirable face. Heretofore in the art, however, the region produced by the preferential growth plane has been exposed.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic of a relationship between three crystallographic planes which are a condition for the practice of the invention.
FIG. 2 is a cross-sectional view of an epitaxial tunnel structure.
FIG. 3 is a cross-sectional view of an epitaxial tunnel structure involving a p-n junction.
FIG. 4 is a cross-sectional view of an epitaxial tunnel structure illustrating variation in cross-sectional shape.
DISCLOSURE OF INVENTION
In crystal growth processes such as chemical vapor deposition, there is a growth rate dependence on the different crystallographic planes of the crystalline structure being produced. Where the growth is performed on a substrate that is oriented such that two crystallographic planes that exhibit preferential growth intersect, a tunnel or a void in the resulting crystal structure can be produced.
In some crystal structures such as the III-V intermetallic compounds, the growth rate difference between one crystallographic plane and another can be as much as a factor of 100.
The tunnels or voids produced may be on the order of ˜3 to 100 micrometers in width and are useful in a variety of instances such as where hard or chemically inert material of that size is desirable or where, since the material is of the semiconductor type, various light emitting properties can be imparted to the structure and thus the tunnels can be employed for optical transmission purposes.
BEST MODE FOR CARRYING OUT THE INVENTION
The substrate is selected with a crystallographic orientation on which the growth of the crystalline structure is to be performed such that there will be two intersection high growth rate planes.
Referring to FIG. 1, the substrate 1 would be a monocrystalline material having a crystallographic orientation such that the face 2 on which the growth was to take place would have intersecting it two crystallographic planes 3 and 4 which would grow from the face 2. Under these conditions were the growth to be maintained long enough, the intersecting planes 3 and 4 would meet. Where the planes 2, 3 and 4 exhibit preferential growth, the intersection occurs rapidly.
Referring now to FIG. 2, the substrate 1 has a growth inhibiting shape defining material 5, usually of a growth inhibiting resist, in a proper shape placed on the surface 2. The surface 2 is of a crystallographic orientation such that preferential planes 3 and 4 will intersect thereby forming an enclosed structure 6 having therein a void or tunnel 7. The tunnel 7 may be any shape configured by the initial resist 5 that is applied to the substrate 1.
While the invention is applicable to any crystalline material that can have two intersecting preferential growth planes, the intermetallic semiconductor compounds in the III-V and II-VI categories exhibit ease of preferential growth when the substrate face 2 is of the [100] crystallographic orientation and the intersecting planes 3 and 4 are the [111B] crystallographic planes.
Continuing to refer to FIG. 2, in fabrication, the substrate 1 may be of the III-V category such as gallium arsenide having a narrow stripe of about 3 micrometers to 100 micrometers shown as element 5. This may, for example, be of SiO 2 , Al 2 O 3 or Mo. The crystalline material 6 is then grown in accordance with the standard vapor growth techniques using a GaAs source and HCl as a transport agent.
The HCl+H 2 is passed over pieces of GaAs source material at 850° C. to transport it to the substrate which is maintained at 750° C.
A GaAs wafer substrate oriented nominally 3° off a [100] crystallographic plane toward the [110] crystallographic plane is chemically polished with Br 2 -methanol and is provided with a film of 200 nm of SiO 2 or Al 2 O 3 . The stripe 5 is patterned on the oxide film using photoresist with the axis of the stripe being in one of the [110] crystallographic directions on the [100] crystallographic planes, that is, the planes that form an acute angle with the stripe 5 and as epitaxial material is formed the void is ultimately covered. The wider the oxide stripe 5, the larger the bore of the void or tunnel will be. Tunnels having sides 3 to 100 micrometers are the general order of relative size.
It should be noted that the stripe 5 extends beyond the intersection of the planes 3 and 4 with the surface 2. This is done to accommodate the fact that as the slow growing planes propagate in a direction toward each other, the fast growing planes are closing the void or tunnel 7. The selection of the width of the stripe 5 should be done with this in consideration.
In the semiconductor intermetallic compounds, the III-V compounds gallium arsenide and gallium phosphide and the III-VI compound zinc selenide are preferred.
In the case of the III-V composed gallium arsenide, the depositing GaAs does not nucleate on molybdenum, consequently Mo stripes may be also used in such a situation in addition to the other examples of silicon dioxide and aluminum oxide. Mo is inert in halogen chemical vapor deposition reactions.
An empirical method for choosing the [110] crystallographic directions on the [100] crystallographic substrate surface of the example gallium arsenide has been devised. A GaAs wafer with an oxide film on the polished surface is immersed in a 3:1:1:H 2 O:H 2 O 2 :NH 4 OH solution for about 3 minutes. Wherever there is a pin hole in the oxide an etch pit with an elongated outline formed. If the oxide stripes are parallel to the long axis of the pit, the tunnels of the invention will result. When, however, the stripes are perpendicular to the long axis, grooves will result. If a pin hole in the oxide cannot be found, the etch figures on the bottom of the wafer are rotated 90° from those on top and they can be used as a guide. If the stripe axes are in each of the <100> directions in the {100} surface, vertical walls will result.
As an example of an elemental crystal, tunnels or voids may also be formed in the material silicon by placing narrow stripes in either of the [110] directions on a [100] crystallographic surface of the substrate. The difference in growth rates is not as pronounced in elemental crystals as it is in intermetallic crystals. As taught in U.S. Pat. No. 3,884,733 discussed above, the [113] crystallographic plane is one of the faster growing planes in silicon.
Further, the tunnels of the invention in addition to their uses in forming shapes in hard material also have a particular advantage in the semiconductor field where a p-n junction is incorporated in the structure.
This may be seen in FIG. 3 wherein the substrate 1 has grown thereon the surface 2, an n-region 8 which forms a p-n junction 9 with a p-region 10 so that the edges of the p-n junction 9 are exposed in the planes 3 and 4 in the cavity 7. This provides light emitting properties in the tunnel.
Since the tunnel can be tapered by tapering the resist 5 in manufacture, point sources of light may be easily provided which in turn can be electrically modulated. Thus a wide variety of very precisely fabricated electro-optical structures ave available.
It will be apparent to one skilled in the art that void or tunnel cross sections other than triangular may be provided by, for example, grooving the substrate in the first instance. Such an example for silicon or gallium arsenide is shown in FIG. 4 wherein all reference numerals have been maintained and a groove 8 is provided in the [100] oriented substrate and the stripe 5 is laid down in and adjacent to the groove 8.
What has been described is a technique of producing tunnel shaped voids in crystalline materials by using the fact that two preferential growth planes can be caused to intersect and create a void in the grown crystal. | Epitaxial tunnels may be formed in crystalline bodies of crystalline materials by growth of the material on a substrate having two intersecting crystallographic planes that exhibit rapid epitaxial growth and by maintaining the growth until the structure forming along those planes closes, thereby producing a tunnel. P-n junction structures can be made in semiconductor devices by appropriate techniques. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a circuit for detecting motion of pictures in HDTV (High Definition Television) receiver, and in more particular to a motion detection circuit for use in the HDTV receiver for receiving a bandwidth compressed television transmission signal.
2. Description of the Prior Art
A multiple subsampling transmission system that achieves interframes and interfields offset subsampling, is one of various methods to transmit a television signal, that is, HDTV picture signal by bandwidth compression. An embodiment of such a transmission system is called MUSE (Multiple Sub-Nyquist Sampling Encoding) system, which performs effective bandwidth compression in transmission of television picture signals.
The multiple subsampling transmission system conventionally includes means for processing a still picture-area (portions of a field where the picture is still), means for processing a moving picture-area, a motion detector for detecting motion information from a difference signal of adjacent interframes, a mixer for mixing the moving picture with the still picture in accordance with a motion amount detected from the motion detector, and means for interframe offset sampling a signal from the mixer.
Further, the means for processing the still picture-area generally includes an interfield prefilter for removing high-frequency components in an oblique direction of a picture signal with a 24 MHz bandwidth limitation, a sampling circuit for receiving a signal from the interfield prefilter and for performing interfield offset subsampling in the 24 MHz sampling frequency, and a sampling frequency converter for changing only the sampling frequency from 24 MHz to 32 MHz.
Furthermore, the means for processing the moving picture-area generally includes an intrafield prefilter for limiting in 12 MHz a frequency bandwidth of the picture signal with the above-described bandwidth limitation and for removing the high-frequency components in the oblique direction, so as to prevent occurrence of aliasing, a sampling circuit for sampling an output of the intrafield prefilter in the 24 MHz sampling frequency, and a sampling frequency converter for changing only the sampling frequency from 24 MHz to 32 MHz.
The moving and still pictures, are each output by their respective processing means, are mixed together in linear mode by the mixer, according to an amount of motion detected by the motion detector. To an output of the mixer, the interframe offset subsampling is taken at 16 MHz sampling frequency by the interframe offset subsampling means, so that the moving picture signal would not have any aliasing portions in the 0 to 4 MHz frequency band. Along with various control signals necessary to reconstruct the original picture in a receiving end, for motion vector to compensate a movement of picture that may result from movement or tilting of a camera, the subsampling signal is transmitted in a 8 MHz base band for example.
FIG. 1 is a block diagram illustrating a portion of a decoder in a receiving end of the above-described system. A picture signal separated from a multiple subsampling transmission signal delivered from a transmitting end, is applied to an input terminal 10. An interframe interpolation filter 13, a sampling frequency converter 14 and an interfield interpolation filter 15 constitute a still picture processor 12 for reproducing a still picture portion out of the picture signal received. Here, by replacing a picture element not sampled by the interframe offset subsampling with a picture element of a preceding frame, the interframe interpolation filter 13 processes the still picture. The sampling frequency converter 14 converts a frequency of the interpolated output of the interframe interpolation filter 13 to the 24 MHz sampling frequency from the former 32 MHz frequency. In order to obtain a still picture with a 24-MHz signal band without aliasing, the interfield interpolation filter 15 is adopted. In addition, the interframe interpolation filter 13 and the interfield interpolation filter 15 serve to compensate for a motion of the picture resulting from a panning phenomena such as movement or tilting of the camera, in response to a motion vector provided from a separator (not shown in the drawing).
An intrafield interpolation filter 17 and a sampling frequency converter 18 constitute a moving picture processor 16 for reproducing a moving picture portion out of the picture signal received. The intrafield interpolation filter 17 is used to reproduce a moving picture signal without aliasing in a 0 to 12 MHz frequency band, from a moving picture signal aliased in 4 to 8 MHz frequency band. The sampling frequency converter 18 changes a frequency of the reproduced moving picture signal to the 24-MHz sampling frequency from 32-MHz signal.
A motion detector 20 limits a bandwidth of and the input signal up to 4 MHz to obtain an adjacent interframe difference signal, that is, an amount of motion from the moving picture signal. The still picture of the still picture processing means 12 and the moving picture of the moving picture processing means 16 are mixed together in a linear mode at a mixer 22, according to the amount of motion delivered from the motion detector 20, and thereafter applied to a Time Compressed Integration (TCI) decoder, not shown in the drawing.
U.S. Pat. No. 4,692,801, which was issued on 8 Sep. 1987, discloses the aforesaid system (MUSE II).
A method of detection of a motion area in the receiver of the aforesaid system is, to obtain an adjacent interframe difference signal from a moving picture signal of the picture signal received and then carry out the linear mixing operation of the still picture and the moving picture according to an amount of motion of said interframe difference signal.
In the meanwhile, referring to another MUSE system (see U.S. Pat. No. 4,745,459) including a frame memory and a temporal interpolator as a so-called still picture processing means, further having a spatial interpolator as a so-called moving picture processor, the motion detector achieves detection of such a motion area owing to a difference signal of two adjacent interframes.
Hence, the above-described prior art system generally has a problem owing to complication of detection of the motion area. Moreover, the complication of its circuit construction in the receiver will make it difficult to achieve economy its cost.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a motion area detector capable of simple detection of a motion picture-area in a HDTV receiver of a multiple subsampling transmission system.
It is another object of the present invention to provide a motion area detector capable of greatly eliminating the complication of detection of the motion picture-area in the HDTV receiver.
It is still another object of the present invention to provide a motion area detector capable of achieving economy in the cost of manufacturing a HDTV receiver.
To achieve the foregoing objects and other various advantages of the invention, there is provided a detection circuit for motion area including a still picture processing means for reproducing a still picture from a picture signal received into the detection circuit in a receiver of a multiple subsampling transmission system, a moving picture processing means for reproducing a moving picture from the picture signal received thereto, a mixer for carrying out a linear mixing operation between the still picture and the moving picture, and a motion detector for detecting a motion area from a mixed picture signal of the mixer and from the still picture signal reproduced at the still picture processing means and for providing information of a mixing ratio between the still picture and the moving picture.
The motion detector further includes a frame memory for storing the picture signal of the mixer, a stage for computing an absolute value of the difference between the picture signal stored in the frame memory and the still picture signal, and a smoothing circuit for making smooth a boundary line of the motion area and for removing spot errors therein.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings, wherein:
FIG. 1 is a block diagram showing a motion detection circuit in a prior-art HDTV receiver;
FIG. 2 is a block diagram showing a preferred embodiment of a motion detection circuit according to the present invention;
FIG. 3 is a block diagram showing in more detail a motion detector portion in FIG. 2; and
FIGS. 4A to 4D are schematic diagrams for describing the operation of the motion detection circuit according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The above and other objects, effects and features of the present invention will become more apparent from the following description of preferred embodiments thereof taken in conjunction with the accompanying drawings. The same reference numerals are used to designate similar parts throughout the figures.
Referring to FIG. 2, a moving-picture processor 16 and a still-picture processor 12, in the same way as those described above with reference to the FIG. 1 system, provide respectively an intrafield interpolated, moving-picture signal IMPS and an interframe and interfield interpolated, still-picture signal ISPS, in response to a picture signal received in an input terminal 10. The signal ISPS from the still-picture processing means 12 will be a signal interpolated by two frames as well as an interfield. Hence, when a movement of picture occurs in two successive frames by movement of an object, the still-picture signal ISPS includes a motion area of the picture signal received.
Both the signals ISPS and IMPS are mixed together in a linear mode by a mixer 22 according to a motion detection signal from a motion detector 24, so that an original picture signal corresponding to a picture signal of the last one of the two successive frames can be obtained by the mixer 22. Therefore, in accordance with the characteristic of the present invention, the motion detector 24 detects a motion area from the picture signal obtained in the preceding frame by the mixer and from the picture signal including a motion area obtained by the interframe interpolation between the current frame of the still-picture processing means 12 and its preceding frame, and thereby provides a motion detection signal with an appropriate value for picture elements located within the detected motion area.
FIG. 3 shows a detailed block diagram of the motion detector 24, in which a frame memory 26 stores the output of the mixer 22. A subtracter 28 provides a difference signal between picture elements of the picture signal obtained in a preceding frame stored in the frame memory 26 and picture elements of the picture signal including the motion area obtained through the interframe interpolation between the current frame of the still-picture processing means 12 and its preceding frame.
An absolute value circuit 30 converts the difference signal between the respective picture elements of the subtracter 28 into an absolute value. Therefore, an output of the absolute value circuit 30 is zero for picture elements corresponding to the still area of the picture signal from the still-picture processing means 12, while it has a certain value for picture elements corresponding to the motion area of the picture signal. As a result, the output of the absolute value circuit 30 will be a value detecting the motion area. However, due to aliasing in the motion area, spot errors may occur in the detected motion area, thereby resulting in an uneven boundary line of the motion area. To eliminate the spot error and smooth the boundary of the motion area, a smoothing circuit 32 is employed. A known intermediate value filter or mean value filter, which takes an intermediate value of three values applied from the absolute value circuit 30 against two picture elements adjacent to a particular picture element, may be employed as the smoothing circuit 32. Though there may be used an intermediate value filter taking an intermediate value of five values if necessary, the known intermediate value filter for three values will be preferable to avoid complication of its circuit construction.
Assuming that a number of bits provided from the smoothing circuit 32 is "n" and an output value of the same smoothing circuit, that is, a detection value of the motion area is "M", a mixing ratio alpha (α) of the mixer 22 will be expressed in a following formula:
α=M/(2.sup.n -1) (1)
In addition, an output signal MS from the mixer will be taken in the following formula:
MS=α·IMPS+(1-α)·ISPS (2)
As understood from the above formula (2), the output of the mixer upon the still area of the picture signal is a picture signal of the still-picture processing means owing to the relationship α=0, and by applying an appropriate value of α to the motion area, reproduction of the original picture will be able to be achieved.
In general, a number of bits in the output of the smoothing circuit 32 is preferably four per picture element, which is to achieve simplification of the circuit in use. However, when the bit number of the output of the smoothing circuit 32 exceeds four, for example, if it is 8-bit or 16-bit, a bit converter for 4-bit converting operation may be used between the smoothing circuit and the mixer. The bit converter may be accomplished by using at least one Read Only Memory (ROM), wherein if taking a 8-bit device, the 4-bit output will be easily achieved by eliminating both the uppermost two bits and the lowermost two bits of the eight bits.
FIGS. 4A to 4D are schematic diagrams for giving easy understanding of the operation according to the inventive motion detection system, wherein FIG. 4A illustrates a case where a circle 40 at (n-1)th frame shifts to a dotted circle 42 at the (n)th frame. Now, it is assumed that the circle 40 was not moved up to the (n)th frame. Then, into the frame memory 26 of the motion detector 24 is stored a picture signal shown in FIG. 4B. Since the picture of FIG. 4B is a picture obtained by a still picture, it can be reproduced without any deterioration of picture quality, which is extremely close to its original picture. If a picture signal of the dotted circle 42 is transmitted at the (n)th frame, a still picture signal ISPS from the still-picture processing means 12 will be a still picture signal of FIG. 4C, obtained by interframe interpolation between the (n-1)th frame and the (n)th frame. As is well understood from FIG. 4C, the signal ISPS has both a signal for a still area 44 and a signal for a motion area 46. Since the moving area 46 of FIG. 4C is an area reproduced irrespectively of the interframe correlation, the picture quality of picture elements in the motion area 46 has deteriorated considerably. In the meantime, the moving picture signal IMPS from the moving-picture processing means 16 is a moving picture signal of FIG. 4D, obtained from the intrafield interpolation by a current frame, that is, the (n)th frame. Hence, the picture signal of FIG. 4B and the still picture signal of FIG. 4C stored into the frame memory 26 are processed at the subtractor 28, and an absolute value of a difference between the two picture signals is generated at the absolute value circuit 30. Accordingly, the output of the absolute value circuit 30 has a given value that is a detection value of its motion area upon the picture elements located in the motion area 46, while it is zero for other picture elements located in the still area 44. This will achieve the detection of a motion area according to the invention.
The operation of the smoothing circuit 32 and the mixer 22 to be continued subsequently, is all the same way as the aforementioned explanation.
As apparent from the aforementioned description of the invention, the motion detection system has the motion detector for detecting the motion area by an absolute value of a difference signal between the output of the mixer and the still picture signal of the still-picture processing means and also for providing a motion area detection signal to smooth boundary lines of the motion area as well as to eliminate spot errors therein, and the mixer for mixing the moving picture signal to the still picture signal under the control of the motion area detection signal, so that it enables easier detection of a motion area and simpler circuit construction, compared to prior motion detection systems.
The foregoing description shows only a preferred embodiment of the present invention. Various modifications are apparent to those skilled in the art without departing from the scope of the present invention which is only limited by the appended claims. Therefore, the embodiment shown and described is only illustrative, not restrictive. | A motion area detector capable of simple detection of a moving picture-area in a HDTV receiver of a multiple subsampling transmission system is disclosed. The motion area detector includes a still-picture processor for reproducing a still picture from a picture signal applied into the detection circuit of the receiver, a moving-picture processor for reproducing a moving picture from the picture signal, a mixer for carrying out a linear mixing operation between the still picture and the moving picture, and a motion detector for detecting a motion area from a mixed picture signal of the mixer and from the still picture signal reproduced by the still picture processor and for providing information concerning a mixing ratio between the still picture and the moving picture. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to a substrate processing apparatus, a method of manufacturing a semiconductor device, and a substrate processing method.
DESCRIPTION OF THE RELATED ART
[0002] With the miniaturization of semiconductors and the increase in the diameter of wafers, the volume of a semiconductor device housing has become large. Therefore, a supply gas flow rate increases as compared with a conventional processing process. Thus, it is difficult to perform an exhaust pressure control in the same manner as a conventional processing process. In order to avoid this, it is essential to increase an amount of exhaust. In order to increase the amount of exhaust, it is necessary to make an exhaust pipe thick and reduce conductance. A main valve is disposed near a reaction chamber so as to shorten a pipe as much as possible. However, if a valve or a pipe is simply made thick, a pipe is laid out in an outer side than a width of a substrate processing apparatus, thus increasing a footprint of the apparatus.
[0003] FIG. 7 illustrates a conventional exhaust system. Pipes 704 a and 704 b are connected to a pump 703 through a main valve (pressure control valve: APC) 702 disposed at a position closest to a reaction chamber 701 . In a conventional processing process, a supply gas flow rate and a pressure control are possible in this system. However, due to an increase in a diameter of a wafer, a flow rate in a process of processing a semiconductor device is increased about 1.5 times as compared with a conventional processing process. Therefore, in order to perform a pressure control, it is necessary to increase a diameter of a pipe (see FIG. 8 ). A layout of a conventional apparatus is illustrated in FIG. 8 . A reaction chamber 701 and an APC 702 are connected through a pipe 704 and are laid out not to come out from a lateral width of the substrate processing apparatus. However, if the diameter of the pipe 704 or the APC 702 increases, the pipe 704 or the APC 702 is disposed to greatly come out from the lateral width of the substrate processing apparatus as illustrated in the layout of FIG. 8 . Therefore, there is a problem that the footprint increases.
SUMMARY OF THE INVENTION
Technical Problem
[0004] The present invention is directed to provide a substrate processing apparatus, a method of manufacturing a semiconductor device, and a substrate processing method, which solve a problem that it is difficult to perform the same exhaust pressure control as the conventional art when a supply gas flow rate is increased by an increase in a volume of a reaction tube due to an increase in a diameter of a substrate to be processed.
Solution to Problem
[0005] In order to achieve the above object, a substrate processing apparatus according to the present invention is a substrate processing apparatus, including: a reaction tube configured to process substrates by carrying in a substrate holder holding a plurality of substrates; a gas supply unit configured to supply a processing gas into the reaction tube; an exhaust unit including at least two exhaust pipes configured to exhaust gas supplied by the gas supply unit, and valves provided in the at least two exhaust pipes to control exhaust amount of the at least two exhaust pipes; and a control unit configured to control the valves provided in the exhaust unit at a predetermined timing.
[0006] Furthermore, a method of manufacturing a semiconductor device includes: carrying in a substrate holder holding a plurality of substrates into a reaction tube; supplying a processing gas from a gas supply unit into the reaction tube; after the process of supplying the processing gas, exhausting the processing gas by an exhaust unit, the exhaust unit including at least two exhaust pipes and at least two valves provided in the at least two exhaust pipes so as to control exhaust amount of the at least two exhaust pipes; and controlling the at least two valves provided in the exhaust unit at a predetermined timing.
[0007] Furthermore, a substrate processing method includes: carrying in a substrate holder holding a plurality of substrates into a reaction tube; supplying a processing gas from a gas supply unit into the reaction tube; and after the process of supplying the processing gas, controlling at least two exhaust pipes and at least two valves so as to adjust exhaust amount of the exhaust pipes.
Advantageous Effects of Invention
[0008] According to the present invention, it is possible to provide a substrate processing apparatus, a method of manufacturing a semiconductor device, and a substrate processing method, which are capable of performing an exhaust pressure control of a processing gas through a simple configuration in association with an increase in a diameter of a substrate to be processed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a substrate processing apparatus that is applied to the present invention.
[0010] FIG. 2 is a side perspective view of the substrate processing apparatus that is applied to the present invention.
[0011] FIG. 3 is a diagram illustrating a configuration of a controller of the substrate processing apparatus to which the present invention is applied.
[0012] FIG. 4 is a schematic longitudinal sectional view of a substrate processing apparatus according to an embodiment of the present invention.
[0013] FIG. 5 is a schematic horizontal sectional view of a substrate processing apparatus according to an embodiment of the present invention.
[0014] FIG. 6 is a diagram illustrating an example of a process event according to an embodiment of the present invention.
[0015] FIG. 7 is a schematic longitudinal sectional view of a substrate processing apparatus according to the related art.
[0016] FIG. 8 is a schematic horizontal sectional view of a substrate processing apparatus, so as to describe the related art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] First, a vertical heat treatment apparatus, which uses an example of the present invention, will be described with reference to FIGS. 1 and 2 . A substrate processing apparatus of FIGS. 1 and 2 is diagrams for describing a configuration of a semiconductor manufacturing apparatus that performs a processing process in a method of manufacturing a semiconductor device (IC). As a substrate processing apparatus, a case where a vertical heat treatment apparatus (hereinafter, simply referred to as a processing apparatus) performing oxidation, a diffusion process, a CVD process, or the like on a substrate is applied will be described below. FIG. 1 is a perspective view of a processing apparatus that is applied to the present invention. Also, FIG. 2 is a side perspective view of the processing apparatus illustrated in FIG. 1 .
[0018] As illustrated in FIGS. 1 and 2 , the processing apparatus 101 of the present invention includes a housing 111 as a substrate processing apparatus body, which uses a FOUP (also called a cassette or a pod, and hereinafter referred to as a pod) 110 as a wafer carrier that accommodates a plurality of wafers (substrates) 200 made of silicon or the like and is used as a storage container. The wafers 200 are transferred in a state of being charged and sealed in the pod 110 .
[0019] As a port disposed to be maintenance-possible, a front maintenance port 103 is disposed in a front anterior portion of a front wall 111 a of the housing 111 . A front maintenance door 104 is provided so as to open and close the front maintenance port 103 . In the maintenance door 104 , a pod carrying-in/carrying-out port 112 is disposed to communicate with the inside and the outside of the housing 111 . The pod carrying-in/carrying-out port 112 is opened and closed by a front shutter 113 . In a front anterior side of the pod carrying-in/carrying-out port 112 , a load port 114 used as a carrying-in/carrying-out portion is provided. The load port 114 is configured such that the pod 110 is placed and aligned. The pod 110 is carried in to the load port 114 and is carried out from the load port 114 by an in-process transfer device (not illustrated).
[0020] In an upper portion of a substantially central part of the housing 111 in a front-back direction, a pod shelf (housing shelf) 105 is provided. The pod shelf 105 is configured to store a plurality of pods 110 at multiple stages along multiple rows. The pod shelf 105 includes a support portion 116 which is vertically erected, and multi-stage placement portions 117 which are held to be independently movable in a vertical direction at each position of the upper, middle, and lower stages with respect to the support portion 116 . The pod shelf 105 is configured to hold a plurality of pods 110 in a state of being placed in the multi-stage placement portions 117 . That is, the pod shelf 105 accommodates a plurality of pods 110 at multiple stages in a vertical direction, for example, by placing two pods 110 to face the same direction on a straight line.
[0021] A pod transfer device (accommodation container transfer mechanism) 118 is installed between the load port 114 and the pod shelf 105 in the housing 111 . The pod transfer device 118 includes a pod elevator 118 a as an a shaft portion which is vertically movable while holding the pods 110 , and a pod transfer portion 118 b as a transfer portion which transfers the pods 110 placed thereon in a horizontal direction. The pod transfer device 118 is configured to transfer the pods 110 among the load port 114 , the pod shelf 105 , and a pod opener 121 by a continuous operation of the pod elevator 118 a and the pod transfer portion 118 b.
[0022] In a lower portion of the substantially central part of the housing 111 in a front-back direction, a sub-housing 119 is built up over a rear end. A pair of wafer carrying-in/carrying-out ports 120 for carrying in and out the wafer 200 with respect to the sub-housing 119 is provided to be opened in a two-upper/lower-stage alignment in a vertical direction in a front wall 119 a of the sub-housing 119 , and a pair of pod openers 121 and 121 is provided at two-upper/lower-stage wafer carrying-in/carrying-out ports 120 and 120 . The pod opener 121 includes placement tables 122 and 122 on which the pod 110 is placed, and cap attaching/detaching mechanisms 123 and 123 which attach and detach a cap of the pod 110 that is used as a sealing member. The pod opener 121 is configured to open and close a wafer loading/unloading port of the pod 110 by attaching and detaching the cap of the pod 110 placed on the placement table 122 by the cap attaching/detaching mechanism 123 .
[0023] The sub-housing 119 constitutes a transfer chamber 124 that is fluidically isolated from an installation space of the pod transfer device 118 or the pod shelf 105 . In a front region of the transfer chamber 124 , a wafer transfer mechanism 125 is installed. The wafer transfer mechanism 125 includes a wafer transfer device 125 a which can rotate or linearly move the wafer 200 in a horizontal direction, and a wafer transfer device elevator 125 b which elevates the wafer transfer device 125 a . As schematically illustrated in FIG. 1 , the wafer transfer device elevator (not illustrated) is installed between a right end portion of a pressure-resistant housing 111 and a right end portion of the front region of the transfer chamber 124 of the sub-housing 119 . Due to a continuous operation of the wafer transfer device elevator 125 b and the wafer transfer device 125 a , tweezers (substrate holder) 125 c of the wafer transfer device 125 a are configured as a placement portion of the wafer 200 such that the wafer 200 is charged and discharged with respect to a boat (substrate holding tool) 217 .
[0024] In a rear region of the transfer chamber 124 , a standby portion 126 is configured to accommodate the boat 217 and make the boat 217 stand by. Above the standby portion 126 , a processing furnace 202 used as a processing chamber is provided. A lower end portion of the processing furnace 202 is configured to be opened and closed by a furnace port shutter 147 .
[0025] As schematically illustrated in FIG. 1 , a boat elevator 115 for elevating the boat 217 is installed between the right end portion of the pressure-resistant housing 111 and the right end portion of the standby portion 126 of the sub-housing 119 . A seal cap 219 as a lid is configured to be horizontally mounted in an arm 128 as a connecting tool connected to an elevation table of the boat elevator 115 , and the seal cap 219 is configured to vertically support the boat 217 and close the lower end portion of the processing furnace 202 .
[0026] The boat 217 includes a plurality of holding members and is configured to horizontally hold a plurality of wafers 200 (for examples, 50 to 125 wafers) in a state of being arranged in a vertical direction, with the centers of the wafers 200 being aligned.
[0027] As schematically illustrated in FIG. 1 , a clean unit 134 is provided in the left end portion being an opposite side of the boat elevator 115 side and the wafer transfer device elevator 125 b side of the transfer chamber 124 . The clean unit 134 includes a supply fan and a dust-proof filter and supplies clean air 133 that is a cleaned atmosphere or inert gas. Although not illustrated, a notch alignment device is installed between the wafer transfer device 125 a and the clean unit 134 as a substrate alignment device which aligns positions of the wafers in a circumferential direction. The clean air 133 blown from the clean unit 134 circulates through the notch alignment device 135 , the wafer transfer device 125 a , and the boat 217 of the standby portion 126 , is suctioned by a duct (not illustrated), and is exhausted to the outside of the housing 111 , or circulates to a primary side (supply side) being a suction side of the clean unit 134 and is blown into the transfer chamber 124 again by the clean unit 134 .
[0028] Next, the operation of the substrate processing apparatus 100 will be described with reference to FIGS. 1 to 3 . In the following description, the operations of the respective components constituting the substrate processing apparatus 100 are controlled by a controller 240 . The configuration of the controller 240 is illustrated in FIG. 3 . The controller 240 controls the pod transfer device 118 , the pod shelf 105 , the wafer transfer mechanism 125 , the boat elevator 115 , and the like through an input/output device 241 . As illustrated in FIGS. 1 and 2 , when the pod 110 is supplied to the load port 114 , the pod carrying-in/carrying-out port 112 is opened by the front shutter 113 , and the pod 110 on the load port 114 is carried in from the pod carrying-in/carrying-out port 112 to the inside of the housing 111 by the pod transfer device 118 . The carried-in pod 110 is automatically transferred and delivered to the designated placement portion 117 of the pod shelf 105 by the pod transfer device 118 and is temporarily stored. Then, the pod 110 is transferred and delivered from the pod shelf 105 to one pod opener 121 and is temporarily stored. Then, the pod 110 is transferred from the pod shelf 105 to one pod opener 121 and is delivered on the placement table 122 , or is directly transferred to the pod opener 121 and is delivered on the placement table 122 . At this time, the wafer carrying-in/carrying-out port 120 of the pod opener 121 is closed by the cap attaching/detaching mechanism 123 , and the clean air 133 is circulated and filled in the transfer chamber 124 . For example, the transfer chamber 124 is filled with a nitrogen gas as the clean air 133 , and an oxygen concentration is 20 ppm or less, which is much lower than an oxygen concentration of the inside of the housing 111 (ambient atmosphere).
[0029] An opening-side end surface of the pod 110 placed on the placement table 122 is pressed against an opening edge portion of the wafer carrying-in/carrying-out port 120 in the front wall 119 a of the sub-housing 119 , and the cap of the pod 110 is detached by the cap attaching/detaching mechanism 123 to open the wafer loading/unloading port. When the pod 110 is opened by the pod opener 121 , the wafer 200 is picked up from the pod 110 through the wafer loading/unloading port by the tweezers 125 c of the wafer transfer device 125 a . After the wafer 200 is aligned by the notch alignment device 135 , the wafer is carried in to the standby portion 126 in the rear side of the transfer chamber 124 and is charged in the boat 217 . The wafer transfer device 125 a which has delivered the wafer 200 to the boat 217 is returned to the pod 110 and charges a next wafer 200 in the boat 217 .
[0030] During the operation of charging the wafer to the boat 217 by the wafer transfer mechanism 125 in one pod opener 121 (upper stage or lower stage), another pod 110 is transferred and delivered by the pod transfer device 118 from the pod shelf 105 to the other pod opener 121 (lower stage or upper stage). The operation of opening the pod 110 by the pod opener 121 is simultaneously performed.
[0031] When a previously designated number of wafers 200 are charged into the boat 217 , the lower end portion of the processing furnace 202 , which has been closed by the furnace port shutter 147 , is opened by the furnace port shutter 147 . Subsequently, the boat 217 holding a group of the wafers 200 is carried in (loaded) to the inside of the processing furnace 202 when the seal cap 219 moves upward by the boat elevator 115 .
[0032] After the loading, any processing is performed on the wafer 200 in the processing furnace 202 . After the processing, except for a wafer matching process in the notch alignment device 135 (not illustrated), the wafer 200 and the pod 110 are delivered in an order reverse to the above description.
[0033] Next, an exhaust system according to the present invention will be described with reference to FIGS. 4 to 6 . FIG. 4 is a schematic longitudinal sectional view of the substrate processing apparatus according to the embodiment of the present invention, and FIG. 5 is a schematic horizontal sectional view of the substrate processing apparatus according to the embodiment of the present invention.
[0034] In the embodiment illustrated in FIG. 4 , a film-forming gas or a doping gas, a processing gas such as an etching gas, a purge gas such as an inert gas, or a mixed gas thereof is supplied into the reaction tube 202 from a gas supply unit 401 passing through the reaction tube 202 (or a support member such as a manifold (not illustrated) which supports the reaction tube). In the embodiment of the present invention, an exhaust pipe is connected to the reaction tube 202 (or the support member such as a manifold (not illustrated) which supports the reaction tube), and the exhaust pipe is configured to become two systems in the same conductance (exhaust amount) at a downstream side of the connection portion with the reaction tube 202 . A variable valve (for example, APC valve or the like, and hereinafter described as APC valve being used) 303 which can control a valve opening degree so as to adjust the exhaust amount by the controller 240 is provided in one exhaust pipe. A fixed valve (hereinafter described as ON/OFF valve) 304 which can control only the ON/OFF switching is provided in parallel in the other exhaust pipe. In this way, the exhaust amount in the processing furnace 202 is controlled. In the embodiment of the present invention, the exhaust pipes which are divided into two systems are merged in the downstream and are connected to an exhaust pump 305 . As illustrated in FIG. 5 , this configuration makes it possible to increase the exhaust amount without greatly increasing the footprint.
[0035] Here, in the embodiment of the present invention, the exhaust system, that is, the exhaust line (exhaust part), is configured by the exhaust pipe, the APC valve 303 , the ON/OFF valve 304 , a pressure sensor (not illustrated), and the like. When necessary, the exhaust pump 305 , a trap device (not illustrated) or a damage prevention device (not illustrated) may be included in the exhaust system.
[0036] Next, an exhaust control method performed using the substrate processing apparatus according to the embodiment of the present invention will be described in detail with reference to FIG. 6 . FIG. 6 is a diagram illustrating an example of a process event according to an embodiment of the present invention.
[0037] In FIG. 6 , a vertical direction represents a pressure inside the reaction tube, and a horizontal direction represents the elapse of time. In the embodiment of the present invention, a process of forming a film by using two types of processing gas with different processing pressures during a deposition process for depositing a desired film will be described.
[0038] As described above, when the boat 217 carrying the wafer 200 is loaded into the processing furnace 202 , it is necessary to reduce a pressure from the atmospheric pressure to a desired pressure by evacuating the processing furnace 202 . At this time, when a large amount of exhaust is rapidly performed by fully opening the APC valve 303 and the ON/OFF valve 304 being the exhaust valves, a load may be applied to the valves or the exhaust pump 305 and each component may be damaged. Therefore, during a predetermined period, the controller 240 performs control such that the APC valve 303 is opened to a predetermined opening degree while the ON/OFF valve is closed. Due to such a control, the processing furnace is slowly exhausted (slow exhaust) (S 1 ).
[0039] After the slow exhaust is performed for the previously determined time, or after the pressure is reduced to a desired slow exhaust pressure, the exhaust is performed at a maximum exhaust amount by opening the ON/OFF valve 304 while fully opening the valve opening degree of the APC valve 303 until a desired vacuum exhaust pressure is achieved (S 2 ). At this time, as illustrated in FIG. 6 , the control may be performed such that when the pressure becomes the desired vacuum exhaust pressure, that pressure is maintained (S 2 ).
[0040] When the processing furnace has the desired vacuum exhaust pressure, a furnace purge is performed by supplying an inert gas such as N 2 so as to clean the furnace (S 3 ). At this time, in order to maintain a furnace purge pressure, the pressure control is performed by closing the ON/OFF valve 304 and controlling the opening degree of the APC valve 303 through the controller 240 .
[0041] After the furnace purge is performed for the previously determined time, the purge gas is completely exhausted (S 4 ), and then, a processing gas A is supplied (S 5 ). In order to maintain the processing pressure P 1 during the supply of the processing gas A, the pressure control is performed by closing the ON/OFF valve 304 and controlling the opening degree of the APC valve 303 through the controller 240 . At this time, as illustrated in FIG. 6 , the control may be performed such that when the pressure becomes the desired vacuum exhaust pressure, that pressure is maintained (S 4 ).
[0042] When the processing process using the processing gas A is completed, a processing process using a processing gas B is performed.
[0043] After the supply of the processing gas A, in order to exhaust the processing gas A, the exhaust is performed at a maximum exhaust amount by opening the ON/OFF valve 304 while fully opening the valve opening degree of the APC valve 303 until a desired vacuum exhaust pressure is achieved (S 2 ′).
[0044] When the processing furnace has a predetermined vacuum exhaust pressure, a furnace purge is performed by supplying an inert gas such as N 2 so as to clean the furnace (S 3 ′). At this time, in order to maintain a furnace purge pressure, the pressure control is performed by closing the ON/OFF valve 304 and controlling the opening degree of the APC valve 303 through the controller 240 .
[0045] After the furnace purge is performed for the previously determined time, the purge gas is completely exhausted (S 4 ′), and then, a processing gas B is supplied (S 5 ′). In order to maintain the processing pressure P 2 during the supply of the processing gas B, the pressure control is performed by closing the ON/OFF valve 304 and controlling the opening degree of the APC valve 303 through the controller 240 . By performing these operations S 2 to S 5 ′ once or more, it is possible to form a film or a stacked film such as a laminated structure having a desired thickness.
[0046] Hereinafter, the sequence of the present embodiment will be described in detail. Here, when assuming that the processing gas A is a titanium (Ti)-containing gas and the processing gas B is a nitrogen-containing gas, a processing process of forming a titanium nitride film (TiN film) by using these gas will be described as an example.
[0047] As the titanium-containing gas, for example, titanium tetrachloride (TiCl 4 ) or tetrakis dimethyl amino titanium (Ti[N(CH 3 ) 2 ] 4 , abbreviation: TDMAT) may be used. As the nitrogen-containing gas, gas obtained by exciting an N 2 gas, an NF 3 gas, and an N 3 H 8 gas by plasma or heat as well as gas obtained by exciting an NH 3 gas by plasma or heat may be used. Gas obtained by diluting these gas with a rare gas such as argon (Ar), helium (He), neon (Ne), or xenon (Xe) gas may be excited by plasma or heat and used.
[0048] When the plurality of wafers 200 is charged into the boat 217 (wafer charging), as illustrated in FIG. 1 , the boat 217 supporting the plurality of wafers 200 is lifted by the boat elevator 115 and is loaded into the processing chamber (reaction chamber) of the reaction tube 202 (boat loading). In this state, the seal cap 219 is in a state of sealing the lower end portion of the reaction tube 202 through an O-ring 220 .
[0049] The processing furnace is evacuated by the vacuum pump 305 such that the inside of the processing furnace has a desired pressure (vacuum degree). At this time, the pressure inside the processing furnace is measured by a pressure sensor (not illustrated). The processing furnace is slowly exhausted by a feedback control performed by the controller 240 such that the ON/OFF valve 304 is in an OFF state for a predetermined time and the APC valve 303 is opened to a predetermined opening degree, based on the measured pressure (S 2 ).
[0050] When it is detected by the pressure sensor that the pressure inside the processing furnace is reduced to the desired pressure by the slow exhaust, the controller 240 controls the APC valve 303 and the ON/OFF valve 304 such that the opening degree of the APC valve 303 is fully opened to the maximum exhaust amount and the ON/OFF valve 304 is opened.
[0051] (Furnace Purge Process S 3 )
[0052] When the processing furnace has the desired pressure (vacuum exhaust pressure), the furnace purge is performed by supplying an inert gas such as N 2 gas, which is a purge gas for cleaning the furnace (S 3 ). At this time, the controller 240 performs the pressure control by closing the ON/OFF valve 304 and controlling the opening degree of the APC valve 303 , so that the pressure inside the furnace becomes the purge pressure.
[0053] (Processing Gas A Supply Process S 5 )
[0054] After the furnace purge is performed for the previously determined time, the controller 240 stops supplying the inert gas and controls the opening degree of the APC valve 303 to completely exhaust the insert gas supplied to the processing furnace (S 4 ). After that, the titanium-containing gas, which is the processing gas A, is supplied (S 5 ). At this time, the inside of the processing chamber 201 is heated by a heater (not illustrated) to be a desired temperature. At this time, the energization state of the heater is feedback-controlled based on temperature information detected by a temperature sensor (not illustrated), such that the inside of the processing chamber 201 has a desired temperature distribution (temperature adjustment). The wafer 200 is rotated by the rotation of the boat 217 by a rotation mechanism (not illustrated) (wafer rotation).
[0055] In the processing furnace 202 , the titanium-containing gas is supplied to the wafer 200 for a predetermined time. The controller 240 controls the APC valve 303 and the ON/OFF valve 304 such that the processing furnace 202 has a predetermined processing pressure P 1 (for example, the controller 240 performs control such that both of the APC valve 303 and the ON/OFF valve 304 are closed, or only the APC valve 303 is opened to a predetermined opening degree). By supplying the titanium-containing gas, the titanium-containing gas contacts the surface of the wafer 200 to form a titanium-containing layer as a “first element-containing layer” on the surface of the wafer 200 . The titanium-containing layer is formed to have a predetermined thickness and a predetermined distribution according to, for example, the pressure inside the processing furnace 202 , the flow rate of the titanium-containing gas, and the processing time in the processing furnace 202 . After the elapse of a predetermined time, the controller 240 stops supplying the titanium-containing gas.
[0056] (Processing Gas A Exhaust Process S 2 ′)
[0057] After the supply of the titanium-containing gas is stopped, the controller 240 performs control such that the titanium-containing gas existing within the processing furnace 202 is exhausted by fully opening the APC valve 303 and opening the ON/OFF valve 304 , and the processing furnace 202 has a desired pressure (vacuum exhaust pressure) (S 2 ′).
[0058] (Furnace Purge Process S 3 ′)
[0059] When the processing furnace has the desired pressure (vacuum exhaust pressure), the furnace purge is performed by supplying an inert gas such as N 2 gas, which is a purge gas for cleaning the furnace (S 3 ′). At this time, the controller 240 performs the pressure control by closing the ON/OFF valve 304 and controlling the opening degree of the APC valve 303 , so that the pressure inside the furnace becomes the purge pressure.
[0060] (Processing Gas B Supply Process S 5 ′)
[0061] After the furnace purge is performed for the previously determined time, the controller 240 stops supplying the inert gas and controls the opening degree of the APC valve 303 to completely exhaust the insert gas supplied to the processing furnace (S 4 ′). After that, the nitrogen-containing gas, which is the processing gas B, is supplied (S 5 ′).
[0062] In the processing furnace 202 , the nitrogen-containing gas excited by plasma or heat is supplied on the wafer 200 for a predetermined time. The titanium-containing layer already formed on the wafer 200 is modified by the excited nitrogen-containing gas, thereby forming a TiN layer containing the titanium element and the nitrogen element on the wafer 200 .
[0063] The modified layer containing the titanium element and the nitrogen element is formed to have a predetermined thickness, a predetermined distribution, and a penetration depth of a predetermined nitrogen component with respect to the titanium-containing layer, for example, according to the pressure inside the processing furnace 202 , the flow rate of the excited nitrogen-containing gas, or the like. After the elapse of a predetermined time, the controller 240 stops supplying the nitrogen-containing gas.
[0064] (Processing Gas B Exhaust Process)
[0065] After the supply of the nitrogen-containing gas is stopped, the controller 240 performs control such that the nitrogen-containing gas existing within the processing furnace 202 is exhausted by fully opening the APC valve 303 and opening the ON/OFF valve 304 , and the processing furnace 202 has a desired pressure (vacuum exhaust pressure).
[0066] By performing these operations S 2 to S 5 ′ once or more, it is possible to form a TiN film having a desired thickness.
[0067] As described above, according to the present invention, since it is unnecessary to increase the diameter of the exhaust pipe or increase the size of the exhaust valve, it is possible to achieve the effect that can perform the same pressure control as the related art while suppressing an increase in the footprint.
[0068] In addition, as described above, the embodiment of the present invention has been specifically described, but the present invention is not limited to the above-described embodiment. Various modifications can be made without departing from the scope of the present invention and the effects can also be achieved according to the modifications.
[0069] For example, in the above-described embodiment of the present invention, in the furnace purge processes S 3 and S 3 ′ and the processing gas A and processing gas B supply processes S 5 and S 5 ′, the pressure inside the furnace is controlled by closing the ON/OFF valve 304 and controlling the opening degree of the APC valve 303 , but the present invention is not limited thereto. The control may be performed to maintain the pressure inside the furnace by closing both the APC valve 303 and the ON/OFF valve 304 . In addition, when the control of the pressure inside the furnace, for a cleaning process or the like other than above-described processes, is required, the pressure control may be performed using the APC valve 303 . Furthermore, when an exhaust, in which the control of the pressure inside the furnace is unnecessary, for a vacuum exhaust process or the like other than the above-described processes, is required, the ON/OFF valve 304 may be used.
[0070] In addition, in the above-described embodiment of the present invention, it has been described that one of at least two valves provided in the exhaust pipe is the APC valve, and the other valve is the valve that can control only the ON-OFF switching, but the present invention is not limited thereto. Both valves may use the APC valves that can control the valve opening degree. Furthermore, the type of the valve is not limited to the APC valve. Any variable valve may be used as long as the valve opening degree of the valve can be controlled by the controller and the valve can change the conductance.
[0071] In addition, in the above-described embodiment of the present invention, it has been described that the exhaust amount when the opening degree of the APC valve is maximum and the exhaust amount when the ON-OFF valve is opened are provided to be equal to each other, but the present invention is not limited thereto. The exhaust amount when the opening degree of the APC valve is maximum and the exhaust amount when the ON-OFF valve is opened may be different from each other. For example, the exhaust amount when the ON-OFF valve is opened may be larger than the exhaust amount when the opening degree of the APC valve is maximum. The exhaust amount when the ON-OFF valve is opened may be smaller than the exhaust amount when the opening degree of the APC valve is maximum.
[0072] In addition, in the above-described embodiment of the present invention, the process of forming the titanium nitride film (TiN film) by using the titanium (Ti)-containing gas as the processing gas A and the nitrogen-containing gas as the processing gas B. However, a silicon nitride film (SiN film) may be formed by using silicon (Si)-containing gas as the processing gas A and a nitrogen-containing gas as the processing gas B. A silicon oxide film (SiO film) may be formed by using silicon-containing gas as the processing gas A and an oxygen-containing gas as the processing gas B. An aluminum nitride film (AlN film) may be formed by using aluminum (Al)-containing gas as the processing gas A and a nitrogen-containing gas as the processing gas B. An aluminum oxide film (AlO film) may be formed by using aluminum (Al)-containing gas as the processing gas A and an oxygen-containing gas as the processing gas B. In this case, as the silicon-containing gas, for example, organic raw materials, such as aminosilane-based tetrakis dimethyl amino silane (Si(N(CH 3 ) 2 )) 4 , abbreviation: 4DMAS) gas, trisdimethylaminosilane (Si(N(CH 3 ) 2 )) 3 H, abbreviation: 3DMAS) gas, bis diethylaminosilane (Si(N(C 2 H 5 ) 2 ) 2 H 2 , abbreviation: 2DEAS) gas, bis-tertiary-butyl-amino-silane (SiH 2 (NH(C 4 H 9 )) 2 , abbreviation: BTBAS) gas, as well as inorganic raw materials, such as dichlorosilane (SiH 2 Cl 2 , abbreviation: DCS) gas, tetrachlorosilane (SiCl 4 , abbreviation: TCS) gas, hexachlorodisilane (Si 2 Cl 6 , abbreviation: HCD) gas, and monosilane (SiH 4 ) gas can be used. As the oxygen-containing gas, for example, oxygen (O 2 ) gas, ozone (O 3 ) gas, nitric oxide (NO) gas, nitrous oxide (N 2 O) gas, and water vapor (H 2 O) can be used. As the aluminum-containing gas, for example, trimethylaluminum (Al(CH 3 ) 3 , abbreviated: TMA) can be used.
[0073] In addition, in the above-described embodiment of the present invention, the processing process using the processing gas A and the processing gas B has been described, but the present invention is not limited thereto. The processing processes S 2 to S 5 using only the processing gas A may be repeatedly performed.
[0074] As the substrate processing apparatus 101 , the semiconductor manufacturing apparatus is configured to perform the method of manufacturing the semiconductor device (IC), but the present invention can also be applied to an apparatus for processing a glass substrate, such as an LCD device, as well as the semiconductor manufacturing apparatus.
[0075] Examples of the film-forming process performed by the substrate processing apparatus 101 include a CVD, a PVD, an ALD, an Epi, a process of forming an oxide film or a nitride film, and a process of forming a metal-containing film. Furthermore, the film-forming process may include an annealing processing, an oxidation process, a diffusion process, and the like.
[0076] In addition, in the present embodiment, the substrate processing apparatus is described as the vertical processing apparatus 101 , but the present invention can be equally applied to a single-wafer type device. Furthermore, the present invention can be equally applied to an etching apparatus, an exposure apparatus, a lithography apparatus, a deposition apparatus, a molding apparatus, a development apparatus, a dicing apparatus, a wire bonding apparatus, an inspection apparatus, and the like.
[0077] <Preferred Aspects of Present Invention>
[0078] Hereinafter, preferred aspects of the present invention will be additionally described.
[0079] (Supplementary Note 1)
[0080] A substrate processing apparatus including: a reaction tube configured to process substrates by carrying in a substrate holder holding a plurality of substrates; a gas supply unit configured to supply a processing gas into the reaction tube; an exhaust unit including at least two exhaust pipes configured to exhaust gas supplied by the gas supply unit, and valves provided in the at least two exhaust pipes to control exhaust amount of the at least two exhaust pipes; and a control unit configured to control the valves provided in the exhaust unit at a predetermined timing.
[0081] (Supplementary Note 2)
[0082] The substrate processing apparatus as described in Supplementary Note 1, in which the valves include at least one variable valve configured to adjust exhaust amount according to the control of the control unit.
[0083] (Supplementary Note 3)
[0084] The substrate processing apparatus as described in Supplementary Note 2, in which the control unit adjusts the pressure inside the reaction tube to a second pressure by controlling the at least one variable valve and closing the other valves until the pressure inside the reaction tube changes from an atmospheric pressure to a first pressure and opening all of the other closed valves and the variable valves when the pressure inside the reaction tube reaches the first pressure; adjusts the pressure inside the reaction tube to a third pressure by controlling the at least one variable valve and closing the other valves during the process of cleaning the reaction tube; adjusts the pressure inside the reaction tube to the second pressure by opening all of the at least one variable valve and the other valves after the cleaning process; and controls the gas supply unit to supply the processing gas to the reaction tube after the pressure inside the reaction tube reaches the second pressure.
[0085] (Supplementary Note 4)
[0086] A method of manufacturing a semiconductor device including: carrying in a substrate holder holding a substrate into a reaction tube; supplying a processing gas from a gas supply unit into the reaction tube; after the process of supplying the processing gas, exhausting the processing gas by an exhaust unit, the exhaust unit including at least two exhaust pipes and at least two valves provided in the at least two exhaust pipes so as to control exhaust amount of the at least two exhaust pipes; and controlling the at least two valves provided in the exhaust unit at a predetermined timing.
[0087] (Supplementary Note 5)
[0088] A method of manufacturing a semiconductor device including: carrying in a substrate holder holding a of substrate into a reaction tube; at least two exhaust pipes connected to the reaction tube to exhaust an atmosphere in the reaction tube and valves connected to the exhaust pipe, at least one of which is a variable valve capable of changing an exhaust amount being provided, exhausting the reaction tube from an atmospheric pressure to a first pressure by controlling the variable valve; after the pressure inside the reaction tube is exhausted from the atmospheric pressure to the first pressure, exhausting the reaction tube to a second pressure by opening all of the variable valve and the other valves; after the process of exhausting to the second pressure, purging the inside of the reaction tube by supplying a purge gas by a gas supply unit provided in the reaction tube; after the supply of the purge gas, exhausting the reaction tube again to the second pressure by opening all of the variable valve and the other valves; and after the pressure inside the reaction tube reaches the second pressure again, forming a desired film by supplying the processing gas by the gas supply unit.
[0089] (Supplementary Note 6)
[0090] The substrate processing method including: carrying in a substrate holder holding a substrate into a reaction tube; supplying a processing gas from a gas supply unit into the reaction tube; and after the process of supplying the processing gas, controlling at least two exhaust pipes and at least two valves for adjusting exhaust amount of the exhaust pipes at a predetermined timing.
[0091] (Supplementary Note 7)
[0092] A substrate processing method including: carrying in a substrate holder holding a substrate into a reaction tube; supplying a processing gas from a gas supply unit into the reaction tube; at least two exhaust pipes connected to the reaction tube to exhaust an atmosphere in the reaction tube and valves connected to the exhaust pipe, at least one of which is a variable valve capable of changing an exhaust amount being provided, exhausting the reaction tube from an atmospheric pressure to a first pressure by controlling the variable valve; after the pressure inside the reaction tube is exhausted from the atmospheric pressure to the first pressure, exhausting the reaction tube to a second pressure by opening all of the variable valve and the other valves; after the process of exhausting to the second pressure, purging the reaction tube by supplying a purge gas by a gas supply unit provided in the reaction tube; after the supply of the purge gas, exhausting the reaction tube again to the second pressure by opening all of the variable valve and the other valves; and after the pressure inside the reaction tube reaches the second pressure again, forming a desired film by supplying the processing gas by the gas supply unit.
INDUSTRIAL APPLICABILITY
[0093] As described above, the present invention can be used in a substrate processing apparatus, a method of manufacturing a semiconductor device, and a substrate processing method, which are capable of performing an exhaust pressure control of processing gas in association with an increase in the diameter of a substrate to be processed by a simple configuration.
REFERENCE SIGNS LIST
[0000]
101 substrate processing apparatus
110 pod
124 transfer chamber
200 wafer (substrate)
202 reaction tube
217 boat
240 controller
303 APC valve (variable valve)
304 valve (ON/OFF valve)
401 gas supply unit | With the miniaturization of semiconductors and the increase in the diameter of wafers, the wafer size increases. Therefore, a supply gas flow rate also increases as compared with a process of a conventional wafer size. Thus, it is difficult to perform an exhaust pressure control in the same manner as a conventional processing process. ON/OFF valves provided in a plurality of exhaust pipes communicating with a processing chamber and a vacuum pump, and a controller configured to control the ON/OFF valves are provided, and it is possible to cope with the increase in the diameter of the wafer by performing a valve on/off and pressure control operation in a process event. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to a method and apparatus for assembling a stack of business forms in a test dummy and more particularly to an improved and more versatile method and manually operable apparatus for economically assembling print out paper for on site test purposes to more accurately reflect actual operating conditions.
2. Summary of the Prior Art
Computer print out paper or business forms are arranged in a stack, which today contain as many as, for example, 15 copies and interleaved carbons for imprinting by computer print out machines, as against only three or four copies used in previous years. These copies must be accurately imprinted, however the great variety in the character of the paper, the carbons and the type and condition of the print-out machine requires that the paper and carbon be carefully selected and positioned in accordance with the character of the machine in order to accurately imprint all copies in stacks of this size.
It is therefore a custom in the business of supplying such forms to test the paper prior to purchase by running a test dummy or stack through the customer's print-out machine to simulate actual running or operating conditions for determining such factors as proper paper weight or character.
In such facsimile of operating conditions, the salesman will make up a stack or manifold of business forms containing a desired number of papers of various thicknesses at selected locations in the stack together with interleaved carbon paper. The carbon paper is required in the event the paper does not have transfer means. This is usually done by inserting the paper sheets and interleaved carbon in a pocket carrier strip to which the front and back sheets of the stack are pasted with a window in the carrier permitting printing of the stack. Since the carrier is quite thick, adjustment of the print out machine to reflect the actual stack thickness is not feasible nor is proper tension provided on the paper, since only the carrier feed holes are engaged with the printer traction pins during the test run. Thus most of the forms and their carbons are simply floated in the carrier. In addition the window in the carrier being cut to a smaller dimension than the paper creates a framing effect and an unrealistic print image.
Another approach is to use live samples for the test run. The use of live samples on the other hand often requires the acquisition of a stack of previously manufactured paper forms, peeling them apart and re-collation or recombination to create the desired combinations. There is no effective means of fastening the stack of re-combinations, which are therefore difficult to run. Since the old carbon paper in the original stack can provide a better image than fresh carbon paper these re-combined stacks are in addition to being time consuming to assemble also are inappropriate for accurately reflecting actual operating or running conditions.
A third approach is to machine manufacture the test samples prior to test, however, so many combinations of paper numbers and thicknesses are required that this is not a viable alternative, especially since an inventory is necessary to avoid setting up the machine just prior to a test. An inventory in turn leads to aging of the carbon paper.
Because of the many variables and the failure of the test dummies to accurately reflect operating conditions, disputes often arise as to the source of subsequent problems, which may lie either in the paper, the carbon or in the machine adjustment or character.
SUMMARY OF THE INVENTION
The present invention proposes a solution to the aforementioned problems by providing a test dummy comprising a stack or manifold of business forms which accurately simulate operating conditions. This is done despite the large stack thickness and large number of required holes by means of portable apparatus enabling the facile manual simultaneous perforation and crimping of the stack. The crimping holds the papers of the stack together for forming a test dummy. The perforations fit the printer traction pins so that each paper is under tension. The need for a carrier therefore is eliminated so that the printer or print out machine may be adjusted for actual stack thickness. In addition a group of said stacks are spliced in end-to-end relationship to form a web and so that they can be folded zig-zag fashion in a pile for simulating the actual condition in which they are drawn in sequence to the printer.
The portable manually operable perforating and crimping apparatus is carried on a common base plate so that a number of diffirent stacks may be easily assembled on the customer's premises. The plate also carries a splicing jig to permit the stacks to be assembled in serial end-to-end relationship to form a web.
The perforating and crimping apparatus includes a punch and die assembly of economical manufacture utilizing a common cam surface to simultaneously operate both the perforating and crimping punches carried in a common punch holder. The perforating punches are located in vertically offset positions so that they sequentially perforate the stack with a minimum of manual force.
With this arrangement test dummies or stacks may be easily made up on site with different numbers or paper thicknesses and/or carbon combinations and when a suitable combination is found, it may be cut into separate portions each containing the papers of the stack and one portion retained by the customer and the others by the vendor and manufacturing plant respectively for subsequent reference and comparison with the later delivered product to resolve questions or disputes.
It is therefore among the primary objects of the present invention to provide an improved and more economical method and/or apparatus for forming a business form test dummy capable of providing an accurate facsimile of actual operating conditions.
Other objects and features of the present invention will become apparent on examination of the following specification and claims together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view partially broken apart and partially exploded of the apparatus utilized in practicing the invention.
FIG. 2 is a front elevational view partially broken away of the apparatus shown in FIG. 1.
FIG. 3 is a sectional view taken generally along the line 3--3 in FIG. 2.
FIG. 4 is a sectional view taken generally along the line 4--4 of FIG. 2, and
FIG. 5 is a fragmentary enlarged view of a portion of the stack to illustrate the perforation and crimping.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An assembly 10 for manually perforating and crimping a stack or sandwich 12 of test dummy business forms with interleaved carbon papers is shown in FIGS. 1 and 2. The assembly 10 is a dummy maker and comprises a base plate 14 having an elongate punch and die set or assembly 16 located parallel to and adjacent one edge of the plate 14. A splicing jig assembly 18 is located adjacent another edge of plate 14 transverse to the one edge. A stop rail or locating bar 20 is positioned parallel to the elongate axis of the assembly 16 for locating one edge of the stack 12 relative the assembly 16. A second stop rail or locating bar 22 extends perpendicular to bar 20 and along a perpendicular edge of plate 14 spaced from the splicing jig assembly 18 to properly position the stack 12 longitudinally relative the punch and die assembly 16.
The punch and die assembly 16 comprises a support plate 24 which is fixed to plate 14 along one nestingly engaged overlapping edge of each plate. Plate 24 includes a die block portion 26 between a pair of standards or guide blocks 28.
The die block portion 26 is provided with a series of perforating dies 30 seen in FIG. 2 longitudinally aligned parallel to the longitudinal axis of the block 26 and a smaller series of crimp or lance die buttons 32 also longitudinally aligned parallel to but offset from the series of perforating dies 30 for enabling the stack 12 to be perforated and crimped in one operation.
A punch holder 34 is located above the die block portion 26 with the ends of the holder 34 located in and guided by the standards 28 for movement perpendicular to the plane of plate 14. The punch holder 34 carries a series of perforating punches 36 each aligned with a respective one of the perforating dies 30 and a series of crimp or lance punches 38 each aligned with a respective one of the lance dies or buttons 32. The perforating dies 30 and flat face punches 36 together with lance dies 32 and punches 38 are of conventional design and fixed in the respective block for perforating the stack 12 in a conventional fashion with as many as twenty two 5/32 inch perforations spaced on 0.5 inch centers and as many as five crimps. The punch holder 34 is biased upwardly from the die block portion 26 by a pair of spaced springs 40 each located adjacent a respective one of the standards 28.
The locating bar 20 is actually fixed to one edge of plate 24 and it carries a guide plate or stripper 42 which extends between the die block portion 26 and the punch holder 34 for guiding and holding stack 12 between the punches and dies. A series of openings 44 and 46 each aligned with one of the perforating punches and lance punches respectively are formed in the guide plate 42 to permit the punches to pass therethrough. The guide plate 42 also has the important function of preventing the endge of any papers in stack 12 from overriding the bar 20 and becoming misaligned.
A solid elongate cam 48 is engaged with the upper surface of the punch holder 34 and is pivotally supported adjacent the upper ends of the standards 28 for eccentric movement of the accurate cam surface to move the punch holder 34 toward the plate 24.
The cam 48 is provided with a flat surface portion which engages the flat upper surface of the punch holder in the home or rest position of the punch holder as best seen in FIG. 4. The flat surface portion on the cam provides a rest position for the cam in the normal upward movement of the punch holder under the spring force, since the corners of the flat resist additional rotation and ensures that the cam has a stable orientation relative the punch holder. A wire or rod handle 50 having spaced legs fixed to the cam 48 permits the cam 48 to be manually rotated about the pivot against the bias of springs 40 for driving the punch holder 34 downwardly to perforate and crimp the stack 12. It will be noted that the cam 48 is provided with a continuous surface in engagement with a continuous surface on the punch holder extending between the spaced punches to simplify the construction of the cam and punch holder. In addition the handle provides considerable force multiplication, since the handle length is substantially longer than the maximum cam radius.
The flat faced punches 36 project different distances below the punch holder 34 so that they engage the stack at different portions of the perforating and crimping stroke or cycle. Thus different groups or gangs of punches 36 perforate the stack 12 in sequence substantially reducing the manual force required to operate the ganged punches.
A canopy or housing 52 is fixed to the upper surface of the standards 28 and it has a pair of spaced slots 54 through which the handle legs pass with the back wall of the slots serving to prevent the cam from being driven in a direction reverse to that for proper perforation and crimping.
The splicing jig 18 comprises two pair of bullet nosed locating pins 56, 58, 60 and 62 with one pair of pins 56 and 58 spaced from the other pair of pins 60 and 62 by a distance sufficient to accommodate the edges of two stacks as indicated by the lines 12 and 12a in FIGS. 2 and 3. The pins 58 and 62 are carried in a block 64 having dovetail edges for receipt in a dovetail guide 66 formed in plate 14 to permit longitudinal adjustment of pins 58 and 62 relative pins 58 and 60 under control of a stop nut 68. The block 64 is reversible in the guide 66 for positioning pins 58 and 62 to receive either the 81/2 inch or 11 inch edge of the forms respectively.
In operation a stack 12 is formed by collating a desired number of business forms or papers of selected thickness at various positions in the stack, which is appropriately interleaved with carbon paper, if the forms do not carry reproducing means. The stack which may contain as many as fifteen forms and fourteen carbons is inserted beneath guide plate 42 and between the punch holder 34 and the die block portion 26 with one 81/2 inch or 11 inch edge, as required, of the stack 12 located against the bar 20 and a perpendicular or transverse edge of the stack abutting bar 22 to properly locate the stack relative the punches and dies. The handle 50 is now operated in the direction of arrow 70 to rotate the cam 48 through an arc, which drives the punch holder 34 far enough toward the plate 24 against the bias of the springs 40 and with sufficient force to perforate and crimp the stack. The force necessary to perforate the stack is greatly reduced by the projecting ends of the punches engaging the stack at three different portions of the cycle to avoid the large manual force required to simultaneously pierce all holes with the large numbers and size of the punches. The handle size and length provides sufficient leverage to be exerted for perforating the stack.
The stack being perforated and crimped along one edge as indicated by the perforation 72 and crimp 74 shown in FIG. 5 is now removed from between the punch holder and die block and the opposite edge of the stack inserted for perforating and crimping the opposite stack edge. With the stack perforated and crimped along both edges it is now held securely together by the crimp and may be easily handled.
When several stacks or manifolds have been composed, the perforations of one stack 12 may be engaged with pins 56 and 58, while the corresponding perforations of another stack 12a are engaged with pins 60 and 62 of the splicing jig 18 and shown in FIGS. 2 and 3. The exposed surface of each stack between the pins is now taped with a conventional splicing tape and the two stacks removed from the pins and the opposite surface between the two edges taped after alignment on the pins of the splicing jig. The pins 58 and 62 are of course adjustably positioned relative pins 56 and 60 to accommodate different paper widths or perforation spacing. In this manner a series of stacks may be strung serially together and these may be folded along the taped edges to form a package for simulating a complete run through the print out machine.
After a run in which a satisfactory paper combination is found, the stack may be sliced into parts with one part left with the purchaser and the other parts retained by the vendor or manufacturer for further or future comparison or reference in the event of a question as to whether a fault lies with the paper or with the machine adjustment.
The foregoing constitutes a description of an improved method and/or apparatus for forming a test dummy of business forms whose inventive concepts are believed set forth in the accompanying claims. | The following specification describes a method together with portable apparatus for forming on site test dummies of stacks of business forms to provide a facsimile of actual conditions under which the paper is imprinted. This is done by simultaneously manually perforating and crimping a stack of paper containing a desired number and type then aligning a plurality of serially arranged stacks in a web by means of a splicing jig to enable the simulation of an actual run. The portable apparatus includes a plate carrying perforating and crimping dies and punches together with the splicing jig. The punches are operated by a cam having a continuous surface engaged with a punch holder. The punches protrude from the holder by different distances so that they pierce the paper at different times to reduce the manual force required for operation. | 1 |
RELATED APPLICATIONS
[0001] The present U.S. non-provisional patent application is related to and claims priority benefit of the U.S. provisional patent application titled METHOD OF PRODUCING RECOMBINANT PLASMID DNA, Ser. No. 61/516,795, filed Apr. 8, 2011. The identified prior-filed application is hereby incorporated by reference into the present application as though fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention broadly relates to methods for producing recombinant plasmid deoxyribonucleic acid (DNA).
[0004] 2. Background
[0005] The field of recombinant plasmid DNA is rapidly expanding. Uses for this technology include non-viral gene therapeutics, DNA vaccines, and gene substitution vectors. Several recombinant plasmid DNA products are currently approved and licensed for veterinary applications, and several more are moving toward clinical trials as human vaccines. One obstacle standing in the way of commercializing this technology is the difficulty of efficiently and cost-effectively producing large amounts of the recombinant plasmid DNA, including problems with efficiently and cost-effectively generating a sufficient biomass of the host organism. Furthermore, different forms of recombinant plasmid DNA can require different production methods.
[0006] The prior art industrial production process 10 , shown in FIG. 1 , uses bio-reactors for large-scale liquid fermentation 12 in large culture volumes to generate a large amount of the host organism. Costly facilities and equipment are required to produce large amounts of product. Metabolic overload and stress is a common problem because the host cell is burdened with plasmid maintenance. Furthermore, the prior art fermentation process requires intense process development and tight control of process parameters such as carbon source concentration, temperature, pH, and dissolved oxygen. To increase product yields and ensure consistent product quality, key issues of conventional liquid fermentation process optimization and scale-up are aimed at maintaining optimum and homogenous reaction conditions, minimizing microbial stress exposure, and enhancing metabolic accuracy. For example, host cells close to the nutrient injection port are exposed to a high concentration of nutrients whereas cells at other locations are starved of substrate; the pressurized culture regime used to increase oxygen transfer may enhance the detrimental effect of carbon dioxide; and high cell density cultures, especially in large-scale fermentation, can generate detrimental levels of heat.
[0007] The problem of insufficient mixing at larger scales is aggravated by increasing vessel sizes: The opposing substrate and oxygen gradients along the vessel height, which are formed as a result of conventional fermenter design in which substrate feed usually occurs from the top and aeration usually occurs from the bottom, are more pronounced in larger reactors due to the longer distances to be covered. This leads to larger substrate and oxygen depletion zones, larger volumes of culture broth to be stirred, longer mixing times, and stronger hydraulic pressure gradients influencing the oxygen-transfer rate. In the case of glucose feeding, cells at the top of the fermenter are exposed to excess glucose concentrations and simultaneously suffer from oxygen limitations, whereas those at the bottom suffer from glucose starvation. Excess glucose concentrations result in overproduction of acetate, and the simultaneous deficiency of oxygen induces the formation of ethanol, hydrogen, formiate, lactate, and succinate.
[0008] Plasmid stability is the stable propagation of plasmids to daughter cells, and is an essential prerequisite for high product yields particularly in larger-scale production in which cultures pass a higher number of generations due to larger culture broth volumes and longer inoculation chains from the cell bank to the production stage. Plasmid stability is influenced by the plasmid properties as well as by process parameters like temperature, growth rates, and substrate concentrations. Thus, plasmid stability and plasmid numbers are adversely influenced, more difficult to control, and less easy to maintain in conventional larger-scale liquid fermentation.
[0009] Complex medium components are also a major source of process variability in liquid fermentation. For example, major constraints of high productivity recombinant bio-molecule expression during aerobic growth of Escherichia coli are the secretion of acetic acid, the effect of the medium, the effect of dissolved oxygen, and the lowering of the specific cellular protein yield.
[0010] Due to these and other problems and disadvantages in the prior art, a need exists for an improved method of producing recombinant plasmid DNA.
SUMMARY OF THE INVENTION
[0011] The present invention addresses the above-discussed problems and disadvantages in the prior art to provide an improved method of producing recombinant plasmid DNA. Importantly, the present invention uses substantially solid growth medium and disposable vessels in place of conventional liquid fermentation processes, and provides a significant increase in recombinant plasmid DNA yield. More specifically, the present invention provides a method of large-scale production of recombinant plasmid DNA, wherein the method broadly comprises the steps of inoculating a host organism containing the recombinant plasmid DNA onto a substantially solid growth medium in a disposable vessel; allowing the host organism to grow on the growth medium under conditions conducive to such growth; removing the host organism from the growth medium and lysing the host organism to access the recombinant plasmid DNA; and purifying the recombinant plasmid DNA.
[0012] In various embodiments and implementations, the method may additionally or alternatively include one or more of the following features. The host organism may be a prokaryotic bacteria, such as Escherichia coli. The substantially solid nutrient medium may include one or more of sorbitol, sucrose, glucose, peptone, and yeast extract; one or more antibiotics; one or more trace elements or minerals for optimal growth of the host organism; or isopropyl-beta-D-thiogalactopyranoside at a concentration of less than approximately 25 micro-moles per milliliter. The host organism may be allowed to grow at a temperature of approximately between 15 degrees Celsius and 45 degrees Celsius. The recombinant plasmid DNA may contain a pUC temperature-inducible or chemical-inducible replication origin; a non-pUC replication origin; a viral or mammalian promoter DNA sequence; or a non-viral promoter DNA sequence. The recombinant plasmid DNA may also contain one or more consensus gene sequences that code for the production of immunogenic proteins or antigens; one or more targeted gene sequences for expression at required levels in the host organism; or one or more consensus targeted gene sequences for expressing immunogenic proteins or antigens at required levels in the host organism, leading to the production of antibodies or monoclonal antibodies. The step of purifying the recombinant plasmid DNA may be performed using column chromatography.
[0013] These and other features of the present invention are discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention is described herein with reference to the following drawing figures:
[0015] FIG. 1 (PRIOR ART) is a high-level flowchart of steps involved in a prior art method using liquid fermentation to produce recombinant plasmid DNA; and
[0016] FIG. 2 is a high-level flowchart of steps involved in an embodiment of the method of the present invention for producing recombinant plasmid DNA.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The content of U.S. Pat. No. 7,229,792, issued Jun. 12, 2007, titled METHOD OF PRODUCING RECOMBINANT PROTEINS, is hereby incorporated by reference into the present application.
[0018] With reference to the various drawing figures, a method of producing recombinant plasmid DNA is herein described, shown, and otherwise disclosed in accordance with one or more preferred embodiments of the present invention. Broadly, the present invention concerns a method of producing recombinant plasmid DNA or shuttle plasmid DNA in a host organism grown on a substantially solid, i.e., solid or semi-solid, growth medium in a disposable vessel. The host organism may be, for example, a prokaryotic bacteria such as Escherichia coli, Pseudomonas fluorescens, or Corynebacterium glutamicum. The host cells are harvested from the substantially solid growth medium, and the plasmid DNA is recovered.
[0019] With reference to FIG. 2 , in one embodiment the method of the present invention of producing recombinant plasmid DNA may proceed broadly as follows. In a first step 100 , a recombinant host organism is created or otherwise obtained containing a recombinant, or “heterologous”, plasmid DNA including one or more targeted gene sequences to be expressed at sufficient levels. As necessary or desired, the recombinant plasmid DNA may contain one or more of the following: A pUC temperature-inducible or a chemical-inducible replication origin; a non-pUC replication origin; a viral promoter DNA sequence; a mammalian promoter DNA sequence; a non-viral promoter DNA sequence; or one or more consensus gene sequences that code for the production of immunogenic proteins or antigens.
[0020] In a second step 102 , the host organism is inoculated onto the substantially solid growth medium in a disposable custom tray or other disposable vessel. The growth medium provides a source of necessary or desirable nutrients, antibiotics, and other components. For example, depending on the host organism, the growth medium may contain sorbitol, sucrose, glucose, peptone, and yeast extract; antibiotics such as kanamycin, ampicillin, or streptomycine; or essential trace elements/minerals such as selenium, nickel, or molybdenum to optimize the host organism's production of the recombinant plasmid DNA. The growth medium may also contain isopropyl-beta-D-thiogalactopyranoside at a concentration of less than approximately 25 micro-moles per milliliter. In a third step 104 , the host organism is allowed to grow on the growth medium at an appropriate temperature and under any other necessary or desirable growth conditions. In a fourth step 106 , the host organism is removed, or “harvested”, from the growth medium and lysed to access the contents. In a fifth step 108 , the lysed host cells are centrifuged again. In a sixth step 110 , the recombinant plasmid DNA is purified. In a seventh step 112 , the purified recombinant plasmid DNA is recovered.
[0021] In one possible implementation of this method, in which the host organism is the prokaryotic bacteria E.coli strain DH5a, the above-described steps may proceed more specifically as follows. In the first step 100 , the recombinant E.coli is created or otherwise obtained containing the recombinant plasmid DNA sequence that allows the one or more targeted gene sequences to be expressed at sufficient levels. In the second step 102 , the host organism is inoculated onto the substantially solid growth medium containing nutrients such as carbon, nitrogen, minerals, and vitamins, in a disposable vessel. In the third step 104 , the host organism is allowed to grow on the growth medium within a temperature range of approximately between 15 degrees C. and 45 degrees C.
[0022] In the fourth step 106 , the host organism is harvested and lysed as follows. The organism is suspended in liquid and centrifuged at 10,000×g for 10 minutes to obtain a pellet of cells. The supernatant is removed and the tube is blotted upside-down on a paper towel to remove excess liquid. The cell pellet is re-suspended in an appropriate volume of cell re-suspension solution. Complete re-suspension can be important for obtaining optimal yields. An appropriate volume of alkaline cell lysis solution is added and mixed by inverting the tube and the resulting cell suspension. Host cells are lysed in NaOH/SDS buffer in the presence of RNase A. Phospholipid and protein components of the cell membrane are solubilized. As the cells are lysed, the cells' contents are released and the chromosomal and plasmid DNA and proteins are denatured.
[0023] When the lysis time is optimized, the recombinant plasmid DNA is released but the chromosomal DNA is not. In the fifth step 108 , the lysed host cells are mixed with an appropriate volume of neutralization solution, and then centrifuged at 14,000×g for 30 minutes at 4 degrees C. The supernatant is decanted to a new tube while avoiding the precipitate. Alternatively, the cleared supernatant can be transferred by filter paper or an autoclaved coffee filter into a new centrifuge tube.
[0024] In the sixth step 110 , the recombinant plasmid DNA is purified as follows. The filtered lysate is applied to an appropriate chromatography column and allowed to enter the resin by gravity flow. The column is washed with an appropriate volume of wash solution, and the wash solution is allowed to move through the column by gravity flow. The first half of the volume of wash solution should be sufficient to remove all contaminants in the majority of recombinant plasmid DNA preparations. The second half may be necessary when dealing with large volumes producing large amounts of carbohydrates. The plasmid is eluted with an appropriate volume of elution solution or sterile pure water. The plasmid DNA is precipitated by adding an appropriate volume of room-temperature isopropanol to the eluted DNA.
[0025] In the seventh step 112 , the purified recombinant plasmid DNA is recovered as follows. The result of the preceding step is mixed and centrifuged at approximately 15,000×g for 30 minutes at 4 degrees C. The supernatant is carefully removed. The plasmid DNA pellet is washed with an appropriate volume of endotoxin-free room-temperature 70% ethanol and centrifuged at approximately 15,000×g for 30 minutes. The supernatant is removed without disturbing the pellet. The pellet is air-dried for 15 minutes, and the plasmid DNA is re-dissolved in an appropriate volume of endotoxin-free solution.
[0026] To illustrate the efficiency of the method of the present invention, two different recombinant plasmid DNA products were produced using disposable multi-liter solid medium vessels. After approximately 16 to 18 hours of bacterial growth, the average yield of biomass (gram wet biomass weight/liter of culture medium) was approximately 40 grams per liter and the corresponding average mean specific plasmid DNA yield (mg of plasmid/g wet weight) was approximately 8 micrograms of plasmid DNA per gram of wet biomass weight. This high specific yield significantly reduces the burden on the plasmid DNA production processes.
[0027] By way of comparison, whereas a conventional fermentation process produces a biomass yield of 23 grams per liter and a specific yield of 0.7 micrograms per gram, and whereas a conventional wave bioreactor process produces a biomass yield of 27 grams per liter and a specific yield of 1 microgram per gram, the method of the present invention produces a biomass of 40 grams per liter and a specific yield of 8 micrograms per gram (wherein specific yield values have been normalized to represent the micrograms of plasmid obtained per gram of harvested bacteria).
[0028] Thus, increased plasmid DNA production occurs along with host cell growth on the substantially solid growth medium using a disposable vessel. This addresses problems associated with prior art processes that are dependent on liquid-medium fermentation. Unlike prior art processes, the method of the present invention provides constitutive high plasmid production throughout the host's growth phase. Maintaining increased plasmid DNA production during the biomass accumulation creates an environment that is adverse to plasmid-free host cells. Thus, maintaining constant conditions, such as temperature, pH, and composition of the growth medium, throughout the process is desirable and leads to increased plasmid yields while preserving plasmid quality.
[0029] Other benefits of the method of the present invention include: The method reduces or eliminates expensive and unreliable equipment, which minimizes overall capital investment; it provides total product isolation in a continuous flow-path; it provides gentle but robust processing which results in higher specific yield ratios of plasmid DNA to host organism biomass; it is easily scalable from research and development levels to production levels; it provides improved batch control; it reduces or eliminates toxic chemicals, uses less water, and produces fewer waste products; and it uses disposable vessels which eliminates labor costs associated with cleaning, eliminates the potential for product cross-contamination, and allows for quicker turn-around times and multiple production runs in a day.
[0030] Although the invention has been disclosed with reference to various particular embodiments, it is understood that equivalents may be employed and substitutions made herein without departing from the contemplated scope of the invention. | A method of producing recombinant plasmid DNA using substantially solid growth medium and disposable vessels in place of conventional liquid fermentation processes. The method includes inoculating a host organism containing the recombinant plasmid DNA onto the substantially solid growth medium in a disposable vessel; allowing the host organism to grow on the growth medium under conditions conducive to such growth; removing the host organism from the growth medium and lysing the host organism to access the recombinant plasmid DNA; and purifying the recombinant plasmid DNA. | 2 |
CROSS-REFERENCE TO PRIOR APPLICATION
This application is a continuation-in-part of prior application U.S. Ser. No. 08/663,383, entitled “A Polyaxial Pedicle Screw”, filed Jun. 13, 1996, now U.S. Pat. No. 5,669,911 and which, in turn, was a continuation-in-part of Ser. No. 08/421,087, filed Apr. 13,1995, now issued U.S. Pat. No. 5,520,690, entitled “An Anterior Spinal Polyaxial Locking Screw Plate Assembly”.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a polyaxial screw and coupling apparatus for use with orthopedic fixation systems. More particularly, the present invention relates to a screw for insertion into spinal bone, and a coupling element polyaxially mounted thereto, via a two-piece interlocking coupling element having a socket portion and a threaded compression member, for coupling the screw to an orthopedic implantation structure, such as a rod, therein enhancing the efficacy of the implant assembly by providing freedom of angulation among the rod, screw and coupling element.
2. Description of the Prior Art
The bones and connective tissue of an adult human spinal column consists of more than 20 discrete bones coupled sequentially to one another by a tri-joint complex which consist of an anterior disc and the two posterior facet joints, the anterior discs of adjacent bones being cushioned by cartilage spacers referred to as intervertebral discs. These more than 20 bones are anatomically categorized as being members of one of four classifications: cervical, thoracic, lumbar, or sacral. The cervical portion of the spine, which comprises the top of the spine, up to the base of the skull, includes the first 7 vertebrae. The intermediate 12 bones are the thoracic vertebrae, and connect to the lower spine comprising the 5 lumbar vertebrae. The base of the spine is the sacral bones (including the coccyx). The component bones of the cervical spine are generally smaller than those of the thoracic and lumbar spine. For the purposes of this disclosure, however, the word spine shall refer only to the cervical region.
Referring now to FIGS. 1, 2 , and 3 , top, side, and posterior views of a vertebral body, a pair of adjacent vertebral bodies, and a sequence of vertebral bodies are shown, respectively. The spinal cord is housed in the central canal 10 , protected from the posterior side by a shell of bone called the lamina 12 . The lamina 12 includes a rearwardly and downwardly extending portion called the spinous process 16 , and laterally extending structures which are referred to as the transverse processes 14 . The anterior portion of the spine comprises a set of generally cylindrically shaped bones which are stacked one on top of the other. These portions of the vertebrae are referred to as the vertebral bodies 20 , and are each separated from the other by the intervertebral discs 22 . The pedicles 24 comprise bone bridges which couple the anterior vertebral body 20 to the corresponding lamina 12 .
The spinal column of bones is highly complex in that it includes over twenty bones coupled to one another, housing and protecting critical elements of the nervous system having innumerable peripheral nerves and circulatory bodies in close proximity. In spite of these complexities, the spine is a highly flexible structure, capable of a high degree of curvature and twist in nearly every direction. Genetic or developmental irregularities, trauma, chronic stress, tumors, and disease, however, can result in spinal pathologies which either limit this range of motion, or which threaten the critical elements of the nervous system housed within the spinal column. A variety of systems have been disclosed in the art which achieve this immobilization by implanting artificial assemblies in or on the spinal column. These assemblies may be classified as anterior, posterior, or lateral implants. As the classifications suggest, lateral and anterior assemblies are coupled to the anterior portion of the spine, which is the sequence of vertebral bodies. Posterior implants generally comprise pairs of rods, which are aligned along the axis which the bones are to be disposed, and which are then attached to the spinal column by either hooks which couple to the lamina or attach to the transverse processes, or by screws which are inserted through the pedicles.
“Rod assemblies” generally comprise a plurality of such screws which are implanted through the posterior lateral surfaces of the laminae, through the pedicles, and into their respective vertebral bodies. The screws are provided with upper portions which comprise coupling elements, for receiving and securing an elongate rod therethrough. The rod extends along the axis of the spine, coupling to the plurality of screws via their coupling elements. The rigidity of the rod may be utilized to align the spine in conformance with a more desired shape.
It has been identified, however, that a considerable difficulty is associated with inserting screws along a misaligned curvature and simultaneously exactly positioning the coupling elements such that the rod receiving portions thereof are aligned so that the rod can be passed therethrough without distorting the screws. Attempts at achieving proper alignment with fixed screws is understood to require increased operating time, which is known to enhance many complications associated with surgery. Often surgical efforts with such fixed axes devices cannot be achieved, thereby rendering such instrumentation attempts entirely unsucessful.
The art contains a variety of attempts at providing instrumentation which permit a limited freedom with respect to angulation of the screw and the coupling element. These teachings, however, are generally complex, inadequately reliable, and lack long-term durability. These considerable drawbacks associated with prior art systems also include difficulty properly positioned the rod and coupling elements, and the tedious manipulation of the many small parts in the operative environment.
It is, therefore, the principal object of the present invention to provide a pedicle screw and coupling element assembly which provides a polyaxial freedom of implantation angulation with respect to rod reception.
In addition, it is an object of the present invention to provide such an assembly which comprises a reduced number of elements, and which correspondingly provides for expeditious implantation.
Accordingly it is also an object of the present invention to provide an assembly which is reliable, durable, and provides long term fixation support.
Other objects of the present invention not explicitly stated will be set forth and will be more clearly understood in conjunction with the descriptions of the preferred embodiments disclosed hereafter.
SUMMARY OF THE INVENTION
The preceding objects of the invention are achieved by the present invention which is a polyaxial locking screw and coupling element for use with rod stabilization and immobilization systems in the spine. More particularly, the polyaxial screw and coupling element assembly of the present invention comprises a bone screw having a head which is curvate in shape, for example semi-spherical, and a two-piece interlocking coupling element mounted thereto. This combination is mounted inside the bottom of an internal channel of a cylindrical body member.
More specifically, with respect to the cylindrical body member, the tubular body comprises a rod receiving channel formed in the upper portion thereof, with a threading formed on the remaining upper elements so that a rod securing nut and/or set screw may be threaded thereon once a rod has been placed in the channel. The body further includes an axial bore which includes extends from the rod receiving channel through to the bottom of the cylinder. The portion of the axial bore which is below the channel forms a receiving chamber, the upper portion thereof having a constant diameter, and the lower portion of the chamber being inwardly tapered. The inner surface of the upper portion of the chamber and/or the inner surface of the portion of the axial bore which is above the chamber may further include a threading.
The two-piece interlocking coupling element comprises and socket portion and a cap portion. The socket portion is designed with an interior semi-spherical volume, so that it may receive the semi-spherical head of a corresponding bone screw. The interior volume of the socket portion is open at both axial ends thereof. The exterior surface of the socket portion, at the bottom thereof, includes a first set of slots which extend upwardly from the opening so that the interior semi-spherical volume may be expanded or contracted by the application of a radial force. In addition, the exterior surface at the bottom is tapered so that it is narrower at the bottom than at a midpoint. This taper is designed to mate with and nest in the tapered lower portion of the socket portion of the axial bore of the body member.
The upper exterior surface of the socket portion comprises a second set of slots, directed axially along the element to the midpoint, such that the upper opening of the socket element may expand and contract in accordance with the application of a radial force thereon. The exterior surface of this upper section of the socket portion is not tapered and is narrower than the widest taper position of the bottom of the socket portion. The upper section, however, does further include an outwardly extending annular lip at the uppermost axial position. This upper section is designed to be inserted into, and joined with, the cap portion of the coupling element.
The cap portion has a generally cylindrical shape, having an open bottom. The open bottom is inwardly tapered, forming an inwardly extending annular lip, so that as the upper end of the socket portion is inserted, its upper slots are narrowed. Once axially inserted beyond this taper, the upper section of the socket portion expands outward over the inwardly extending annular lip. The inwardly extending annular lip engages the outwardly extending lip of the socket portion so as to prevent disengagement of the two pieces. The socket portion is then permitted to slide into the cap portion, until the larger diameter of the tapered lower portion of the socket contacts the entrance of the cap portion.
The exterior surface of the cap portion may be threaded, so that it may engage a threading of the upper portion of the socket portion and/or the inner surface of the axial bore which is above the socket portion. In addition, the top of the cap includes an opening so that a screw driving tool may directly engage the top of the screw.
The assembly of the entire device begins with the joining of the socket portion to the cap portion of the two-piece interlocking coupling element. This is achieved by the slideable interlocking mating of the two elements. Next, the semi-spherical head of the screw is inserted into the socket portion through the lower expandable opening in the taper portion. Once these parts have been assembled the screw and coupling element should be polyaxially rotateable relative to one another. The screw and coupling element are then inserted through the axial bore of the body (which may require the threading the cap portion of the coupling element along the threading on the inner surface of the axial bore and/or the threading of the cap along the threading of the upper portion of the chamber) until the socket portion nests in the tapered lower portion of the axial bore. If the upper portion of the chamber includes a threading it should not extend beyond the point of the initial nesting of the coupling element in the chamber. This is important because the cap portion must be able to move relative to the socket portion.
In this initial position, the top of the cap portion should rest above the bottom of the rod receiving channel so that a rod, when placed therein, seats directly onto the top of the cap. This direct contact provides the downward force necessary to compress the coupling element into the chamber so that the socket portion is compressed in the tapered portion and locks to the head of the screw.
In a preferred variation of this embodiment, the interior surface of the cap portion includes a slight narrowing taper so that as the cap is compressed downward by the rod, the upper slots of the socket portion are also narrowed, further increasing the crush locking effect on the head of the screw.
The implantation of this screw by a surgeon may proceed first by the assembly of the screw into its initial state. The shaft of the screw is then driven into the vertebral bone at the desired angulation. A rod is then introduced into the rod receiving channel, and the body is angulated into the most ideal position for receiving the rod. A nut and/or set screw is then used to secure the rod in the channel, and simultaneously to provide a sufficient downward translational force to cause the socket portion to be driven into the tapered portion of the chamber in the axial bore, and further to cause the cap portion to drive downwardly also (this further compression locking the screw head in the embodiment wherein the sliding of the cap portion toward the socket portion provides an additional compression on the top of the socket portion and therefore onto the head of the screw).
In a preferred variation, the locking nut comprises a cap nut which has a central post which is designed to provide additional structural support to the inner walls of the element at the top thereof, as well as providing a central seating pressure point for locking the rod in the channel. In either variation, the locking nut seats against the rod and prevents it from moving translationally, axially and rotationally.
Multiple screw assemblies are generally necessary to complete the full array of anchoring sites for the rod immobilization system, however, the screw assembly of the present invention is designed to be compatible with alternative rod systems so that, where necessary, the present invention may be employed to rectify the failures of other systems when the surgery may have already begun.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a top view of a human vertebra, which is representative of the type for which the present invention is useful for coupling thereto a rod apparatus;
FIG. 2 is a side view of a pair of adjacent vertebrae of the type shown in FIG. 1;
FIG. 3 is a posterior view of a sequence of vertebrae of the type shown in FIGS. 1 and 2;
FIG. 4 is a side view of a screw having a curvate head which is an aspect of the present invention;
FIG. 5 is a side view of a two-piece interlocking coupling element of present invention;
FIG. 6 is a side view of a two-piece interlocling coupling element of present invention mounted around the head of a screw of the type shown in FIG. 4;
FIG. 7 is a side cross-sectional view of a cylindrical body having a chamber for receiving the two-piece interlocking coupling element and the screw of the present invention;
FIG. 8 is a side cross-sectional view of a top locking nut which is an aspect of the present invention;
FIG. 9 is a side cross-sectional view of an embodiment of the present invention in its fully assembled disposition having a rod securely locked therein; and
FIG. 10 is a side view of an alternative embodiment of the present invention in its fully assembled disposition having a rod securely locked therein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which particular embodiments and methods of implantation are shown, it is to be understood at the outset that persons skilled in the art may modify the invention herein described while achieving the functions and results of this invention. Accordingly, the descriptions which follow are to be understood as illustrative and exemplary of specific structures, aspects and features within the broad scope of the present invention and not as limiting of such broad scope.
Referring now to FIG. 4, a side view of the screw portion of the present invention, comprising a curvate head, is shown. The screw 120 comprises a head portion 122 , a neck 124 , and a shaft 126 . In FIG. 4, the shaft 126 is shown as having a tapered shape with a high pitch thread 128 . It shall be understood that a variety of shaft designs are interchangeable with the present design. The specific choice of shaft features, such as thread pitch, shaft diameter to thread diameter ratio, and overall shaft shape, should be made be the physician with respect to the conditions of the individual patient's bone, however, this invention is compatible with a wide variety of shaft designs.
The head portion 122 of the screw 120 comprises a semi-spherical shape, which has a recess 130 in it. It is understood that the semi-spherical shape is a section of a sphere, in the embodiment shown the section is greater in extent than a hemisphere, and it correspondingly exhibits an external contour which is equidistant from a center point of the head. In a preferred embodiment, the major cross-section of the semi-spherical head 122 (as shown in the two dimensional illustration of FIG. 4) includes at least 270 degrees of a circle.
The recess 130 defines a receiving locus for the application of a torque for driving the screw 120 into the bone. The specific shape of the recess 122 may be chosen to cooperate with any suitable screw-driving tool. For example, the recess 130 may comprise a slot for a screwdriver, a hexagonally shaped hole for receiving an allen wrench, or most preferably, a threading for a correspondingly threaded post. It is further preferable that the recess 130 be co-axial with the general elongate axis of the screw 120 , and most particularly with respect to the shaft 126 . Having the axes of the recess 130 and the shaft 126 co-linear facilitates step of inserting the screw 120 into the bone.
The semi-spherical head portion 122 is connected to the shaft 126 at a neck portion 124 . While it is preferable that the diameter of the shaft 126 be less than the diameter of the semi-spherical head 122 , it is also preferable that the neck 124 of the screw 120 be narrower than the widest portion of the shaft 126 . This preferable dimension permits the screw to swing through a variety of angles while still being securely joined to the locking collar (as set forth more fully with respect to FIGS. 5, 8 - 9 ).
Referring now to FIG. 5, the two elements which form the two-piece interlocking coupling element of the present invention are shown in a side cross-section view. Phantom lines show the interior structure of the elements along the diametrical cross section. With specific reference to the socket portion 132 , the coupling element comprises a roughly cylindrical shape having an interior volume 134 in which the semi-spherical head 122 of the screw 120 is disposed. The interior volume 134 is open at the top 136 of the socket portion 132 and at the bottom thereof 138 . The lower section 131 of the socket portion 132 comprises a set of slots 133 which extend vertically from the bottom 138 of the socket portion 132 to a position above the maximum diameter of the semi-spherical interior volume 134 . These slots 133 permit the interior volume to expand and contract in accordance with the application of a radial force thereon. The external surface 135 of the lower section 131 of the socket portion 132 is tapered such that the narrowest part of the lower section 131 is at the bottom 138 .
The upper section 139 of the socket portion 132 has a generally constant diameter, which is less than the diameter at the uppermost position 137 of the taper of the lower section 131 . A second set of vertical slots 141 are provided in this upper section 139 so that it may also expand and contract in accordance with radial forces applied thereto. In addition, the uppermost end of this upper section 139 comprises an outwardly extending annular lip 140 .
The cap portion 142 of the coupling element comprises an opening 143 in the bottom thereof, having an inwardly tapered entrance surface conformation 144 . As the upper section 139 of the socket portion 132 is inserted into the opening 143 in the cap portion 142 , the taper 144 of the opening 143 provides an inwardly directed force which causes the upper section 139 to contract (causes the slots 141 to narrow). This tapered entrance 144 opens to form an annular lip 145 which is useful for engaging and retaining the annular lip 140 of the upper section 139 of the socket portion 132 . The interior surface 146 of the cap portion has a constant diameter, therein permitting the inserted upper section 139 of the socket portion 132 to slide and rotate relative to the cap portion 142 .
The exterior surface of the cap portion 142 comprises a threading 147 which is designed to engage threadings 211 disposed in the axial bore of the rod receiving body member (see FIG. 7 ). In addition, the cap portion 142 comprises an axial hole 148 through which a surgeon may insert a screw driving tool to access the head of the screw which is positioned in the interior volume 134 of the socket portion 132 .
More particularly, with respect to the disposition of the head 122 of the screw 120 in the socket portion 132 , and with reference to FIG. 6, a partially assembled screw 120 and coupling element is shown in a side cross-section view. The top 136 of the socket portion 132 is inserted into the opening in the cap portion 142 until the annular lip 140 of the socket 132 seats into the cap 142 . The screw 120 is loosely held within the socket 132 , which is, in turn, loosely retained within the cap 142 .
Referring now to FIG. 7, the rod receiving body member 200 of the present invention is shown in a side view, wherein critical features of the interior of the element are shown in phantom. The body member 200 , which comprises a generally cylindrical tubular body having an axial bore 201 extending therethrough, may be conceptually separated into a chamber portion 202 at the bottom of the axial bore 201 , and an upper rod receiving channel portion 204 , each of which shall be described more fully hereinbelow.
The upper rod receiving channel portion 204 of the body 200 includes a channel 206 formed therein, having rounded bottom surfaces 207 . The channel 206 , in turn, divides the walls of the cylindrical body of the upper portion 204 into a pair of upwardly extending members 214 a, 214 b. As shown in the embodiment illustrated in FIG. 7, the vertical distance from the top 208 of the channel to the curvate bottom 207 thereof, is larger than the diameter of the rod which is to be provided therein. This distance is necessarily larger than the diameter of the rod (see FIGS. 9 and 10) so that the rod may be fully nested in the channel 206 . In addition, the depth of the bottom curvate surface 207 of the channel is such that the cap portion 142 of the two-piece interlocking coupling element initially seats above the curvate bottom 207 of the body 200 .
The upwardly extending members 214 a, 214 b further have, disposed thereon, a threading 216 (which may be provided on the inner and/or outer circumferential surfaces, but which is shown in FIGS. 7, 9 and 10 as being on the inner circumferential surface). This threading 216 is ideally suited for receiving a top locking nut (see FIG. 8 ).
Referring now to the lower portion of the body, the chamber portion 202 can further be subdivided into a lower chamber portion 203 which includes an inwardly tapered surface, and an upper chamber portion 205 which has a constant diameter. The inwardly tapered portion 203 defines a nesting volume into which the socket portion 132 may nest. Prior to its being fully driven into this nesting volume, the socket portion 132 and the screw 120 disposed therein may be angulated relative to one another, and the screw 120 may be angulated relative to the body 200 . Once driven fully into the tapered lower chamber portion 203 , however, the taper of the axial bore 201 provides the necessary inwardly directed radial force to cause the socket portion 132 to crush lock to the head 122 of the screw 120 .
The force which causes the socket portion 132 to be driven downwardly into the tapered lower chamber portion 203 is provided by the cap portion 142 . More specifically, as stated above, when the initially assembled screw 120 and coupling element combination 132 and 142 (see FIG. 6) is advanced into the bottom of the axial bore 201 of the body 200 , and the socket portion 132 nests in the lower chamber portion 203 , the top of the cap portion 142 is positioned to receive the rod (see FIGS. 9 and 10) directly thereon. The locking of the rod in the channel 206 of the body 200 causes the cap portion 142 to be forced downwardly onto the socket portion 132 , which in turn drives the socket portion 132 into the tapered lower chamber portion 203 and causes it of compression lock to the head 122 of the screw 120 .
Referring now to FIG. 8, a top locking nut 185 is shown in side cross-section view. The nut 185 comprises post portion 186 and a flange portion 187 , each of which is rotafionally free, relative to the other. The post portion 186 includes a threading 188 thereon, for engaging and advancing along a threading 216 on the inner surface of the upwardly extending members 214 a, 214 b of the upper portion 204 of the body 200 . The bottom surface 189 of the flange portion 187 (which does not rotate relative to the body as the post portion 186 is rotationally advanced) is intended to seat against the top surface of the rod 250 .
Referring now to FIG. 9, in which the fully assembled and body member 200 , screw 120 , coupling element portions 132 and 142 , rod 250 and locking nut 185 are shown in side cross-section views, the implantation of this embodiment is described. First, the screw 120 and the two portions 132 and 142 of the coupling element are assembled into their initial association (see FIG. 6 ). The combination of the screw 120 and the two coupling element portions 132 and 142 are then advanced down the axial bore 201 of the body 200 until the socket portion 132 nests in the lower chamber 203 and the top of the cap portion 142 seats above the bottom 207 of the channel 206 . (This insertion of the subassembly of the screw 120 and coupling element portions 132 and 142 into the axial bore 201 of the body 200 may require the threaded advance of the cap portion 142 along the interior threads 216 of the body.)
The shaft of the screw 120 is then inserted and driven downward into the vertebral bone at the desired angle. Once properly positioned, the body 200 is rotated into the ideal rod receiving position. The rod 250 is then inserted into the channel 206 and the top locling nut 185 is threaded onto the threading 216 and compresses the rod 250 to securely lock it in the channel 206 . This downward force of the nut 185 and the rod 250 onto the cap portion 142 causes the cap portion to translate downward thus causing the socket portion 132 to translate downward in the tapered chamber 203 and contract to crush against the head 122 of the screw 120 . The assembly is thereby fully locked in position.
Referring to FIG. 10, a variation of the above device is shown in a similar cross-section view. In this embodiment, the inner surface 146 ′ of the cap portion 142 is tapered inwardly in the vertical direction so that the downward translation of the cap portion 142 causes the annular lip 140 of the socket portion 132 to be compressed inwardly. This causes the slots 141 of the upper section 139 of the socket portion 132 to narrow. This may be utilized to further clamp the interior volume 134 against the head 122 of the screw 120 .
While there has been described and illustrated embodiments of a polyaxial screw and coupling element assembly for use with posterior spinal rod implantation apparatus, it will be apparent to those skilled in the art that variations and modifications are possible without deviating from the broad spirit and principle of the present invention. The present invention shall, therefore, be limited solely by the scope of the claims appended hereto. | A polyaxial orthopedic device for use with rod implant apparatus includes a screw having a curvate head, a two-piece interlocking coupling element which mounts about the curvate head, and a rod receiving cylindrical body member having a tapered socket into which both the screw and the interlocking coupling element are securely nested. The interlocking coupling element includes a socket portion which is slotted and tapered so that when it is radially compressed by being driven downwardly into the tapered socket in the cylindrical body it crush locks to the screw. The securing of the rod in the body member provides the necessary downward force onto the socket portion through a contact force on the top of the cap portion. Prior to the rod being inserted, therefore, the screw head remains polyaxially free with respect to the coupling element and the body. In a preferred embodiment, the cap portion and the socket portion are formed and coupled in such a way that when the cap portion is compressed toward the socket portion, there is an additional inward radial force applied by the cap portion to the socket portion, thereby enhancing the total locking force onto the head of the screw. | 0 |
This application is a continuation of application Ser. No. 07/215,076, filed July 5, 1988 which is a continuation of Ser. No. 06/800,506 filed Nov. 21, 1985 and both now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is in the field of dry cleaning solvent recovery. More particularly, this invention relates to a device and process for recovering dry cleaning solvent while minimizing losses of solvent to waste and/or release of solvents to the environment.
2. Prior Art
Dry cleaning processes employ halohydrocarbon liquids such as perchloroethylene, tetrachloroethylene, trichlorofluoromethane, trichlorofluoroethylene or the like to remove a mixture of fatty acids, oils, oil-soluble and insoluble dirt and soil, water and body moisture, and water-soluble dirt and soil from garments and other fabric products. Commonly, the garment or other fabric is contacted with the halohydorcarbon solvent with agitation and the soiled solvent is continuously passed through a filter to isolate the various contaminants picked up by the solvent and return clean solvent to the contacting zone.
Two filtration processes are widely employed. One process uses fabric bag filters coated with filter aids such as diatomaceous earth, carbon black, surfactants, and the like, through which the soiled solvent is passed. The other common process employs disposable filter cartridges having paper or fiber filter elements and carbon.
With either filtration process, the pressure drop across the filter is monitored and when the pressure drop rises to a critical level, the filter is cleaned. This is carried out in the case of filter bags by backwashing and in the case of cartidges by replacement.
The filter bag backwash liquid contains substantial amounts of solvent and is commonly flashed to recover a substantial fraction of the solvent. Nevertheless, the solid residue which results from the flash of the backwash liquid often contains 40%, 50%, 60% or more of solvent. Similarly, the discarded filter cartridges contain large proportions of solvent.
Simple disposal of the solvent-laden residue or filters is not attractive. One problem is that the solvent is expensive and its regular discard in multigallon quantities can add up to a large cost. A more pressing problem is that halohydrocarbon cleaning solvent is considered environmentally hazardous, and its release into the atmosphere or into dump sites is being increasingly regulated. One cannot freely discard such wastes but should treat them as hazardous substances.
Devices have been proposed heretofore for reducing the solvent content of used filters. These devices have been self-contained systems which employ jets of steam to strip out solvent. These devices condense the outflow to give a liquid product. These devices offer the advantage of speed, but are energy and labor intensive and are expensive.
It is an object of this invention to provide a device and method for removing and recovering halohydrocarbon dry cleaning solvent from spent filters or residues which device and method are energy and labor efficient and relatively inexpensive to use and install.
It is a further object to provide a device and method which will reduce the solvent content of spent filters or residues to a level which will permit their disposal as nonhazardous substances--which level is often 1% solvent or less.
STATEMENT OF THE INVENTION
It has now been found that residual solvent is inexpensively and efficiently removed from dry cleaning residues--solids or pastes or spent filter elements--by enclosing the residues in a vapor-sealed enclosure, passing a gradual flow of air over said residues at ambient to moderately elevated temperature to form a solvent-rich air phase; conducting this solvent-rich air phase to the vent scrubber commonly found in dry cleaning establishments and in that vent scrubber removing the solvent from the solvent-rich air phase and recovering the solvent in the vent scrubber.
In another aspect, this invention provides the contacting enclosure for carrying out the ambient to moderately elevated temperature contacting of the residue with the air stream.
DETAILED DESCRIPTION OF THE INVENTION
Brief Descriptions of the Invention
The invention will be described with reference being made to the appended drawings in which:
FIG. 1 is a diagram of solvent flow in a typical dry cleaning plant, illustrating one application of the present invention.
FIG. 2 is a partial flow diagram illustrating another application of this invention.
FIG. 3 is a perspective view of a residue enclosure provided by the present invention.
FIG. 4 is a partially cut away side view of the enclosure of FIG. 3, and
FIG. 5 is a detail of an air admission valve which can be used in an enclosure provided by the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Turning to FIG. 1, a dry cleaning machine 11 is shown into which soiled fabric, clothes, etc. are added. Dry cleaning solvent from tank 13 is added to machine 11 via line 12. Typical dry cleaning solvents include perchloroethylene, trichlorofluoroethylene, and trichlorofluoromethylene, and mixtures thereof. Very typically, the solvent will contain 0.1-2.0% especially 0.75 to 1.5% of a detergent such as the material marketed by Streets under the trade name Staticol. Such solvent, during contact with the soiled clothes, etc., picks up soil, including moisture (water), grease and oils, dyes, fatty acids, soaps, solids such as dirt and sand, and the like. The soiled solvent is continuously removed from machine 11 via valved line 15 to filter 16. In filter 16 the soiled solvent passes through filter bag 17, which is covered with various filter aids to facilitate the deposit of soil on the filter. Such filter aids can include silica, diatomaceous earth, clays, carbon black (known in the trade as "Darco"), and the like. Clean solvent is collected on the other side of the bag and removed via valved line 19 for recycle to tank 13. The pressure drop across bag 17 is watched. When it exceeds an acceptable level, it is an indication that the bag is becoming overloaded with soil. Line 15 is closed and the filter bag is backwashed such as by flowing solvent back through the filter while agitating the filter contents by means not shown. This gives rise to a soil and filter aid laden solvent which is removed from filter 16 via valved line 20 to flasher 21, where an overhead fraction containing solvent and water is taken off via line 22 and condensed in condensor 24. The liquid condensate is passed through line 25 to phase separator 26, where a light water phase is taken off for discard via line 27 and a heavy solvent phase is taken off through line 29 for recycle to tank 13 via lines 40, 30 and 31. A vapor phase containing residual amounts of dry cleaning solvent is removed from condensor 24 and passed through line 32 to vent scrubber 34. Vent scrubber 34 is present in all modern cleaning plants, and consists of a system for removing the last remaining traces of solvent from the air going to vent 35. Such scrubbers work using various principles--including condensation or adsorption and desorption of solvent molecules on beds of activated carbon and the like. A typical vent scrubber is the unit marketed by Hoyt under the trade name Sniff-O-Miser. Typically, such units have limited capacity for solvent such as up to 2, 4, or 8 gallons per day. The solvent removed from the vent in scrubber 34 is recovered therein either continuously or in batch and removed via line 36 to separator 37, where again water is taken off via line 39 and halohydrocarbon is taken off via line 40 for recycle via lines 30 and 31.
Another vent stream taken directly from machine 11 by line 41 is treated similarly first to remove and recover solvent for recycle using condensor 42, line 44, separator 45, line 46, and line 47. The vapor phase from condensor 42 goes via line 49 and line 32 to scrubber 34, as well.
The foregoing system generates, in flasher 21, a bottom residue which is rich in solids but which also contains a large proportion of solvent. This material can be "cooked" in the flasher reboiler to try to drive off as much solvent as possible. However, this cooking, even at best yields a product containing about 50% by weight of solvent. This bottoms product is removed from flasher 21 and manually transferred (as shown by the dashed line) to aftercooker enclosure 50. Aftercooker enclosure 50 carries a lid 51 which sealably engages the open end of 50 so as to create a vapor-tight enclosure when closed. The residue 52 is placed in a suitable tray or similar receptacle 62 and lid 51 is sealably closed. A stream of air is passed into enclosure 50 via line 54. Line 54 carries a valve 55 so that the flow can be regulated. An outflow stream of air exits enclosure 50 via line 61 for conduction to vent scrubber 34. In practice, scrubber 34 presents a small negative pressure, such as from 0 psig to about -1 psig so that line 61 pulls a small vacuum on enclosure 50. In this setting line 54 can be merely an aperture and valve 55 can be a damper or the like regulating the flow of air drawn into enclosure 50 by means of the vacuum drawn through line 61. The flow of air through enclosure 50 is a gradual flow. That is it is not a high velocity flow that drives or knocks solvent from the residue. Rather it is a flow having an average velocity of less than about 10 feet/sec and preferably less than about 1 feet/sec, more preferably less than about 1 or 2 feet/min. which relies on simple evaporation to remove solvent. Enclosure 50 is equipped with a device for varying its internal temperature. This device is shown in FIG. 1 as a stream line 56, which passes a controlled flow of steam through regulation 57 to coil 59 and then to exit line 60. This steam coil can raise the temperature inside the enclosure from ambient (or in some cases, a few degrees below ambient because of evaporative cooling) to up to about 160° F. or 175° F. or so. In usual operation, the temperature is begun at ambient temperature and gradually raised over a period of several days to 125°-140° F. maximum. These moderate temperatures are advantageous for several reasons. For one, they minimize any breakdown of the halohydrocarbon. For another, they are energy efficient such that minimal heat is lost from the device in use. For another, they eliminate operation burn hazards. Other means for heating, such as electric heating can be employed if desired. The after cooker can also be used at higher temperatures such as up to 175° F., if desired. These higher temperatures can serve to more quickly remove solvent or to more thoroughly remove final traces of solvent.
The flow of air through enclosure 50 and the temperature of enclosure 50 are each regulated to take off an amount of halohydrocarbon which does not exceed the amount which can be recovered in scrubber 34. As previously noted, scrubber 34 may have a nominal capacity of 2 to 8 or more gallons of solvent per day.
The residue is held in the enclosure for an extended period, such as from about 3 days to about 30 days to reduce its solvent content to below about 10% by weight, preferably to below about 5% by weight, more preferably to below about 1% by weight.
A number of factors come into play in determining the length of time employed to "cook down" a residue. One factor is temperature. As a general and approximate rule, a 40° F. increase in temperature doubles the rate at which solvent is removed. At about 100°-115° F., solvent content has a half life of about 3 days (a day is 6-8 hours) in the unit of this invention. Thus, a residue containing 50% solvent would have its solvent content reduced to about 25% after 3 days or so, at 110° F. or to about 25% after 1-2 days or so at 150° F. In this much time again, the content would drop to 10-15%, etc. Using this "half life" one can see that at 110° F., a 50% starting material will be to below 1% in about 18 days and at 150° F., this level can be achieved in about 9 days. All of the numbers are approximate and depend upon numerous variables but are a good estimate of the excellent results which may be achieved with the present invention.
Turning to FIG. 2, an alternate design for the dry cleaning filter system is shown in which cartridge filters 17' held within holder 16' replace the bag filter used in the system depicted in FIG. 1. The other elements shown in FIG. 2 are the same as those shown in FIG. 1. With cartridge filters, when they become overloaded, conventionally they are merely drained in place and then discarded, causing considerable loss of solvent. In accord with the present invention, they are removed and placed in an aftercooker of this invention.
Turning to FIGS. 3 and 4, a more detailed perspective view and a partially cut away side view of an aftercooker of this invention are shown. This aftercooker includes an enclosure 50, carrying a residue tray 62 into which the residue--either in the form of solids 52 or used filter cartridges 17'--is placed. The size of enclosure 50 should be selected to conveniently accomodate the residue. Typically the filter cartridges are about 13-15 inches long and a very convenient size for enclosure 50 and the residue tray 62 is such as to accomodate, 6, 8, 12, 20, or 24 such cartridges. The aftercooker includes a sealable lid 51 which is shown carrying a gasket 64 which achieves the desired seal. Lid 51 is held closed by latch 67/68. This latch is shown in the form of a screw latch but other functionally equivalent closure devices can be employed. A controlled flow of air is admitted to enclosure 50 through damper valve 55. Valve 55 allows the amount of air to be varied. The flow of air is exhausted from the enclosure through line 61 to the vent scrubber which is not shown in these figures but which is described hereinabove with reference to FIG. 1.
A flow of steam is admitted to heating coil 59. This flow of steam is inputted through regulated line 56 and exhausted through return line 60. Control valve 57 controls the amount or pressure of steam admitted to the coil 52 within the enclosure and thus the temperature achieved in the enclosure. The embodiment shown in these figures employs a manually actuated valve 57. It will be appreciated that an automatic valve that is controlled to give a programmed flow of steam and thus to provide an ever-increasing temperature during the aftercooker cycle could also be employed, if desired. The temperature within the enclosure and the steam pressure are indicated on guages 65 and 66.
Turning now to FIG. 5, a specialized form of the air inlet is show. This inlet includes the wall of enclosure 50, and air inlet line 54 in which is inserted damper valve 55. Line 54 also communicates with flapper valve 69 which is pivotably attached to hinge 70. Flapper valve 69 is held in a normally closed position by gravity but can pivot open by means of an air flow into enclosure 50. When no air is flowing the flapper valve closes. This prevents backflow of vapor into the environment and allows the aftercooker to be sealed during periods when the vent scrubber is shut off, such as in the evenings and on holidays when the dry cleaning establishment may not be operating.
This invention will be further described by means of the following Examples. This example is provided for purposes of illustration and is not to be construed as a limitation on the scope of the invention which is instead defined by the appended claims.
EXAMPLE I
A dry cleaning plant such as is shown in FIG. 1 is operated until bag filters 17 begin to show a significant pressure drop. The filters are backwashed and the backwash liquid is collected and flashed. The flasher residue is heated in place to drive off solvent as thoroughly as possible. This yields 84.5 pounds of a sludge-like residue which is heavily loaded with perchloroethylene solvent. This solid residue is transferred to an aftercooker as shown in FIGS. 3 and 4. The temperature is initially 70°-85° F. and is gradually raised to 118° F. The aftercooker is operated during normal work hours (about 8 hours per day) and allowed to cool during off hours. The weight of the residue was monitored periodically. The results are shown in Table I.
TABLE I______________________________________ Net Wt. Solvent Weight Estimated*** Temp., Residue, Recovery, Change, SolventDay ° F. Lbs. Lbs. % Remaining %______________________________________0 110 84.5 0 0 402 115 70.5 14.0 16.6 23.43 115 68.0 16.5 19.5 20.57* 117 59.25 25.25 29.88 10.110** 118 55.5 29.0 34.3 5.711 118 53.75 30.75 35.2 4.815 120 52.25 32.25 38.2 1.8______________________________________ *Does not include 2 weekend days when shut down. **Does not include 4 weekend days when shut down. ***Based on exponential plot straight line.
These results demonstrate that the aftercooker of the invention can significantly reduce the solvent content of dry cleaning residues and can reduce solvent content to 1% level or less. If a higher temperature had been employed a faster cook down would have resulted. The appearance of the residue as it is removed from the aftercooker also reflects this reduction. The product is a dry powder having minimal odor of perchloroethylene. The material as added was a solvent-saturated paste.
It should be noted that the material treated in this example was very well dried before it was placed in the aftercooker. Very typically this residue could have weighed as much as 100 to 110 lbs. with the additional weight being in the form of extra solvent. With such a waste product the waste aftercooker of this invention could exhibit even better results, in terms of weight of solvent recovered.
EXAMPLE II
The device and process of the invention as shown in Example I is also used to remove solvent from spent cartridges. Ten conventional "Puritan" 141/2"×71/2" cartridges are drained for five days and placed in the cooker of Example I. They have a total weight of 240 lbs. The results of an initial cook down period are given in Table II and demonstrate that the aftercooker is effective in this setting as well.
TABLE II______________________________________ Net Wt. Solvent Weight Temp., Residue, Recovery, Change,Day °F. Lbs. Lbs. %______________________________________0 120 240 06 hr 120 221.5 18.5 7.72 118 209 31 12.93 110 193 47 19.64* 110 179.5 60.5 25.25 118 166.5 73.5 30.66 125 155 85 35.47 126 146.5 93.5 398** 130 135 105 43.79 130 126.5 113.5 47.310 130 121 119 49.6______________________________________ *Does not include 2 weekend days when shut down. **Does not include 4 weekend days when shut down. | An aftercooker device for reducing the solvent content of drycleaning solid residues is disclosed as is its application in dry cleaning processes. The aftercooker is adapted for use with fouled disposable filters as well as with the solids which result from the flashing of soil-containing filter backwash. The aftercooker and its use are characterized by the use of ambient to moderately elevated temperatures and low velocity flows of air to remove solvent from residues and to the use of a vent scrubber to recover the solvent so removed. | 3 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to electronic circuits, and in particular, to power consumption in electronic circuits.
2. Description of Related Art
As engineers seek ever increasing speeds in VLSI chips, complex problems continue to rise to the forefront. Power consumption in digital logic is dominated by clocks used to control and synchronize circuit operations across a logic domain or an electronic chip. The digital logic consists of circuit elements such as NAND and NOR logic gates and latches being used as clocked gates. VLSI technology continues to advance by increasing the number of circuit elements on VLSI chips and increasing the frequency at which these circuit elements are driven.
The frequency is increased further by reducing the number of logic gates between latches. These methods result in an increased amount of overall power consumption by these circuit elements and an even higher portion taken up by clocked gates. However, only a fraction of these clocked gates are, in any large design, on cycle time limiting paths.
Some prior art power consumption reduction mechanisms have primarily focused on logic reduction and logic gate sizing. However, selective reduction of clock power by substitution of clock gates addresses the main source of power consumption in state-of-the-art digital circuits.
Therefore, it would be advantageous to provide an active circuit that can reduce power consumption, such as is produced by high power consumption clocked gates, and it would be particularly advantageous to provide an active circuit to reduce power consumption by replacing those high power consumption clocked gates with lower power consumption clocked gates without affecting the target cycle time of the circuit.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for reducing the power consumption of a clocked circuit containing a plurality of latches. A first latch, within the plurality of latches, is located which has more than a predetermined slack. The possibility of substituting an available second latch (requiring less power to operate) is then determined, subject to the constraint that the slack after substitution should still be positive, although it may be less than the predetermined number mentioned above. Where such a possibility is determined to exist, the first latch is then replaced with the available second latch.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of a clock distribution system in accordance with a preferred embodiment of the present invention;
FIG. 2 is a circuit diagram of a latch circuit in accordance with a preferred embodiment of the present invention;
FIG. 3 is an exemplary illustration of the timing constraint for data input into a latch in a clocked circuit in accordance with a preferred embodiment of the present invention;
FIG. 4 is an exemplary illustration of a process of power reduction in a clocked circuit by replacing high power latches with low power latches and a high power local clock buffer with a low power local clock buffer in accordance with a preferred embodiment of the present invention; and
FIG. 5 is an exemplary flowchart illustrating the process of power reduction in a clocked circuit by replacing high power latches with low power latches and a high power local clock buffer with a low power local clock buffer in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a method and apparatus for power reduction in clocked circuits. The criticality of any clocked gate is identified to a target cycle time objective. A clocked gate with positive slack is replaced with a lower power consumption version of the clocked gate. Latches may have to meet a set slack threshold. Input slack, may be, for example, greater than 100 ps (picoseconds) and output slack, may be, for example, greater than 300 ps. If a latch does have sufficient slack time according to a predetermined slack threshold, this latch may be replaced by a low-power version of the latch. The mechanism of replacing low power latches in and out of a netlist may enable fine tuning of a clocked circuit design after technology mapping and during a timing correction process occurring after the initial physical design.
The clocked gate with the lower power consumption does not adversely affect the target cycle time. The ability to apply this replacement technique of a higher power consuming clocked gate with a lower power consuming clocked gate late in a design process of an electronic circuit maximizes the benefit of reduced power consumption without constraining the design process in the early stages. To minimize impact on a given electronic circuit design, an electrical equivalent and physically compatible replacement clocked gate is provided.
Referring now to FIG. 1 , a schematic diagram of a clock distribution system in accordance with a preferred embodiment of the present invention. A clock source 105 is input into chip 110 from an oscillator source such as a saw-tooth wave generator or a phase-locked loop type clock source by way of wiring 115 on the chip. This oscillator signal is input into two receiver circuits 120 . Receiver circuits 120 each drive two central clock buffers 125 . Each clock buffer 125 in turn drives an H-tree that terminates with 16 sector buffers 130 used to re-power the clock signal. Each sector buffer 130 then drives a secondary H-tree (not shown) which terminates onto a single clock mesh (not shown), also called a clock grid, covering the entire chip area. The clock mesh is a series of vertical and horizontal low resistive wires that short together the outputs of all the clock buffers of the secondary H-tree, thus minimizing clock skew across the chip.
The clock mesh serves as the clock reference point (mclk) for the chip. The mclk signal is a “free-running” clock signal in that the clock never stops unless there is a problem with the clock source or distribution system. Devices such as latches, dynamic logic, and RAMs tap onto the mesh through local clock buffer circuits which are attached to the mesh. Some devices also connect directly to the mesh without being gated by a local clock buffer. One skilled in the art will recognize that other methods of distributing the clock may be implemented without departing from the scope and spirit of the invention.
FIG. 2 is a circuit diagram of a latch circuit in accordance with a preferred embodiment of the present invention. Latch circuit 210 includes inverters 211 - 213 and transistors 214 - 219 . Latch circuit 210 also includes clock signal 201 , data input 202 , and output 203 . The clock load represented by the latches is dependent on the size of the clock gates inside the latch. The data delay through the latch is directly dependent upon the clock gates inside the latch.
FIG. 3 is an exemplary illustration of the timing constraint for data input into a latch in a clocked circuit in accordance with a preferred embodiment of the present invention. In this example, data 302 is input into latch 304 . When clock signal 310 transitions from low to high, as illustrated by clock signal waveform 309 at point 332 , data 302 is sent to logic device 306 . Data 302 may remain in logic device 306 for maximum logic delay 316 until 340 before sent to latch 308 . As represented by timing diagram the time between points 334 and 340 is the maximum logic delay 316 . Therefore, for proper transmission of data 302 , data 302 must be transferred between latch 304 and latch 308 within maximum logic delay 316 , illustrated by points 334 and 340 . Data 302 must be launched from latch 304 by point 334 and be received by latch 308 by point 340 .
However, actual logic delay through logic 306 may be smaller than maximum logic delay 316 such that the characteristic of each latch may be altered, for example, latch 304 and 308 . Latch 304 may include latch 304 low power with increased launch time represented by the distance between points 334 and 336 . Latch 308 may include latch 308 low power with increased setup time represented by the distance between points 338 and 340 . Therefore, for proper transmission of date between latch 304 , logic device 306 and latch 308 , these low power logic delays may be taken into account.
FIG. 4 is an exemplary illustration of a process of power reduction in a clocked circuit by replacing high power latches with low power latches and high power local clock buffer with low power local clock buffer in accordance with a preferred embodiment of the present invention. In this example, high power latches 402 - 412 may be replaced by low power latches 420 - 430 . When clock input 418 is input into a clocked circuit, replacement of a high clock power local clock buffer 414 by a low power local clock buffer 432 may complement the process of replacing one or more high power latches 402 - 412 with one or more low power latches 420 - 430 . As described above in FIG. 1 , mesh clock 416 serves as the clock reference point. Devices such as latches 402 - 412 tap onto the mesh through local clock buffer circuits, such as high clock power local clock buffer 414 which may be attached to the mesh. Based on the availability of a low power latch, one or more of high power latches may be replaced.
A timing procedure is run to test the clocked circuit. A determination is then made as to whether or not any of the latches within the plurality of latches in the clocked circuit has a slack greater than a slack threshold. If there is a latch within the plurality of latches with a slack greater than a slack threshold, then a determination is made as to whether or not this latch can be replaced by an equivalent latch with a slack still greater than zero. Furthermore, a determination is made as to whether or not any of the local clock buffers within the plurality of local clock buffers has upon latch replacement a lowered loading on the clock net example 418 to allow replacement by a low power local clock buffer.
FIG. 5 is an exemplary flowchart illustrating the process of power reduction in a clocked circuit by replacing high power latches with low power latches and a high power local clock buffer with a low power local clock buffer in accordance with a preferred embodiment of the present invention. In this example, the operation begins by designing a clocked circuit (step 502 ). Then the clocked circuit is built per the design (step 504 ). The circuit may consist of a plurality logic gates and a plurality of latches. Then a timing procedure is run to test the clocked circuit (step 506 ). A determination is then made as to whether or not any of the latches within the plurality of latches in the clocked circuit have a slack greater than a threshold slack (step 508 ). If there is not a latch within the plurality of latches with a slack greater than a threshold slack (step 508 :NO), a determination is then made as to whether or not local clock buffers with a reduced load is located (step 510 ). If local clock buffers with a reduced load is not located (step 510 :NO), the operation terminates. If local clock buffers with a reduced load are located (step 510 :YES), then the existing local clock buffers are replaced with local clock buffers with a lower power (step 512 ), and thereafter the operation terminates.
Returning to step 508 , if there is a latch within the plurality of latches with a slack greater than a threshold slack (step 508 :YES), then the latch with slack greater than the threshold slack is replaced with a latch with a slack greater than zero (step 514 ). Then the modified circuit design is retimed (step 516 ). Then a determination is made as to whether or not the slack is less than zero for the modified circuit design (step 518 ). If the slack is not less than zero for the modified circuit design (step 518 :NO), the operation returns to step 510 in which a determination is made as to whether or not there is a latch with a slack greater than the threshold slack. If the slack is less than zero for the modified circuit design (step 518 :YES), then replacement of the latch is reversed (step 520 ) and then the operation returns to step 510 in which a determination is made as to whether or not there is another latch with a slack greater than the threshold slack.
Therefore, the present invention provides a mechanism by which power consumption of an active circuit can be reduced, such as produced by high power consumption clocked gates, and to provide an active circuit to reduce power consumption by replacing those high power consumption clocked gates with lower power consumption clocked gates without affecting the target cycle time of the circuit. If such a replacement is made, the modified circuit is then tested to determine whether the slack of such clocked circuit is still greater than zero. If such condition in the clocked circuit is found, the replacement latch remains in the circuit. However, if the characteristics of the clocked circuit results in slack less than zero, then the replacement latch is taken out of the modified circuit and the original latch reinserted. Upon completion of latch replacement, the load characteristic of all latches driven by a given local clock buffer is evaluated and a lower power level is inserted based on the actual load reduction on, for example, clock net 418 in FIG. 4 .
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. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | A method and apparatus for reducing power consumption of a clocked circuit containing a plurality of latches is provided. A first latch, within the plurality of latches, is located which has more than a predetermined slack. The possibility of substituting an available second latch, that requires less power to operate, is then determined, subject to the constraint that the slack after substitution should still be positive, although it may be less than the predetermined number mentioned above. Where such a possibility is determined to exist, the first latch is then replaced with the available second latch. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to devices and methods for pulling of metal fence posts or the like from the ground, and more particularly to a solution employing pivotal cam-shaped grippers that are actuated by application of an upward pulling force on the post puller by the lifting arrangement of a working machine.
BACKGROUND
[0002] Metal (typically steel) posts or pickets are commonly employed for temporary fencing measures, and most commonly feature a T-shaped, t-shaped, Y-shaped, or star-shaped cross section. In a common temporary fencing setup, a series of posts are driven into the ground at spaced apart positions along the intended fence line, and then wire mesh is strung up between adjacent posts using a series of teeth that are provided on a flange or web of the post. When it becomes desirable to take down or relocate the fence, the mesh is removed and rolled up, and the posts are pulled free of their previously embedded positions in the ground.
[0003] A number of devices have been previously proposed for the purpose of pulling posts from the ground, including those disclosed in U.S. patents U.S. Pat. No. 1,774,661, U.S. Pat. No. 4,422,621, U.S. Pat. No. 4,721,335, U.S. Pat. No. 5,011,117, U.S. Pat. No. 5,368,277, U.S. Pat. No. 7,059,587, U.S. Pat. No. 7,290,754, U.S. Pat. No. 7,963,051, U.S. Pat. No. 8,608,132 and U.S. Pat. No. 8,453,993; U.S. Patent Application Publications US2007/0183121, US2012/0279737 and US20090028649; and PCT Publication WO2012116405.
[0004] Of these references, U.S. Pat. No. 1,774,661 and U.S. Pat. No. 8,453,993 employ a cam-based post gripping mechanism that is most comparable to that of the present invention, but rely on manual levers to provide the post gripping and pulling forces required to grip the post and pull it free from the ground. Other references make use of external equipment to provide the lifting and gripping force, but not in a manner compatible with a cam-based gripping mechanism like that employed in the present invention.
[0005] Applicant has therefore developed a unique solution for actuating post grippers of a post puller using a skid steer, front end loader, excavator, back hoe or other working machine with a powered lifting arrangement.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the invention there is provided a post puller for pulling a post from a ground embedded position standing upright from a ground surface, the post puller comprising:
[0007] a lifting member having a coupling point thereon that is configured for attachment to lifting arrangement of a working machine to enable upward lifting of said lifting member by the lifting arrangement of the working machine;
[0008] a sliding sleeve attached to the lifting member;
[0009] a guide shaft about which the sliding sleeve is disposed for axial sliding of the sleeve up and down along a longitudinal axis of the guide shaft;
[0010] a pair of movable grippers pivotally supported on the guide shaft by respective pivotal connections on opposing sides of a central longitudinal plane thereof at a fixed location along the longitudinal axis of the guide shaft, each movable gripper having an inner end with a cam-shaped gripping surface that faces across the central longitudinal plane of the guide shaft toward the cam-shaped gripping surface of the other movable gripper, and an opposing outer end spaced laterally outward to a respective side of the guide shaft, each cam-shaped gripping surface increasing in a radial distance thereof from a pivot axis of the respective pivotal connection in a direction moving upward from an imaginary axis intersecting the pivot axes of the pivotal connections;
[0011] a pair of links having upper ends pivotally coupled to the lifting member and respective lower ends each pivotally coupled to a respective one of the movable grippers proximate the outer end thereof, whereby raising of the lifting member by the working machine with a web or flange of the post received in a space between the inner ends of the movable grippers lifts the outer ends of the movable grippers via the pair of links, thereby lowering the inner ends of the grippers about the pivot axis and bringing the cam-shaped gripping surfaces into closer proximity to one another to grip the web or flange of the post between the gripping surfaces and pull the post from the embedded position under further raising of the lifting member by the working machine.
[0012] Preferably there are provided upper and lower braces situated above and below the movable grippers on a same side of the guide post as said movable grippers, each brace defining a slot for receiving the web or flange of the post therein to align the web or flange in the space between the inner ends of the grippers.
[0013] Preferably there is provided a ledge projecting outward from the guide shaft to a same side thereof at which the movable grippers are disposed for resting of said ledge atop the post during placement of the post puller in an operational position situating the web or flange of the post in the space between the inner ends of the grippers.
[0014] Preferably the ledge resides at a position above the upper brace.
[0015] Preferably the lower brace resides below the fixed position of the movable grippers at a further distance therefrom than the upper brace.
[0016] Preferably there is provided at least one handle attached to the guide shaft.
[0017] Preferably the at least one handle extends to a side of the guide shaft opposite the movable grippers.
[0018] Preferably the at least one handle comprises a pair of handles each extending laterally outward from the post to a respective side thereof in opposing directions away from the central longitudinal plane of the guide shaft.
[0019] Preferably each handle comprises an open grip handle having upper and lower arms attached to the guide shaft at spaced apart positions along the longitudinal axis, a central span joining the upper and lower arms together at a radial distance outward from the guide shaft, and an open space bound between the arms, the central span and the guide shaft for gripping of the handle through said open space.
[0020] According to a second aspect of the invention, there is provided a method of pulling a post from a ground embedded position standing upright from a ground surface, the method comprising:
[0021] (a) positioning the post puller according to anyone of claims 1 to 9 in an operating position in which the web or flange of the post is received in the space between the movable grippers;
[0022] (b) supporting the post puller in the operating position independently of the lifting member thereof such that lifting member and links are gravitationally biased downward to push downwardly on the outer ends of the gripping members and raise the inner ends of the gripping members into an open position maximizing the space between the cam shaped gripping surfaces of the gripping members;
[0023] (c) pulling upwardly on the lifting member using the lifting arrangement of the working machine, and thereby displacing the sliding sleeve upwardly along the guide shaft and pivoting the movable grippers in a direction moving the cam-shaped gripping surfaces closer together and into frictional engagement with the flange or web received in the space between the gripping surfaces; and
[0024] (d) with the flange or web frictionally gripped between the gripping surfaces of the movable grippers, pulling the lifting member further upward using the lifting arrangement of the working machine, thereby pulling the post out of the embedded position.
[0025] Supporting the post puller independently of the lifting member in step (b) preferably comprises seating the post puller atop the post at an upper end thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
[0027] FIG. 1 is an elevational front view of a post puller of the present invention in a ready state for acceptance of a web or flange of a post (not shown) between two movable grippers of the puller.
[0028] FIG. 2 is an elevational front view of the post puller in an actuated state gripping state in which gripping surfaces of the grippers have been brought together for the purpose of gripping the web or flange of the post (not shown) between the grippers.
[0029] FIG. 3 is an elevational side view of the post puller.
[0030] FIG. 4 is a rear elevational view of the post puller in the ready state.
[0031] FIG. 5 is a perspective view of the post puller in the gripping state during use, in which the post puller is lifted by a cable, strap, or line coupled to the lifting arms of a skid steer, front end loader, excavator, back hoe, or other working machine.
[0032] In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
[0033] FIGS. 1 to 4 illustrate a post puller 10 according to one embodiment of the present invention, which is generally made up of a upright guide shaft 12 , a hollow sliding sleeve 14 , a lifting member 16 , a pair of links 18 , a pair of movable grippers 20 , a pair of braces 22 , a resting ledge 28 and a pair of handles 26 . The terms vertical and horizontal are used herein in relation to the illustrated orientation of the post puller shown in the drawings, in which the guide shaft 12 stands vertically upright so as to lie parallel to a vertical fence post when used thereon. However, in actual practice, fence posts will of course not always stand truly vertical, and so the orientation of the tool will likewise deviate from the vertical orientation described and shown. The terms horizontal and vertical are therefore used only to distinguish the components that lie more vertical than horizontal from those that lie more horizontal than vertical.
[0034] The guide shaft 12 and sliding sleeve 14 are both formed of rectangular metal tubing, and the sliding sleeve 14 has a slightly larger cross-sectional area and is concentrically disposed around the guide shaft 12 for sliding movement upwardly and downwardly therealong in the upright longitudinal direction of the shaft 12 . A resting ledge 28 in the form of a small flat horizontal plate welded or otherwise attached to the shaft extends forwardly therefrom at a distance below the top end of the shaft 12 . The sliding sleeve is disposed around the shaft 12 at the portion thereof residing above this resting ledge 28 . The ledge 28 thus defines a stop that prevents the sleeve 14 from sliding downwardly past the ledge 28 , thereby constraining the sleeve's range of travel to an upper portion of the guide shaft 12 .
[0035] The lifting member 16 is a flat plate welded or otherwise attached to the front side of the sliding sleeve 14 in a position residing parallel thereto at a short distance forwardly outward therefrom. A coupling point 30 is provided near the top of the lifting member 16 in the form of a through-hole passing horizontally therethrough. Near two lower corners of the lifting member 16 , the two links 18 are respectively coupled to the front face of the lifting member 16 by respective pivot pins 32 passing horizontally through the lifting member 16 in the same direction as the coupling point through hole 30 . As a result, each link 18 is pivotal about a horizontal pivot axis that passes perpendicularly through the lifting member plate 16 . The links are therefore pivotal within a vertical plane lying parallel to the lifting member plate 16 on the front side thereof opposite the shaft 12 .
[0036] At an intermediate location along the length of the shaft 12 , a mounting bracket 34 is welded or otherwise attached thereto in a position jutting outwardly from the shaft 12 on at least the front and lateral sides thereof. At a front end of the bracket 34 , each one of the movable grippers 20 is pivotally coupled thereto by a respective pivot pin 36 that passes horizontally through the mounting bracket 34 on a respective side of the shaft 12 in a direction parallel to the pivot pins 32 at the upper ends of the links 18 . A respective cotter pin 38 or other suitable locking secures each of the pivot pins 36 in place by cooperating with the head 36 a of each pivot pin 36 at the other end thereof to prevent sliding of the pivot pin out of the mounting bracket 34 in either direction. This set of pivot pins 36 cooperates with the mounting bracket 34 affixed on the shaft to pivotally mount the movable grippers 20 on the shaft, and therefore may also be referred to herein as mounting pins 36 in order to better distinguish same over the other pivot pins used elsewhere in the assembled post puller.
[0037] Yet another pair of pivot pins 36 are used to pivotally connect the movable gripping members 20 to the links 18 that hang downwardly from the lifting member 16 . These pivot pins 36 are also referred to herein as connection pins 40 to better distinguish same over the other pivot pins in the assembled post puller. Each connection pin 40 extends through the respective gripper 20 near the outer end thereof that lies distal to the guide shaft 12 , and lies parallel to the other two sets of pivot pins 32 , 36 . The mounting pins 36 extend through the movable grippers 36 near the inner ends thereof that reside adjacent to a central longitudinal plane of the shaft 12 on opposite sides of this central longitudinal plane. The inner end of each movable gripper 20 is curved non-concentrically around the axis of the respective mounting pin 36 to create a cam-shape that increases in its radial distance from the mounting pin axis in a direction moving upward from an imaginary horizontal axis that perpendicularly intersects the axes of the mounting pins 36 . An upper portion of the inner end of each gripper 20 is serrated to define a series of gripping teeth, therefore defining a gripping surface 20 a that faces toward that of the other gripper across the gap or open space left between the inner ends of the grippers.
[0038] An upper brace 22 a of the post puller resides at a location below the resting ledge 28 and above the mounting bracket and movable grippers. The brace 22 features a small horizontal plate welded or otherwise attached to the shaft 12 in a position projecting forwardly outward from the front side thereof on the same side of the shaft 12 as the linkage formed by the lifting member 16 , links 18 and grippers 20 . A lower brace 22 b likewise projects forwardly from the shaft, but at the lower end thereof situated at a distance below the mounting bracket and movable grippers 20 . Each brace 22 a , 22 b features a linear slot 42 that cuts into the brace plate from the distal end thereof that lies opposite to the shaft 12 , whereby the remaining intact portions of the brace plate on opposite sides of the slot define a pair of tongs. Beneath the ledge 28 , a pair of side walls 44 depend vertically downward from the ledge 28 toward the upper brace 22 a on opposite sides of the shaft 12 . In the illustrated embodiment, the resting ledge 28 , upper brace 22 a and side walls 44 are separately defined by respective plates, but in other embodiments, one or more of these components may be integrally combined into a single piece unit. For example, the resting ledge 28 , upper brace 22 a and side walls 44 may be integrally defined by a piece of rectangular tubing that is laser-cut or otherwise configured into a suitable shape for mounting to the guide shaft.
[0039] Completing the structure of the post puller are the pair of handles 26 , each of which is provided in the form of a three-segment bar. Each bar-type handle 26 has a lower arm 26 a jutting horizontally outward from the shaft 12 at or near the lower end thereof at an oblique angle so as to span laterally and rearwardly away from the shaft 12 . A similar upper arm 26 b likewise juts horizontally outward from the shaft at an oblique angle matching that of the lower arm 26 a , but farther up the shaft 12 , for example at the same elevation as the upper brace 22 a . A central span 26 c of each bar-type handle spans vertically between the upper and lower arms 26 a , 26 b thereof to complete an open-handle configuration that features an open handle space 46 bound by cooperation of the arms and central span of the handle with the shaft 12 .
[0040] Having defined the structure of the post puller, attention is now turned to the operation of its grippers. Due to the linkage defined by the pivotal connection of the links 18 between the lifting member 16 and the grippers 20 , raising of the lifting member 16 relative to the shaft 12 pulls the outer ends of the grippers 20 upward about the axes of mounting pins 36 , which causes the inner ends of the grippers 20 to pivot downwardly about the axes of the mounting pins 36 . Due to the cam-shaped configuration of the serrated gripping surfaces 20 a of the grippers 20 , this causes the gripping surfaces 20 a to move closer together across the central longitudinal plane of the shaft 12 , thereby reducing the width of the gap or space therebetween. FIG. 1 shows the post puller in its default ready state, where the weight of the sleeve 14 and attached lifting member gravitationally bias the lifting member 16 into a lowered position seated atop the resting ledge 28 . This gravitational action biases the outer ends of the grippers 20 downwardly about the axes of the mounting pins 36 , which in turn biases the gripping surfaces 20 a at the inner ends of the grippers upwardly about these axis, and away from one another. Accordingly, in the default state of the post puller, the gap or space between the gripping surfaces 20 a of the grippers is maximized.
[0041] With reference to FIG. 2 , when the lifting member 16 is lifted up relative to the shaft, thereby lifting the sleeve 14 up off of the resting ledge 28 , this lifting action raises the outer ends of the grippers 20 about the axes of the mounting pins 36 , which in turn lowers the inner ends of the grippers about the axes of the mounting pins and thereby forces the serrated gripping surfaces 20 a at the inner ends of the grippers toward the central longitudinal plane of the shaft, thus moving these gripping surfaces closer together to reduce the width of the gap or space between them.
[0042] Turning to FIG. 5 , use of the post puller to remove a post 100 from its embedded position in the ground is now described as follows. A user grips the two handles 26 in his or her hands and uses same to manually lift the post puller to a position raising the resting ledge 28 to a height great than the top end of the post 100 . With the slots 42 in the two braces 22 a , 22 b aligned with a web or flange 102 of the post 100 , the post puller is manually displaced in a horizontal direction toward the post from the side thereof to which this web or flange 102 extends, until either the free outer edge of the web or flange bottoms out in the slots of the braces 22 a , 22 b or the distal ends of the prongs of the braces 22 a , 22 b are brought into contact with other flanges of the post 100 . As best seen in FIG. 3 , the distance by which the resting ledge 28 projects from the shaft 12 is greater than the projecting distance of the braces 22 a , 22 b , whereby this horizontal shifting of the braces into engagement with the post acts to place the resting ledge 28 in a position overlying the top end of the post, thereby effectively seating or hanging the post puller on the post 100 . The side walls 44 beneath the resting ledge prevent the post puller from falling laterally off the top end of the post.
[0043] Turning back to FIG. 5 , a strap, cable, chain, rope or other flexible lifting line 104 is connected to the lifting member 16 , for example by coupling a clevis 106 to the lifting member 16 by way of a clevis pin 108 fed through the coupling point hole 30 at the top of the lifting member 16 . The other end of the flexible lifting line 104 is securely fastened to the lifting arrangement of a skid steer loader, front end loader, excavator, back hoe or other working machine having a raisable and lowerable lifting arrangement. The lifting line 104 may be coupled to a bucket or other implement mounted on the lifting arms or boom of such a working machine, or coupled directly to the lifting arms or boom if a suitable connection point is found thereon. The flexible lifting line may be connected to the lifting member of the post puller prior to placement of the post puller onto the post, and optionally used to help in the initial lifting of same, provided that the final placement of the post puller onto the post is performed manually so as to leave slack in the lifting line so that the upward pulling force on the lifting member is removed to allow the grippers to move into their default open position in which the gap space between them is greater than the width of the flange or web of the post.
[0044] With post puller seated atop the post, as shown in FIG. 5 , the lifting arrangement of the working machine is raised, thereby pulling upward on the lifting member 16 of the post puller to cause the gripping surfaces of the grippers 20 to move toward one another and frictionally grip the web or flange 102 of the post 100 between them, whereupon continued raising of the lifting arrangement of the working machine will pull the post free from the ground.
[0045] As best shown in FIG. 3 , each link 18 of the illustrated embodiment is made up of two matching link plates 18 a , 18 b disposed in front of and behind the plane of the lifting member 16 and grippers 20 , but it will be appreciated that each link may alternatively be defined by a single unitary piece. Likewise, although the inclusion of two braces 22 a , 22 b spaced notably apart along the longitudinal direction of the shaft provides an effective stabilizing function to keep the post puller 10 in-line with the post 100 , it may be possible to rely on only a single brace, or to even omit the braces altogether without detriment to the gripping and pull efficiency of the post puller 10 . Likewise, the inclusion or configuration of the handles may vary, although the use of two obliquely oriented handles 26 that extend both rearwardly and laterally from the shaft provide for a confident two-handed grip that is balanced across the shaft while keeping the user's hands well back from the post/puller interface during use to avoid inadvertent injury.
[0046] Although the use of rectangular tubing maintains proper alignment of the lifting member and links with the shaft-carried grippers at the front side of the shaft, tubing of other non-circular cross-sectional shape may similarly maintain such alignment by preventing relative rotation between the shaft and sleeve to minimize stress on the linkage. Alternatively, circular tubing may be used, either with suitable anti-rotation means acting between the shaft and tube or relying on the linkage itself to self-maintain alignment between its components. Although a hollow shaft is in the best interest of weight reduction and material efficiency, the invention is not limited specifically to the use of a hollow tubing to define the guide shaft for the sliding movement of the sleeve.
[0047] In addition to being usable on the post types mentioned in the background section above in the context of temporary fencing, the present invention can also be used with others post types that similarly have an accessible web or flange engagable by the grippers, for example including angle iron or U-channel posts used for road signage support or other ground-embedded applications.
[0048] Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the scope of the claims without departure from such scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | A post puller features a lifting member that is slidably disposed on a guide shaft and attachable to a lifting arrangement of a working machine. A pair of movable grippers are pivotally supported on the guide shaft at a fixed position therealong, and a pair of links are pivotally connected between the lifting member and the grippers. With a web or flange of the post received in a space between inner ends of the movable grippers, raising of the lifting member by the working machine lifts the outer ends of the movable grippers via the pair of links, thereby lowering inner ends of the grippers into closer proximity to one another to grip the web or flange of the post between the grippers. With the post gripped in this manner, further raising of the lifting member by the working machine pulls the post from the ground. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a cover for receiving a potted plant.
Potted plants are frequently covered for use directly in the home with foil or polymeric film preshaped into a size into which a pot will fit. Although such covers for conventional plastic pots or clay pots allow the homeowner to display the potted plant without the expense of replanting the plant in an expensive decorative flower pot, such foil and plastic covers are not particularly attractive. Also, such covers are typically preformed to an existing inexpensive flower pot and cannot be removed or used for a variety of different sized flower pots.
Accordingly, there exists a need for a pot cover which is durable, can be employed for a variety of pot sizes and shapes, and yet provide a quality decorative container for displaying live plants in a home or business environment.
SUMMARY OF THE INVENTION
The pot cover of the present invention satisfies these needs by providing a foldable die cut pattern which can be imprinted on its exterior surfaces with any of a number of designs to provide the purchaser with a selection of decorative pot covers to conform to the décor of the location in which a plant will be displayed. It achieves this goal by utilizing a relatively inexpensive paperboard which is laminated on at least one side with a polymeric film and printed on its exterior with a decorative design. In a preferred embodiment of the invention, the pot cover is formed from a die cut pattern which can be folded into overlapping flaps and tabs which are folded and interlocked to define a generally trapezoidal pot cover which can receive a variety of different pot sizes and types and resists moisture. The die cut pattern forming the pot cover can be of a universal shape but formed in a variety of different sizes to accommodate different sized potted plants.
In a preferred embodiment of the invention, the pot covers can be shipped prior to assembly to a retail establishment, such as a nursery, florist, or mass merchandise outlet and either assembled by the merchant or provided with assembly instructions for the purchaser. The pot covers can also be preassembled by the manufacturer and shipped in stacked relationship to the retail merchant. Regardless of the manner in which they are provided to the customer, the pot covers are durable, attractive and provide the consumer with a wide selection of sizes and decorative patterns. The cover defines a container which also can be used to hold fresh flower arrangements, gifts, gourmet foods, candy, or other gift items.
These and other features, objects and advantages of the present invention will become apparent upon reading the following description thereof together with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a die cut pattern for forming a pot cover of the present invention;
FIG. 2 is an illustration of the pot cover shown during a first step of assembly;
FIG. 3 is a perspective view of the pot cover shown in a second step of assembly;
FIG. 4 is a perspective view of a pot cover shown in a third step of assembly;
FIG. 5 is a perspective view of a pot cover shown in a fourth step of assembly;
FIG. 6 is a perspective view of a pot cover shown in a fifth step of assembly;
FIG. 7 is a perspective view of a pot cover shown in a sixth step of assembly;
FIG. 8 is a perspective view of a pot cover shown in a seventh step of assembly; and
FIG. 9 is a perspective view of a completed pot cover embodying the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIGS. 1 and 9 , there is shown a pot cover 1 embodying the present invention, which is formed from a die cut pattern 4 made of a suitable paperboard material. In one embodiment, the material is a C1S (coated one side) SBS (solid bleached sulfate) about 14 point to about 22 point paperboard laminated with a polyethylene film of from about 0.005 to about 0.0075 inches thick. The material forming the die cut pot cover 1 can be poly-coated on both sides and, as seen in FIG. 1 , the interior side of the pot cover is shown, which is always poly-coated. The opposite surface of the die cut pattern forming the outer surface of the pot cover is printed with decorative indicia 2 , which can be any type of design. The printing can have a holiday theme, such as Christmas decorations, photographic scenes, a Valentine's Day theme, and any decorative pattern or style desired. Thus, the use of a die cut pattern for forming the pot cover 1 allows one side of the material to be printed with practically any desired indicia 2 including foil, textured foil and the like. The resultant, generally trapezoidal pot cover 1 , as seen in FIG. 9 , has a relatively large rectangular top opening 3 which allows the easy insertion of a pot therein. By providing the generally trapezoidal sides of the pot cover 1 , a unique design appearance is provided by the pot cover which further enhances its aesthetic appearance.
Referring now to FIG. 1 , there is shown a die cut pattern or form 4 for a pot cover 1 embodying the present invention. The pattern integrally includes a generally square base 10 , having a first side panel 12 integrally extending therefrom with two generally triangular side flaps 14 and 16 . An end flap 18 integrally extends from side 12 and includes outwardly extending tabs 20 and 22 . On the opposite side of base 10 is a second integral side 26 extending from base 10 and integrally including triangular flaps 30 and 32 and an outwardly extending top flap 28 . Flap 28 also includes outwardly extending tabs 34 and 36 for locking the pot cover in an assembled position as described below. Each of the flaps 18 and 28 also include a slot 24 and 38 , respectively, for providing a gripping handhold.
Additional side panels 40 and 56 integrally extend from base 10 in a direction orthogonal to side panels 12 and 26 . Panel 40 integrally includes triangular flaps 42 and 44 on opposite sides, which adjoin and are integrally coupled to flaps 14 and 30 . Side 40 includes an outwardly extending end flap 46 , which includes laterally extending tabs 52 and 54 coupled to the generally rectangular flap 46 by angled corners 48 and 50 . On the opposite side of base 10 is a similar side panel 56 integrally bordered by triangular flaps 58 and 60 , which integrally adjoin flaps 16 and 32 , respectively. Extending outwardly from side 56 is a generally rectangular flap 62 having outwardly extending tabs 68 and 70 with angled corners 64 and 66 , respectively. The integral triangular flaps 14 , 42 ; 16 , 58 ; 30 , 44 ; and 32 , 60 form a foldable web between the sides 12 , 26 and 40 , 56 , as seen in the assembly steps illustrated in FIGS. 3-8 .
The phantom lines shown in FIGS. 1-8 represent fold lines for the assembly process, which can either be manual or can be machine assembled if desired. The assembly (i.e., folding) process is shown in FIGS. 2-8 in which first the end flaps 46 and 62 are folded over onto sides 40 and 56 , respectively, in the direction of arrow A in FIG. 2 . The inner surfaces of flaps 46 and 62 may, if desired, be adhesively attached to the inside of sides 40 and 56 . Such step may, however, be unnecessary with the interlocking flaps and tabs holding the pot cover in an assembled state. The outer surfaces of the panels and flaps shown in FIG. 1 are identified in the remaining drawing figures with the same number incremented by a single digit. Thus, for example, in FIG. 2 , the outer surface of flap 62 is identified as 63 .
Next, as illustrated in FIG. 3 , the adjacent triangular panels 14 , 42 , 16 , 58 , 32 , 60 , 30 , and 44 are deflected inwardly as shown by arrow B in FIG. 3 .
This process is continued, as illustrated by arrow B in FIG. 4 , until the sides 40 and 56 are substantially vertical, as shown in FIG. 5 . The outer surface 57 of panel 56 is imprinted with an indicia 2 , as shown in FIG. 9 , as are the remaining external surfaces of the pot cover 1 . With the sides 40 and 56 substantially in the position shown in FIG. 5 , the sides 12 and 26 are then folded inwardly, as indicated by arrow D in FIG. 6 , such that with the tabs 68 , 70 , 52 , and 54 project inwardly from sides 40 and 56 and lie adjacent triangular flaps 58 , 60 ; and 42 , 44 , respectively.
Next, the end flaps 18 and 28 are folded over, as shown by arrow D in FIG. 6 , and tabs 34 and 36 and 20 and 22 are tucked over tabs 52 , 54 , 68 , and 70 , respectively, and under flaps 46 and 62 , as seen in FIGS. 7 and 8 , to interlock the edges of the pot cover to a completely assembled position as shown in FIG. 9 . The outer surface 13 of panel 12 likewise is imprinted with indicia 2 as are the remaining outer surfaces, including the outer surfaces 47 of flap 46 , 63 of flap 62 , surface 19 of flap 18 and surface 29 of flap 28 . Thus, the exposed surfaces of pot cover 1 which are visible, including the outer surfaces of the cover itself, and the inner surfaces of the flaps which are exposed when looking downwardly from the top edge of the cover are decoratively imprinted. The indicia 2 can be printed in any commercially known manner. The slots 24 and 38 in flaps 18 and 28 , respectively, provide handholds for lifting the cover and plant if a potted plant is to be moved.
Thus, by providing interlocking tabs 52 , 54 , 68 , and 70 with tabs 20 , 22 and 34 , 36 folded over and under flaps 46 and 62 , respectively, the top edges of the pot cover interlock. By providing the V-shaped notches 80 , 82 , 84 , and 86 between adjacent triangular panels 14 , 42 ; 44 , 30 ; 32 , 60 ; and 16 , 58 , respectively, clearance is provided for the interlocking tabs and flaps to allow the ready assembly of the pot cover. Handholds 24 and 38 are interior of the pot cover and, therefore, are relatively unobtrusive and do not detract from the ornamental appearance of the resultant pot cover when assembled as seen in FIG. 9 .
The pot cover 1 is preferably made to accommodate standard sized pots, such as 4″, 6″, and 8″ pots, although any desirable size can be employed. For a 6″ pot, for example, the square bottom 10 was approximately 4½″ on each side while the sides had a height of approximately 5¼″ and a width at the top of 6″. The overlapping and interlocking flaps 18 , 28 , 46 and 62 extended downwardly into the pot cover approximately 2½″. For different sized pots, these dimensions will be varied proportionally. Although the poly-coated paperboard, which is film covered on one or both sides and printed with a decorative design on the exterior surface, is preferred, other foldable, interlocking materials could be employed.
It will become apparent to those skilled in the art that various modifications to the preferred embodiment of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims. | A foldable pot cover provides a foldable die cut pattern which can be imprinted on its exterior surfaces with any of a number of designs. The pot cover is formed from a die cut pattern which can be folded into overlapping flaps and tabs which are folded and interlocked to define a generally trapezoidal pot cover which can receive a variety of different pot sizes and types and resists moisture. The die cut pattern forming the pot cover can be of a universal shape but formed in a variety of different sizes to accommodate different sized potted plants. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of and claims priority to U.S. application Ser. No. 12/900,225, filed on Oct. 7, 2010, which is a continuation of U.S. application Ser. No. 11/159,689, filed on Jun. 23, 2005, which is a utility conversion of Provisional Application Ser. No. 60/582,160, filed on Jun. 24, 2004. The disclosures of U.S. application Ser. Nos. 12/900,225 and 11/159,689 and U.S. Provisional Patent Application No. 60/582,160 are incorporated herein by reference in their entirety.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This present invention relates to a means of increasing the load capacity of a monopole tower and in particular, an apparatus and method for increasing the load capacity and stability of the tower to support the weight of additional communication equipment as well as the environmental forces exerted on the tower.
2. Brief Description of Prior Art
Single-pole towers, also referred to as monopole towers are used in the telecommunications industry. In particular, such towers are used to support equipment for wireless phones and other communication devices.
The increase in wireless communications has resulted in an increase of mounted communication equipment of all kinds. Not only do wireless service providers need to install equipment covering new geographic areas, competing wireless service providers need to install additional equipment covering the same or similar geographic areas. The solution to the foregoing problem is to either purchase additional land to erect new towers, or install additional equipment on existing towers. Purchasing land to install additional towers is increasingly expensive, as well as the expense associated with the construction and the maintenance of a new tower.
Towers are designed generally to support the weight of the communications equipment originally installed on the tower, as well as to withstand forces exerted on the tower by environmental factors, such as wind and ice, for example. Towers are generally not designed with sufficient stability to enable the tower to allow for the installation of additional equipment. As a result, prior art methods of increasing the stability of the tower in order to support additional equipment are known to consist basically of familiar, expected and obvious structural configurations, typically reinforcing the weak area of the tower (the area where the additional equipment is to be installed) by means of a weld repair, such as an overlay of welding material. Installing the welding material can be done manually, or by using an automatic welding machine.
Therefore, it can be appreciated that there exists a continuing need for an apparatus and method for increasing the load capacity and stability of a tower to enable the tower to support the weight of additional communication equipment as well as the environmental forces exerted on the tower.
As will be seen from the subsequent description, the preferred embodiments of the present invention overcome limitations of monopole tower arrangements.
SUMMARY OF THE INVENTION
With the proliferation of cell phones and personal communications devices comes the need for towers to support additional equipment for wireless phone and other communication devices. The present invention is designed to increase the load capacity and stability of a tower to enable the tower to support the weight of additional communication equipment as well as the environmental forces exerted on the tower. The preferred embodiment generally includes vertical flat bars disposed about the tower and mounted to the tower with one-sided bolts. A joining plate is further disclosed when joining a first vertical flat bar with a second vertical flat bar.
The presence of the tower support elements of the present invention increases the load capacity and stability of the tower. Specifically, the vertical flat bars provide reinforcement to the tower to allow for the installation of additional equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the present invention, a reinforced tower.
FIG. 1A is a detail view of bolt spacing for an end of a vertical flat bar and joining plate.
FIG. 1B is a detail view of a section of the apparatus of FIG. 1 .
FIG. 1C is a detail view of a full penetration weld between the vertical flat bar and the base flange.
FIG. 2 is a top view of the tower reinforcement apparatus of FIG. 1 , illustrating the preferred spacing between the vertical flat bars.
FIG. 3 is a perspective view of the vertical flat bar and joining plate.
FIG. 3A is a detail view of an end of the vertical flat bar and joining plate.
FIG. 4 is a perspective view of a monopole tower showing field drilled holes for receiving one-sided bolts.
FIG. 5 is a perspective view of a monopole tower showing installed one-sided bolts.
FIG. 6 is a cutaway detail view of the present invention showing one-sided bolts, the vertical flat bar, and the tower section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-6 illustrate a preferred embodiment of a tower reinforcement apparatus 1 made in accordance with the present invention. In the preferred embodiment, the tower reinforcement apparatus 1 is attached to a prior art monopole tower 100 at selected locations to maximize the strength of the tower 100 and reinforce the tower 100 in order to enable the tower 100 to support the weight of additional communication equipment (not shown) as well as the environmental forces exerted on the tower 100 .
The prior art monopole tower 100 is generally attached to a base flange 110 and is comprised of a solid sheet of formed metal that forms a structure capable of supporting the various communication equipment that may be attached to the prior art tower 100 .
In general, the prior art monopole tower 100 is designed to support the weight of the communications equipment originally installed on the tower 100 , as well as to withstand forces exerted on the tower 100 by environmental factors, such as wind and ice, for example. The monopole towers of the prior art are generally not designed with sufficient stability to enable the tower 100 to allow for the installation of additional equipment. The tower reinforcement apparatus 1 is designed to attach to the prior art monopole tower 100 at selected locations where additional equipment will be installed in order to maximize the strength and provide reinforcement to the tower 100 at such selected locations.
In application, the tower 100 is drilled with a plurality of holes 105 at selected locations as shown in FIG. 4 for receipt of one-sided bolts 150 preferably one-sided stitch bolts 150 as shown in FIG. 5 . A vertical flat bar 10 having a plurality of apertures 11 attaches to the prior art monopole tower 100 with the plurality of one-sided stitch bolts 150 and nuts 150 A. The vertical flat bar 10 is attached to the tower 100 at selected locations in order to maximize the strength and provide reinforcement to the tower 100 at those selected locations. Further, the spacing of the bolts 150 along the vertical flat bar 10 can be considerably narrower to further increase the reinforcement. In the preferred embodiment, at least one one-sided termination bolt 155 and nut 155 A (shown in FIG. 1B ) is installed at the approximate top end of the flat bar 10 to further secure the vertical flat bat 10 to the tower 100 .
As should be understood, the longer the vertical flat bar's 10 length, the more difficult the vertical flat bar 10 is to manage and handle when attaching the bar 10 to the tower 100 in the field. As such, when longer lengths of flat bar 10 is required, it is preferred to apply multiple vertical flat bars 10 to maximize the strength and provide reinforcement to the tower 100 .
As an example, and referring to FIGS. 1 and 1B , a first vertical flat bar designated in FIG. 1 as 10 A is attached at its upper end to the tower 100 as discussed above, and a second vertical flat bar designated as 10 B in FIG. 1 is attached to the tower 100 with an upper end 10 A′ of the first vertical flat bar 10 A in abutting communication with a lower end 10 B′ of the second vertical flat bar 10 B. A joining plate 20 having a plurality of apertures 21 is attached to the first and second flat bars 10 A, 10 B, respectively, where the ends 10 A′ 10 B′ abut. In this configuration, the ends 10 A′ 10 B′ of the first and second vertical flat bars 10 A, 10 B are sandwiched between the exterior surface 102 of the tower 100 and the joining plate 20 . The joining plate 20 is attached to the tower 100 (with the flat plate bars sandwiched therebetween) using a plurality of bolts 160 preferably a plurality of one-sided splice plate bolts 160 and nuts 160 A.
Referring to FIG. 1B , which shows attachment of abutting ends 10 A′ and 10 B′ and the joining plate 20 , a spacing 24 can exist between the upper end 10 A′ of the first vertical flat bar 10 A and the joining plate 20 . This spacing 24 occurs due to the prior art monopole's 100 construction namely, the overlap of the monopole's 100 sections that form the monopole 100 . When this occurs, a spacer plate 30 can be inserted within the spacing 24 between the outer surface of the vertical flat bar 10 A and the joining plate 20 such that the attached joining plate 20 is attached to a substantially level solid surface.
As best shown in FIG. 1C , the tower 100 is affixed to the base flange 110 with means known in the art. The vertical flat bar 10 , when required, can be attached to the tower 100 so that a lower end designated as 10 C in FIG. 1C is positioned adjacent, but not in abutting relationship with, the base flange 110 . To further strengthen the tower reinforcement apparatus 1 , a full penetration weld 50 is disposed between the end 10 C of the vertical flat bar 10 and the base flange 110 . It should be noted that for safety measures, and other concerns relating to welding to monopole towers, the only welding operation when attaching the tower reinforcement apparatus 1 of the present invention is the weld 50 between the lower end 10 C of the vertical flat bar 10 and the base flange 110 .
The vertical flat bar 10 is selectively positioned along the length of the tower 100 in order to add support to that area of the tower 100 where additional communication equipment is to be installed. As discussed, multiple vertical bars 10 are preferably joined with joining plates 20 to maximize the strength and provide reinforcement to the tower 100 . In the preferred embodiment, a plurality of vertical flat bars 10 and joining plates 20 may be used in order to strengthen the approximate upper region of the tower 100 where added support is needed, as well as the approximate lower region of the tower 100 where added support is needed. Further, and as illustrated in FIG. 2 , the preferred spacing between vertical flat bars 10 about the outer perimeter surface 102 of the tower 100 is approximately 120 degrees. As can be seen in cross-section FIG. 2 , the monopole tower 100 is a 12 sided hollow column with each vertical flat bar 10 spaced 4 sides apart on one of the 12 flat sides of the tower 100 .
By installing multiple vertical flat bars 10 as described above, shorter lengths of flat bars 10 may be used for easier field assembly. As a result, it is possible to attach communication equipment and/or other types of loads directly to the tower 100 . Such loads may be attached to the tower 100 at any point along the vertical length of the installed tower reinforcement apparatus 1 .
By installing the tower reinforcement apparatus 1 to the tower 100 as described above, bending moments experienced by the tower 100 may be passed into and absorbed by the tower reinforcement apparatus 1 , thereby increasing the load capacity and stability of the tower 100 in order to enable the tower 100 to support the weight of additional communication equipment as well as the environmental forces exerted on the tower.
The tower reinforcement apparatus 1 may be installed on towers which are not yet installed or which is not vertical, or on previously installed towers.
Metal, such as steel or aluminum, is the preferred material of construction of the preferred embodiment of the vertical flat bars 10 and the joining plates 20 .
The preferred bolts 150 , 155 and 160 are known in the art. The size of the bolts 150 , 155 and 160 and spacing of the bolts 150 , 155 and 160 is determined by the amount of reinforcing required. Further, the extent of reinforcing also determines the size and length of the vertical flat bars 10 . In the preferred embodiment, the vertical flat bars 10 are installed continuous up the length of the tower 100 . Again, this is accomplished by installing the joining plate 20 to the ends of abutting vertical flat bars 10 .
In operation, to reinforce an existing tower 100 to which additional equipment is to be added, a series of holes 105 , as shown in FIG. 4 would be drilled along the length of at least one flat side of the tower 100 . The placement and spacing of the holes 105 could be designed based on the added load of the additional equipment. Typically 3 flat sides, spaced at approximately 120 degree spacings around the tower, would each receive holes 105 .
With the holes 105 in place, flat bars 10 with clearances 11 matching the spacing of holes 105 are placed against each flat side of the perimeter 102 of the tower 100 and are bolted to the tower using bolts. All of the holes 105 and 11 can be pre-drilled prior to placing the flat bars 10 in place or some of the holes 11 , 105 might be drilled after the flat bars are in place. Most towers 100 are tall enough to require multiple sections of flat bar 10 . A first flat bar 10 A is placed and then a second flat bar 10 B is placed aligned with the first bar 10 A and with ends 10 A′ and 10 B′ adjacent to each other forming a joint space. In these cases a plate 20 is placed over the joint space to support it. A series of holes 21 are drilled through the plate 20 and bolts 160 secure the plate 20 to the end of bars 10 A and 10 B. Again, holes 21 can be pre-drilled or drilled at the time of installation. As shown in FIG. 3 , the plate 20 can be pre-attached to one of the flat bars 10 A prior to installation. Once in place an end of the bottom most bar 10 A is welded to a base flange 110 of the tower 100 .
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention.
It will be obvious to those skilled in the art that modifications may be made to the embodiments described above without departing from the scope of the invention. Thus the scope of the invention should be determined by the claims in the formal application and their legal equivalence, rather than by the examples given. | A method and apparatus for creating a reinforced vertical multi-sided monopole tower for supporting equipment including a multi-sided monopole, a plurality of holes on three equally spaced sides of the multi-sided monopole tower and tower reinforcement apparatus mounted to the holes. The tower reinforcement apparatus includes bolts supporting a first flat bar and a second flat bar on each side of the tower. The upper end of the first flat bar abuts a lower end of the second bar and a plate is bolted over adjacent ends connecting the first and second flat bar such that the first and second flat bars are sandwiched between the plate and a side of the perimeter of the monopole. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a lubricating oil cooling system for a liquid cooled internal combustion engine incorporated in an automotive vehicle such as a passenger car, and more particularly relates to such a lubricating oil cooling system which is suitable for utilization in an automotive vehicle which has its liquid cooled internal combustion engine located behind at least part of the passenger compartment of said vehicle, as, for example, a rear engined or mid engined passenger automobile.
Rear engined and mid engined automobiles are becoming relatively popular in recent times. In these rear and mid engined automobiles, certain problems arise with respect to provision of adequate cooling for the lubricant oil in the engine, because the considerable draft of air caused by the relative wind due to the forward motion of the vehicle does not give such a high cooling effect to the engine, particularly to the lower parts of the engine where the lubricating oil pan is located as in the front engined automobiles. Accordingly there is a risk that the temperature of the lubricating oil should rise so high as to reach an undesirably high value which can cause loss of lubricating quality of the lubricating oil and breakdown of the proper film of lubricating oil required to keep the relatively moving parts of the engine separated and functioning smoothly without undue friction.
As a device for restricting the rise in temperature of the lubricating oil of the internal combustion engine in a rear engined or mid engined automotive vehicle, a per se well known lubricating oil cooling device commonly called a heat exchanger or oil cooler might be considered for application. Now, in the case of a rear engined or mid engined automotive vehicle, the application of an air cooled heat exchanger is not suitable, because as explained above no strong air current will be available unless such an air cooled heat exchanger is provided at the front end portion of the vehicle, but it is undesirable for the lubricating oil passages to be so very long as would be required if such an air cooled heat exchanger were mounted at the front end of the vehicle to receive the impact of a strong draft thereupon. Thus, in the case of such a vehicle, it is desirable to use a a cooling fluid cooled type of heat exchanger for the lubricating oil, provided that the engine is of a cooling fluid cooled type.
However, in the design of the circulation system for the cooling fluid of such a rear engined or mid engined automotive vehicle, problems also arise with regard to minimizing the flow resistance thereof, since inevitably the cooling fluid passage system leading heated cooling fluid from the internal combustion engine to the radiator, and leading cooled cooling fluid back from the radiator to the internal combustion engine, is required to be considerably long, since the radiator is required to be at the front end of the vehicle so as to receive a good draft of air. These problems can be overcome; but the incorporation of a conventional type of cooling fluid cooled heat exchanger for the lubricating oil in such a construction gives rise to additional problems with regard to increasing the flow resistance of the cooling fluid passage system. Accordingly, the integration of such a lubricating oil heat exchanger into the cooling system of a rear engined or mid engined vehicle requires an inventive development.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of the present invention to provide a lubricating oil cooling system which is suitable for incorporation into a rear engined or mid engined automotive vehicle in which the internal combustion engine is cooled by flow of cooling fluid therethrough.
It is a further object of the present invention to provide such a lubricating oil cooling system for such an automotive vehicle, which minimizes problems associated with flow resistance of the cooling fluid conduits between the internal combustion engine and the radiator of the vehicle.
It is a further object of the present invention to provide such a lubricating oil cooling system for such an automotive vehicle, which keeps the lubricating oil of the internal combustion engine at a desirably low temperature without giving rise to problems with regard to circulation of the cooling fluid of the internal combustion engine.
It is a yet further object of the present invention to provide such a lubricating oil cooling system for such an automotive vehicle, which can achieve the above mentioned objects while minimizing the associated complexity thereof, weight, and number of parts.
It is a yet further object of the present invention to provide such a lubricating oil cooling system for such an automotive vehicle, which provides cooling for the lubricating oil of the internal combustion engine only when really necessary.
According to the most general aspect of the present invention, these and other objects are accomplished for a vehicle having a passenger compartment and a liquid cooled internal combustion engine mounted at least partly behind said passenger compartment with regard to the forward moving direction of said vehicle, by providing a lubricating oil system comprising a cooling fluid jacket for circulation of cooling fluid therethrough for cooling said internal combustion engine; a radiator for cooling cooling fluid mounted in front of said passenger compartment with regard to the forward moving direction of said vehicle; and means for conducting flow of cooling fluid between said cooling fluid jacket of said internal combustion engine and said radiator in both directions: a cooling system for lubricating oil of said internal combustion engine, comprising: a heat exchanger formed with a cooling fluid passage and a lubricating oil passage arranged to exchange heat therebetween, lubricating oil of said internal combustion engine flowing through said lubricating oil passage and the cooling fluid for cooling said internal combustion engine flowing through said cooling fluid passage; said cooling fluid passage of said heat exchanger being a part of said cooling fluid flow conducting means.
According to such a structure, it is possible to effectively cool the lubricating oil of the internal combustion engine by the flow of the cooling fluid of the engine which is anyway passing through the cooling fluid flow conducting means in order to be circulated between the engine and the radiator; and thereby the length of the cooling fluid flow conducting means is not required to be particularly extended to any more than its already necessary length in order to fit the heat exchanger for lubricating oil to the vehicle, thus avoiding a situation where the flow resistance of the cooling fluid conduits between the engine and the radiator becomes unduly high, and avoiding problems arising with regard to circulation of the cooling fluid of the internal combustion engine, as well as minimizing the associated complexity thereof, weight, and number of parts.
Further, according to a more particular aspect of the present invention, these and other objects are more particularly and concretely accomplished by a lubricating oil cooling system as described above, wherein said cooling fluid passage of said heat exchanger forms a portion a part of said cooling fluid flow conducting means which conducts a flow of cooling fluid from said cooling fluid jacket of said engine towards said radiator.
According to such a structure, the heat picked up by this cooling fluid which has cooled the lubricating oil in the heat exchanger is then dissipated in the radiator of the vehicle, and is not undesirably returned to the engine. This ensures that the temperature of the cooling fluid flowing through the cooling fluid jacket of the engine is kept at a proper level.
Further, according to another more particular aspect of the present invention, these and other objects are more particularly accomplished by a lubricating oil cooling system of either of the types described above, wherein the direction of fluid flow through said cooling fluid passage of said heat exchanger is generally opposite to the direction of fluid flow through said lubricating oil passage of said heat exchanger.
According to such a structure, the effectiveness of heat exchange between the cooling fluid flowing in the cooling fluid passage of the heat exchanger and the lubricating oil flowing in the lubricating oil passage thereof is maximized.
Further, according to a yet more particular aspect of the present invention, these and other objects are more particularly accomplished by a lubricating oil cooling system as first described above, wherein said heat exchanger is constructed with said cooling fluid passage and said lubricating oil passage being coaxial cylinders one inside the other.
According to such a structure, a long heat interchange portion can be provided between the cooling fluid passage and the lubricating oil passage, with minimum increase of flow resistance to both the flow of cooling fluid and the flow of lubricating oil.
Further, according to yet another more particular aspect of the present invention, these and other objects are more particularly accomplished by a lubricating oil cooling system as first described above, wherein said internal combustion engine comprises a lubricating oil pump and a relief valve which feeds lubricating oil to said lubricating oil passage of said heat exchanger when the pressure delivered by said pump becomes greater than a predetermined pressure value.
According to such a structure, lubricating oil is only fed to said heat exchanger to be cooled in those circumstances in which the internal combustion engine is rotating quickly so that the lubricating oil pump thereof is delivering a high output pressure so as to cause relief lubricating oil to be supplied by said relief valve, and since these are the type of circumstances in which there is a strong risk of the lubricating oil of the engine overheating, this method of operation provides cooling for the lubricating oil of the engine just when it is required. Further, since according to this particular specialization of the present invention only the relief or blowoff lubricating oil is cooled, the operation of cooling the lubricating oil has no substantial effect on the lubricating oil pressure of the engine either to raise it or to lower it, which is appropriate in view of the desirability of restricting fluctuations of the lubricating oil pressure of the engine.
Further, according to a yet more particular aspect of the present invention, these and other objects are more particularly and concretely accomplished by a lubricating oil cooling system as proximately described above, wherein said internal combustion engine comprises a second relief valve which vents lubricating oil not to supply lubricating oil towards said lubricating oil passage of said heat exchanger when the pressure delivered by said pump becomes greater than a threshold pressure value which is substantially higher than said predetermined pressure value.
According to such a structure, a backup relief function is assured for preventing the lubricating oil pressure of the internal combustion engine rising above said threshold pressure value. This is important because flow resistance of the lubricating oil passage of the heat exchanger might otherwise undesirably deteriorate the venting function of the first relief valve.
Further, according to another yet more particular aspect of the present invention, these and other objects are more particularly and concretely accomplished by a lubricating oil cooling system as first described above, said vehicle further comprising a transmission, further comprising a cooling system for lubricating oil of said transmission, comprising: a second heat exchanger formed with a cooling fluid passage and a lubricating oil passage arranged to exchange heat therebetween, the lubricating oil of said transmission flowing through said lubricating oil passage and the cooling fluid flowing through said cooling fluid passage; said cooling fluid passage of said second heat exchanger being a part of said cooling fluid flow conducting means.
According to such a structure, also the lubricating oil of the transmission is cooled, in a similar manner to that described above. In this case, it may be that said cooling fluid passage of said first heat exchanger is a part of a part of said cooling fluid flow conducting means which conducts a flow of cooling fluid from said cooling fluid jacket of said internal combustion engine towards said radiator, and said cooling fluid passage of said second heat exchanger is a portion of a part of said cooling fluid flow conducting means which conducts a flow of cooling fluid from said radiator towards said cooling fluid jacket of said internal combustion engine. This will not cause any problem with regard to heating of the cooling fluid flowing into the cooling fluid jacket of the internal combustion engine, because typically the amount of heat required to be dissipated from the lubricating oil of the transmission is relatively small.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be shown and described with reference to the preferred embodiment thereof, and with reference to the illustrative drawings. It should be clearly understood, however, that the description of the embodiment, and the drawings, are all of them given purely for the purposes of explanation and exemplification only, and are none of them intended to be limitative of the scope of the present invention in any way, since the scope of the present invention is to be defined solely by the legitimate and proper scope of the appended claims. In the drawings, like parts and features are denoted by like reference symbols in the various figures thereof, and:
FIG. 1 is a part phantom schematic perspective view of the body of an automotive vehicle and an internal combustion engine and a transmission unit incorporated therein along with various other parts thereof, said vehicle incorporating a lubricating oil cooling system according to the preferred embodiment of the present invention;
FIG. 2 is a schematic sectional view of said internal combustion engine and said transaxle unit and of various parts of the cooling system therefor;
FIG. 3 is a plan view of a first heat exchanger included in said lubricating oil cooling system according to the present invention;
FIG. 4 is a transverse sectional view of this first heat exchanger taken in a plane perpendicular to the central longitudinal axis thereof and indicated by the arrows IV--IV in FIG. 3; and
FIG. 5 is a longitudinal sectional view of this first heat exchanger taken in a plane containing to the central longitudinal axis thereof and indicated by the arrows V--V in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described with reference to the preferred embodiment thereof, and with reference to the appended drawings. Referring to FIG. 1, the body of the automotive vehicle is partly shown in phantom form by the double dotted lines, and the passenger compartment thereof is schematically indicated by the symbol "C". This automotive vehicle is of the previously described type with its engine and transmission unit mounted in the rear of its body behind the passenger compartment C with the central axis of said engine and transmission unit extending transversely to the longitudinal axis of the vehicle, and with its radiator mounted in the front of its body before the passenger compartment C.
In more detail, the automotive vehicle incorporates a liquid cooled internal combustion engine, denoted by the reference numeral 1, and a transaxle unit denoted by the reference numeral 2 which is secured to the engine 1 and which comprises a per se well known automatic transmission unit and a differential device; and this combination of the engine 1 and the transaxle unit 2 is transversely mounted in the vehicle body behind the passenger compartment C (the front of the vehicle is to the left in FIG. 1), the transaxle unit of course being drivingly connected to the rear wheels, not shown, of the vehicle, via drive shafts also not shown.
Referring to FIG. 2 in particular, which includes a schematic sectional view of said liquid cooled internal combustion engine 1 and said transaxle unit 2 and of various parts of the cooling system therefor, the internal combustion engine 1 has a cooling fluid jacket 3 which is defined in the cylinder block and the cylinder head thereof and which generally surrounds the cylinders and the cylinder chambers thereof (not particularly shown), and during operation of the vehicle this cooling fluid jacket 3 is filled with cooling fluid such as a water and antifreeze mixture which absorbs heat generated in said cylinders and cylinder chambers by the operation of the internal combustion engine 1 in a per se well known fashion. This cooling fluid jacket 3 has a cooling fluid outlet 3a and a cooling fluid inlet, and a cooling fluid pump 25 of a per se well known sort, which has a cooling fluid inlet and a cooling fluid outlet which is communicated directly to said cooling fluid inlet of said cooling fluid jacket 3, is driven by the rotation of the internal combustion engine 1 and pumps cooling fluid from its cooling fluid inlet into the cooling fluid jacket 3, said cooling fluid after having been heated in the cooling fluid jacket 3 then passing out of the cooling fluid outlet 3a thereof, as schematically indicated by the arrows in the figure. The cooling fluid inlet of the cooling fluid pump 25 is communicated to the cooling fluid outlet of a per se well known temperature sensitive valve 24, which has a cooling fluid inlet 3b. This temperature sensitive valve (or thermostat) 24 is so arranged as to open, i.e. to communicate its cooling fluid inlet 3b to its cooling fluid outlet, when the temperature of the cooling fluid is greater than a certain predetermined threshold temperature value, and to close, i.e. to discommunicate its cooling fluid inlet 3b from its cooling fluid outlet, when the temperature of the cooling fluid is less than said predetermined threshold temperature value. The internal combustion engine 1 also has a bypass passage (not shown) of a restricted size which directly communicates the cooling fluid inlet 3b of the temperature sensitive valve 24 to the cooling fluid inlet of the cooling fluid pump 25.
In the front end of the automotive vehicle before the passenger compartment C there is mounted a radiator 12, which is constructed in this particular application of the present invention as a side flow type with two side tanks 13 and 15 and with a plurality of substantially horizontal tubes 16 connecting together these side tanks 13 and 15, the radiator 12 being mounted so that these horizontal tubes 16 extend transversely to the longitudinal axis of the vehicle. A plurality of cooling fins 17 are mounted between the tubes 16 for providing good cooling therefor, and the radiator 12 is vertically mounted, so that the relative wind due to the motion of the vehicle relative to the air impinges on the front side of the radiator and blows between the tubes 16 and the fins 17. The inlet side tank 13 has a cooling fluid inlet 14 at its upper portion, and the outlet side tank 15 has a cooling fluid outlet 18 at its lower portion.
The cooling fluid outlet 3a of the cooling fluid jacket 3 of the engine 1 is connected to the cooling fluid inlet 14 of the side tank 13 of the radiator 12 via a first cooling fluid passage construction A, and the cooling fluid inlet 3b of the temperature sensitive valve 24 is connected to the cooling fluid outlet 18 of the other side tank 15 of the radiator 12 via a second cooling fluid passage construction B. These cooling fluid passage constructions A and B run under the passenger compartment C of the vehicle in a protected tunnel shape formed on the floor thereof and only schematically shown in the figure.
With regard to the details of these cooling fluid passage constructions A and B, which are shown in detail in FIG. 1 but are not completely shown in FIG. 2, the first cooling fluid passage construction A comprises, in order in the direction of cooling fluid flow therealong, a first rubber hose member 4 the upstream end of which is connected to the cooling fluid outlet 3a of the cooling fluid jacket 3, a cooling fluid supplying member 6 the upstream end of which is connected to the downstream end of the first rubber hose member 4 and which incorporates an inlet 5 for addition of cooling fluid when so required, a second rubber hose member 7 the upstream end of which is connected to the downstream end of the cooling fluid supplying member 5, a first heat exchanger 8 for cooling the lubricating oil of the internal combustion engine 1 which will be explained in detail later and the upstream cooling fluid inlet end of which is connected to the downstream end of the second rubber hose member 7, a third rubber hose member 9 the upstream end of which is connected to the downstream cooling fluid outlet end of the first heat exchanger 8, a first long metallic tube 10 the upstream end of which is connected to the downstream end of the third rubber hose member 9 and which extends through the aforesaid protected tunnel shape formed on the floor of the passenger compartment C of the vehicle, and a fourth rubber hose member 11 the upstream end of which is connected to the downstream end of the first long metallic tube 10 and the downstream end of which is connected to the cooling fluid inlet 14 of the side tank 13 of the radiator 12. On the other hand, the second cooling fluid passage construction B comprises, also in order in the direction of cooling fluid flow therealong, a fifth rubber hose member 19 the upstream end of which is connected to the cooling fluid outlet 18 of the side tank 15 of the radiator 12, a second long metallic tube 20 the upstream end of which is connected to the downstream end of said fifth rubber hose member 19 and which also extends parallel to and alongside the first long metallic tube 10 through the aforesaid protected tunnel shape formed on the floor of the passenger compartment C of the vehicle, a sixth rubber hose member 21 the upstream end of which is connected to the downstream end of said second long metallic tube 20, a second heat exchanger 22 for cooling the lubricating oil or working fluid of the transaxle device 2 which will be explained in detail later and the upstream cooling fluid inlet end of which is connected to the downstream end of said sixth rubber hose member 21, and a seventh rubber hose member 23 the upstream end of which is connected to the downstream cooling fluid outlet end of said second heat exchanger 22 and the downstream end of which is connected to the cooling fluid inlet 3b of the temperature sensitive valve 24. Thus, particularly according to the present invention, the first heat exchanger 8 is provided directly in the flow path of cooling fluid from the liquid cooled internal combustion engine 1 at the rear of the automotive vehicle to the radiator 12 at the front of the vehicle, with no particular special auxiliary conduits being required for the conduction of cooling fluid to said first heat exchanger 8; and also particularly according to the present invention the second heat exchanger 22 is similarly provided directly in the flow path of cooling fluid from the radiator 12 at the front of the vehicle to the liquid cooled internal combustion engine 1 at the rear of the automotive vehicle, with no particular special auxiliary conduits being required for the conduction of cooling fluid to said second heat exchanger 22.
The internal combustion engine 1 comprises a lubricating oil pan 26 which serves as a reservoir for a pool of lubricating oil used by said engine 1, and lubricating oil is sucked up from said pool by a lubricating oil pump 28 via a strainer 27 and is pressurized in a conventional fashion, to be then supplied to a lubricating oil conduit 30 which leads to a first relief valve 31, which may be of a conventional spring type. After passing through the first relief valve 31, this pressurized lubricating oil is then supplied via another lubricating oil conduit 32 to various parts of the internal combustion engine 1 which are to be lubricated and cooled such as valve driving mechanisms and crankshaft bearings and so on which are not particularly shown in the figures but are schematically indicated by an arrow. From these lubricated and cooled mechanisms, the used lubricating oil is returned via a lubricating oil conduit 33 and is drained back to the lubricating oil pool in the lubricating oil pan 26. When the lubricating oil pressure at the first relief valve 31 starts to rise up to be higher than a certain first predetermined pressure value, then a sufficient flow of lubricating oil is released by this first relief valve 31 to a relief lubricating oil conduit 34 to bring the lubricating oil pressure down to said certain first predetermined pressure value. This relief lubricating oil conduit 34, as will be explained in detail shortly, conducts this relief lubricating oil flow to the lubricating oil path of the first heat exchanger 8, so as to cool said relief lubricating oil flow by exchanging some of its heat to the cooling fluid flowing through the cooling fluid flow path of said first heat exchanger 8, before said relief lubricating oil is returned to the lubricating oil pool in the lubricating oil pan 26 via a drain conduit 51.
In the shown construction, additionally the lubricating oil pump 28 incorporates a second relief valve 36, which is preset to open at a certain second predetermined pressure value which is substantially higher than the predetermined first pressure value relating to the first relief valve 31, so as then to vent a relief flow of lubricating oil to the lubricating oil pool in the lubricating oil pan 26 via a conduit 35. The reason for the provision of this second relief valve is as follows. If the pressure of the lubricating oil output from the lubricating oil pump 28 tries to rise above said first predetermined value, as explained above the first relief valve 31 allows some flow of lubricating oil to escape to the relief lubricating oil conduit 34 so as to limit the lubricating oil pressure at said first relief valve 31 to be substantially equal to said first predetermined lubricating oil pressure value; but this action is only effective, so long as this relief lubricating oil conduit 34 can accept this relief lubricating oil flow. Now, because as will be seen from the following the first heat exchanger 8 has a by no means negligible flow resistance, if this relief flow of lubricating oil is thus required to become too great, as when the revolution speed of the internal combustion engine 1 becomes very high, there is a risk that this flow cannot be pushed through the first heat exchanger 8 by the pressure available to do so; and in such a case the output pressure in the lubricating oil conduit 32 of the lubricating oil supplied to lubricate and cool the parts of the internal combustion engine 1 would undesirably rise. However, this rise of the pressure in the lubricating oil conduit 32 is effectively stemmed by the provision of the second relief valve 36, which does not allow said pressure to rise to greater than said second predetermined value: the difficulty relating to the first relief valve described above does not apply to this second relief valve 36, because the relief lubricating oil path (incorporating the conduit 35) from this second relief valve 36 has no very substantial flow resistance.
Similarly, the transaxle device 2 comprises a lubricating oil pan 52 which serves as a reservoir for a pool of lubricating oil or working fluid (which will hereinafter be referred to as lubricating oil, since it partakes of the characteristics thereof) used by said transaxle device 2, and lubricating oil is sucked up from said pool by a lubricating oil pump 53 via a strainer 54 and is pressurized in a conventional fashion, to be then supplied to a lubricating oil conduit 55 which leads to a relief valve (or line lubricating oil pressure control valve) 56, which again may be of a conventional spring type. After passing through said relief valve 56, this pressurized lubricating oil is then supplied via another lubricating oil conduit to various parts of the transaxle device 2 which are to be supplied with lubricating oil, such as a torque converter and gear systems and a hydraulic fluid pressure control device and so on which are not particularly shown in the figures but are schematically indicated by an arrow. From these various mechanisms, the used lubricating oil is returned via a lubricating oil conduit and is drained back to the lubricating oil pool in the lubricating oil pan 52. When the lubricating oil pressure at the relief valve 56 starts to rise up to be higher than a certain third predetermined pressure value, then a sufficient flow of lubricating oil is released by this relief valve 56 to a relief lubricating oil conduit 59 to bring the lubricating oil pressure down to said certain third predetermined pressure value. This relief lubricating oil conduit 59, as will be explained in detail shortly, conducts this relief lubricating oil flow to the lubricating oil path of the second heat exchanger 22, so as to cool said relief lubricating oil flow by exchanging some of its heat to the cooling fluid flowing through the cooling fluid flow path of said second heat exchanger 22, before it is returned to the oil pool in the lubricating oil pan 52 via a drain conduit 60.
Now the construction of the first heat exchanger 8, in this preferred embodiment, will be described. FIG. 3 is a plan view of said first heat exchanger 8, and shows that it comprises an outer tube or body member 40 with two conical cap shaped end members: a cooling fluid inlet member 41a formed with a cooling fluid inlet aperture at its apex and mounted at the right end in the figure of said outer tube member 40, and a cooling fluid outlet member 41b similarly formed with a cooling fluid outlet aperture at its apex and mounted at the left end in the figure of said outer body tube member 40. The internal details of said first heat exchanger 8 can be seen in FIGS. 4 and 5: FIG. 4 is a transverse sectional view of this first heat exchanger 8 taken in a plane perpendicular to the central longitudinal axis thereof and indicated by the arrows IV--IV in FIG. 3, and FIG. 5 is a longitudinal sectional view of this first heat exchanger 8 taken in a plane containing to the central longitudinal axis thereof and indicated by the arrows V--V in FIG. 4. As can be seen from these figures, within the outer body tube member 40 there is coaxially provided an inner double walled tube assembly 42, which comprises an intermediate tube member 42a and an inner tube member 42b mounted coaxially therein. The inner tube member 42b is fixedly supported within the outer tube member 42a by end caps shaped as conical members (only one of which can be seen in the figures) and also by a crinkled or wavy radiation fin member 48 which is shaped as an elongated member creased in its longitudinal direction so that its outer surface touches the inside surface of the outer tube member 42a along a plurality of generatrices thereof while its inner surface touches the outside surface of the inner tube member 42b likewise along a plurality of generatrices thereof. Thus, considering the inner tube assembly 42 only, it defines an inner cylindrical space 46 open at both its ends to the outside of said assembly 42, and, surrounding said inner cylindrical space 46, an outer hollow cylindrical shaped space 47 closed at both its ends between the inside surface of the outer tube member 42a and the outside surface of the inner tube member 42b. The inner tube member 42b is fixedly supported within the outer tube member 42a by a lubricating oil inlet member 43 and a lubricating oil outlet member 44, both of which are shaped as short tubes which extend in generally radial directions from the outside inwards through apertures formed in the material of the outer tube member 40 at its opposite ends, being fixed in a liquid tight fashion to the peripheries of said apertures, with their ends being fixed to the outside surface of the outer tube member 42a and with their interior holes being communicated to the respective ends of the hollow cylindrical shaped space 47 defined between the inside surface of the outer tube member 42a and the outside surface of the inner tube member 42b. Thereby, around the hollow cylindrical shaped space 47, another hollow cylindrical shaped space 45 is defined between the inside surface of the outer body tube member 40 and the outside surface of the outer tube member 42a, open at its both ends to the respective end cap members 41a and 41b, as is the inner cylindrical space 46.
Inlet and outlet mounting pipe members 49 and 50 are respectively provided as fitted into the holes of the lubricating oil inlet member 43 and the lubricating oil outlet member 44, and the inlet mounting pipe member 49 is connected to the relief lubricating oil conduit 34, previously mentioned as leading from the first lubricating oil relief valve 31 for the lubricating oil which lubricates the internal combustion engine 1, while the outlet mounting pipe member 50 is connected to the drain lubricating oil conduit 51, previously mentioned as leading to the lubricating oil pan 26 of the internal combustion engine 1 to drain cooled lubricating oil thereto. Particularly according to a particular specialization of the present invention, the lubricating oil inlet mounting pipe member 49 is provided at that end of the first heat exchanger 8 at which cooling fluid is fed out, i.e. at the end thereof at which the cooling fluid outlet member 41b (which is connected to the upstream end of the third rubber hose member 9) is provided, and the lubricating oil outlet mounting pipe member 50 is provided at that end of the first heat exchanger 8 at which cooling fluid is fed in, i.e. at the end thereof at which the cooling fluid inlet member 41a (which is connected to the downstream end of the second rubber hose member 7) is provided. Thus, in the first heat exchanger 8, during operation of the lubricating oil cooling system according to the preferred embodiment of the present invention, the directions of the flows of cooling fluid and of lubricating oil are opposite with the reason for this being explained later.
The second heat exchanger 22 is made in a similar fashion to the first heat exchanger 8, and accordingly details of its interior construction will be omitted for the sake of brevity of explanation. Its inlet mounting pipe member is connected to the relief lubricating oil conduit 59 of the transaxle device 2, previously mentioned as leading from the second lubricating oil relief valve 56 for the lubricating oil which lubricates the transaxle device 2, while its outlet mounting pipe member is connected to the drain lubricating oil conduit 60, previously mentioned as leading to the lubricating oil pan 52 of the transaxle device 2 to drain cooled lubricating oil thereto. It is important to note that, similarly to the case with the first heat exchanger 8 as explained above, the lubricating oil inlet mounting pipe member of the second heat exchangers 22 is provided at that end thereof at which cooling fluid is fed out, i.e. at the end thereof to which the upstream end of the seventh rubber hose member 23 is connected, and the lubricating oil outlet mounting pipe member of the second heat exchanger 22 is provided at that end thereof at which cooling fluid is fed in, i.e. at the end thereof to which the downstream end of the sixth rubber hose member 21 is connected. Thus, in the second heat exchanger 22 as in the first heat exchanger 8, during operation of the lubricating oil cooling system according to the preferred embodiment of the present invention, the directions of the flows of cooling fluid and of lubricating oil are opposite with the reason for this again being explained later.
Now, during operation of the vehicle incorporating this cooling system, the flow of cooling fluid is as outlined above, according to the propelling action of the cooling fluid pump 25: cooling fluid which has been heated up in the cooling fluid jacket 3 is expelled from the cooling fluid outlet 3a thereof, is driven through the first cooling fluid passage construction A including the cooling fluid passage of the first heat exchanger 8 (consisting of the parallel combination of the inner cylindrical space 46 and the hollow cylindrical shaped space 45) through which it flows in the right to left direction in FIG. 2 towards the radiator 12 at the front of the vehicle, passes through said radiator 12 while being cooled therein, is sucked through the second cooling fluid passage construction B including the cooling fluid passage of the second heat exchanger 22 through which it flows in the right to left direction in FIG. 2 towards the internal combustion engine 1 at the rear of the vehicle, and is sucked into the cooling fluid inlet 3b of the temperature sensitive valve 24, to be then returned to the cooling fluid jacket 3. Meanwhile, if the revolution speed of the internal combustion engine 1 is high enough to cause the lubricating oil pump 28 to generate sufficient lubricating oil pressure to cause a flow of lubricating oil to be vented by the first relief valve 31 to the relief lubricating oil conduit 34 (which is considered, in this preferred embodiment, to be the circumstance in which danger arises of overheating of the lubricating oil of the internal combustion engine 1), then this vented lubricating oil is supplied via the conduit 34 and the lubricating oil inlet mounting pipe member 49 and the lubricating oil inlet member 43 to the lubricating oil passage of the first heat exchanger 8 consisting of the hollow cylindrical shaped space 47, which is in close and heat exchanging relationship with the aforesaid cooling fluid passage of said first heat exchanger 8. After being cooled by exchanging some of its heat with the cooling fluid flowing through said cooling fluid passage of said first heat exchanger 8 (said cooling fluid being at a generally lower temperature than the lubricating oil, although being somewhat heated up), this cooled lubricating oil then is drained from said lubricating oil passage of said first heat exchanger 8 via the lubricating oil outlet member 44 and the lubricating oil outlet mounting pipe member 50 and the conduit 51, to be returned to the lubricating oil pan 26 of the internal combustion engine 1.
Meanwhile, similarly, if the revolution speed of the transaxle device 2 is high enough to cause the lubricating oil pump 53 to generate sufficient lubricating oil pressure to cause a flow of lubricating oil to be vented by the second relief valve 56 to the relief lubricating oil conduit 59 (which is considered, in this preferred embodiment, to be the circumstance in which danger arises of overheating of the lubricating oil of the transaxle device 2), then this vented lubricating oil is supplied via the conduit 59 to the lubricating oil passage of the second heat exchanger 22, which is in close and heat exchanging relationship with the aforesaid cooling fluid passage of said second heat exchanger 22. After being cooled by exchanging some of its heat with the cooling fluid flowing through said cooling fluid passage of said second heat exchanger 22 (said cooling fluid being at a much lower temperature than the lubricating oil, having been cooled in the radiator 12), this cooled lubricating oil then is drained from said lubricating oil passage of said second heat exchanger 22 via the conduit 60, to be returned to the lubricating oil pan 52 of the transaxle device 2.
Now, the advantages of this construction according to the present invention are as follows. The provision of the first heat exchanger 8 directly in the path of the cooling fluid which is passing between the internal combustion engine 1 and the radiator 12, as opposed to any more complicated construction, makes it possible to effectively cool the lubricating oil of the internal combustion engine 1 by the first heat exchanger 8 by using the flow of the cooling fluid of the internal combustion engine 1 which is anyway passing through the cooling fluid flow conducting means A incorporating said first heat exchanger 8 in order to be circulated through the radiator 12. Thereby the length of the cooling fluid flow conducting means A is not required to be particularly extended to any more than its already necessarily rather long length in order to fit the first heat exchanger 8 to the vehicle, thus avoiding that flow resistance of the cooling fluid conduits between the internal combustion engine 1 and the radiator 12 of the vehicle should become unduly high, and avoiding that problems should arise due thereto with regard to circulation of the cooling fluid of the internal combustion engine 1, while also minimizing complication, weight, and number of parts. The particular advantage of making the cooling fluid passage of the first heat exchanger 8 be a part of the part A of the cooling fluid flow conducting means between the internal combustion engine 1 and the radiator 12 which conducts a flow of cooling fluid from said cooling fluid jacket 3 of said internal combustion engine 1 towards said radiator 12 is that, according to such a structure, the heat picked up by the cooling fluid which has cooled the lubricating oil in the first heat exchanger 8 is then dissipated in the radiator 12 and is not undesirably returned to the internal combustion engine 1. This ensures that the temperature of the cooling fluid flowing through the cooling fluid jacket 3 of the internal combustion engine 1 is kept at a proper level; i.e., the cooling performance of the internal combustion engine 1 is not impaired by the functioning of the first heat exchanger 8. By arranging the direction of fluid flow through the cooling fluid passage of the first heat exchanger 8 to be generally opposite to the direction of fluid flow through the lubricating oil passage of said first heat exchanger 8, the effectiveness of heat exchange between this cooling fluid flowing in the cooling fluid passage of the first heat exchanger 8 and the lubricating oil flowing in the lubricating oil passage thereof is maximized.
Further, by making the first heat exchanger 8 with its cooling fluid passage and its lubricating oil passage being coaxial cylinders, the lubricating oil passage being radially sandwiched between two cooling fluid passages and the lubricating oil passage being traversed by axially and radially extending fins connected at the opposite radial ends thereof with the cylinders which define the outside and inside cooling fluid passages, a high capacity of heat interchange portion can be provided between the cooling fluid passage and the lubricating oil passage, with minimum increase of flow resistance. Now, by feeding lubricating oil to the first heat exchanger 8 from the relief side of the first relief valve 31, it is ensured that engine lubricating oil is only fed to said first heat exchanger 8 to be cooled in circumstances in which the internal combustion engine 1 is rotating quickly so that the lubricating oil pump 28 thereof is delivering a high output pressure so as to cause relief lubricating oil to be supplied by said relief valve 31, and, since these are the type of circumstances in which there is a strong risk of the lubricating oil of the internal combustion engine 1 overheating, this method of operation provides cooling for the lubricating oil of the internal combustion engine 1 just when it is required. Further, since only the relief or blowoff lubricating oil is cooled, the operation of cooling the lubricating oil has no substantial effect on the lubricating oil pressure of the internal combustion engine 1 either upwards or downwards, which is appropriate in view of the desirability of restricting fluctuations of the lubricating oil pressure of the internal combustion engine 1. By the provision of the second relief valve 36, as previously explained a backup relief function is assured for preventing the lubricating oil pressure of the internal combustion engine 1 rising above its set threshold pressure value. The provision of the second heat exchanger 22 for cooling the lubricating oil of the transaxle device 2 in a similar manner to the way the engine lubricating oil is cooled is effective for restricting rise in the temperature of said transmission lubricating oil. In this case, although the cooling fluid passage of said second heat exchanger 22 is a part of the part B of the cooling fluid flow conducting means which conducts cooling fluid from the radiator 12 towards the cooling fluid jacket 3 of the internal combustion engine 1, this will not cause any problem with regard to heating of the cooling fluid flowing into said cooling fluid jacket 3 of the internal combustion engine 1, because typically the amount of heat required to be dissipated from the lubricating oil of the transaxle device 2 is relatively small.
Although the present invention has been shown and described with reference to the preferred embodiment thereof, and in terms of the illustrative drawings, it should not be considered as limited thereby. Various possible modifications, omissions, and alterations could be conceived of by one skilled in the art to the form and the content of any particular embodiment, without departing from the scope of the present invention. Therefore it is desired that the scope of the present invention, and of the protection sought to be granted by Letters Patent, should be defined not by any of the perhaps purely fortuitous details of the shown preferred embodiment, or of the drawings, but solely by the scope of the appended claims, which follow. | In a rear engined or mid engined type of automotive vehicle in which a liquid cooled internal combustion engine is mounted at least partly behind a passenger compartment, and a radiator for cooling the cooling fluid of the engine is mounted in front of the passenger compartment, with a mechanism being provided for conducting flow of cooling fluid between the cooling fluid jacket of the engine and the radiator in both directions, a cooling system for lubricating oil of the engine includes a heat exchanger formed with a cooling fluid passage and a lubricating oil passage arranged to exchange heat therebetween to conduct respectively a flow of cooling fluid and a flow of lubricating oil from the internal combustion engine, wherein the cooling fluid passage of the heat exchanger is a part of the cooling fluid flow conducting mechanism, so as not to the heat exchanger without substantially increasing the flow resistance of the cooling fluid flow conducting mechanism. Optionally, the cooling fluid passage and the lubricating oil passage of the heat exchanger may be provided by a plurality of coaxially arranged cylinders wherein the cooling fluid and the lubricating oil flowing axially through the respective cylindrical passages are brought into mutual heat exchange across a cylindrical heat conducting separating wall. | 5 |
BACKGROUND OF THE INVENTION
This invention relates generally to energy cells or batteries of small size adapted for electric or electronic watches, hearing aids, cameras, paging systems and the like.
Small primary energy cells used, for example, in wristwatches and hearing aids are well known. These are generally of a circular configuration and known as "button" cells because of their shape. Such cells are generally inserted into or removed from the watch through an opening in the case back which is locked by a screw cover. The screw cover was heretofore needed to provide a dustproof and watertight closure of the watch case and for retaining under pressure the energy cell in electrical contact with the terminal portions of the watch. Typically, the screw cover formed one of the terminal portions and was, therefore, electrically connected to the watch circuitry. Examples of such cells and their use in electric watches and the like are illustrated in U.S. Pat. Nos. 3,916,613 issued Nov. 4, 1975 to Fred Esselborn; 3,708,343 issued Jan. 2, 1973 to Gerrard Walsh; 3,846,972 issued Nov. 12, 1974 to David Doss; 3,304,708 issued Feb. 21, 1967 to T. Baehni; and 3,670,491 issued June 20, 1972 to Milton E. Weschler. These prior art energy cells are undesirable, however, to the extent that they require a screw cover which both adds to the cost of manufacture of the wristwatch and the difficulty of replacing the battery by the user.
Accordingly, an object of the present invention is to provide an improved button cell configuration whereby the need for a screw cover is eliminated.
A further object of the present invention is to provide an improved button cell configuration which can be snapped-in and snapped-out of a watch or other device.
A still further object of the present invention is to provide an improved button cell configuration whereby electrical contact is established directly between a terminal of the button cell and the watch case without the need for a screw cover.
Another object of the present invention is to provide an improved button cell configuration which, when inserted into a wristwatch, provides a dustproof and watertight seal between the button cell and watch case.
The accompanying drawings diagrammatically illustrate an embodiment of the present invention by way of example. Like numerals refer to like parts throughout.
DRAWINGS
FIG. 1 is a horizontal cross section of the preferred form of the energy cell, and
FIG. 2 is a perspective view, partially cutaway, of an energy cell especially suited for and shown in an electronic wristwatch.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the battery 1 of the present invention includes a bottom can or casing member 2 which can be formed from a conductive material, for example, of a duplex stainless steel phosphor bronze material. The bottom can 2 provides one terminal of the cell, the other terminal being provided by the top cap 3. An annular grommet 4 is positioned between the top cap 3 and the bottom can 2 and electrically insulates the two terminals of the cell.
The internal active materials of the cell, which may be more or less conventional and which are not material to the present invention, are briefly described as follows with reference to FIG. 1. The top cap 3 contains the anode material 5, which may, for example, be a zinc amalgam which is compressed within the top cap 3. Prior to final assembly of the battery, a suitable alkaline electrolyte, such as potassium hydroxide or sodium hydroxide is added to the zinc amalgam anode.
The bottom can 2 contains a depolarizing cathode material 6 such as a mixture of mercuric oxide with a small percentage of graphite.
Separating the anode and cathode materials is a barrier membrane 7, for example, of suitable plastic microporous membrane material, and a cellulosic absorbent separator 8.
In accordance with the preferred embodiment of the present invention, the top cap 3 includes, as an integral portion, major and minor circumferential retaining flanges 9 and 10 respectively, adapted to hold therebetween a gasket or grommet-like ring 11. The major retaining flange 9 has a circumference which is greater than the circumference of the minor retaining flange 10. The minor retaining flange 10 is contoured and dimensioned to enable the cell to be inserted smoothly into the watch case and to provide radially outward pressure against the watch case. The flexing or contracting of the minor flange 10 is provided, for example, by the spring bias action of the concave or U-shaped portion 12 of the top cap 3. The flexing and outward pressure of the top cap 3 against the watch case may be enhanced by the use of a suitable annular grommet 4 which is capable of being compressed or expanded with a change in the pressure being applied thereto by the downwardly extending end portion of the top cap 3.
As shown in FIG. 2, the major flange 9 is shaped and dimensioned to form a retaining ledge which overlaps the case back when the battery is inserted therein. It should be noted, however, that the retaining ledge can be of any shape or size, for example, elliptical, square or triangular, so long as a retaining ledge or rim or similar battery can portion is provided to enable snap-in and snap-out replacement of the cell by the user. The minor flange 10 is shaped and dimensioned to have a snug fit with the juxtaposed case back member 13 and is thereby held, for example, under pressure, in electrical contact to the case back. The annular gasket 11, as noted above, provides an annular seal between the case back member 13 and the battery to substantially prevent dust and water from entering into the body of the watch.
OPERATION
If the button cell is to be exchanged, the button cell can be easily removed from the watch case by wedging an object such as a knife or fingernail between the retaining ledge of the battery and the case back thereby prying the battery upward and out of the watch. Next, the new battery is snapped-in place in the case back to nest snuggly within the watch.
The energy cell above described is particularly useful in electric devices, such as electric watches, where the case of the device and the energy cell, when inserted, are in electrical contact to provide a reference potential path for the device. Thus, for example, if the case of the device is formed from an electrically conductive material, reliable electrical coupling will be provided between the battery cap-terminal portion and the device by mere insertion of the battery into the device.
While there has been shown what is considered to be the preferred embodiment of the invention, it is desired to secure in the appended claims all modifications as fall within the spirit and scope of the invention such as the use of electrically conductive plastic to form the case of the device and/or battery. | An improved button cell configuration for wristwatches which can be snapped into the case back. The button cell has an outer can configuration or shape having major and minor circumferential retaining flanges adapted to hold a gasket therebetween. The outer can flanges and gasket are arranged to mate with the case back to provide a snug snap-in and snap-out fit therewith. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/743,391 filed Oct. 5, 2012, which is a continuation of U.S. application Ser. No. 13/279,907 filed Oct. 24, 2011, the disclosures of which are incorporated in their entirety by reference herein.
TECHNICAL FIELD
[0002] This application relates to a computer viewing apparatus for connection to a hospital bed.
BACKGROUND
[0003] The mental condition of a hospitalized patient can pose serious therapeutic challenges to medical care providers. Often, due to underlying medical conditions, the patient may exhibit serious and potentially life threatening psychological manifestations such as anxiety or delirium. Anxiety may be defined as a “state of intense apprehension or fear of real or imagined danger.” Delirium may be defined as a “state of marked confusion” that can be provoked by an underlying medical condition. Both anxiety and delirium can occur in hospitalized patients in an intensive care unit (ICU), progressive “step-down” medical floors, and general medical floors.
[0004] Many medical conditions can provoke significant anxiety. A pertinent example in the ICU setting is as follows: an elderly nursing home patient overdoses on pain medication, develops unconsciousness, and then aspirates food contents into the trachea and lung. The patient is emergently brought by emergency medical services (EMS) to the nearest emergency room (ER). This patient may require intubation and be placed on a mechanical ventilator (i.e., breathing machine) to facilitate breathing and oxygen/carbon dioxide exchange. During intubation, a tube is inserted through the vocal cords preventing the patient from speaking In addition, the patient is usually hand restrained to prevent accidentally pulling the life-sustaining tube out of her mouth. The above condition necessitates the patient to have a bed position that has the patient invariably looking up at a white-tiled ceiling or the like. In addition, ambient noise from other ICU patients' noise, ventilator/cardiac alarm noise, and conversation noise also contribute to a less than calming and peaceful “healing” environment. Many studies have shown that a typical ICU bed can have noise >75 db. This can lead to sleep deprivation over several days, which can result in altered conscious states and further anxiety and delirium.
[0005] Nursing and other medical staff personnel may make “bedside” attempts to reorient and calm a patient, but these good-intentioned efforts often do not lead to the desired result of a calm, cooperative, and oriented patient in the ICU or other hospital floors. Furthermore, these efforts are time-consuming, costly, and often ineffective due to staffing constraints and priorities. In addition, often there is a language barrier between the patient and the nurse/medical personnel potentially leading to significant more patient anxiety and confusion. The above factors can lead to a recurrent cycle of anxiety and delirium that is very difficult to break on a practical basis. As a consequence, nursing and medical staff personnel are unfortunately then necessitated to use intravenous (IV) anti-anxiety and anti-psychotic medications that have potential significant side effects. These side effects often include hypotension, lethal cardiac arrhythmias, electrolyte imbalance, and even further confusion paradoxically. In addition, several ICU peer-reviewed, evidence-based medical studies and clinical trials have demonstrated that unnecessary sedation medications lead to significant increased length of stay in the ICU, prolonged time on life support breathing machines, and significantly more costs in the thousands of dollars. Unfortunately, due to health care systems' limitations on nursing to patient staffing ratio and hospital financial constraints, constant “bedside” care to minimize anxiety or delirium risk factors have not been optimal.
[0006] If a patient improves in the ICU or other medical floor, the patient can potentially become more interactive with their environment and staff. At this point, the patient can be fully aware and cooperative with others. Unfortunately, many illnesses and just being in a hospital setting can lead to an anxious or even depressed mood. Often patients are spending countless hours waiting for tests to be done. Without connections to outside the hospital environment, patients can become bored, isolated, and detached.
SUMMARY
[0007] In one embodiment, a computer viewing apparatus for connection to a hospital bed is disclosed. The apparatus includes a repositionable flexible arm assembly, an anchoring member at a first end of the flexible arm that attaches the flexible arm to the hospital bed, and a connection member at a second end of the flexible arm that attaches the computer to the flexible arm. The repositionable flexible arm assembly includes conductive wires contained therein to connect a computer to a power source, a flexible spine at least partially surrounding the wires that includes a number of interconnected and universally rotatable members, and a sleeve engaging an outer surface of each of the rotatable members.
[0008] In another embodiment, a computer viewing apparatus is disclosed that includes a connection member securing a computer and having a front and rear surface, and a pair of vertical and horizontal scalable fasteners secured to the connection member front surface. The scalable fasteners secure the computer to the connection member.
[0009] In yet another embodiment, a computer viewing apparatus includes a connection member securing a computer and having a front and rear surface, and a pair of vertical and horizontal scalable fasteners secured to the connection member front surface. The scalable fasteners secure the computer to the connection member. Each scalable fastener includes a bolt and a groove for slidable movement of the scalable fastener relative to the bolt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1 a and 1 b are perspective views of a hospital bed with a computer to facilitate reorientation and reduce anxiety and delirium risk in a patient, wherein the computer is attached to the hospital bed by a flexible arm, and the computer is shown in a first position ( FIG. 1 a ) with the patient in a prone position and a second position ( FIG. 1 b ) with the patient in an upright position;
[0011] FIG. 2 is a perspective view of the computer of FIG. 1 mounted on a connection member at one end of the flexible arm according to one embodiment;
[0012] FIG. 3 is a cross-sectional, cut-away view of the computer and the connection member taken along line 3 - 3 in FIG. 2 ;
[0013] FIG. 4 is a plan view of the computer mounted on a connection member according to another embodiment, also depicting an anchoring member on the other end of the flexible arm that connects the arm to the bed;
[0014] FIG. 5 is a cross-sectional, cut-away view of the computer and the connection member taken along line 5 - 5 in FIG. 4 ;
[0015] FIGS. 6 a - f are screen shots of various example content pages displayed by the computer in which content is communicated from the CPU to the patient to help reorient and reduce anxiety in the patient;
[0016] FIG. 7 a is a screen shot of an interactive menu displayed by the computer operating an active module in which the CPU and the patient communicate interactively, the menu providing example activity options for the patient;
[0017] FIG. 7 b is a screen shot of an interactive menu displayed by the computer operating in the active module, the menu providing example hospital information selections;
[0018] FIG. 7 c is a screen shot of an interactive menu displayed by the computer operating in the active module, the menu providing example selections for a pneumonia diagnosis for the patient;
[0019] FIG. 7 d is a screen shot of an interactive menu displayed by the computer operating in the active module, the menu providing example selections for an atrial fibrillation diagnosis for the patient;
[0020] FIG. 7 e is a screen shot of an interactive menu displayed by the computer operating in the active module, the menu providing example communication and activity selections for the patient; and
[0021] FIGS. 8 a and 8 b are screen shots of an example interface on the computer for a video call and video conference, respectively.
DETAILED DESCRIPTION
[0022] Detailed embodiments of the present invention are disclosed herein. It is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed by the Applicant are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0023] The embodiments described herein relate to a computer system, apparatus, and method for reorienting, decreasing anxiety, and/or reducing delirium risk throughout the course of a patient's hospital stay. Offering a patient specific, non-pharmacological method for reorienting and decreasing patient anxiety may avoid the potentially significantly costly and life threatening effects of medications. In the ICU setting, for example, a passive approach to reorienting the patient and/or improving their anxiety and delirium may be taken. As a patient recovers, embodiments may provide a more interactive/active approach to improving the patient's anxiety, boredom, and detachment from the outside hospital environment, as well as enhancing the overall patient experience.
[0024] Referring to Figures la and lb, a hospital bed 10 is depicted for a patient to rest on while being treated at a hospital or other medical facility. A computer 12 is attached to the bed 10 . The computer 12 may be an IPAD or IPOD (by Apple®), a TABLET (powered by ANDROID OS), a PLAYBOOK (by Blackberry®), and/or other hand-held computers or displays (such as a television) with or without an accompanying touchscreen. The computer 12 has a central processing unit (CPU) that executes machine instructions, and a memory for storing the machine instructions that are to be executed by the CPU. As will be described in further detail, the computer 12 is programmed to facilitate in reorienting, decreasing anxiety, and/or reducing delirium risk in patients. As patients are sometimes unconscious while they are transported to the hospital, or after a medical procedure, or by virtue of their medical condition, patients can be very confused and disoriented when they wake up in a hospital bed. The patients can be anxious about their environment and current medical condition. The screen of the computer 12 faces the patient so that the computer 12 can reorient/calm the patient during periods of consciousness.
[0025] The computer 12 may be mounted to a connection member 14 . The face of computer connection member 14 may be larger in length and width than the computer 12 that it holds. The computer connection member 14 may have a soothing color (e.g., soft blue) or shape (e.g., oval/rounded), so that when the patient awakes from unconsciousness the computer 12 is aesthetically pleasing and calming to the patient. In one embodiment, the connection member 14 is mounted to one end of a flexible arm 16 . The flexible arm 16 is able to be bent and repositioned to a new shape, while rigid enough to maintain that shape. For example, the flexible arm 16 can be easily bent and rotated by the patient or another person so that the computer 12 is within or out of the patient's view and/or reach. In addition, the flexible arm 16 with the computer 12 can easily and quickly be moved to a position that could allow unobstructed routine and emergent care of the patient. An anchoring member 18 mounts the arm 16 to the bed 10 , and is located on the opposite end of the arm 16 from the computer 12 . The anchoring member 18 may be a removable and flexible C-clamp, O-clamp, or other attachment enabling the arm 16 to be efficiently removed from the hospital bed 10 . The anchoring member 18 and attached arm 16 may be configured to be able to slide lengthwise along the hospital bed 10 , as depicted in FIG. 1 . The anchoring member 18 may alternatively be otherwise secured to the bed 10 so that the arm 16 is fixedly secured to the bed 10 , or the arm 16 may be integrally formed with the bed 10 .
[0026] Referring to FIGS. 2 and 3 , in one embodiment, the computer 12 is received within the connection member 14 and secured underneath a cover 13 which extends at least partially over the computer 12 . For example, the cover 13 may extend over a frame portion of the computer 12 while allowing obstructed access to a screen portion of the computer 12 . The cover 13 may be formed of transparent plastic or any other suitable material, and may be received under a lip 15 of the connection member 14 so as to secure the computer 12 to the connection member 14 . Of course, other configurations for holding the cover 13 in position with respect to the connection member 14 are also contemplated, and it is also understood that cover 13 is not required. In another example, a sleeve or the like may be provided as a connection member 14 to receive the computer 12 , such that in this case the face of the connection member 14 is substantially similar in length and width to the computer 12 . Access ports (not shown) may be provided around the connection member 14 to allow access to different computer buttons or computer ports if needed. The arm 16 is attached to the connection member 14 and is described in further detail below.
[0027] Referring to FIG. 4 , in another embodiment, computer fasteners 22 are shown disposed at positions around the perimeter of computer 12 . The fasteners 22 are scalable vertically and horizontally, and attached to the connection member 14 . This enables the fasteners 22 and connection member 14 to accommodate for various sizes and types of computers 12 as previously described. There may also be hook and loop or other fastening means to further or alternatively secure the computer 12 to the connection member 14 .
[0028] The arm 16 may be made of a number of separate rotatable members 24 . These members 24 may interlock with one another, and are each individually rotatable. The implementation of interlocking members 24 in a flexible arm 16 in a hospital room setting allows the computer 12 to be positioned in various angles and positions relative to the patient's hospital bed, and not merely limited to one or two axes of rotation. The computer 12 may be initially positioned in front of and above the patient, as illustrated in FIG. 1 a , so that the computer 12 is one of the first items the patient sees when he becomes conscious. The computer 12 may subsequently be repositioned so that the computer 12 is not facing the patient, but rather facing a doctor or other third party to view and operate. Also, as the patient may later use the computer 12 while the patient is conscious, the flexible arm 16 allows the patient to reposition the computer 12 to multiple locations and distances from the patient's body ( FIG. 1 b ). A sleeve 26 surrounds the outer portion of the interlocked members 24 . Conductive wires (not shown) may be fed within the sleeve 26 so as to be hidden from plain view. The wires connect the computer 12 to a power source (not shown) through a wall outlet, for example.
[0029] Referring to FIGS. 4 and 5 , the scalable fasteners 22 are shown in detail. The scalability of the fasteners 22 may be accomplished by a bolt 30 and groove 32 combination. A bolt 30 is assembled through a groove 32 of the fastener 22 , and into the connection member 14 . When the bolt 30 is slightly loosened, the fasteners 22 can slide along the bolt 30 until a desired location is met, and the bolt 30 is tightened again to fix the fasteners 22 in place. Other scalable or slidable mechanisms known in the art may be substituted for the bolt 30 and groove 32 combination in order for the connection member 14 to accommodate various sizes and types of computers 12 .
[0030] Referring to FIGS. 6-8 , the computer 12 includes a program that may execute a passive module and/or an active module. These modules may be contained within an “app” that can be downloaded from an “app store” such as “App store”™ by Apple Inc. It is understood that any operating system platform could be used to implement the passive and active modules. The passive module is illustrated in FIGS. 6 a thru 6 f . The passive module may initiate and operate while the patient is in the intensive care unit (ICU) or “step-down ICU” setting. Patients in these environments are sometimes streaming intermittently between unconscious and varying levels of consciousness. The patient may intermittently awaken for split second or longer. This patient may wonder, for example, “Where am I? What date is this? What season is this? Have I been unconscious for a long time? Am I in a coma? Why can't I speak? What is my condition? What happened to me? Where is my family? Does my family know I'm here?” During these brief conscious moments, there is often no same-language speaking nurse or medical staff personnel present at the bedside to provide answers to these potential questions. As a result, there is no consistent bedside method to help reduce anxiety and to assist with reorientation to the patient's name, hospital location, time, date, season, “non-speaking” status, and their current serious medical condition, for example. In addition, family members are often not available to constantly be at their bedside to help with this reorientation and anxiety-reducing process. As a result, the patient may feel alone, anxious and can become disoriented, confused, and/or can subsequently develop delirium. In addition, this psychological condition can produce physiological responses such as elevated heart rate, blood pressure and respiratory rate which can mislead medical staff caregivers that a change in medical condition has developed. Unfortunately, this potential misinterpretation can lead to the ordering of many emergency medical tests and medications that can have iatrogenic effects.
[0031] The passive module of computer operation is an aid to reorient and reduce anxiety until the patient regains full or partial consciousness, orientation, and a calm/non-anxious state. A doctor, nurse, or other caregiver may input some basic patient-specific information into the computer. This patient-specific information may include an identification of the patient (such as, but not limited to, the patient's name, age, and birthdate), the location of the patient (such as, but not limited to, the hospital name, city, and state), the diagnosis or medical status of the patient, and the native language that the patient speaks and reads. Other third parties, such as family members of the patient, may also send information to the computer, such as personal photographs, videos, or music. This can be accomplished by directly downloading the content from the internet to the computer, or by transferring the content onto the computer wirelessly through radio waves (e.g., BLUETOOTH/Wi-Fi).
[0032] The patient-specific content is received and processed by the CPU of the computer 12 . Then, during the operation of the passive module, the computer 12 communicates to the patient by displaying this information on the computer screen. In one embodiment, the patient-specific content is native language-specific. The information may be displayed on a single content page or throughout multiple content pages, as shown in FIGS. 6 a thru 6 f . FIG. 6 a shows the computer 12 displaying the patient's name. FIG. 6 b shows the computer 12 displaying the physical location of the patient. In FIG. 6 c , the computer 12 displays the medical status of patient as diagnosed by the doctor, such as “You have a severe concussion,” or “You have pneumonia.” Certain other important and specific information is displayed in FIG. 6 d , such as “You cannot speak,” or “You are on a respirator,” or “Your family is on their way.” In FIG. 6 e , the computer displays the current date, and may also display the day and time. For example, the passive module may indicate the general or specific time of day (e.g., with a sun or moon icon, such as shown in FIG. 6 e , or with an actual a.m. or p.m. time) in an effort to help establish day/night cycle orientation for the patient. FIG. 6 f shows the computer displaying a personalized family photograph uploaded onto the computer from the doctor, a family member, or some other third party. It should be understood that the content and order of these Figures are merely exemplary, and more or less patient-specific content or a different order may be used; these are examples of content pages that are helpful for reorienting and reducing anxiety until a patient regains partial or full consciousness, orientation, and a calm/non-anxious state. In addition, the order in which the content pages are displayed can be customized and selected by a caregiver.
[0033] As described, the patient-specific content may be displayed throughout multiple content pages on the screen. These content pages may be looped in a continuous loop. As it is unpredictable when many patients will regain consciousness, the continuous loop assures that at any point of the loop the patient may be reoriented and have his/her anxiety reduced until the patient regains full or partial consciousness, orientation, and/or a calm/non-anxious state. For example, in one embodiment, the entire loop is about two minutes long. Within the “app” or passive module, this time is adjustable to a longer or shorter time, depending on the condition of the patient. If, for example, the patient is in and out of consciousness/alertness, each content page may be displayed for a longer period of time to decrease the speed of the content page revolution in the loop. In this fashion, the computer system can better attempt to reorient the patient by allowing him to focus on a particular content page and process the information presented for the short period until the patient has regained consciousness with a higher level of alertness and less anxious state. Each content page may alternatively be displayed for a shorter amount of time, such as when the patient is conscious for longer periods of time. The duration of each content page may also be customized, such that certain content pages may have longer dwell times than others, perhaps depending on the type or amount of information presented on a particular content page. Visual aids may be provided for patients with poor sight capabilities.
[0034] Often, due to various hospital environments and other factors, hospitalized patients may not be oriented to day and night hours. As a result, the day and night sleep cycle may be shifted leading to potentially anxiety and delirium. One embodiment, would be have a “daytime program” with, but not limited to, awakening sounds, or brighter video images/cues to establish daytime orientation. Likewise, a “nighttime program” with soothing sounds and dimmer video images/sequences can be automatically programmed. By reestablishing, appropriate day and night cycles, anxiety and delirium can potentially be reduced. This can be implemented automatically within the active module.
[0035] Audio may also be provided that corresponds to the loop of content pages. For example, spoken words may read what is shown on the screen of the computer 12 . In one embodiment, the audio is selected to be in the native language of the patient. The audio may be directly output by the computer 12 through its own internal speakers, or the audio may be output to external speakers or stereo wireless/“Bluetooth”™ headphones placed on the patient. The audio may also be in a soothing voice tone. This may further reorient the patient and reduce anxiety, especially while the patient is semi-conscious or otherwise unable to focus or see computer 12 clearly. In addition, calm music (i.e., waterfall, ocean waves, etc.) may stream continuously through stereo wireless headphones, facilitating decreased anxiety. Other music selections such as, for example, native ethnic music can also be provided for selection by a caregiver or other user. Noise cancellation “sound sequence” programs can also be implemented. This music/sound stream will help to block ambient noise in the ICU or other hospital units and facilitate the reorienting process.
[0036] If a patient improves in the ICU or other medical floor, the patient can potentially become more interactive with their environment and staff. At this point, the patient can be fully aware and cooperative with others. Unfortunately, many illnesses and just being in a hospital setting can lead to an anxious or even depressed mood. Often patients are spending countless hours waiting for tests to be done. Without connections to the outside the hospital environment, patients can become bored, isolated, and detached.
[0037] Under such circumstances, the computer 12 may execute an active module rather than the passive module. The active module and the passive module can either be independent of each other or packaged together, and these modules can be contained within an “app” or “apps” such as from the “App store”™ from Apple Inc. The functional switch from the passive module to the active module may be implemented by a nurse, for example. The patient may rotate the computer 12 and the flexible arm 16 so that the patient may utilize the touch screen on the computer 12 . Throughout the operation of the active module, the patient's touch and interactive input plays a role in the process of reducing anxiety, depressed mood, and boredom. The active module also begins to take a role of a concierge-type service.
[0038] Referring to FIGS. 7 a - 7 e and 8 , the computer 12 is shown operating the active module. In FIG. 7 a , the computer 12 displays an interactive menu from which the patient can choose options. For instance, the touch-screen of the computer 12 may provide the patient with the options to relax by listening to music, to listen to soothing sounds from nature (e.g., waves at the beach), or to look at pictures. The patient may also be able to choose to surf the internet, browse online videos, or learn more about the hospital in which the patient is located ( FIG. 7 b ). Due to a patient potentially feeling depressed about their condition, integrated or links to comedy vignettes can help to uplift patient spirits and detract from their illness.
[0039] As illustrated in FIGS. 7 c and 7 d , the patient may be able to direct the interactive menu to instruct the computer 12 to show information about his/her own condition. Videos of the patient's personal illness, the side effects, and other treatment information may be at the viewing control of the patient. “On-demand” patient-specific educational videos may also be selected by the patient. Some examples include, but are not limited to, how to use an asthma inhaler, how to administer insulin, how to take warfarin/coumadin, etc. Current television or education videos in the hospital are not “on demand” and do not often coincide to when a patient is available to watch in their hospital room. As shown in FIG. 7 e , the patient may also learn more about the food and pharmaceutical stores in the surrounding area outside of the particular hospital. This can function as a concierge-type service—for example, the patient can potentially quickly order a pizza or anxiety—reducing spa services that can be performed in the hospital room. In addition, the patient can find a local drug store that can fill the patient's prescriptions when leaving the hospital. This information can be relayed to family members to aid in the patient's health care recovery. This is also an avenue by which businesses can advertise their services to the patient and his/her family.
[0040] Often, many family members are not able to visit their loved ones in the hospital due to geographic differences. For example, a close family member in California may not be able to directly speak or visualize the condition of the patient in Michigan. As a result, medical decision making may not be optimal without a family member able to aid in this process. Accordingly, with reference to FIGS. 7 e and 8 , one embodiment of the active module in computer 12 may implement a “video cam” function that would allow the patient to interact visually with a next of kin/other family member to guide medical decision making In addition, medical care personnel would also be able initiate a video conference with a geographically remote durable power of attorney/legal guardian with the patient and physicians/nurses at the patient bedside. Currently, this mode of communication between the patient and his/her family members and medical personnel is not readily available or utilized. In one embodiment, a specific app/source code within the iOS (Apple Inc.) called FaceTime™ could facilitate this two way video conference interaction between an IPAD/IPOD and be implemented within the active module. Such a module integrated and interactive capability may serve to decrease a patient's anxiety when making important end of life or other serious decisions regarding a patient's health.
[0041] FIGS. 6-8 do not depict an exhaustive list of content or options available to the patient. For example, the patient may also be able to play a game or select a different language for the computer 12 to communicate with the patient. The patient may also select an option that displays a “virtual nurse” that can direct the patient to information about his/her condition in a personal way or to guide the patient on how to use and interact with the active module and system. It is understood that content described with reference to the passive or active module may be appropriate for use with the other, and the active module may also display patient-specific information from the passive module in an appropriate format, such as adjacent menu options. After choosing any of the options available, the patient may return to the interactive menu by simply pressing an on-screen button that directs the computer 12 back to the menu.
[0042] A computer system with an active module, such as the system described herein, may aid the patient to a more rapid recovery. The interaction between the computer 12 and the patient allows the patient to not only decrease anxiety, but also serves to increase patient satisfaction for their “consumer experience” in the hospital. This can lead to more patient loyalty to a particular hospital. Local restaurants and stores can advertise for their services through the computer 12 . For example, the patient may look at the map of the surrounding areas, and the local businesses may advertise by placing their logo on their corresponding location on the map with a web link. The above features implemented within the active module can offer concierge-type consumer experience for the patient and his/her family while the patient is still hospitalized.
[0043] In one embodiment, a database server and database (not shown) may also be provided. The database server is adapted to communicate with multiple computers 12 and CPUs within the hospital. Each computer 12 is given its own identification so that the server can directly communicate with each dedicated computer 12 individually. This provides the hospital with the ability to better manage each computer's content from one location. For example, hospital employees, may input and transmit patient-specific content to the database, which then transmits the content to the corresponding computer 12 associated with the specified patient. Other permitted remote users, such as family members of patients, may be given the ability to access the database server remotely, and upload pictures, messages, videos, or audio files to the server. The server then transmits this data to the patient's specific computer for the patient to access during use of the active or passive module. Remote users may be given a password that allows them to access a limited portion of the database so that the remote users can only send content to the designated computer that is used by the intended recipient patient. Peer-to-peer sharing of content between computers 12 , such as for transferring patient-specific content between computers 12 when a patient is moved between the ICU, step-down ICU/progressive care units, general medical floor is also contemplated.
[0044] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosure. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the disclosure. | A computer viewing apparatus for connection to a hospital bed is provided. The computer viewing apparatus includes a repositionable flexible arm assembly, an anchoring member at a first end of the flexible arm that attaches the flexible arm to the hospital bed, and a connection member at a second end of the flexible arm that attaches the computer to the flexible arm. The flexible arm assembly includes conductive wires contained therein to connect a computer to a power source, a flexible spine at least partially surrounding the wires that includes a number of interconnected and universally rotatable members, and a sleeve engaging an outer surface of each of the rotatable members. | 6 |
BACKGROUND OF THE INVENTION
This is a Continuation of application Ser. No. 08/290,446, filed Aug. 15, 1994, now abandoned which is a continuation of Ser. No. 08/044,138, filed Apr. 8, 1993, now abandoned, which is a continuation-in-part of co-pending U.S. application Ser. No. 07/755,276 filed Sep. 5, 1991, now abandoned which is a continuation-in-part of U.S. Ser. No. 07/734,830, filed Jul. 24, 1991, now abandoned which is a continuation-in-part of U.S. Ser. No. 07/685,329, filed Apr. 15, 1991, now U.S. Pat. No 5,258,408, which is a continuation of U.S. Ser. No. 07/612,747 filed, Nov. 13, 1990, now U.S. Pat. No. 5,182,304, which is a continuation of U.S. Serial No. 07/267,141, filed Nov. 4, 1988, now U.S. Pat. No. 5,006,562, which is a continuation-in-part of U.S. patent applications Ser. No. 06/894,985, filed Aug. 8, 1986, now abandoned and Ser. No. 07/071,305, filed Jul. 16, 1987, now U.S. Pat. No. 4,804,683, the disclosures of which are incorporated herein by reference.
This invention relates to liquid detergent compositions suitable for cleaning hard surfaces and which impart insect repelling properties. More particularly, this invention relates to liquid all purpose detergent compositions containing an insect repellent material, and to a process for cleaning and repelling insects from surfaces and articles to which such detergent compositions are applied.
Many types of insects common in households, such as German (Blattela germanica) or house cockroaches, are classified as pests, and much effort has been made to eradicate or at least to control them. Mosquito repellents have long been marketed and various chemicals that are effective in repelling roaches have been discovered. Typically, these chemicals and repellents are used in the household by applying or spraying them to surfaces of walls, floors, cabinets, drawers, packages, containers, rugs, upholstery and carpeting, and in potential nesting places for insects, such as inside walls and between floors. However, heretofore insect repellents have not been generally used in conjunction with hard surface cleaners so as to effectively clean a hard household surface, such as a kitchen wall, oven top, bathroom floor or the like, while at the same time applying a film of insect repellent material which is sufficiently substantive to the surface to which the composition is applied to repel insects therefrom.
The incorporation of an insect repellent into a polishing product for household floors is known in the art. U.S. Pat. No. 3,018,217 to Bruce discloses floor wax coating compositions containing dibutyl succinate as an insect repellent. U.S. Pat. No. 3,034,950 to Goodhue et al, discloses a class of insect repellent compounds which may be applied to surfaces dispersed in a wax. In U.S. Pat. No. 4,455,308 to Smolanoff, there are described insect repellent formulations containing a liquid carrier such as liquid aliphatic or aromatic hydrocarbons. An emulsifying agent such as a nonionic surfactant may be added to the liquid hydrocarbon to permit the composition to be dispersed in water for end use application. U.S. Pat. No. 4,822,614 to Rodero, discloses an insect-repellent ingredient in a hydrocarbon-based solvent such as isoparaffinic hydrocarbons.
SUMMARY OF THE INVENTION
The present invention provides an aqueous liquid detergent composition capable of cleaning a hard surface and repelling insects therefrom comprising (i) a detersive proportion of a surface active detergent compound selected from the group consisting of anionic, nonionic, cationic and amphoteric detergent compounds; (ii) at least about 50%, by weight, water; and (iii) an effective amount of an insect repellent material which is sufficient to repel insects from such hard surface after application of the detergent composition thereto. The liquid detergent composition is free of an insecticide.
The present invention is predicated on the discovery that the insect repellent properties of a repellent material is enhanced with regard to a specific area or location when such area or location is cleaned with a detergent composition as herein described. This effect may be attributed to the natural tendency of insects to preferentially congregate in soiled areas rather than upon a cleaned surface as well as the increased substantivity of the insect repellent material to such washed or cleaned surfaces.
The term "insect" is used herein in its broad sense and, is intended to encompass cockroaches, such as the German (Blattela germanica) and American (Periplaneta americana) roach, as well as mosquitoes, moths, flies, fleas, ants, lice and arachnids, such as spiders, ticks and mites.
The term "insect repellent material" is intended to encompass a wide variety of materials having insect repellent properties which are compatible with the type of detergent composition described herein and which manifest a sufficient substantivity to the hard surface to which the detergent composition is applied to be efficacious as a repellent.
Included among the insect repellent materials useful for the present invention are the following compounds which may be used individually or in combination with other repellent materials, the designation in parenthesis following certain compound names referring to its commercial or common designation:
N-alkyl neoalkanamides wherein the alkyl is of 1 to 4 carbon atoms, and the neoalkanoyl moiety is of 7 to 14 carbon atoms:
N,N-diethyl-meta-toluamide (DEET);
2-Hydroxyethyl-n-octyl sulfide (MGK 874); 1
N-Octyl bicycloheptene dicarboximide (MGK 264);
A preferred mixture of the above two materials comprising 66% MGK 264 and 33% MGK 874;
Hexahydrodibenzofuran carboxaldehyde (MGK 11);
Di-n-propyl isocinchomerate (MGK 326);
2-Ethyl-1,3-hexanediol (Rutgers 612);
2-(n-butyl)-2-ethyl-1,3-propanediol;
Dimethyl phthalate;
Dibutyl succinate (Tabutrex);
Piperonyl butoxide; and
Pyrethrum
Although the above-mentioned insect repellent materials are longer lasting and are preferred for purposes of the present invention, other useful repellent materials include essential oils such as Mentha arvensis (Cornmint); Mentha piperita (Peppermint); Mentha spicata (American Spearmint); Mentha cardica (Scotch Spearmint); Lemongrass East Indian Oil; Lemon Oil; Citronella; Cedarwood (Juniperus virginiana L.); and Pine Oil. Terpenoids are another class of materialshaving insect repellent properties, the most useful being (-)-Limonene; (+)-Limonene; (-)-Carvone; Cineole (Eucalyptol); Linalool; Gum Camphor; Citronellal; Alpha and Beta -Terpineol; Fencholic acid; Borneol, iso Borneol, Bornyl acetate and iso Bornyl acetate.
Among the non-commercial repellent materials useful for the invention are the following:
N,N-Diethyl cyclohexylacetamide (DECA)
1,2,3,6-Tetrahydro-1-(2-methyl-1-oxopentyl) piperidine
N,N-Diethyl-3-cyclohexyl propionamide (DCP)
2-Ethyl-1-(2-methyl-1-oxo-2-butenyl) piperidine
N,N-diethyl nonanamide, and
N,N-Diethyl Phenylacetamide.
With regard to the aforementioned N-alkyl neoalkanamides, the alkyl group is preferably methyl or ethyl, and most preferably is methyl. The neoalkanoyl moiety is preferably neodecanoyl or neotridecanoyl.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph showing the number of days with 90% repellency as a function of the percent of MNDA in the test composition.
DETAILED DESCRIPTION OF THE INVENTION
The detergent compositions of the invention contain a detersive proportion of one or more surface active detergent compounds from among anionic, nonionic, cationic and amphoteric detergents, which generally will be in the range of from about 1 to about 30%, by weight, of the composition, preferably from about 2 to about 20%, by weight. The detergent is preferably a synthetic organic detergent of the anionic or nonionic type and often a combination of anionic and nonionic detergents will be most preferred. Descriptions of many such detergents are found in the text Surface Active Agents and Detergents, Vol, II, pages 25-138, by Schwartz, Perry and Berch, published in 1958 by Interscience Publishers, Inc. Such compounds are also described in a 1973 publication by John W. McCutcheon, entitled Detergents and Emulsifiers. Both such publications are incorporated herein by reference.
The anionic detergents employed will normally be salts of alkali metals, such as sodium or potassium or ammonium or lower alkanolammonium salts, e.g., triethanolamine salts. The anionic detergent may be a sulfate, sulfonate, phosphate or phosphonate or salt of other suitable acid but usually will be a sulfate or sulfonate. The anionic detergents include a lipophilic group, which will normally have from 10 to 18 carbon atoms, preferably in linear higher alkyl arrangement, but other lipophilic groups may be present instead, preferably including 12 to 16 carbon atoms, such as branched chain alkyl benzene. Examples of suitable anionic detergents include higher fatty alcohol sulfonates, such as sodium tridecyl sulfonate; sodium linear alkyl benzene sulfonates, e.g., sodium linear dodecyldecylbenzene sulfonate; olefin sulfonates; and paraffin sulfonates. The anionic detergents are preferably sodium salts but potassium, ammonium and triethanolammonium salts are often more desirable for some liquid compositions.
The suitable nonionic detergents will normally be condensation products of lipophilic compounds or moieties and lower alkylene oxides or polyalkoxy moieties. Highly preferable lipophiles are higher fatty alcohols of 10 to 18 carbon atoms but alkyl phenols, such as octyl and nonyl phenols, may also be used. The alkylene oxide of preference is ethylene oxide and normally from 3 to 30 moles of ethylene oxide will be present per mole of lipophile. Preferably such ethoxylate content will be 3 to 10 moles per mole of higher fatty alcohol and more preferably it will be 6 to 7 moles, e.g., 6.5 or 7 moles per mole of higher fatty alcohol (and per mole of nonionic detergent). Both broad ranges ethoxylates and narrow range ethoxylate (BRE's and NRE's) may be employed, with the difference between them being in the "spread" of number of ethoxylate groups present, which average within the ranges given. For example, NRE's which average 5 to 10 EtO groups per mole in the nonionic detergent will have at least 70% of the EtO content in polyethoxy groups of 4 to 12 moles of EtO and will preferably have over 85% of the EtO content in such range. BRE nonionic detergents have a broader range of ethoxy contents than NRE's, often with a spread from 1 to 15 moles of EtO when the EtO chain is in the 5 to 10 EtO range (average). Examples of the BRE nonionic detergents include those sold by Shell Chemical Company under the trademark Neodol®, including Neodol 25-7, Neodol 23-6.5 and Neodol 25-3. Supplies of NRE nonionic detergents have been obtained from Shell Development Company, which identifies such materials as 23-7P and 23-7Z.
Cationic surface active compounds may also be employed. They comprise surface active detergent compounds which contain an organic hydrophobic group which forms part of a cation when the compound is dissolved in water, and an anionic group. Typical cationic detergents are amine and quaternary ammonium compounds.
The quaternary ammonium compounds useful herein are known materials and are of the high-softening type. Included are the N 1 N-di(higher) C 14 -C 24 , N 1 N-di(lower C 1 -C 4 alkyl quaternary ammonium salts with water solubilizing anions such as halide, e.g. chloride, bromide and iodide; sulfate, methosulfate and the like and the heterocyclic amides such as imidazolinium.
For convenience, the aliphatic quaternary ammonium salts may be structurally defined as follows: ##STR1## wherein R and R 1 represent alkyl of 14 to 24 and preferably 14 to 22 carbon atoms; R 2 and R 3 represent lower alkyl of 1 to 4 and preferably 1 to 3 carbon atoms, X represents an anion capable of imparting water solubility or dispersibility including the aforementioned chloride, bromide, iodide, sulfate and methosulfate. Particularly preferred species of aliphatic quats include:
distearyl dimethylammonium chloride
di-hydrogenated tallow dimethyl ammonium chloride
di tallow dimethyl ammonium chloride
distearyl dimethyl ammonium methyl sulfate
di-hydrogenated tallow dimethyl ammonium methyl sulfate.
Amphoteric detergents are also suitable for the invention. This class of detergents is well known in the art and many operable detergents are disclosed by Schwartz, Perry and Berch in "Surface Active Agents and Detergents", Vol. II, Interscience Publishers, Inc., New York (1958)in Chapter 4 thereof. Examples of suitable amphoteric detergents include: alkyl betaiminodipropionates, RN(C 2 H 4 COOM) 2 ; and alkyl beta-amino propionates, RN(H)C 2 H 4 COOM.
Builders may be present in the liquid detergent composition in an amount of from about 1 to 20% to improve the detergency of the synthetic organic detergents. Such builders may be inorganic or organic, water soluble or water insoluble. Included among such builders are polyphosphates, e.g., sodium tripolyphosphate; carbonates, e.g., sodium carbonate; bicarbonates, e.g., sodium bicarbonate; borates, e.g., borax; and silicates, e.g., sodium silicate; water insoluble inorganic builders, including zeolites, e.g., hydrated Zeolite 4A; and water soluble organic builders, including citrates, gluconates, NTA, and polyacetal carboxylates.
Various adjuvants may be present in the detergent compositions such as fluorescent brighteners, antistatic agents, antibacterial agents, fungicides, foaming agents, anti-foams, flow promoters, suspending agents, antioxidants, anti-gelling agents, soil release promoting agents, and enzymes.
The liquid detergent compositions of the invention will generally comprise from about 2 to 20% of surface active detergent compounds which are preferably anionic and/or nonionic, from about 1 to 20%, by weight, of builder salts for such detergents and from about 0.2 to 20%, preferably 0.5 to 10%, by weight, of the insect repellent material, the balance being predominantly water, adjuvants and optionally an emulsifying agent, or hydrotrope such as sodium toluene sulfonate or a solvent suitable for the insect repellent material such as isopropyl alcohol or acetone. To facilitate the incorporation of a fragrance or perfume into the aqueous liquid detergent composition, it is often advantageous to formulate the liquid detergent composition in microemulsion form with water as the continuous phase and oil or hydrocarbon as the dispersed phase.
In practical tests, on actual kitchen floors, counters, drainboards and walls, and in kitchen cabinets and under refrigerators, in roach-infested apartments, significantly fewer roaches will be observed on surfaces to which or near which the invented liquid detergent compositions are applied than on control surfaces, and fewer roaches are found on the bottoms and shelves of cabinets and pantries when walls thereof are treated with the invented detergent compositions. When floors, walls, counters, sinks, cabinets and doors in a house or apartment are treated with the liquid detergent compositions of the invention, the incidence of cockroach infestation is reduced, compared to control apartments where no repellent is applied.
EXAMPLE 1
A single composition in accordance with the invention formulated as shown below was used as the starting material to prepare by dilution six liquid compositions of varying degrees of dilution containing six correspondingly different levels of N-methyl neodecanamide (MNDA) insect repellent material.
______________________________________LIQUID HARD SURFACE CLEANER WEIGHTCOMPONMENT PERCENTAGE______________________________________Sodium linear dodecylbenzene sulfonate 4Nonionic detergent.sup.(1) 2MNDA 2.0Coconut fatty acid 0.5Soda ash 2Sodium bicarbonate 1Isopropyl alcohol 4Water BalanceFragrance 1______________________________________ .sup.(1) Condensation product of one mole of a mixture of fatty alcohols of 9-11 carbon atoms with 6 moles of ethylene oxide.
The percentage of MNDA in each of the six tested detergent compositions varied, respectively, as follows: 0.12, 0.20, 0.22, 0.29, 0.4 and 2.0%
The insect repellency of each of these six hard surface cleaning detergent compositions was tested by the procedure described below and compared with the repellency imparted by three repellent-containing comparative compositions, i.e. three solutions of acetone containing 0.25, 0.5 and 1.0%, by weight, respectively, of MNDA.
TEST PROCEDURE
Insects--German and American cockroaches were from established colonies maintained at 27° C. Carpenter ant workers were collected from a log containing a queenright colony and were kept in the same conditions as the cockroaches.
Bioassay--Forty-eight hours prior to initiation of an assay, 50 male German cockroaches were allowed to acclimate to the plastic test cages (51×28×20 cm) with food and water available in the center. A thin film of teflon emulsion (Fluon AD-1, Northern products, Woonsocket, R.I.) on the sides of the cages restricted the insects to the floor of the cage. The assays used either 50 female German cockroaches, 20 males American Cockroaches, or 50 carpenter ant workers.
The repellency of the various compositions to be tested were evaluated over time. The procedure consisted of arranging five 3×3 inch asphalt tiles into a cubic shelter ("cup") and treating the tiles with the various test compositions. The treated sides faced inward. The method relies on the light avoidance response of the cockroaches. Two milliliters of a test composition was applied to the entire inside surface of the cup. Control cups were treated with acetone or water only. The cups were allowed to dry for 1 hr and then a control and a treated cup were inverted into each of the test cages. Food and water were provided in the center of each cage, outside of the cups. The number of insects resting on the inner walls of each cup were recorded in the middle of the photophase daily for 25 days or until equal numbers were found in treated and untreated cups. After each count the insects were disturbed and the positions of the treated and control cups were reversed. Accordingly, the distribution of cockroaches for any given day is considered independent of the previous days distribution.
Repellency was defined as the percentage of insects that avoided the treated surfaces and was calculated as ##EQU1## where N t is the number of insects on the treated surface and N c is the number on the acetone treated control surfaces. The repellency of compounds was evaluated on the basis of the number of days of 90% repellency which is based on (i) the number of days of complete (100%) repellency and (ii) a maximum likelihood probit analysis of time/repellency (SAS User's Guide, SAS Institute 1985) from which a measure was calculated of the number of days of 90% repellency (RT 90-10 % of the insects on the treated surface, 90% on the control surface).
The results of the repellency tests are indicated in FIG. 1 which is a graph showing the number of days with 90% repellency as a function of the percent of MNDA in the test composition.
As noted in the FIGURE, the comparative compositions not in accordance with the invention were unable to achieve 90% repellency at a level of MNDA repellent of 0.25%. In contrast thereto, the compositions of the invention were able to provide almost 3 days of 90% repellency at a 0.2% level of MNDA. | An aqueous liquid detergent composition is provided for cleaning a hard surface and for repelling insects therefrom comprising a detersive proportion of a surface active detergent compound, an effective amount of an insect repellent material which is sufficient to repel insect from the hard surface after application of the detergent composition thereto, the liquid detergent composition being substantially free of a liquid hydrocarbon. | 2 |
RELATED APPLICATION
[0001] This application claims the benefit of and priority to U.S. provisional patent application Ser. No. 61/417,738, filed 29 Nov. 2010; and U.S. non-provisional application Ser. No. 13/373,774, filed 29 Nov. 2011, the contents of which are hereby incorporated in their entirety for any and all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to objective methods for assessing the status of Reward Deficiency Syndrome (RDS) behaviors in subjects known to have or suspected of being afflicted with RDS.
[0004] 2. Overview
[0005] There exists great controversy regarding appropriate testing of gene polymorphisms and their role in disease and bodily function. As resources are limited, the debate revolves around whether enough progress has been made towards identifying the single nucleotide polymorphisms (SNPs) that are likely to contribute most to disease causation in order to justify investment in functional follow-up. Fortunately, nucleic acid sequencing and proteomics technologies are becoming less expensive and more accessible, allowing investigation of the causative role of strongest candidate SNPs available to date. What makes for strong candidates are significant disease associations with transcript expression and/or protein levels in various tissues.
[0006] Reward Deficiency Syndrome (RDS) results from a dysfunction in the Brain Reward Cascade that directly links abnormal craving behavior with a deficit in a number of reward genes, including dopaminergic, serotonergic, endorphinergic, catechoaminegic, gabaergic, adrenergic, opioidergic, and cholinergic genes, as well as many second messengers. As one example, dopamine is a very powerful neurotransmitter, which controls feelings of well-being. This sense of well-being is produced through the interaction of dopamine and neurotransmitters such as serotonin, the opioids (neuropeptides), and other powerful brain chemicals. For example, low serotonin has been associated with depression. High levels of opioids (the brain's opium) are associated with a sense of well-being.
[0007] 3. Definitions
[0008] Before describing the instant invention in detail, several terms used in the context of the present invention will be defined. In addition to these terms, others are defined elsewhere in the specification, as necessary. Unless otherwise expressly defined herein, terms of art used in this specification will have their art-recognized meanings.
[0009] Causal variant: In the context of GWAS it represents the SNP that is mechanistically linked to risk enhancement. This is distinct from SNPs that do not have any functional impact but are statistically associated with the disease phenotype because it is in linkage disequilibrium with the causal variant.
[0010] ChIP-Seq: Chromatin immunoprecipitation (ChIP) is a method to study protein-DNA interactions. It identifies genomic regions that are binding sites for a known protein. Analysis of these regions is typically performed by PCR, when there is a hypothesized known binding site, or through the use of genomic microarrays (ChIP-chip). Alternatively, analysis can be done using next-generation sequencing (Seq) technology to analyze DNA fragments.
[0011] CNV: Copy number variation is a type of structural variation in which a particular segment of the genome, typically larger than 1 kb, is found to have a variable copy number from a reference genome. Deep sequencing: a sequencing strategy used to reveal variations present at extremely low levels in a sample. For example, to identify rare somatic mutations found in a small number of cells in a tumor, or low abundance transcripts in transcriptome analysis.
[0012] DNA Methylation: A modification of the DNA that involves predominantly the addition of a methyl group to the 5 position of the pyrimidine ring of a cytosine found in a CpG dinucleotide sequence.
[0013] Epigenetic markers: an array of modifications to DNA and histones independent of changes in nucleotide sequence but rather the addition of methyl a methyl group to cytosine and a series of post-translation modifications of histone including methylation, acetylation, and phosphorylation.
[0014] Fine mapping: a strategy to identify other lower frequency variants in a disease-associated region (typically spanning a haplotype block) not represented in the initial genotyping platform with the goal of uncovering candidate causal variants. It can include data mining of publically available sequencing efforts, such as the 1000 Genomes Project and targeted resequencing. Functional variant: a variant that confers a detectable functional impact on the locus. It can represent a change in coding region but also changes in regulatory regions that have an impact on function.
[0015] GWAS: genome-wide association study is a case-control study design in which most loci in the genome are interrogated for association with a trait (disease) through the use of SNPs by comparing allele frequencies in cases and controls. Haplotype block: linear segments of the genome comprising coinherited alleles in the same chromosome.
[0016] Homologous recombination: an error-free recombination mechanism that exchanges genetic sequences between homologous loci during meiosis, and utilizes homologous sequences such as the sister-chromatid to promote DNA repair during mitosis.
[0017] Linkage disequilibrium: a nonrandom association between two markers (e.g. SNPs), which are typically close to one another due to reduced recombination between them. Supporting MicroRNAs: endogenous short (˜23 nt) RNAs involved in gene regulation by pairing to mRNAs of protein coding mRNAs.
[0018] Next gen sequencing: a technology to sequence DNA in a massively parallel fashion, therefore sequencing is achieved at a much faster speed and lower cost than traditional methods.
[0019] Non-coding variant: a variant that is located outside of the coding region of a certain locus.
[0020] Tagging variant: a variant (SNP) that defines most of the haplotype diversity of a haplotype block.
[0021] Transcriptome: The complete set of transcripts in a cell. In some cases it can also include quantitative data about the amount of individual transcripts.
[0022] RNA-Seq: a method to obtain genome-wide transcription map using deep sequencing technologies to generate short sequence reads (30-400 bp). It reveals a transcriptional profile and levels of expression for each gene.
[0023] A “patentable” composition, process, machine, or article of manufacture according to the invention means that the subject matter satisfies all statutory requirements for patentability at the time the analysis is performed. For example, with regard to novelty, non-obviousness, or the like, if later investigation reveals that one or more claims encompass one or more embodiments that would negate novelty, non-obviousness, etc., the claim(s), being limited by definition to “patentable” embodiments, specifically exclude the unpatentable embodiment(s). Also, the claims appended hereto are to be interpreted both to provide the broadest reasonable scope, as well as to preserve their validity. Furthermore, the claims are to be interpreted in a way that (1) preserves their validity and (2) provides the broadest reasonable interpretation under the circumstances, if one or more of the statutory requirements for patentability are amended or if the standards change for assessing whether a particular statutory requirement for patentability is satisfied from the time this application is filed or issues as a patent to a time the validity of one or more of the appended claims is questioned.
[0024] A “plurality” means more than one.
[0025] The term “treatment” or “treating” of a disease or disorder includes preventing or protecting against the disease or disorder (that is, causing the clinical symptoms not to develop); inhibiting the disease or disorder (i.e., arresting or suppressing the development of clinical symptoms; and/or relieving the disease or disorder (i.e., causing the regression of clinical symptoms). As will be appreciated, it is not always possible to distinguish between “preventing” and “suppressing” a disease or disorder since the ultimate inductive event or events may be unknown or latent. Accordingly, the term “prophylaxis” will be understood to constitute a type of “treatment” that encompasses both “preventing” and “suppressing.” The term “treatment” thus includes “prophylaxis”.
SUMMARY OF THE INVENTION
[0026] The field is still making the first forays into the functional characterization of SNPs. Without wishing to be bound by theory, it is believed that causality can be inferred as being associated with a particular disease, condition, or affliction if a SNP leads to expression differences in reliable in vitro and/or in vivo assays. Thus, in the context of RDS behaviors, for example, a Substance Use Disorder (SUD) differential expression of one or more RDS behavior-associated genes (as analyzed, for example, by gene-based microarray analysis of isolated mRNA preparations and/or by analysis of the levels of proteins encoded by such genes) in response to various drugs of abuse or other addictive behaviors provides an avenue to objectively assess (on a qualitative, semi-quantitative, or quantitative basis) treatment outcomes, particularly for, for example, hypodopaminergic genes.
[0027] Thus, one aspect of the invention concerns methods of objectively assessing, qualitatively, semi-quantitatively, or quantitatively, a Reward Deficiency Syndrome (RDS) behavior in a subject known to have or suspected of having RDS. Such methods comprise obtaining a first expression profile (preferably of mRNA or protein) on a biological sample obtained from the subject at a first time point and a second expression profile on a biological sample obtained from the subject at a second time point, wherein the first and second expression profiles comprise measuring a level of an expression product, optionally a messenger RNA (mRNA) or a protein, for at least one gene selected from the group consisting of TrkB, Pomc, D4, prodynorphin (PDYN), Mu receptors, Kappa receptors, Dyn, Gpr88, Sgk, Cap1, PSD95, CamKII, DRD1A, Grm5, Adora2a, Homer1, Cnr1, Gpr6, hsp90beta, ProorphaninFQ/N, Orexin, cAMP-PKA, CART, micro-RNA miR-181a, NRXN3 beta, En1, D3 receptor, Preproenkephalin, mGluR8, GluR1, MOR, CREB phosphorylation, c fos, delta receptor, FTO, glucocorticoid receptor, G-alpha q-endogenous negative regulator of VMAT2, 5HT-2C, TH, alpha synuclein, intracellular JAK-STAT, Gsta4 (glutathione-S-transferase alpha 4), BDNF I, DeltaFosB, Dopamine D(2) receptor, tyrosine hydroxylase, alpha 6 subunit in catecholaminergic nuclei, c-jun, jun B, zif268, CCK, Neurotensin, dopamine reuptake transporter, COMT, MAO-A, Slc12a6, Dlgap2, Etnk1, Palm, Sqstm1, Nsg1, Akap9, Apba1, Stau1, Elavl4, Kif5a, Syt1, Hipk2, Araf, Cmip, NMDA, and NR1.
[0028] In preferred embodiments, the first expression profile is conducted prior to delivering a therapy to the subject intended to treat or alter the course of the Reward Deficiency Syndrome (RDS) behavior. In other embodiments, the second expression profile is conducted after delivering a therapy to the subject intended to treat or alter the course of the Reward Deficiency Syndrome (RDS) behavior. The biological samples are preferably derived from tissue samples obtained from the subject, wherein optionally the tissue samples are cell-containing samples optionally selected from the group consisting of blood, hair, mucous, saliva, and skin
[0029] In still other embodiments, the methods further include performing an allelic analysis on a biological sample from the subject to determine if the subject's genome contains at least one RDS-associated allele for each of two genes selected from the group consisting of DRD1, DRD2, DRD3, DRD4, DRD5, DAT1, PPARG, CHREBP, FTO, TNF-alpha, MANEA, Leptin OB, PEMT, MOM, MOAB, CRH, CRHEP, CRHR1, CRHR2, GAL, NPY, NPY1R, NPY2R, NPYY5R, ADIPOQ, STS, VDR, DBI, 5HTTIRP, GABRA2, GABRA3, GABBRA4, GABRA5, GABRB1, GABRB2, GABRB3, GABRD, GABRE, GARG2, GABRG2, GABRG3, GARBQ, SLC6A7, SLC6A11, SLC6A13, SLC32A1, GAD1, GAD2, DB1, MTHFR, VEGF, NOS3, HTR3B, SLC6A3, SLC6A4, COMT, DDC, OPRD1, OPRM1, OPRK1, ANKK1, HTR2A, HTR2C, HTRIA, HTR1B, HTR2A, HTR2B, HTR2C, HTR3A, HTR3B, ALDH1, ALDH2, CAT, CYP2E1, ADH1A, ALDH1B, ALDH1C, ADH4, ADH5, ADH6, ADH7, TPH1, TPH2, CNR1, CYP2E1, OPRKI, PDYN, PNOC, PRD1, OPRL1, PENK, POMC, GLA1, GLRA1, GLRB, GPHN, FAAH, CHRM1, CHRM2, CHRM3, CHRM4, CHRM5, CHRNA4, CHRNB2, ADRA1A, ADRA2B, ADRB2, SLC6A2, DRA2A, DRA2C, ARRB2, DBH, SCL18A2, TH, GR1K1, GRIN1, GRIN2A, GRIN2B, GRIN2C, GRM1, SLC6A4, ADCY7, AVPR1A, AVPRIB, CDK5RI, CREB1, CSNKIE, FEV, FOS, FOSL1, FOSL2, GSKK3B, JUN, MAPK1, MAPK3, MAPK14, MPD2, MGFB, NTRK2, NTSRI, NTSR2, PPP1R1B, PRKCE, BDNF, CART, CCK, CCKAR, CCKBR, CLOCK, HCRT, LEP, OXT, NR3C1, SLC29A1, and TAC1, wherein the allelic analysis is performed before, concurrently, or after the first expression profile; and, optionally determining a genetic addiction risk based on the results of the allelic analysis, wherein the genetic addiction risk takes into the account the presence of one or more of RDS-associated alleles among the genes analyzed, wherein the presence of at least one RDS-associated allele indicates a genetic addiction risk.
[0030] In still other preferred embodiments, the invention concerns methods wherein the RDS behavior is the subject's self-administration of a substance or activity of choice. For example, such substances or activities, and profiles to be assessed, include:
a. high fat food (HFF), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of TrkB, Cart, Pomc, D2 receptor, D4 receptor, BDNF, Agrp, NPY, and Orexin receptor 2; b. nor-binaltorphimine (opioid receptor antagonist), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of PDYN and PENK; c. housing and cognitive enrichment, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of amygdala KOR and DOR opioid receptors and NPY5R; d. morphine, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Mu receptors, Kappa receptors, PENK, PDYN, DYN, Gpr88, Sgk, Cap1, PSD95, CamKII, DRD1A, Grm5, Adora2a, Homer1, Cnr1, Gpr6, hsp90beta, ProorphaninFQ/N, POMC, CryB, CCK, Aq4, Gpr123, Gpr5 and Gal; e. morphine withdrawal, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Mu receptors, POMC, orexin, PENK and Alpha-synuclein; f. ethanol, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Mu receptors, PENK, POMC, PDYN, cAMP-PKA, CART, PNOC, OPRL-1, Drd2, all 8 GABA receptor subunits, 4 of 5 subunits of different glutamate receptors, and 7 enzymes involved with GABA and glutamate production (GAD-65, GAD-67, glutaminase, glutamate dehydrogenase, glutamine synthetase, aspartate aminotransferase (cytosolic and mitochondrial), cytochrome oxidase subunit III, VIc, ATP synthase subunits A and C, Na K ATPase subunit alpha 1 and beta 1)); g. cocaine, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Mu receptors, PENK, PDYN, micro-RNA miR-181a, NRXN3 beta expression, CART, En1, CD81, D3 receptor, Depamine receptors, ppDYN, DYN, Kappa Receptors, micro-RNAs miR-124, BDNF, D3R, orexin, Nurr1, Pitx3 and tyrosine hydroxylase; h. cocaine withdrawal, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Mu receptors, PDYN, orexin, ppDYN and PENK; i. Amphetamine, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of PENK, PDYN, mGluR8, GluR1 and GluR2; j. amphetamine withdrawal, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Mu receptors and PDYN; k. Chronic nicotine treatment, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Mu receptors, POMC, PDYN, c-Fos, CREB phosphorylation, dopamine D2 receptor and tyrosine hydroxylase; l. Alcohol cessation, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of delta receptor; m. Cannabinoid agonists (THC, CP-55,940 or R-methanandamide), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of PENK and POMC; n. cannabinoid withdrawal, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of PENK; o. Kappa receptor agonists (U-69593 or U-50,488H), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of PDYN; p. Methamphetamine, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of PDYN and TNF-alpha; q. food (effects on hypothalamic FTO), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of FTO; r. Leucine, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of FTO; s. dual orexin receptor antagonist (DORA)-antagonist of OX1R and OX2R, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of t. Aging, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of orexin-receptor 2; u. CREB, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of v. dopamine transporter (DAT—as influenced by overexpression or silencing in the nucleus accumbens), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of w. CREB, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of CART; x. deoxyribozyme 164 (DRz164)—cleaves Period 1 gene (Per1) mRNA. Injection with DRz164 before morphine treatment, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of ERK and CREB; y. para-chloroamphetamine (depletes 5-HT), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of glucocorticoid receptor and BDNF; z. predisposition for obesity (normal diet), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Galphaq, tyrosine hydroxylase, VMAT2, DAT, and D2S presynaptic autoreceptor; aa. editing of serotonin 2C receptor mRNA (via ADAR enzyme), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of 5HT-2C; bb. Heroin, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of PENK, D2 receptor, DAT, Nurr1 and tyrosine hydroxylase; cc. social isolation, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D2 receptor; dd. HSV vector mediated elevations in GluR1 or GluR2, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of GluR1 and GluR2; ee. high or low consumption of sugar, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of 5HT2A, mGlu1, AMPA, GluR1, adrenergic alpha 2A, NMDA NR2B, GABA Alpha 3, adrenergic alpha2B, GluR2, GluR3, 5HT1B and GABA alpha5; ff. Leptin receptor expression in VTA, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of gg. ethanol preference, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Gsta4, FAAH and CB1; hh. morphine response (mice), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of Atp I aw, COMT, Gabra I, GABA-A, Gabra2, Grm7, Kcnj 9, Syt4, Gfap, Mtap2, and Hprt I; ii. psychostimulant (e.g. cocaine, amphetamine), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of CART, cAMP and CREB; jj. forskolin (intra-accumbal injection in rat), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of CART; kk. intrastriatal infusion of cholinergic muscarinic antagonist, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of ll. Delta-tetrahydrocannabinol, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of BDNF, zif268 and MAPK/ERK; mm. DeltaFosB, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of nn. Nandrolone decanoate, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D2 receptor and D1 receptor; oo. Voluntary wheel running in addicted Lewis rats, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of pp. Substance P (during morphine withdrawal), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D2 receptor; qq. U99194A (D(3) dopamine receptor antagonist), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of c-Fos; rr. cocaine, cocaine +nondrolone, or nandrolone alone, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of ss. Dextromethorphan, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of tyrosine hydroxylase; tt. Running, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of DYN, GluR1, AMPA, NGFI-B and Nor1; uu. Amitriptyline, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D1, D2 and D3 receptors; vv. Desipramine, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D3 receptor; ww. Imipramine, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D1, D2 and D3 receptors; xx. Tranylcypromine, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D3 receptor; yy. electroconvulsive therapy, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D3 receptor; zz. Fetal alcohol syndrome, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of c-fos, c-jun, jun B, zif268 and junB; aaa. S(−)- and R (+)-salsolinol, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of POMC and cAMP; bbb. peripheral nerve injury (unilateral chronic constriction of sciatic nerve), wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of tyrosine hydroxylase and DRD2; and ccc. alcohol and splice variants, wherein optionally the first and second expression profile experiments assess the mRNA of at least one gene selected from the group consisting of D2L/D2S receptor ratio and NMDA NR1
[0086] These and other aspects and embodiments of the invention are discussed in greater detail in the sections that follow.
BRIEF DESCRIPTION OF THE FIGURES
[0087] This application contains at least one FIGURE executed in color. Copies of this application with color drawing(s) are available upon request and payment of the necessary fee. A summary of each FIGURE appears below.
[0088] FIG. 1 : FIG. 1 (A) Schematic represents the normal physiologic state of the neurotransmitter interaction at the mesolimbic region of the brain. Briefly in terms of the “Brain Reward Cascade” first coined by Blum and Kozlowski [X]: serotonin in the hypothalamus stimulates neuronal projections of methionine enkephalin in the hypothalamus which in turn inhibits the release of GABA in the substania nigra thereby allowing for the normal amount of Dopamine to be released at the Nucleus Accumbens (reward site of Brain). (B) Represents hypodopaminergic function of the mesolimbic region of the brain. It is possible that the hypodopaminergic state is due to gene polymorphisms as well as environmental elements including both stress and neurotoxicity from aberrant abuse of psychoactive drugs (i.e. alcohol, heroin, cocaine etc). Genetic variables could include serotonergic genes (serotonergic receptors [5HT2a]; serotonin transporter 5HTIPR); endorphinergic genes (mu OPRM1 gene; proenkephalin (PENK) [PENK polymorphic 3′ UTR dinucleotide (CA) repeats}; GABergic gene (GABRB3) and dopaminergic genes (ANKKI Taq A; DRD2 C957T, DRD4 7R, COMT Val/met substation, MAO-A uVNTR, and SLC6A3 9 or 10R). Any of these genetic and or environmental impairments could result in reduced release of dopamine and or reduced number of dopaminergic receptors.
DETAILED DESCRIPTION OF THE INVENTION
[0089] This invention concerns methods to assess biomarkers, particularly the level of gene products such as a messenger RNAs (mRNAs) and/or the proteins encoded by such mRNAs, common to overall wellness and, as such, attenuation of aberrant craving behaviors, including other detrimental behaviors in drug dependency. Particular emphasis is placed on individual drug or activity of choice. Such methods will benefit chemical dependency programs worldwide, as well as bariatric centers involved in the treatment of obesity or food cravings, as well as centers involved in gambling, internet, or sexual addiction, to name a few. This application is supported by a new definition of addiction as developed and release by American Society of Addiction Medicine (ASAM).
[0090] Short Definition of Addiction:
[0091] Addiction is a primary, chronic disease of brain reward, motivation, memory, and related circuitry. Dysfunction in these circuits leads to characteristic biological, psychological, social, and spiritual manifestations. This is reflected in an individual pathologically pursuing reward and/or relief by substance use and other behaviors.
[0092] Addiction is characterized by inability to consistently abstain, impairment in behavioral control, craving, diminished recognition of significant problems with one's behaviors and interpersonal relationships, and a dysfunctional emotional response. Like other chronic diseases, addiction often involves cycles of relapse and remission. Without treatment or engagement in recovery activities, addiction is progressive and can result in disability or premature death.
[0093] Addiction affects neurotransmission and interactions within reward structures of the brain, including the nucleus, accumbens, anterior cingulate cortex, basal forebrain and amygdala, such that motivational hierarchies are altered and addictive behaviors, which may or may not include alcohol and other drug use, supplant healthy, self-care related behaviors. Addiction also affects neurotransmission and interactions between cortical and hippocampal circuits and brain reward structures, such that the memory of previous exposures to rewards (such as food, sex, alcohol, and other drugs) leads to a biological and behavioral response to external cues, in turn triggering craving and/or engagement in addictive behaviors.
[0094] The neurobiology of addiction encompasses more than the neurochemistry of reward. The frontal cortex of the brain and underlying white matter connections between the frontal cortex and circuits of reward, motivation and memory are fundamental in the manifestations of altered impulse control, altered judgment, and the dysfunctional pursuit of rewards (which is often experienced by the affected person as to desire to “be normal”) seen in addiction—despite cumulative adverse consequences experienced from engagement in substance use and other addictive behaviors. The frontal lobes are important in inhibiting impulsivity and in assisting individuals to appropriately delay gratification. When persons with addiction manifest problems in deferring gratification, there is a neurological locus of these problems in the frontal cortex. Frontal lobe morphology, connectivity and functioning are still in the process of maturation during adolescence and young adulthood, and early exposure to substance use is another significant factor in the development of addiction. Many neuroscientists believe that developmental morphology is the basis that makes early-life exposure to substances such an important factor.
[0095] Genetic factors account for about half of the likelihood that an individual will develop addiction. Environmental factors interact with the person's biology and affect the extent to which genetic factors exert their influence. Resiliencies the individual acquires (through parenting or later life experiences) can affect the extent to which genetic predispositions lead to the behavioral and other manifestations of addiction. Culture also plays a role in how addiction becomes actualized in persons with biological vulnerabilities to the development of addiction.
[0096] Other factors that can contribute to the appearance of addiction, leading to its characteristic bio-psycho-socio-spiritual manifestations, include:
a. the presence of an underlying biological deficit in the function of reward circuits, such that drugs and behaviors which enhance reward function are preferred and sought as reinforcers; b. the repeated engagement in drug use or other addictive behaviors, causing neuroadaptation in motivational circuitry leading to impaired control over further drug use or engagement in addictive behaviors; c. cognitive and affective distortions, which impair perceptions and compromise the ability to deal with feelings, resulting in significant self-deception; d. disruption of healthy social supports and problems in interpersonal relationships which impact the development or impact of resiliencies; e. exposure to trauma or stressors that overwhelm an individual's coping abilities; f. distortion in meaning, purpose and values that guide attitudes, thinking and behavior; g. distortions in a person's connection with self, with others and with the transcendent (referred to as God by many, the Higher Power by 12-steps groups, or higher consciousness by others); and h. the presence of co-occurring psychiatric disorders in persons who engage in substance use or other addictive behaviors.
Addiction is characterized by:
a. inability to consistently abstain; b. impairment in behavioral control; c. craving; or increased “hunger” for drugs or rewarding experiences; d. diminished recognition of significant problems with one's behaviors and interpersonal relationships; and e. a dysfunctional emotional response.
[0110] The power of external cues to trigger craving and drug use, as well as to increase the frequency of engagement in other potentially addictive behaviors, is also a characteristic of addiction, with the hippocampus being important in memory of previous euphoric or dysphoric experiences, and with the amygdala being important in having motivation concentrate on selecting behaviors associated with these past experiences.
[0111] Although some believe that the difference between those who have addiction, and those who do not, is the quantity or frequency of alcohol/drug use, engagement in addictive behaviors (such as gambling or spending), or exposure to other external rewards (such as food or sex), a characteristic aspect of addiction is the qualitative way in which the individual responds to such exposures, stressors and environmental cues. A particularly pathological aspect of the way that persons with addiction pursue substance use or external rewards is that preoccupation with, obsession with and/or pursuit of rewards (e.g., alcohol and other drug use) persist despite the accumulation of adverse consequences. These manifestations can occur compulsively or impulsively, as a reflection of impaired control.
[0112] Persistent risk and/or recurrence of relapse, after periods of abstinence, is another fundamental feature of addiction. This can be triggered by exposure to rewarding substances and behaviors, by exposure to environmental cues to use, and by exposure to emotional stressors that trigger heightened activity in brain stress circuits.
[0113] In addiction there is a significant impairment in executive functioning, which manifests in problems with perception, learning, impulse control, compulsivity, and judgment. People with addiction often manifest a lower readiness to change their dysfunctional behaviors despite mounting concerns expressed by significant others in their lives; and display an apparent lack of appreciation of the magnitude of cumulative problems and complications. The still developing frontal lobes of adolescents may both compound these deficits in executive functioning and predispose youngsters to engage in “high risk” behaviors, including engaging in alcohol or other drug use. The profound drive or craving to use substances or engage in apparently rewarding behaviors, which is seen in many patients with addiction, underscores the compulsive or avolitional aspect of this disease. This is the connection with “powerlessness” over addiction and “unmanageability” of life, as is described in Step 1 of 12 Steps programs.
[0114] Addiction is more than a behavioral disorder. Features of addiction include aspects of a person's behaviors, cognitions, emotions, and interactions with others, including a person's ability to relate to members of their family, to members of their community, to their own psychological state, and to things that transcend their daily experience.
[0115] Behavioral manifestations and complications of addiction, primarily due to impaired control, can include:
a. Excessive use and/or engagement in addictive behaviors, at higher frequencies and/or quantities than the person intended, often associated with a persistent desire for and unsuccessful attempts at behavioral control; b. Excessive time lost in substance use or recovering from the effects of substance use and/or engagement in addictive behaviors, with significant adverse impact on social and occupational functioning (e.g. the development of interpersonal relationship problems or the neglect of responsibilities at home, school or work); c. Continued use and/or engagement in addictive behaviors, despite the presence of persistent or recurrent physical or psychological problems which may have been caused or exacerbated by substance use and/or related addictive behaviors; d. A narrowing of the behavioral repertoire focusing on rewards that are part of addiction; and e. An apparent lack of ability and/or readiness to take consistent, ameliorative action despite recognition of problems.
Cognitive changes in addiction can include:
a. Preoccupation with substance use; b. Altered evaluations of the relative benefits and detriments associated with drugs or rewarding behaviors; and c. The inaccurate belief that problems experienced in one's life are attributable to other causes rather than being a predictable consequence of addiction.
Emotional changes in addiction can include:
a. Increased anxiety, dysphoria and emotional pain; b. Increased sensitivity to stressors associated with the recruitment of brain stress systems, such that “things seem more stressful” as a result; and c. Difficulty in identifying feelings, distinguishing between feelings and the bodily sensations of emotional arousal, and describing feelings to other people (sometimes referred to as alexithymia).
[0127] The emotional aspects of addiction are quite complex. Some persons use alcohol or other drugs or pathologically pursue other rewards because they are seeking “positive reinforcement” or the creation of a positive emotional state (“euphoria”). Others pursue substance use or other rewards because they have experienced relief from negative emotional states (“dysphoria”), which constitutes “negative reinforcement.” Beyond the initial experiences of reward and relief, there is a dysfunctional emotional state present in most cases of addiction that is associated with the persistence of engagement with addictive behaviors. The state of addiction is not the same as the state of intoxication. When anyone experiences mild intoxication through the use of alcohol or other drugs, or when one engages non-pathologically in potentially addictive behaviors such as gambling or eating, one may experience a “high”, felt as a “positive” emotional state associated with increased dopamine and opioid peptide activity in reward circuits. After such an experience, there is a neurochemical rebound; in which the reward function does not simply revert to baseline, but often drops below the original levels. This is usually not consciously perceptible by the individual and is not necessarily associated with functional impairments.
[0128] Over time, repeated experiences with substance use or addictive behaviors are not associated with ever increasing reward circuit activity and are not as subjectively rewarding. Once as person experiences withdrawal from drug use or comparable behaviors, there is an anxious, agitated, dysphoric and labile emotional experience, related to suboptimal reward and the recruitment of brain and hormonal stress systems, which is associated with withdrawal from virtually all pharmacological classes of addictive drugs. While tolerance develops to the “high,” tolerance does not develop to the emotional “low” associated with the cycle of intoxication and withdrawal. Thus, in addiction, persons repeatedly attempt to create a “high”—but what they mostly experience is a deeper and deeper “low.” While anyone may “want” to get “high”, those with addiction feel a “need” to use the addictive substance or engage in the addictive behavior in order to try to resolve theft dysphoric emotional state or their physiological symptoms of withdrawal, Persons with addiction compulsively use even though it may not make them feel good, in some cases long after the pursuit of “rewards” is not actually pleasurable. Although people from any culture may choose to “get high” from one or another activity, it is important to appreciate that addiction is not solely a function of choice. Simply put, addiction is not a desired condition.
[0129] As addiction is a chronic disease, periods of relapse, which may interrupt spans of remission, are a common feature of addiction. It is also important to recognize that return, to drug use or pathological pursuit of rewards is not inevitable.
[0130] Clinical interventions can be quite effective in altering the course of addiction. Close monitoring of the behaviors of the individual and contingency management, sometimes including behavioral consequences for relapse behaviors, can contribute to positive clinical outcomes. Engagement in health promotion activities which promote personal responsibility and accountability, connection with others, and personal growth also contribute to recovery. It is important to recognize that addiction can cause disability or premature death, especially when left untreated or treated inadequately.
[0131] The qualitative ways in which the brain and behavior respond to drug exposure and engagement in addictive behaviors are different at later stages of addiction than in earlier stages, indicating progression, which may not be overtly apparent. As is the case with other chronic diseases, the condition must be monitored and managed over time to:
a. Decrease the frequency and intensity of relapses; b. Sustain periods of remission; and c. Optimize the person's level of functioning during periods of remission.
[0135] In some cases of addiction, medication management can improve treatment outcomes. In most cases of addiction, the integration of psychosocial rehabilitation and ongoing care with evidence-based pharmacological therapy provides the best results. Chronic disease management is important for minimization of episodes of relapse and theft impact. Treatment of addiction saves lives.
[0136] Addiction professionals and persons in recovery know the hope that is found in recovery. Recovery is available even to persons who may not at first be able to perceive this hope, especially when the focus is on linking the health consequences to the disease of addiction. As in other health conditions, self-management, with mutual support, is very important in recovery from addiction. Peer support such as that found in various “self-help” activities is beneficial in optimizing health status and functional outcomes in recovery.
[0137] While there are many approaches to treatment no one has ever developed a novel test to determine outcome following treatment whether it involves just talk therapy, holistic modalities, neuro-genetic targeting, psychopharmacology, genomics and/or a combination of all of these worthy approaches. With this mind the inventors propose the first ever-test to determine outcome by tracking pre- and post mRNA gene expression as described herein.
[0138] The site of the brain where one experiences feelings of well being is the meso-limbic system. This part of the brain has been termed the “reward center”. The chemical messages include serotonin, enkephalins, GABA and dopamine, all working in concert to provide a net release of DA at the Nac (a region in the mesolimbic system). It is well known that genes control the synthesis, vesicular storage, metabolism, receptor formation and neurotransmitter catabolism. The polymorphic versions of these genes have certain variations that can lead to an impairment of the neurochemical events involved in the neuronal release of DA. The cascade of these neuronal events has been termed “Brain Reward Cascade”. A breakdown of this cascade will ultimately lead to a dysregulation and dysfunction of DA. Since DA has been established as the “pleasure molecule” and the “anti-stress molecule,” any reduction in function could lead to reward deficiency and resultant aberrant substance seeking behavior and a lack of wellness.
[0139] Homo sapiens physiology is motivationally programmed to drink, eat, have sex, and desire pleasurable experiences. Impairment in the mechanisms involved in these natural processes lead to multiple impulsive, compulsive and addictive behaviors governed by genetic polymorphic antecedents. While there are a plethora of genetic variations at the level of mesolimbic activity, polymorphisms of the serotonergic-2A receptor (5-HTT2a), dopamine D2 receptor (DRD2) and the Catechol-o-methyl-transferase (COMT) genes predispose individuals to excessive cravings and resultant aberrant behaviors.
[0140] An umbrella term to describe common genetic antecedents of multiple impulsive, compulsive and addictive behaviors is Reward Deficiency Syndrome (RDS). Individuals possessing a paucity of serotonergic and/or dopaminergic receptors and an increased rate of synaptic DA catabolism, due to high catabolic genotype of the COMT gene, are predisposed to self-medicating any substance or behavior that will activate DA release including alcohol, opiates, psychostimulants, nicotine, glucose, gambling, sex, and even excessive internet gaming, among others.
[0141] Acute utilization of these substances induces a feeling of well being. But, unfortunately, sustained and prolonged abuse leads to a toxic pseudo feeling of well being resulting in tolerance and disease or discomfort. Thus, low DA receptors due to carrying the DRD2 A1 allelic genotype results in excessive cravings and consequential behavior, whereas normal or high DA receptors results in low craving-induced behavior. In terms of preventing substance abuse, or excessive glucose craving, one goal would be to induce a proliferation of DA D2 receptors in genetically prone individuals. Experiments in vitro have shown that constant stimulation of the DA receptor system via a known D2 agonist results in significant proliferation of D2 receptors in spite of genetic antecedents. In essence, D2 receptor stimulation signals negative feedback mechanisms in the mesolimbic system to induce mRNA expression causing proliferation of D2 receptors. This molecular finding serves as the basis to naturally induce DA release to also cause the same induction of D2-directed mRNA and thus proliferation of D2 receptors in the human. This proliferation of D2 receptors in turn, will induce the attenuation of craving behavior. In fact this has been proven with work showing DNA-directed overexpression (a form of gene therapy) of the DRD2 receptors and significant reduction in both alcohol and cocaine craving-induced behavior in animals.
[0142] Finally, utilizing the long term dopaminergic activation approach will ultimately lead to a common safe and effective modality to treat RDS behaviors including Substance Use Disorders (SUD), Attention Deficit Hyperactivity Disorder (ADHD), and Obesity among other reward deficient aberrant behaviors. Support for the impulsive nature of individuals possessing dopaminergic gene variants is derived from a recent article suggesting that variants in the COMT gene predicts impulsive choice behavior and may shed light on treatment targets. The importance of neurochemical mechanisms involved in drug induced relapse behavior cannot be ignored. Using a drug relapse model, it has been shown previously that relapse can be induced by re-exposing rats to heroin-associated contexts, after extinction of drug-reinforced responding in different contexts, reinstates heroin seeking. This effect is attenuated by inhibition of glutamate transmission in the ventral tegmental area and medial accumbens shell, components of the mesolimbic dopamine system. This process enhances DA net release in the N. accumbens. This fits well with Li's KARG addiction network map.
EXAMPLES
[0143] This section provides a number of examples whereby specific drugs and neuro-pathways interact in the genome to influence the biological function of mRNA as it relates to neurotransmission, enzymes involved in neurotransmitter metabolism as well as specific neuronal receptors common in producing a feeling of well-being in the animal or human.
[0144] In the basal ganglia, convergent input and dopaminergic modulation of the direct striatonigral and the indirect striatopallidal pathways are critical in rewarding and aversive learning and drug addiction. To explore how the basal ganglia information is processed and integrated through these two pathways, a reversible neurotransmission blocking technique was developed in which transmission of each pathway was selectively blocked by specific expression of transmission-blocking tetanus toxin in a doxycycline-dependent manner. The results indicated that the coordinated modulation of these two pathways was necessary for dopamine-mediated acute psychostimulant actions. This modulation, however, shifted to the predominant roles of the direct pathway in reward learning and cocaine sensitization and the indirect pathway in aversive behavior. These two pathways thus have distinct roles: the direct pathway critical for distinguishing associative rewarding stimuli from non-associative ones and the indirect pathway for rapid memory formation to avoid aversive stimuli. As for the role of drugs of abuse on mRNA involved in these pathways, thoughtful exploration, the following map has been developed, yielding for the first time a comprehensive set of gene-based biomarkers (e.g., mRNAs and/or the proteins encoded thereby) one, some, or all of which can be assayed utilizing, for example, array analysis to detect up- or down-regulation depending on the activity or substance (frequently a prescribed drug or drug of abuse) in question for a particular subject. (see Table 2, below).
Example 1
Utilizing GARS
[0145] In this test a Genetic Addiction Risk Score (GARS) is used to identify genes and related mRNA. See U.S. Ser. No. 13/092,894, which is hereby incorporated by reference.
Detailed Embodiment
[0146] Over half a century of dedicated and rigorous scientific research on the meso-limbic system provided insight into the addictive brain and the neurogenetic mechanisms involved in man's quest for happiness. In brief, the site of the brain where one experiences feelings of well-being is the meso-limbic system. This part of the brain has been termed the “reward center”. Chemical messages including serotonin, enkephalins, GABA and dopamine (DA), work in concert to provide a net release of DA at the nucleus accumbens (NAc), a region in the mesolimbic system. It is well known that genes control the synthesis, vesicular storage, metabolism, receptor formation and neurotransmitter catabolism. The polymorphic-versions of these genes have certain variations that could lead to an impairment of the neurochemical events involved in the neuronal release of DA. The cascade of these neuronal events has been termed “Brain Reward Cascade” (see FIG. 1 ). A breakdown of this cascade will ultimately lead to a dysregulation and dysfunction of DA. Since DA has been established as the “pleasure molecule” and the “anti-stress molecule,” any reduction in function could lead to reward deficiency and resultant aberrant substance seeking behavior and a lack of wellness.
[0147] Homo sapiens are biologically predisposed to drink, eat, reproduce and desire pleasurable experiences. Impairment in the mechanisms involved in these natural processes lead to multiple impulsive, compulsive and addictive behaviors governed by genetic polymorphic antecedents. While there are a plethora of genetic variations at the level of mesolimbic activity, polymorphisms of the serotonergic-2A receptor (5-HTT2a); serotonergic transporter (5HTTLPR); (dopamine D2 receptor (DRD2), Dopamine D4 receptor (DRD4); Dopamine transporter (DAT1); and the Catechol-o-methyl-transferase (COMT), monoamine-oxidase (MOA) genes as well as other candidate genes predispose individuals to excessive cravings and resultant aberrant behaviors.
[0148] An umbrella term to describe the common genetic antecedents of multiple impulsive, compulsive and addictive behaviors is Reward Deficiency Syndrome (RDS). Individuals possessing a paucity of serotonergic and/or dopaminergic receptors and an increased rate of synaptic DA catabolism, due to high catabolic genotype of the COMT gene, or high MOA activity are predisposed to self-medicating with any substance or behavior that will activate DA release including alcohol, opiates, psychostimulants, nicotine, glucose, gambling, sex, and even excessive internet gaming, among others. Use of most drugs of abuse, including alcohol, is associated with release of dopamine in the mesocorticolimbic system or “reward pathway of the brain. Activation of this dopaminergic system induces feelings of reward and pleasure [6.7]. However, reduced activity of the dopamine system (hypodopaminergic functioning) can trigger drug-seeking behavior. Variant alleles can induce hypodopaminergic functioning through reduced dopamine receptor density, blunted response to dopamine, or enhanced dopamine catabolism in the reward pathway. Possibly, cessation of chronic drug use induces a hypodopaminergic state that prompts drug-seeking behavior in an attempt to address the withdrawal-induced state.
[0149] Acute utilization of these substances can induce a feeling of well being. But, unfortunately sustained and prolonged abuse leads to a toxic pseudo feeling of well being resulting in tolerance and disease or discomfort. Thus, low DA receptors due to carrying the DRD2A1 allelic genotype results in excessive cravings and consequential behavior. Whereas normal or high DA receptors results in low craving induced behavior. In terms of preventing substance abuse, or excessive glucose craving, one goal would be to induce a proliferation of DA D2 receptors in genetically prone individuals. Experiments in vitro have shown that constant stimulation of the DA receptor system via a known D2 agonist in low doses results in significant proliferation of D2 receptors in spite of genetic antecedents. In essence, D2 receptor stimulation signals negative feedback mechanisms in the mesolimbic system to induce mRNA expression causing proliferation of D2 receptors. This molecular finding serves as the basis to naturally induce DA release to also cause the same induction of D2-directed mRNA and thus proliferation of D2 receptors in the human. This proliferation of D2 receptors in turn, will induce the attenuation of craving behavior. In fact this has been proven with work showing DNA-directed overexpression (a form of gene therapy) of the DRD2 receptors and significant reduction in both alcohol and cocaine craving-induced behavior in animals.
[0150] These observations are the basis for the development of a functional hypothesis of drug-seeking and drug use. The hypothesis is that the presence of a hypodopaminergic state, regardless of the source, is a primary cause of drug-seeking behavior. Thus, genetic polymorphisms that induce hypodopaminergic functioning may be the causal mechanism of a genetic predisposition to chronic drug use and relapse. Finally, utilizing the long term dopaminergic activation approach will ultimately lead to a common safe and effective modality to treat RDS behaviors including Substance Use Disorders (SUD), Attention Deficit Hyperactivity Disorder (ADHD), and Obesity among other reward deficient aberrant behaviors.
[0151] Support for the impulsive nature of individuals possessing dopaminergic gene variants is derived from a number of important studies illustrating the genetic risk for drug-seeking behaviors based on association and linkage studies implicating these alleles as risk antecedents having impact in the mesocorticolimbic system. The prime genes include but are not limited: least one of the RDS-associated alleles is an allele for a gene selected from the group consisting of DRD1, DRD2, DRD3, DRD4, DRD5, DAT1, PPARG, CHREBP, FTO, TNF-alpha, MANEA, Leptin OB, PEMT, MOM, MOAB, CRH, CRHEP, CRHR1, CRHR2, GAL, NPY, NPY1R, NPY2R, NPYY5R, ADIPOQ, STS, VDR, DBI, 5HTTIRP, GABRA2, GABRA3, GABBRA4, GABRA5, GABRB1, GABRB2, GABRB3, GABRD, GABRE, GARG2, GABRG2, GABRG3, GARBQ, SLC6A7, SLC6A11, SLC6A13, SLC32A1, GAD1, GAD2, DB1, MTHFR, VEGF, NOS3, HTR3B, SLC6A3, SLC6A4, COMT, DDC, OPRD1, OPRM1, OPRK1, ANKK1, HTR2A, HTR2C, HTRIA, HTR1B, HTR2A, HTR2B, HTR2C, HTR3A, HTR3B, ALDH1, ALDH2, CAT, CYP2E1, ADH1A, ALDH1B, ALDH1C, ADH4, ADH5, ADH6, ADH7, TPH1, TPH2, CNR1, CYP2E1, OPRKI, PDYN, PNOC, PRD1, OPRL1, PENK, POMC, GLA1, GLRA1, GLRB, GPHN, FAAH, CHRM1, CHRM2, CHRM3, CHRM4, CHRM5, CHRNA4, CHRNB2, ADRA1A, ADRA2B, ADRB2, SLC6A2, DRA2A, DRA2C, ARRB2, DBH, SCL18A2, TH, GR1K1, GRIN1, GRIN2A, GRIN2B, GRIN2C, GRM1, SLC6A4, ADCY7, AVPR1A, AVPRIB, CDK5RI, CREB1, CSNKIE, FEV, FOS, FOSL1, FOSL2, GSKK3B, JUN, MAPK1, MAPK3, MAPK14, MPD2, MGFB, NTRK2, NTSRI, NTSR2, PPP1R1B, PRKCE, BDNF, CART, CCK, CCKAR, CCKBR, CLOCK, HCRT, LEP, OXT, NR3C1, SLC29A1, and TAC1.
[0152] The need to genetically test individuals especially at entry into a residential or even non-residential chemical dependency program has been suggested by scientists and clinicians alike here and abroad. In fact the most recent work of Conner et al. has suggested the importance of multiple hypodopaminergic gene polymorphisms as a possible predictive tool to identify children at risk for problematic drug use prior to the onset of drug dependence. A current exploratory study is in agreement with this prediction in terms of the development of a novel genetic test using an algorithm to determine the proposed GARS. To reiterate, it has been found that a high percentage (75%) of subjects carry a moderate to high GARS whereby 100% of individuals tested posses at least one risk allele tested.
Preferred Embodiment for GARS Test
[0153] The hypodopaminergic state is likely due to gene polymorphisms as well as environmental elements including both stress and neurotoxicity from aberrant abuse of psychoactive drugs (i.e alcohol, heroin, cocaine etc). Genetic variables could include serotonergic genes (serotonergic receptors [5HT2a]; serotonin transporter 5HTIPR); endorphinergic genes (mu OPRM1 gene; proenkephalin (PENK) [PENK polymorphic 3′ UTR dinucleotide (CA) repeats}; GABergic gene (GABRB3) and dopaminergic genes (ANKKI Taq A; DRD2 C957T, DRD4 7R, COMT Val/met substation, MAO-A uVNTR, and SLC3 9 or 10R). Any of these genetic and or environmental impairments could result in reduced release of dopamine and or reduced number of dopaminergic receptors.
RDS Gene Panel Based on Meta-Analysis 1
[0154]
[0000]
Gene
Significance
Comment
ALDH2**
P = 5 × 10 −37
With alcoholism and alcohol-
induced medical diseases
ADH1B**
P = 2 × 10 −21
With alcoholism and alcohol-
induced medical diseases
ADH1C**
P = 4 × 10 −33
With alcoholism and alcohol-
induced medical diseases
DRD2*
P = 1 × 10 −8
With alcohol and dug abuse
DRD4*
P = 1 × 10 −2
With alcohol and drug abuse
SLC6A4
P = 2 × 10 −3
With alcohol, heroin, cocaine,
methamphetamine dependence
HTRIB*
P = 5 × 10 −1
With alcohol and drug abuse
HTRI2A*
P = 5 × 10 −1
With alcohol and drug abuse
TPH*
P = 2 × 10 −3
With alcohol and drug abuse
MAOA*
P = 9 × 10 −5
With alcohol and drug abuse
OPRD1**
P = 5 × 10 −1
With alcohol and drug abuse
GABRG2**
P = 5 × 10 −4
With alcohol and drug abuse
GABRA2*
P = 7 × 10 −4
With alcohol and drug abuse
GABRA6**
P = 6 × 10 −4
With alcohol and drug abuse
COMT*
P = 5 × 10 −1
With alcohol and drug abuse in
Asians
DAT1*
P = 5 × 10 −1
With alcohol and drug abuse in
Asians
CNR1*
P = 5 × 10 −1
With alcohol and drug abuse
CYP2E1**
P = 7 × 10 −2
With alcohol LIVER DISEASE
[0155] Therefore utilizing GARS the mRNA outcome test for each patient follows the GARS diagnosis as they enter the treatment facility or primary care program.
[0000]
TABLE 2
Substances/Activites of choice
This table describes genes (and gene products, eg., mRNA or protein) that can be analyzed in the context
of the invention with respect to various substances or activites of choice before and/or after ingestion or undertaking.
Substance or Activity
mRNA increase
mRNA decrease
Citation(s)
high fat food (HFF)
46% increase in TrkB in the VTA after 30 min of
38% decrease in BDNF in VTA after 60 min of HFF
[1] Cordeira, et al.; J Neurosci 2010 Feb 17;
HFF consumption [1]
consumption [1]
30(7): 2533-41
Anorexigenic Cart upregulated 1.3-fold and Pomc
Orexigenic Agrp downregulated 3-fold, NPY 0.57-fold
[2] Lee, et al.; Nutrition 2010 Apr; 26(4):411-22
1.4-fold in hypothalamus [2]
in hypothalmaus by HFF [2]
[3] Tsuneki, et al.; Acta Physiol (Oxf) 2010
D2 receptor and/or the caudate putamen [4]
Orexin receptor 2 in the hypothalamus [3]
Mar;198(3): 335-48
D4 receptor and/or the ventromedial
[4] Huang, et al.; Brain Res Mol Brain Res.
hypothalamic nucleus and ventral part of lateral
2005 Apr; 135(1-2): 150-61
spetal nucleus [4].
nor-binaltorphimine (opioid
prodynorphin (PDYN) in NAc of DBA/2J and
PENK (lower in DBA/2J and SWR/J than in
[1] Gieryk, et al.; Psychopharmacology (Berl)
receptor antagonist)
SWR/J mice (higher than C57BL/6J) [1]
C57BL/6J) [1]
2010 Feb; 208(2): 291-300
housing and cognitive
amygdala KOR and DOR opioid receptors;
[1] Kalbe, et al.; Genes Brain Behav 2010
enrichment
hypothalamic neuropeptide Y 5 receptor (NPY5R) [1]
Feb; 9(1): 75-83
morphine
Mu recpetors in mediobasal hypothalamus;
Mu receptors in NAc, caudate putamen (CPu), PAG;
[1] Le Merrer, et al.; Physiol Rev 2009
Kappa receptors in MBH; Penk in HPC,
Kappa receptors in NAc, striatum, PAG; Penk in
Oct; 89(4): 1379-412
whole cortex, spinal cord; Pdyn or Dyn in
NAc, CPu, HPT (PVN), FrCx, medula oblongata
[3] Salas, et al.; Brain Res Bull. 2007 Jul
CPu and NAc [1]
(MO), nucleus paragigantocellularis; POMC in MBH
12; 73(4-6): 325-9
Gpr88, Sgk, Cap1, PSD95, CamKII, DRD1A,
and Arc, as well as HPT when withdrawl was precipitated
[4] Liu, et al.; Neuroscience 2005 ; 130(2): 282-8
Grm5, Adora2a, Homer1, Cnr1, Gpr6 [2]
by naltrexone; Pdyn or Dyn in CPu and NAc [1]
[5] Romualdi, et al.; Neuroreport 2002 Apr
hsp90beta [3]
16; 13(5): 645-8
ProorphaninFQ/N in nucleus accumbens,
CryB, CCK, Aq4, Gpr123, Gpr5, Gal [2]
temporo-parietal cortex and striatum area in
Chronic administraion caused decrease of proorphaninFQ/N in striatum
response to single injection 10 mg/kg. Chronic
and nucleus accumbens [5]
administraion caused significant increase in
ventral tegmental area [5]
morphine withdrawl
Mu receptors in NAc, CPu, LH; Penk in striatum
Penk in cpu, NAc, pons, spinal cord; depending on
[1]Le Merrer, et al.; Physiol Rev 2009
and HPT; POMC in pituitary [1]
how withdrawl was induced (spontaneously or by injecting an
Oct; 89(4): 1379-412
orexin in lateral hypothalamus of Fischer 344
opioid antagonist), a decrease or no change in Penk expression
[2]Zhou, et al.; 2008 Neuroscience
inbred rats (w/ no change in ppDyn) [2]
measured in rostral PAG [1]
[4] Bice, et al.; Mamm Genome 2008
POMC in anterior pituitary, mu opioid receptor
Alpha-synuclein in mouse basolateral amygdala, dorsal striatum, nucleus
Feb; 19(2): 69-76
in lateral hypothalamus, nucleus, nucleus
accumbens, and ventral tegmental area [6]
[5]Zhou, et al.; J Endocrinol. 2006
accumbens core, and caudate-putamen; orexin
Oct; 191(1): 137-45
in lateral hypotalamus [5]
[6] Ziolkowska, et al.; J Neurosci. 2005 May
18; 25(20): 4996-5003
ethanol
Mu receptors in inferior colliculus; Penk
Mu receptors in HPT in both alcohol preferring and
[1] Le Merrer, et al.; Physiol Rev 2009
expression in PVN; POMC in MBH after 3
non-preferring following chronic ethanol; Kappa receptors in
Oct; 89(4): 1379-412
weeks of gradual removal of ethanol; Pdyn in
VTA and NAc following chronic ethanol; Penk in striatum,
[2] Kuzmin, et al.; Brain Res 2009 Dec 11; 1305
HPC; Pdyn in CPu, Tu, and NAc in response to
Pir, and Tu. Penk expression decreased in VMH; POMC in MBH;
[3] Mendez, et al.; J Mol Neurosci 2008
ethanol withdrawl [1]
Pdyn in HPT, hippocampus [1]
Mar; 34(3): 225-34
proenkephalin in caudate-putamen [3]
pronociceptin (PNOC), 1.7-fold in hippocampus of alcoholics
[4] Vasdasz, et al.; Genomics 2007
cAMP-PKA signaling in prefrontal cortex, lateral
opiate receptor-like 1 (OPRL-1) 1.4-fold in amygdala of alcoholics [2]
Dec; 90(6_: 690-72
and medial septum, basolateral amygdala,
proenkephalin in substantia nigra pars compacta and pars reticulata [3]
[5] Asyyed, et al.; Brain Res. 2006 Aug
paraventricular and anterior hypothalamus,
Drd2 in nucleus accumbens and hippocampus [4]
23; 1106(1): 63-71
centromedial thalamus, CA1region of hippocampus
Pro-opiomelanocortin mRNA expression of beta-endorphin neurons in
[6] Salinas, et al.; J Neurochem 2006
and denate gyrus, substantia nigra pars compacta,
the arcuate nucleus of rats [7]
Apr; 97(2): 408-15
ventral tegmental area, geniculate nucleus and superior
All GABA receptor subuntis, 4 of 5 subunits of different glutamate
[7] Checn, et al.; J Neurochem 2004
colliculus [5]
receptors, and 7 enzymes involved with GABA and glutamate production
Mar; 88(6): 1547-54
Cart in nucleus accumbens (effect blocked by both SCH-
(GAD-65, GAD-67, glutaminase, glutamate dehydrogenase, glutamine
[8] Eravci, et al.; Br J Pharmacol. 200
23390 and raclopride pretreatment) [6]
synthetase, asparate aminotransferase (cytosolic and mitochondrial),
Oct; 131(3)423-32
PENK in nucleus accumbens 1 h after onset of
cytochrome oxidase subunit III, VIc, ATP synthase subunits A and C, Na K
[9] Li, et al.: Brain Res 1998 May 25; 794(1):
intragastric infusion [9]
ATPase subunit alpha 1 and beta 1)) were reduced almost exclusively in the
35-47
parieto-occipital cortex [8]
cocaine
Mu receptors in NAc and rostral cingulate cortex; Increased
Decreased kappa receptor expression in NAc and VTA when cocaine
[1] Le Merrer, et al.; Physiol Rev 2009
Penk in CPu, NAc*; Pdyn in CPu, denate gyrus of HPC [1]
administered alone or in combination with ethanol; Kappa receptors
Oct; 89(4): 1379-412
micro-RNA miR-181a in mesolimbic dopaminergic system [2]
decreased in SN under chronic binge cocaine (but not after withdrawl);
[2] Chandrasekar et al 2009
NRXN3 beta expression in the globus pallidus [4]
hypothalamic Pdyn [1]
[3] Zhou et al 2008 Neuroscience
CART in sublenticular extended amygdala [5]
micro-RNAs miR-124, let-7d in dopaminergic reward system, leading to
[4]Kelai et al.; Neuroreport 2008 May
Chronic cocaine upregulates En1 [6].
downregulation of BDNF and D3R [2]
7; 19(7): 751-5
CD81 (tetaspanin transmembrane protein involved in cell
orexin after cocaine place conditioning in lateral hypothalmus of Spraugue-
[5] Fagergren, et al.; hysiol Behav 2007 Sep
adhesion) in nucleus accumbens following acute cocaine
Dawley rats [3]
10; 92(1-2): 218-25
treatment. [8]
Chronic cocaine downregulates Nurr1 and Pitx3 [6].
[6] Riva, et al.; Exp Neurol 2007
Dynorphin in medial caudate putamen [9]
Prodynorphin in animals with perinatal drug exposure [10]
Feb; 203(2): 472-80
CART in amygdala [10]
Tyrosine hydroxylase in midbrain [12]
[7] Hall, et al.; Neuropsychopharmacology.
D3 receptor in nucleus accumbens increased 6-fold in cocaine
2003 Aug; 28(8)1485-90
overdose victims [11]
[8] Brenz, et al.; Mol Cell Neurosci 2001
Dopamine receptors; preprodynorphin and preproenkephalin;
Feb;17(2): 303-16
dynorphin in striatum, enkephalin in both frontal cortex and
[9] Werme, et al.; Eur J Neurosci 200
striatal areas [12]
aug;12(8): 2067-74
[10] Hurd, et al.; Ann NY Acad Sci 1999 Jun
29; 877: 499-506
[11] Segal, et al.; Brain Res Mol Brain Res
1997 May; 45(2): 335-9
[12] Chai, et al.; J Neurosci 1997 Feb
1; 17(3): 1112-21
cocaine withdrawl
Mu receptors in frontal cortex; Pdyn in CPu [1]
Penk in CPu and NAc, VMN, CeA; Pdyn in CPU [1]
[1] Le Merrer, et al.; Physiol Rev 2009
orexin and ppDyn in the lateral hypothalamus [2]
Oct; 89(4): 1379-412
[2] Zhou et al 2008 Neuroscience
Amphetamine
Penk in frontal cortex; Pdyn in AMG [1]
Penk in CeA and anterior medial CPu [1]
[1] Le Merrer, et al.; Physiol Rev 2009
mGluR8 in rat dorsal and ventral striatum, as well as cortex,
GluR1 in nucleus acumbens shell, GluR2 in core and shell [3]
Oct; 89(4): 1379-412
inc. cingulate and sensory but not piriform cortex (increase
[2] Parelkar et al.; Neurosci Lett. 2008 Mar
sustained up to 21 days of withdrawl) [2]
15; 433(3): 250-4
After 3 days of withdrawl, GluR1 in PFC [3]
[3] Lu, et al.; Synapse 1999 May; 32(2): 119-31
amphetamine withdrawl
Mu receptors in VTA; Pdyn in CPu and NAc [1]
[1] Le Merrer, et al.; Physiol Rev 2009
Oct; 89(4); 1379-412
Chronic nicotine treatment
Mu receptors in VTA; POMC in Arc; POMC in AL of the
POMC in MBH which was observed after 21 days of spontaneous
[1] Le Merrer, et al.; Physiol Rev 2009
pituitary; Pdyn in CPu after nicotine withdrawl; Pdvn in HPT [1]
withdrawl from nicotine; Pdyn in ventral shell of NAc [1]
Oct; 89(4): 1379-412
c-fos in bed nucleus of stria terminalis, nucleus accumbens shell
Dopamine D2 receptor and tyrosine hydroxylase in PC12 clonal cell line
[2] Naha et al 2009
and VTA. c-fos in central amygdala, locus coeruleus, nucleus
from chromaffin adrenal cells [2]
[3] Shram, et al.; Neurosci Lett. 2007 May
accumbens, paraventricular nucleus of hypothalamus, and lateral
18; 418(3): 286-91
septum [3].
[4] Walters, et al.; Neuron 2005 Jun
CREB phosphorylation when exposed to situation where
16; 46(6); 933-43
previous nicotine reward was experienced [4]
[5] Leslie, et al.; Ann NY Acad Sci. 2004
MOR expression [4]
Jun; 1021: 148-59
c fos in limbic regions of adolescents [5]
Alcohol cessation
delta receptor transcripts in striatum of alcohol-avoiders[1]
[1] Le Merrer, et al.; Physiol Rev 2009
Oct; 89(4): 1379-412
Cannabinoid agonists (THC,
Increased Penk in NAc and CPu, Tu and Pir, HPT (both PVN
[1] Le Merrer, et al.; Physiol Rev 2009
CP-55,940 or R-
and VMH), mammillary area and PAG; Increased POMC in Arc,
Oct; 89(4): 1379-412
methanandamide)
lasting up to 14 days following cessation [1]
cannabinoid withdrawl
Penk in CPu, NAc, Tu, Pir. [1]
[1] Le Merrer, et al.; Physiol Rev 2009
Oct; 89(4): 1379-412
Kappa receptor agonists (U-
Pdyn in HPT [1]
Pdyn in CPu, HPC, FrCx HPT [1]
[1] Le Merrer, et al.; Physiol Rev 2009
69593 or U-50, 488H)
Oct; 89(4): 1379-412
Methamphetamine
Pdyn in HPT [1]
Animals that are TNF-alpha (−/−) have attenuated meth-induced increases
[1] Le Merrer, et al.; Physiol Rev 2009
Increased TNF-alpha in normal animals [2]
in extracellular striatal DA [2]
Oct; 89(4): 1379-412
[2] Nakajima, et al.; J Neurosci. 2004 Mar
3; 24(9): 2212-25
food (effects on hypothalamic
Deprivation upregulated FTO [1]
[1] Olszewski, et al.; BMC Neurosci 2009 Oct
FTO)
27; 10: 129
Leucine
FTO in hypothalamus of rodents [1]
[1] Olszewski, et al.; BMC Neurosci 2009 Oct
27; 10: 129
dual orexin receptor atagonist
Inhibits ability of subchronic amphetamine to produce
[1] Winrow, et al.; Neuropharmacology 2010
(DORA) -antagonist of OX1R
behavioral sensitization and blocks alteration of gene expression
Jan; 58(1): 185-94
and OX2R
levels in response to amphetamine exposure (particularly those
associated with synaptic plasticity in the VTA). DORA attenuates
the ability of nicotine to induce reinstatement of extinguished
responding for reinforcer [1]
Aging
orexin-receptor 2 mRNA in hypothalamus [1]
[1] Tsuneki, et al.; Acta Physiol (oxf) 2010
Mar; 198(3): 335-48
CREB
mCREB (a dominant-negative CREB which acts as a CREB
Overexpression of mutant CREB leads to a decrease in dynorphin
[1] Dinieri, et al.; J Neurosci 2009 Feb
atagonist) animals are more sensitive to rewarding effects of
transcription [2]
11; 29(6): 1855-9
cocaine, and insensitive to depressive-like effects of kappa opioid
Blockade of kappa oioid receptors (on which dynorphin acts) antagonizes
[2] Carlezon, et al.; Science 1998 Dec
receptor agonist U50,488 [1]
the negative effect of CREB on cocaine reward [2]
18282(5397): 2272-5
Overexpression CREB in mice leads to increased dynorphin
transcription [2]
dopamine transporter (DAT -
DAT overexpressing rats showed increased impulstivity and risk
[1] Adriani, et al.; Neuroscience 2009 Mar
as influenced by over
proneness - thus reduced dopaminergic tone following altered
3; 159(1): 47-58
expression or silencing in the
accumbal DAT function subserve a sensation-seeker phenotype
nucleus accumbens)
and vulnerability of impulse-control disorders [1]
CREB
CART in the nucleus accumbens [1]
[1] Rogge, et al.; Brain Res 2009 Jan
28; 1251: 42-52
deoxyribozyme 164
[1] ERK and CREB in frontal cortex, hippocampus, and striatum
[1] Li, et al.; Am J Drug Alcohol Abuse 2008;
(DRz164) - cleaves Period
34 (64); 673-82
1 gene (Per1) mRNA.
Injection with DRz164 before
morphine treatment
para-chloroamphetamine (
[1] repeated stress in pre-treated animals led to less
[1] repeated stress in pre-treated rats led to downregulation of BDNF mRNA
[1] Zhou, et al.; Behav Brain Res 2008 Dec
depletes 5-HT)
glucocorticoid receptor increase
16; 195(1): 129-38
predispostion for obesity (
G-alpha q - endogenous negative regulator of VMAT2 [1]
tyrosine hydroxylase, VMAT2, DAT, D2S presynaptic autoreceptor [1]
[1] Geiger, et al.; FASB J . 2008
normal diet)
Aug; 22(8): 2740-6
editing of serotonin 2C
5HT-2C expression and editing in the Nucleus Accumbens shell
[1] Dracheva, et al.;
receptor mRNA (via ADAR
compared with PC and VTA - also in general editing is higher in
Neuropsychopharmacology. 2009
enzyme)
rats with a locomotor high response [1]
Sep; 34(10): 2237-51
Heroin
PENK polymorphic 3′UTR dinucleotide (CA) repeats common in
DAT in paranigral nucleus and mesolimbic division of the ventral tegmental
[1] Nikoshkov, et al.; Proc Natl Acad Sci USA
heroin abuse. Express higher Penk mRNA [1]
area. Reduction of Nurr1expression with age in heroin users [2]
2008 Jan 15; 105(2): 786-91
TH and alpha synuclein in VTA PN in heroin users with no
tyrosine hydroxylase in mesolimbic dopamine neurons [3]
[2] Horvath, et al.; J Neurosci. 2007 Dec
change in the D2 receptor [2]
5; 27(49): 13371-5
Penk; NAc PENK in Met/Met (control) heroin abusers [3]
[3] Nikoshkov, et al.; Proc Natl Acad Sci USA
2008 Jan ;105(2): 786-91
Social isolation
dopamine D2 receptors in Flinders rats [1]
[1] Bjornebekk, et al.; Neuroreport 2007 Jul
2; 18 (10): 1039-43
HSV vector mediated
Elevated GluR1 transcription when delivered GluR1 by vector [1]
Vector-mediated elevated GluR2 leads to decreases in prodynorphin [1]
[1] Todtenkopf, et al.; J Neurosci 2006 Nov
elevations in GluR1 or GluR2
8; 26(45): 11665-9
high or low consumption of
Differences in expression of 5HT2A, mGlu1 in hippocampus, and
Differences in expression of 5HT2A, mGlu1 in hippocampus, and AMPA
[1] Pickering, et al; Neurobiol Learn Mem.
sugar
AMPA GluR1 and adrenergic alpha 2A in PFC. NMDA NR2B,
GluR1 and adrenergic alpha 2A in PFC. NMDA NR2B, GABA Aplha 3 in
2007 Feb; 87(2)181-91
GABA Alpha 3 in PFC and adrenergic alpha2B and alpha2A.
PFC and adrenergic alpha 2B and alpha2A, AMPA, GluR1, GluR2, GluR3,
AMPA, GluR1, GluR2, GluR3, 5HT1B and GABA alpha 5 in
5HT1B and GABA alpha 5 in hippocampus[1]
hippocampus [1]
Leptin receptor expression in
Leptin activates intracellular JAK-STAT pathway and reduction
Direct administration of leptin to VTA caused decreased food intake while
[1] Hommel, et al.; Neuron 2006 Sep
VTA
in firing rate [1]
long-term RNAi mediated knockdown of Lep in VTA led to increased food
21; 51 (6): 801-10
intake [1]
ethanol preference
Gsta4 (glutathione-S-transferase alpha 4) [1]
decreased fatty acid amidohydrolase (FAAH) expression in PFC of alcohol
[1] Bjork, et al.; FASEB J 2006
preferring animals, accompanied by decreased binding of CB1 receptor
Sep; 20(11): 1826-35
ligand (3)[H]SR141716A and [35S]GTPgammaS incorporation stimulated
[2] Hansson, et al.; Neuropsychopharmacology
by the CB1 agonist WIN 55, 212-2. This suggests an overactive
2007 Jan; 32(1): 117-26
endocannabinoid transmission in PFC of alcohol preferring animals and
compensatory downregulation of CB1 signaling. [2]
morphine response (mice)
Differences in opiate response with corresponding differences
Differences in opiate response with corresponding differences in Atp I aw,
[1] Korostynski, et al.; BMC Genomics 2006
in Atp I aw, COMT, Gabra I, GABA-A, Gabra2, Grm7, Kcnj 9,
COMT, Gabra I, GABA-A, Gabra2, Grm7, Kcnj 9, Syt4, Gfap, Mtap2, and
Jun 13; 7: 146
Syt4, Gfap, Mtap2, and Hrpt I [1]
Hprt I [1]
psychostimulant (e.g. cocaine,
CART in ventral tegmental area, nucleus accumbens [1]
[1] Jaworski, et al.; Peptides 2006
amphetamine)
Modulation of CART peptides by psychostimulants may involve
Aug; 27(8): 1993-2004
corticosterone and/or cAMP response element binding protein
(CREB) [1]
forskolin (intra-accumbal
CART - effect attenuated by inhibition of PKA with H89 [N-(2-
[1] Jones, et al.; J Pharmacol Exp Ther. 2006
injection in rat)
[p-bromocinnamylamino]ethyl)-5-isoquinoline-sulfonamide
Apr; 317(1): 454-61
hudrochloride and adenosine-3′,5′ cyclinc monophosphorothioate,
Rp-isomer, OR Rp-cAMPS alone. [1]
intrastiatal infusion of
striatal enkephalin gene expression, an effect that greatly suppresses food
[1] Kelley, et al.; J Comp Nerol 2005 Dec 5;
cholinergic muscarinic
intake [1]
493(1): 72-85
antagonist
Delta-tetrahydrocannabinol
BDNF in reward center (nucleus accumbens, medial prefrontal
Butkovsky, et al.; J Neurochem 2005
cortex and paraventricular nucleus)[1]
May; 93(4); 802-11
zif268, blocked by SL327 an inhibitor of MAPK/ERK kinase, as
[2] Valijent, et al.; Eur J Neurosci. 2001
well as SCH 2339 [2]
Jul; 14(2): 342-52
THC induces a progressive and transient activation
(phosphorylation) of MAPK/ERK in dorsal striatum and nucleus
accumbens. This activation is totally inhibited by selective
antagonist of CBD cannabinoid recptors, SR 141716A. [2]
DeltaFosB
prolonged DeltaFosB expression increased drug reward [1]
[1] McClung, et al; Nat Neurosci 2003
Nov; 6(11): 1208-15
Nandrolone decanoate
Dopamine D(2) receptor at the lowest doeses in the caudate
Dopamine D(1)-receptor subtype in the caudate putamen and nucleus
Kindlundh, et al.; Brain Res. 2003 Jul 25; 979(1-
putamen and nucleus accumbens [1]
accumbens shell (at higher doses) [1]
2): 37-42
Voluntary wheel running in
addicted Lewis rats
Substance P (during morphine
D2 receptor in nucleus accumbens and frontal cortex [1]
Zhou, et al.; Peptides 2003 Jan; 24(1): 147-53
withdrawl)
U99194A (D(3) dopamine
c-fos (similar pattern to that produced by d-amphetamine) in
Carr, et al.; Psychopharmacology (Berl) 2002
receptor antagonist)
caudate-putamen and nucleus accumbens, blocked by SCH-
Aug; 163(1): 76-84
23390 [1]
cocaine, cocaine + nondrolone,
cocaine alone or cocaine nandrolone caused decrease in NR1 in the
[1] Le Greves, et al.; Acta Psychiatr Scand
or nandrolone alone
nucleus assumbens. Combined treatment significantly down-regulated the
Suppl 2002; (412): 129-32
transcript in the periaqueductal gray compared with other groups. [1]
Dextromethorphan
40 mg/kg ip in rats caused increase of tyrosine hydroxylase (TH)
[1] Zhang, et al.; Neurosci Lett. 2001 Aug
mRNA in VTA and substantia nigra [1]
24; 309 (2): 85-8
Running
dynorphin in medial caudate putamen [1]
AMPA receptor [2]
[1] Werme, et al.; Eur J Neursci ‘00
GluR1 in ventral tegmentum [2]
NGFI-B and Nor1 in cerebral cortex [3]
Aug; 12(8): 2967-74
[1] Makatsori, et al.;
Psychoneuroendocrinology 2003 Jul; 28(5):
702-14
[3] Werme, et al.; J Neurosci 1999 Jul
15; 19(14): 6169-74
Amitriptyline
dopamine D3 receptor mRNA in shell of the nucleus accumbens;
[1] Lammers, et al.; Mol Psychiatry 200
D1 and D2 receptors [1]
Jul; 5(4): 378-88
Desipramine
dopamine D3 receptor mRNA in shell of the nucleus accumbens
[1] Lammers, et al.; Mol Psychiatry 200
[1]
Jul; 5(4): 378-88
Imipramine
dopamine D3 receptor mRNA in shell of the nucleus accumbens;
[1] Lammers, et al.; Mol Psychiatry 200
D1 and D2 receptors [1]
Jul; 5(4): 378-88
Tranylcypromine
dopamine D3 receptor mRNA in shell of the nucleus accumbens
[1] Lammers, et al.; Mol Psychiatry 200
[1]
Jul; 5(4): 378-88
electroconvulsive therapy
10 days of treatment led to increased dopamine D3 receptor
[1] Lammers, et al.; Mol Psychiatry 200
mRNA in shell of the nucleus accumbens [1]
Jul; 5(4): 378-88
Fetal alcohol syndrome
c-fos, c-jun, jun B, and zif268 in prefrontal cortex, hippocampal
junB in caudate nucleus [1]
[1] Nagahara, et al.; Alcohol Clin Exp Res 1995
subfields CA1 and CA3 [1]
Dec; 19(6): 1389-97
S(−)- and R (+)- salsolinol
POMC anterior pituitary cell line [1]
[1] Putcher, et al.; Alcohol 1995 Sep-
Decrease in cAMP level occurs after treatment with S(−)-SAL,
Oct; 12(5): 447-52
whereas R(+)- SAL does not affect cAMP production [1]
peripheral nerve injury (
tyrosine hydroxylase and DRD2 in nucleus accumbens (changes
[1] Austin, et al.; Int J Environ Res Public
unilateral chronic constriction
in DRD2 expression were not observed with disability (only with
Health 2010 Apr; 7(4): 1448-66
of sciatic nerve)
pain resulting from injury)) [1]
Alcohol and splice variants
D2L/D2S receptor ratio in the pituitary gland; ethanol
[1] Sasabe, et al.; Int J Environ Res Public
consumption may increase NMDA NR1 isoforms that are weakly
Health 2010 Apr; 7(4): 1448-66
inhibited by ethanol [1]
Example 3
Commonality Test
[0156]
[0000] TABLE 3 Common RDS gene expression of mRNA (based on drug of choice effects) mRNA up mRNA down TrkB Orexigenic Agrp Pomc NPY D4 Orexin receptor 2 prodynorphin (PDYN) KOR Mu receptors DOR Kappa receptors neuropeptide Y 5 receptor (NPY5R) Dyn Gal Gpr88 CryB Sgk Aq4 Cap 1 Gpr123 PSD95, Gpr5 CamKII opiate receptor-like 1 (OPRL-1) DRD1A All 8 GABA receptor subunits Grm5 glutamate receptors Adora2a, ERK Homer1 Na K ATPase subunit alpha 1 and beta 1 Cnr1 GAD-65 Gpr6 [ GAD-67 hsp90beta Glutaminase ProorphaninFQ/N glutamate dehydrogenase Orexin glutamine synthetase cAMP-PKA asparate aminotransferase CART cytochrome oxidase subunit III micro-RNA miR-181a VIc, NRXN3 beta ATP synthase subunits A and C EN1 Nurr1 D3 receptor Pitx3 Preproenkephalin VMAT2 mGluR8 Fatty acid amidohydrolase (FAAH) Glu1 AMPA receptor MOR CB1 CREB phosphorylation NR1 c fos Nor1 delta receptor NGFI-B FTO ANK11-kinase (Ala239) glucocortoid receptor Neurotensin G-alpha q - endogenous negative regulator of VMAT2 5HT-2c TH alpha synuclein intracellular JAK-STAT Gsta4 (glutathione-S-transferase alpha 4) BDNF i DeltaFosB Dopamine D(2) receptor tyrosine hydroxylase alpha 6 subunit in catecholaminergic nuclei c-jun jun B, zif268 CCK Neurotensin dopamine reuptake transporter COMT MAO-A, Slc12a6 Dlgap2 Etnk1 Palm Sqstm1 Nsg1 Akap9 Apba1 Stau1 Elav14 Kif5a Syt1 Hipk2 Araf, Cmip NMDA NR1
Methods for Detecting mRNA
[0157] This invention involves the collection of any cell-containing tissue (e.g., blood, skin, saliva, a buccal swab, hair, etc.) for extraction of mRNA or protein by any appropriate method.
Whole-Genome Gene Expression Profiling
[0158] In one embodiment, a strategy of detailed time-course studies of gene expression alterations following pre- and post entry to residential and or non-residential treatment using Illumina Whole-Genome 6 microarrays. To analyze the dynamics of early, intermediate and relatively late changes in mRNA abundance, the analysis will be performed at different time points for example: upon entry; two weeks, 4 weeks and during recovery.
[0159] Support for this methodology is based on microarray data analysis using two-way ANOVA identified 42 drug-responsive genes with P<1×10 −6 (corresponding to P<0.05 after adjusting for approximately 48,000 independent tests using Bonferroni correction). Compared to other gene expression profiling studies, the statistical threshold was rather conservative. However, the same threshold is widely accepted in population genetic and genome-wide association studies in humans. The difference between the methodological standards may result from the number of samples and biological replicates usually used in these two types of whole-genome studies.
[0160] In one study, the maximum number of true positive genes altered in the striatum by drugs of abuse (drug factor, 104 transcripts) was found at a 29% FDR. Beyond that level, the number of true positives did not increase. Surprisingly, the number of true positives remained stable (84 to 104 transcripts, mean=94.4±4.9) over a wide range of FDR (4.7 to 56.3%). The results for the drug factor are in contrast to alterations in the striatal gene expression profile related to the time point of the experiment (time factor). The maximum number of true positive genes (5,442 transcripts) for the time factor was found at a 69.8% FDR and increased linearly in the range 0.1 to 69.8% FDR. The above observations suggest a rather unexpected conclusion. While the diurnal cycle alters a vast fraction of the brain transcriptome, drugs regulated the expression of a limited number of genes (approximately 100), and this alteration was robust. The number of genes obtained using Bonferroni correction (42 transcripts) was equal to the number of genes obtained at a 0.1% FDR threshold. Therefore, at the chosen threshold, we identified 40.3% (42 of 104 transcripts) of genes altered by drugs of abuse with 99.9% confidence.
[0161] The changes in mRNA abundance of selected marker genes were validated by quantitative PCR (qPCR) using aliquots of the non-pooled total RNA. (yielding an overall correlation between the microarray and qPCR results of r=0.69 (Spearman's method, P=4.87×10 −24 ). The alterations in mRNA level were also confirmed in an independent experiment. In addition, the expression of the selected genes was evaluated during the acquisition and expression of morphine-induced CPP.
[0000] Correlation with Behavioral Drug Effects
[0162] To link the gene expression patterns with drug-related phenotypes, others have analyzed the correlations between the transcriptional and behavioral drug effects in mice. Mutual interactions between the brain gene expression and behavioral profiles are complex and multidimensional. Therefore, it is difficult to define them using analyses performed with only the few available data points. However, even speculative results obtained from this analysis create the unique possibility of assigning different transcriptional alterations induced by various drugs to drug-related phenotypes. A positive correlation of r=0.62 (Pearson's method, P<0.001) was observed between the level of drug-induced locomotor activation and the degree of transcriptional response of gene expression pattern A. Additionally, a significant correlation between the acute induction of B 1 genes and the rewarding effect of the drug (r=0.7, Pearson's method, P<0.05, was found. This provides confidence that gene expression induced by various drugs are linked to expected behaviors, including RDS behaviors.
[0000] Evaluation of Two Drug-Regulated Genes at the mRNA and Protein Levels
[0163] Western blotting has been used to determine whether the changes in gene expression are translated into alterations in protein levels. As such, the morphine-induced increase in Sgk1 abundance as been associated with a significant decrease in the level of the protein (0.75-fold). Therefore, Sgk1 expression changes might be a compensatory effect to the loss of the protein. Up-regulation of Tsc22d3 has been associated with an increase in the corresponding protein level (approximately 1.5-fold;). Double-immuno-fluorescence labeling with neuronal (NeuN) and astroglial (S100B) markers have been used to identify cells that expressed SGK (Sgk1) and GILZ (Tsc22d3) proteins. In the mouse striatum, both genes appeared to be expressed mainly in neurons.
[0164] The above methodology is presented as an example of how it is feasible to develop assays for the relationship between drugs of abuse and behavioral effects that will lead to a test to determine treatment outcome.
CONCLUSION
[0165] The genetic tests described herein are important for understanding treatment response in any given RDS scenario. While it is not specific for any drug of abuse in terms of treatment program it will be useful for providing important info regarding not only drug abuse treatment but programs involved in treatment of food cravings and obesity. In one example, along with the potential solution involving the formulation KB220Z, information related to an understanding of why this complex could affect mRNA expression in a number of well-known pathways. See U.S. Pat. No. 6,955,873.
[0166] An overwhelming segment of the world's population possesses certain genetic variations that increase risk for genetic predispositions that preclude them from reaching their optimum health potential, contribute to impaired health, and/or can cause involuntary indulgence in detrimental and self-destructive behaviors. This is especially true for products that empower individuals to successfully overcome compulsions and excessive cravings, like those that lead to unwanted and unhealthy weight gain, and other health woes that burden society (i.e. addictions, depression, and other related problems).
[0167] It is believed that the genesis of all behavior, whether so-called normal (socially acceptable) or abnormal (socially unacceptable) behavior, derives from an individual's genetic makeup at birth. This predisposition, due to multiple gene combinations and polymorphisms, is expressed differently based on numerous environmental elements. It is further believed that the core of predisposition to these behaviors is a set of genes, which promote a feeling of well-being via neurotransmitter interaction at the “reward site” of the brain (located in the meso-limbic system), leading to normal dopamine release and influencing dopamine receptor density. The DRD2 gene is responsible for the synthesis of dopamine D2 receptors. And, further depending on the genotype (allelic form A1 versus A2), the DRD2 gene dictates the number of these receptors at post-junctional sites.
[0168] A low number of D2 receptors suggest a hypodopaminergic function as manifested in addictive disorders. When there are a low number of dopamine receptors, the person will be more prone to seek any substance or behavior that stimulates the dopaminergic system (a sort of “dopamine fix”). To understand generalized craving behavior, due to hypodopaminergic function, individuals self-medicate through biochemical (illicit or non-illicit) attempts to alleviate or compensate for the low dopaminergic brain activity via drug-receptor activation (alcohol, heroin, cocaine, glucose, etc.). This will substitute for the lack of reward and yield a temporary compensatory sense of well-being. In order to help explain this so called pseudo self-healing process, it is germane that the reinforcing properties of many drugs of abuse may be mediated through activation of common neurochemical pathways, particularly with regard to the meso-limbic dopamine system and as such these drugs will have profound influence on gene expression thereof.
[0169] In predisposed genotypes, gene polymorphic expression (and resulting aberrant behavior) is amplified in response to chronic nutritional deficiencies from habitual dietary patterns that are chronically unable to meet the greater nutrient needs mandated by those polymorphisms manifesting as RDS. In this regard, glucose, opiates, nicotine, cocaine, tetrahydrocannabinol (THC), and ethanol (among others) have been shown to directly or indirectly enhance release or block re-uptake of dopamine. These findings suggest the importance of genotyping polymorphisms of the dopaminergic and other reward pathways to develop a ‘genetic positioning system’ map (GPS). To date, there are numerous clinical trials showing various recovery benefits from RDS behaviors using KB220.
[0170] The results of these studies support an interaction of KB220 and meso-limbic activation leading to “normalization” of abnormal dopaminergic function in anticipation of patients carrying a number of reward gene polymorphisms. It appears that KB220 is the only natural “Dopamine Agonist” without any negative side-effects that are common among pharmaceutical medications. In fact, KB220 has been able to demonstrate that it was able increase the positive effects of alpha and low beta activity in the Parietal regions of the brain compared to placebo. The fact that KB220 induced an increase in both alpha and low beta activity seems to mimic the protocol used in neurofeedback to treat alcoholics. This indicates that KB220 “normalizes” brain abnormalities associated with drug dependency (alcohol, heroin and psycho stimulants) induced because of dopaminergic deficiency by acting as a Dopaminergic receptor agonist during extended abstinence in polydrug abusers.
[0171] Clinicians are interested in the potential of increasing the number of DR2R that long-term activation of dopaminergic receptors (i.e., DRD2 receptors) by KB220 should accomplish. This phenomena will lead to enhanced “dopamine sensitivity”, greater self-control, and an increased sense of happiness. However, to date there is no outcome measure that definitively enables real objective assessment of patients in terms of outcome. Using the concept of treating RDS victims with KB220Z, as one example of treatment, the methods herein provide novel information for the first time ever.
[0172] Thus, the coupling of these methods as way to display the actual role of treatment will provide a descriptive gene expression and/or protein map.
[0173] All patents, patent applications, and publications mentioned in the specification are indicative of the levels of those of ordinary skill in the art to which the invention pertains. Each patent, patent application, and publication cited herein is hereby incorporated by reference in its entirety for all purposes regardless of whether it is specifically indicated to be incorporated by reference in the particular citation.
[0174] The invention illustratively described herein suitably may be practiced in the absence of any element(s) not specifically disclosed herein. Thus, for example, in each instance herein any of the terms “comprising”, “consisting essentially of”, and “consisting of” may be replaced with either of the other two terms. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. | The present invention relates to methods to objectively assess treatment outcomes in Reward Deficiency Syndrome (RDS) behaviors by obtaining expression profiles (e.g., mRNA expression and/or protein expression profiles) for one or more genes at two or more different time points, for example, before and after treating a subject known to have or suspected of having an RDS affliction. Analysis, for example, of mRNA and/or protein expression levels and/or patterns can be conducted before admission to a treatment facility, followed by testing at one or more various designated times during and after a subject's treatment. Such methods may also be combined with other tests, and can be used in diagnosis and treatment of RDS and RDS behaviors, including drug and/or alcohol abuse and addiction, overeating, gambling, sexual addiction, etc. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a sealing gasket adapted to be interposed between the cover and the frame of a roadway manhole accessing an underground system, particularly a municipal sewage disposal system.
Local ordinances frequently require that roadway manholes accessing sewage disposal systems be sealed to prevent rain water or the like from trickling into the system and thus overloading sewage treatment stations. One approach has been to interpose a simple, sufficiently flexible gasket, for example made of an elastomer having a hardness of between 45° Shore and 60° Shore, between the cover and the frame of the manhole so that it fits snugly against their rough cast surfaces. If the cover is not locked to the frame, however, for example by appropriate edge clamps or a bayonet coupling, the movements of the cover within the frame tend to shear the gasket and thus disrupt its sealing effect. This problem may be offset or at least partially overcome by making the gasket from a harder elastomer on the order of 70° Shore to 80° Shore, but such increased hardness detracts from its sealing effect.
Another approach is to lock the cover to the frame to prevent it from moving, thus reducing the shearing effect on the gasket. For example, U.S. Pat. No. 4,203,686 teaches a roadway manhole in which the cover is held in the frame by a locking ring laid against the upper surface of the cover and having bearing surfaces located opposite corresponding surfaces of the frame. The gasket is interposed between the frame and the cover, and is compressed when the ring is rotated to lock the cover to the frame. Such a construction requires a costly and difficult to fabricate locking mechanism, however, and moreover the frictional forces between the various components are often insufficient to prevent the cover from rotating and thus abrading the gasket upon the passage of a vehicle.
SUMMARY OF THE INVENTION
The present invention is intended to overcome these problems by providing a gasket for an unlocked roadway manhole which establishes and maintains a sufficient seal to prevent the entry of rain water and which withstands the shearing movements of the unlocked cover relative to the frame. More specifically, the gasket, when viewed in cross-section, has a vertical branch extended at its upper end by an outwardly radial horizontal branch which is interposed between facing or bearing surfaces of the cover and the frame. The upper surface of the horizontal branch is provided with two spaced, frustoconical lips converging towards the base of the gasket, and a pair of oppositely extending lips are also preferably provided at the lower end of the vertical branch of the gasket.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial view, in axial section, of a roadway manhole equipped with a gasket in accordance with the invention, and
FIG. 2 is an axial section, on a larger scale, of the gasket in its free or unloaded state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the roadway manhole includes a cover 2 nested or seated in a frame 1, and a gasket 3 interposed between the cover and the frame. The construction is preferably circular about a vertical axis X--X, but it could also be triangular, rectangular or polygonal in shape.
The frame 1 may be made of nodular graphite iron and comprises a continuous skirt 4 extending vertically upwards from a horizontal bearing flange 5 which rests on the top of a shaft (not shown) forming the manhole. A radial collar 6 extends inwardly at the approximate lower third of the skirt, and defines upper and lower faces 7, 8 joined by an inner surface 9 having a slight conicity converging towards the bottom of the frame. The upper face 7 is frustoconical and converges towards the top of the frame, forming an acute angle with the inner surface or face 9 and being joined to the skirt 4 by a fillet 10.
The cover 2 comprises a bowl-shaped structure 11 made of nodular graphite iron and filled with concrete B. It includes a cylindrical upper skirt 12 having an outside diameter less than the inner diameter of the frame skirt 4 but greater than the inner diameter of the frame collar 6. The cover skirt 12 is extended at its lower end by a horizontal bearing surface 13 located at the mid-height of the cover and joining the upper skirt to a lower skirt 14 having an outside diameter less than the inner diameter of the collar 6.
The gasket 3 of the invention is made of an elastomer having a hardness of between 70° Shore and 85° Shore, is circular about the axis X--X, is closed, and has a constant cross-section. It comprises vertical and horizontal branches 15, 16 provided with upper lips 18, 19 and lower lips 17, 20.
As shown in FIG. 2, the vertical branch 15 defines an outer cylindrical surface 21 having a diameter d1 and an inner cylindrical surface 22 having a diameter d2. The branch 15 is extended at its bottom by an outer lip 20 and an inner lip 17. The approximately horizontal outer lip defines a plane or slightly curved upper face 23 and a lower frustoconical face 24 joined by a further frustoconical face 25 converging towards the base of the gasket. The surfaces 21 and 23 are approximately perpendicular. The inner lip 17 has a frustoconical upper face 26 converging downwardly and extending the cylindrical surface 22, and rounding or merging into the surface 24. The angles of the surfaces 24 and 26 relative to the axis X--X are such that the lip 17 tapers towards its end.
The vertical branch 15 is extended at its upper end by a radially outwardly directed, substantially horizontal branch 16 having an upper frustoconical face 27 and a lower curved face 28, the upper face 27 converging towards the top of the gasket. The lower face 28 directly adjoins the outer cylindrical surface 21 of the branch 15, and the upper face 27 adjoins the inner cylindrical surface 22 of the vertical branch via the lip 19 and a curved surface 29. The upper frustoconical face 30 of the lip 19 is tangent to the curved surface 29 and forms an angle T with the axis X--X of about 75°. The lower face 31 of the lip forms a slightly smaller axial angle, thus imparting a slight taper to th lip.
In the radially outward direction the faces 27 and 28 of the horizontal branch 16 are extended by a bead 32 defining a curved upper and side face 33 and an upwardly converging frustoconical lower face 34. The tapered lip 18 extends upwardly and outwardly from the curved face 33 of the bead, and defines downwardly converging frustoconical surfaces 35 and 36. The upper surface 35 of the lip 18 is substantially parallel to the upper surface 30 of the lip 19.
Referring back to FIG. 1, the inner diameter of the frame skirt 4 is less than the outer diameter of the lip 18 of the unloaded gasket and greater than the outer diameter of the bead 32. The outer diameter of the cover skirt 14 is less than the diameter d2 of the gasket surface 22 but greater than the inner diameter of the gasket lip 17, and the diameter d1 of the gasket surface 21 is less than or equal to the inner diameter of the frame collar 6. Finally, the angle of the gasket surface 34 to the axis X--X is less than the angle between the upper surface 7 of the frame collar and the axis.
With such a construction or configuration, when the gasket 3 is fitted onto the frame by pushing it down over the radial collar 6, the lower bead surface 34 engages the upper collar surface 7 and the upper ledge or shoulder surface 23 of the lower lip 20 hooks under the lower collar surface 8. The horizontal branch 16 of the gasket thus bends or deforms upwardly at its neck portion between surfaces 27 and 28, with the bead 32 rising, the angle between surfaces 34 and 21 becoming larger, and the surface 27 curving. The lip 18 is thus no longer parallel to the lip 19, and is disposed in sealing contact with the inner surface of the frame skirt 4.
Once the gasket has been so installed, the cover 2 is lowered into the frame 1 and onto the gasket, which compresses the bead 32 and bends the lip 19 into sealing contact with the bearing surface 13 of the cover. The lower lip 20 forms a barrier seal with the frame collar 6, and the lower lip 17 forms a final barrier seal with the cover skirt 14. Since the deformation of the lip 17 causes an increase in the pressure exerted by the faces 21 and 23 of the gasket against the faces 9 and 8 of the frame collar, the integrity of the seal is further enhanced in this region. The gasket of the invention thus establishes a tight and sustained seal between the manhole frame and its cover, while at the same time experiencing no appreciable deterioration and damage due to vehicle induced movements of the cover relative to the frame. | A sealing gasket for an unlocked roadway manhole accessing a municipal sewage system is interposed between a cover 2 and a frame 1, and has an inverted L or hook-shaped cross-section including two spaced and parallel outwardly extending upper lips 18, 19 and two lower, oppositely extending lips 17, 20. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of application Ser. No. 11/017,488, filed Dec. 20, 2004, based on Provisional application Ser. No. 60/532,163, filed Dec. 23, 2003.
FIELD OF THE INVENTION
[0002] The present invention generally relates to controlling the adjustable gloss of an image printed on various substrates. The present invention also generally relates to creating 3-D imaging effects by controlling the adjustable gloss of a printed image.
BACKGROUND OF THE INVENTION
[0003] A fused toner image is an image formed by toner particles that are melted by heating so as to adhere to the media substrate. Gloss is related to a quantity of light reflectance that can be measured with a gloss meter. Gloss may be controlled by selecting a defined fusing temperature, with higher fusing temperatures, giving higher gloss and lower fusing temperatures giving lower gloss. The amount of gloss enhancement with the conventional fuser temperature control method, however, is limited. Moreover, adjustable gloss between various parts of the image is not possible, as the entire image must be heated uniformly by the fuser.
[0004] In high-speed, high-quality electrophotographic printing applications, it may be desirable to get higher gloss on, for example, the pictorial areas as compared to the text areas. This may be achieved by selectively applying a gloss enhancing toner on the pictorial areas, as disclosed by Ng in U.S. Pat. No. 5,234,783, herein incorporated in its entirety by reference.
[0005] However, in order to gloss-up (that is, increase the gloss of the finished printed image) the pictorial areas, a low viscosity (e.g., about 1300 poise) gloss enhancing toner must be used. There are limitations in the amount of gloss enhancing toner that may be selectively laid-down based on fuser temperature, nip width, and the like. Consequently, there are limitations in the amount of gloss enhancement that may be achieved with conventional methods. Further, by using a low viscosity gloss enhancing toner, the image relief may increase to unacceptable levels and differential gloss, for example, within the pictorial area, may also be at a level (e.g., >30) too high to be acceptable to the end user.
[0006] As can be seen, there is a need for improved adjustable gloss control between different sections of a single printed page.
SUMMARY OF THE INVENTION
[0007] As will be discussed in more detail below, and in accordance with the present invention, using higher and lower viscosity transparent toner (as compared to the viscosity of the color toners) and different amounts of transparent toner lay-down (by, for example, global exposure change, gray level continuous tone, or binary/gray level halftone) coupled with fuser temperature, roller surface and nip width adjustments, one can achieve spot gloss control with different substrates. In conjunction with using negative masks, one can also reduce differential gloss while still maintaining the adjustable gloss on the page. Furthermore, the present inventors have discovered that, because different gloss level outputs can look different at different viewing angles, one can apply extra transparent toner to encode information on the page that can be viewed only at certain angles. Such encoded information may be useful, for example, to authenticate that the printed page is an original copy.
[0008] The term “adjustable gloss” as used herein refers to the ability to selectively adjust the gloss among selected portions of the same printed page.
[0009] The term “appearance” as used herein refers to those qualities well known in the art to those in the printing field. Such qualities include, for example, gloss, color density, differential gloss, and image relief.
[0010] The term “differential gloss” as used herein refers to the differences in image gloss among different portions of the same printed page.
[0011] The term “image relief” as used herein refers to differences in image surface heights along the same printed page.
[0012] The term “low differential gloss” as used herein refers to a difference in gloss value along a printed page of less than about 30, in some instances less than about 20, and in other instances less than about 10.
[0013] The term “inline” as used herein refers to a process occurring without user intervention, usually within the same apparatus as a previous process, while the term “offline” as used herein refers to a process occurring after a break in the overall process, usually requiring the user to continue the process on a different apparatus or at a different location on the same apparatus.
[0014] In one aspect of the present invention, a method of making an image having an adjusted gloss provides laying down a four-color toner image on a media substrate; laying down a transparent toner over a portion of the media substrate, said portion being an adjusted portion for which the adjusted gloss is desired; and fusing the four-color toner and the transparent toner onto the media substrate, wherein the transparent toner is one of a gloss-up transparent toner or a gloss-down transparent toner.
[0015] In another aspect of the present invention, a method of making an image having an adjusted gloss over a pictorial region of the image provides laying down a four-color toner image on a media substrate; laying down one of a gloss-up transparent toner and/or a gloss-down transparent toner over said pictorial region; and fusing the four-color toner and the transparent toner onto the media substrate.
[0016] In yet another aspect of the present invention, a method of matching a gloss level of an image to a gloss level of a media substrate with an absence of the image thereupon, said method provides measuring the gloss level of the media substrate; laying down four-color toner onto the media substrate to form the image thereupon; laying down a first transparent toner to at least one of the image and the media substrate with the absent of the image; and fusing the four-color toner and the transparent toner onto the media substrate.
[0017] In a further aspect of the present invention, a method for controlling an adjusted gloss and a differential gloss of an image printed on a media substrate provides laying down a four-color toner image on the media substrate; calculating parameters for a gloss-based negative mask over at least a portion of the image; laying down one of a gloss-up transparent toner and/or a gloss-down transparent toner over said portion based on the gloss-based negative mask parameters; and fusing the four-color toner and the transparent toner onto the media substrate.
[0018] In still another aspect of the present invention, a method for creating a tilt image on a media substrate provides laying down one of a gloss-up transparent toner and/or a gloss-down transparent toner in a pattern of the tilt image over the media substrate; and fusing the transparent toner onto the media substrate. With the capability to produce variable gloss transparent toner on the substrate, multiple tilt images made from transparent toner of different resultant gloss can be made. Images of different gloss values can be more prominent for viewing at different viewing angles. Therefore multiple transparent toner tilt images of different gloss level can be made on the same page that can be viewed at different viewing angles. Thereby a three dimensional imaging effect can be achieved.
[0019] In yet a further aspect of the present invention, a color image printing device provides a four-station color application section for applying color toner to a media substrate to form a pre-fused image; a transparent toner application section for applying a transparent toner the pre-fused image; a fuser for fusing the pre-fused image into a fused image; and a control device for inputting the desired gloss characteristics for the color image and for adjusting the lay-down of the transparent toner to affect the desired gloss characteristics.
[0020] In yet another aspect of the present invention, a computer readable media for controlling at least one of gloss and differential gloss of at least one specific portion of a printed image on a substrate provides a code segment for obtaining a desired level of gloss and differential gloss for the at least one specific portion of the image from a user; a code segment for reading an original image from which the printed image is to be made and calculating a color toner lay-down of an original image; and a code segment for calculating an appropriate application of transparent toner based on at least one of the color toner lay-down of the original image, the desired level of gloss and differential gloss and the substrate.
[0021] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is an overview flow chart showing a method for achieving adjusted image gloss according to one embodiment of the present invention;
[0023] FIG. 2 is a schematic drawing showing an apparatus for performing the method according to the present invention;
[0024] FIG. 3 is a graph showing how the gloss level of various color patches change with varying amounts of gloss-down transparent toner according to the present invention;
[0025] FIG. 4 shows the relationship between the amount of color toner lay-down and gloss with no gloss-down transparent toner;
[0026] FIG. 5 shows the relationship between the amount of color toner lay-down and gloss with 25% gloss-down transparent toner;
[0027] FIG. 6 shows the relationship between the amount of color toner lay-down and gloss with 55% gloss-down transparent toner;
[0028] FIG. 7 shows the relationship between the amount of color toner lay-down and gloss with 70% gloss-down transparent toner;
[0029] FIG. 8 shows the relationship between the amount of color toner lay-down and gloss with 100% gloss-down transparent toner;
[0030] FIG. 9 shows the relationship between gloss level of an untreated image prior to treatment by the present invention and color toner lay-down;
[0031] FIG. 10 shows gloss level as a function of the amount of one type of clear toner lay-down according to the present invention;
[0032] FIG. 11 shows gloss level as a function of the amount of another type of clear toner lay-down according to the present invention;
[0033] FIG. 12 shows the relationship between gloss and color toner lay-down when treated by the clear toner of FIG. 10 according to the present invention; and
[0034] FIG. 13 shows the relationship between gloss and color toner lay-down when treated by the clear toner of FIG. 11 according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0036] Broadly, the present invention provides for controlling the adjustable gloss on a printed page by adjusting the amount and type of transparent toner laid down over the four-color image. A high viscosity transparent toner may be used as a gloss-down toner to reduce the gloss of certain portions of an image. A low viscosity transparent toner may be used as a gloss-up toner to increase the gloss of certain portions of an image. These gloss-up and gloss-down toners may be applied as a negative mask, that is, the negative of the four-color image in terms of toner height, in order to help control the differential gloss of the image. Negative mask application of either gloss-up or gloss-down transparent toner may also be useful in matching the gloss of pictorial areas with that of those areas with no pictorial areas or with text only. Unlike conventional gloss control techniques, the present invention allows for adjustable gloss within the same page while controlling differential gloss and image relief.
[0037] Conventional gloss control techniques may apply transparent toner over a page, however, it may usually be applied to the entire page, without selecting specific areas, based upon the type of image laid down thereupon, to specifically gloss-up or gloss-down. The present invention allows for creating an image having different gloss value over the page based on the type of image laid down, the user's preference, and the like.
[0038] Referring to FIG. 1 , there is shown an overview of the one embodiment of the present invention, which provides a method 150 for adjusting the gloss in a portion of an image. At step 100 , four-color toner may be laid down onto a media substrate, for example, a sheet or web of paper. At step 110 , a determination may be made as to which areas of the image to adjust the gloss thereupon. This determination may be based on user input or the character of the image (e.g., text, bare substrate, a graphic). At step 120 , a decision can be made whether to gloss-up certain portions of the page or gloss-down certain portions of the page. The determination of which areas to gloss-up or gloss-down, is discussed in more detail below. If glossing-up, the method 150 can proceed to step 126 , wherein a low viscosity toner (as discussed in more detail below) may be laid down to certain areas of the image. If glossing-down, the method 150 can proceed to step 124 , wherein a high viscosity toner (again, as discussed in more detail below) may be laid down to certain areas of the image. Following the gloss-up step 126 or the gloss-down step 124 , the image may be fused at step 130 . The final page may then be finished by, for example, conventional belt fusing at step 140 . This method 150 and variations thereon will be discussed in greater detail in the paragraphs that follow.
[0039] Referring to FIG. 2 , there is shown a schematic depiction of an apparatus 200 for carrying out an exemplary method of the present invention. The apparatus 200 may include a paper path 202 for carrying a paper 204 therethrough. A four-color toner application section 206 may apply four-color toner to the paper 204 . A transparent toner application section 208 may apply transparent toner to the paper 204 , following application of the four-color toner at the four-color toner application section 206 . A fuser 210 may then fuse the image (both the four-color toner and the transparent toner) on the paper 204 . An optional finisher, such as a conventional belt fuser 214 , may finish the surface of the fused image on the paper. A control device 212 may be used for any of the following functions: inputting the image to be laid down onto the page, inputting the desired adjusted gloss/differential gloss characteristics for the page, controlling the application of four-color toner and transparent toner based on the user's desired gloss characteristics, and calculating the necessary gloss-based negative mask, if necessary, to control differential gloss.
[0040] A computer media (not shown) may contain a computer code for carrying out the above functions in control device 212 . The computer media may be external to or imbedded within control device 212 .
[0041] Referring to FIG. 3 , there is shown a graph depicting how the gloss levels of various (numbered) color patches change with varying amounts of gloss-down transparent toner according to the present invention. The color paths are derived from the differential gloss test chart used in Yee S. Ng “Standardization of Perceptual Based Gloss and Gloss Uniformity for Printing Systems (INCITS W1.1), ISET's PICS 2003 Proceedings (pp. 88-93). The data from these curves may be useful in the calculations made in control device 212 when the user selects gloss-down and/or control of differential gloss for a particular area of the image. Using a higher viscosity toner (as compared to the viscosity of the four-color toner set, e.g., about 10,000-80,000 poise) on the same fuser, the adjustable gloss-down of the desired spot image area may be affected by laying down a different amount of transparent toner (see step 124 of FIG. 1 ). The percentages used in this graph (as well as those which follow) for lay down (0 to 100%) refer to toner coverage (continuous-tone, as well as halftone). This graph demonstrates a gloss-down from a maximum gloss, G60, of about 50 to a G60 value of about 19. FIG. 3 shows that uniformity gloss at different colorant coverage can be achieved with the addition of different amount of gloss-down transparent toners and also get a mean adjustable gloss in the range of 15 to 20 at the same time.
[0042] One application of the present invention, using the data from FIG. 3 , from a spot gloss viewpoint, may be to gloss-down and match the overall substrate gloss. In step 120 of FIG. 1 , a decision can be made whether to gloss-up certain portions of the page or gloss-down certain portions of the page. When the user chooses to gloss-down a portion of the image (step 124 ), while trying to match substrate gloss, different amounts of transparent toner can be used on different spot gloss areas to accomplish matching the image gloss to the substrate gloss in some areas, but give an appearance of higher gloss in other spot gloss areas. It is known in the art that the gloss level of a fused image varies with the type of substrate, such as paper 204 , and the amount of color toner lay-down. For example, with a matte-finish substrate (having a surface gloss of about 5-10), as the amount of color toner lay-down increases, the amount of gloss increases. With an intermediate gloss level finish substrate (having a surface of about 30-40), as the color toner lay-down increases, the gloss begins to increase, dips to a lower gloss level, and then increases further as the color toner lay-down increases toward about 300% (see for example, Yee Ng et al., “Gloss Uniformity Attributes for Reflection Images”, IS&T's NIP 17 Proceedings, pp. 718-722, 2001. With a glossy substrate (having a surface gloss of about 60-70), as the color toner lay-down increases, the gloss level decreases. Therefore, by knowing the substrate type and the amount of color toner lay-down (based upon the original image), one can determine the amount and location of gloss-down transparent toner needed to match the image gloss to the substrate gloss.
[0043] Once the gloss of the entire image (bare substrate and fused image) is matched, one may then also create an appearance of higher gloss in some areas by the application of a second gloss-up or a gloss-down toner by passing the paper 204 through the apparatus 200 a second time, which may apply the second gloss-up or gloss-down toner via transparent toner application section 208 .
[0044] Referring now to FIGS. 4 through 8 , there are shown graphs of gloss (GD60) versus color toner lay-down [from 0 to 300% color (i.e., 100% of all three colors) toner lay-down] using an intermediate gloss level (gloss level of about 38) paper for various amounts of gloss-down toner. Generally, each curve shows, as discussed above, that, as the color toner lay-down increases, the gloss begins to increase, dips to a lower gloss level, and then increases further as the color toner lay-down increases toward about 300%. Each curve also slows the effect of gloss-down toner lay-down on the substrate alone, that is, with zero percent color toner lay-down. This data shows the gloss level of the substrate alone (with no color toner lay-down, but with only fused gloss-down toner) changing from about 38 (no gloss-down toner) to about 7 (100% gloss-down toner).
[0045] Referring specifically to FIG. 4 , with no gloss-down toner application, the gloss is variable based on color toner lay-down, giving gloss values from about 20 to about 50.
[0046] Referring specifically to FIG. 5 , with 25% gloss-down toner lay-down, there is some tightening of the curve (that is, less out lying data points from a theoretical best fit line), however no significant control of differential gloss. The gloss value with 25% gloss-down toner lay-down still varies from about 20 to about 50.
[0047] Referring specifically to FIG. 6 , with 55% gloss-down toner lay-down, some differential gloss control is noted, with the gloss values ranging from about 15 to about 48.
[0048] Referring now to FIG. 7 , with 70% gloss-down toner lay-down, substantial tightening of the curve is noted, showing a clearer, almost linear function of color toner lay-down versus image gloss. The gloss values, with 70% gloss-down toner lay-down range from about 14 to about 32, confirming even further control of differential gloss.
[0049] Referring to FIG. 8 , with 100% gloss-down toner lay-down, substantial differential gloss control is achieved, with the gloss level varying from about 7 to about 15 with varying color toner lay-down. Moreover, adjustable gloss may be achieved by spot application of, for example, 100% gloss-down toner. As FIGS. 4 through 8 show, substrate alone may have a gloss value that varies from about 38 to about 7 with varying amounts of gloss-down toner lay-down. Thus, adjustable gloss and reduction in differential gloss may be achieved at the same time by variable application of the amount of gloss-down toner lay-down as shown in FIG. 3 between a gloss range of 15 to 20.
Example
[0050] Referring to FIGS. 9 through 13 , there are shown two examples of a gloss-down transparent toner that may be used to reduce differential gloss on a printed page while still allowing for adjusted gloss within the page.
[0051] More specifically, FIG. 9 shows gloss level of an “untreated” image as a function of the total amount of toner lay-down. By describing the image as “untreated,” it is meant that the image has not been adjusted by any embodiment of the present invention. FIGS. 10 and 11 show the amount of gloss-down that may be achieved by adjusting the lay-down amounts of transparent toners 1 and 2 (Clear1 and Clear 2), respectively using the color separation that has the maximum coverage at that pixel location as reference. FIG. 12 shows the reduction in differential gloss by using Clear1 transparent toner as a function of varying amounts of toner lay-down. By comparing FIG. 12 to FIG. 9 , it can be seen that the differential gloss may be reduced from about 25 (untreated image) to about 9 (image treated with Clear1 transparent gloss-down toner) with an average gloss of 37. FIG. 13 shows the reduction in differential gloss by using Clear2 transparent toner as a function of varying amounts of toner lay-down. By comparing FIG. 13 to FIG. 9 , it can be seen that the differential gloss may be reduced from about 25 (untreated image) to about 15 (image treated with Clear2 transparent gloss-down toner) with an average gloss of 41.
[0052] These two examples show the effect of transparent gloss-down toners Clear1 and Clear2 on the differential gloss of an image regardless of the color toner lay-down. In addition to this reduction in differential gloss, if desired, the image may be imparted with an adjusted gloss by varying the amount of transparent toner lay-down on various portions of the image.
[0053] While the above discussion has focused on gloss-down transparent toner, the present invention is not limited to that particular embodiment. By using a lower viscosity transparent toner (in comparison with the four-color toner set), for example, a transparent toner having a viscosity from about 1000 to about 2000 poise, and the same fusing conditions, one can affect the adjustable gloss-up on the desired spot image area (step 126 of FIG. 1 ). Coupled with a gloss-based negative mask (discussed in more detail in the following paragraph), one can achieve adjustable gloss patches and reduction of differential gloss at those adjustable gloss level patches at the same time. Of course, the range of the gloss adjustment may be further enhanced with various fuser roller surface finishes, fusing temperatures and nip width selections.
[0054] The above-described process may be done inline, within a single printing device by, for example, applying the transparent toner [gloss-up (step 126 ) or gloss-down (step 124 )] to the pre-fused image 204 followed by fusing to supply the finished product. Alternatively, the process may be done offline, requiring the user to feed the prints through another apparatus to fuse the desired transparent toner lay-down thereto. In a hybrid embodiment of the present invention, the four-color image may first be fused to the substrate followed by the appropriate transparent toner lay-down being fused, in a separate step, albeit still inline, to the already fused color image.
[0055] One application of the above observation shown in FIGS. 4 through 8 is to apply gloss-down toner as a negative mask. In other words, the amount of transparent toner laid down (step 124 ) may vary inversely with the amount of the four-color toner lay-down (step 100 ), as shown in optional step 115 for determining the negative mask transparent toner lay-down. However, rather than basing the negative mask lay-down on four-color toner height, the negative mask lay-down may be based on the gloss value anticipated based on the color toner lay-down (as may be determined by the graphs of FIGS. 4 through 8 , or, any similar set of calibration curves generated on a particular substrate for a particular amount of gloss-down and color toner lay-down. By using this gloss-variable negative mask technique, the gloss value may be selectively adjustable between different locations on the image (for example, between text and pictorial areas). Moreover, by using this technique, the differential gloss within a particular area (for example, within a text area) may be controlled to a low differential gloss (e.g., less than about 20).
[0056] As mentioned above, adjustable gloss levels may be used to create a “tilt image” or, in other words, an image that may be viewed at a particular angle due to its different gloss level. Referring back to FIG. 1 , by first adjusting the gloss as desired by laying-down the appropriate transparent toner, as shown in step 124 or 126 , to create an adjusted gloss image, and then creating an “image” with transparent toner (step 170 ) which will impart a different gloss level when fused, a tilt image may be formed. The adjusted gloss image may be fused (step 160 ) prior to the application of the tilt image transparent toner (step 170 ). Alternatively, the entire image, including the tilt image transparent toner, may be fused in a single step (step 130 ) to form the finished product. The finished product may be finished by, for example, conventional roller fusing at step 140 . The tilt image may have a gloss level greater than or less than the gloss level of the surrounding text and graphics. Therefore, when viewed at a particular angle, the different gloss level will impart the visual sensation of an image within the gloss. These tilt images may be useful, for example, as authentication images to verify that certain documents are originals, as the tilt image may not appear in a conventional copy. Moreover, these tilt images may be used to create a three-dimensional effect by varying the amount of gloss by degrees around a particular image.
[0057] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
PARTS LIST
[0000]
100 step of applying four-color toner
110 step of determining which areas to adjust gloss
115 step of determining the negative mask lay-down
120 step of determining to gloss-up or gloss-down
122 step of glossing-up
124 step of glossing-down
130 step of fusing
140 step of finishing (belt fusing)
150 the method of FIG. 1
160 step of fusing prior to laying down the tilt image
170 step of laying down the tilt image
200 apparatus
202 paper path
204 paper
206 four-color toner application section
208 transparent toner application section
210 fuser
212 control device
214 belt fuser | By using a high or low viscosity transparent toner, with respect to the other color toners, and different amounts of transparent toner lay-down, the gloss of an image printed by an electrophotographic device may be adjusted. By also applying the transparent toner as a negative mask, the differential gloss of the image may be reduced while still adjusting the gloss of certain portions of the image. Further, because different gloss levels may appear different at different viewing angles, transparent toner may be laid down to encode a transparent image within the image being printed. Such a transparent image may be useful as, for example, an authentication means for a document. Additionally, by varying the gloss levels on particular aspects of a printed image, multiple images of different gloss levels, which are prominent at different viewing angles can be made, thereby, a three-dimensional image effect can be achieved on the printed page. | 6 |
FIELD OF INVENTION
This invention relates to the field of regenerating dithiophosphorus acid solvent extractants from their oxidized forms.
BACKGROUND OF THE INVENTION
Dithiophosphorus acids are useful extractants for the solvent extraction of metal cations. The dithiophosphorus acids of the specification are represented by the following: ##STR1## wherein R 1 and R 2 are the same or different and are selected from the group consisting of substituted alkyl, cycloalkyl, alkoxyalkyl, alkylcycloalkyl, aryl, alkylaryl, aralkyl and cycloalkylaryl radicals having from about 2 to 24 carbon atoms.
Unfortunately, the dithiophosphorus acid extractants are prone to oxidation during the solvent extraction process. When oxidized, two acid extractant molecules form a sulfur--sulfur bond leading to a disulfide which is incapable of extracting metal cations. These dithiophosphorus acid extractants would not be economic reagents, unless some method of regenerating the active extractant from the disulfide is available.
Rickelton et al., in U.S. Pat. No. 5,759,512 ('512), disclose a process that relies upon active nascent hydrogen to break the sulfur--sulfur bond of the disulfide and regenerate the acid extractant. For example, this process adds zinc powder to an agitated mixture of sulfuric acid solution and the solvent extractant organic solution, generating nascent hydrogen for the extractant regeneration such that all the metal is finally dissolved. Although relatively costly, this regeneration improves the economics of recovering metals with dithiophosphorus extractants, since the partially oxidized extractant solution can be regenerated and, therefore, the original metal loading capacity can be restored.
Specifically, the process of the '512 patent relies upon either nascent hydrogen formed from reacting a metal with a strong acid in aqueous phase or from bubbled hydrogen in the presence of a catalyst. Unfortunately, these processes generate large quantities of unreacted hydrogen gas that require special equipment and precautions to prevent explosions. Furthermore, the nascent hydrogen processes, such as the zinc-sulfuric acid process, require neutralization and disposal of an acidic waste product. Moreover, the metal consumption described in the '512 patent is much larger than what appears to be required by the extractant regeneration stoichiometry, suggesting a poor efficiency of the nascent hydrogen towards regeneration versus hydrogen gas formation.
Denger et al., in "Synthesis, Properties and Structure of Bis (dialkyldithiophosphinato) manganese (II) Complexes," Inorganica Chemica Acta, 132 (1987), disclose reacting powdered manganese with bis(diorganothiophosphoryl) disulf[ide] to form laboratory scale quantities of a manganese (II) dithiophosphinate for x-ray crystallographic studies.
It is an object of the invention to provide a process that regenerates disulfides formed by oxidation of dithiophosphorus acids without reliance upon nascent hydrogen or a catalyst.
It is a further object of the invention to provide a method of regenerating the disulfides formed by oxidation of dithiophosphorus acids without the necessity of having to dispose of an acidic waste stream.
It is a further object of the invention to reduce the amount of metal consumed during regeneration, thereby resulting in a lower cost process.
SUMMARY OF THE INVENTION
A process for the regeneration of organic dithiophosphorus extractant degraded in a solvent extraction process that allows a much longer life expectancy of the extractant mixture. The degraded organic phase consists of an organic solution containing undegraded dithiophosphorus acid, and sulfur--sulfur bonded structures formed from two dithiophosphorus acid molecules, all present in a diluent used in a solvent extraction circuit. This process regenerates dithiophosphorus acids (i.e. dithiophosphinic acids, dithiophosphonic acids and dithiophosphoric acids) by contacting the organic phase with metal. The disulfide reacts directly with the metal and produces a metal complex of the regenerated dithiophosphorus extractant in the organic solution. This metal complex forms without the presence of or the formation of hydrogen. The organic solution containing the regenerated dithiophosphorus extractant can be either directly recycled into a solvent extraction circuit or recycled after the loaded metal is stripped.
DESCRIPTION OF THE DRAWING
FIG. 1 plots DTPA concentrations as a function of time for seven batches regenerated with the same initial batch of nickel powder.
FIG. 2 shows the effect of temperature (40° C., 50° C. and 65° C.) on DTPA regeneration rate.
FIG. 3 plots regeneration rate as a logarithmic function of temperature.
FIG. 4 shows continuous regeneration of DTPA over a seven day period.
DESCRIPTION OF PREFERRED EMBODIMENT
This process transforms disulfides, which are formed in the organic solution by oxidation of the dithiophosphorus acid, back into the metal loaded form of the dithiophosphorus acid by contacting the organic solution with a metal. Any sacrificial metal which can form a complex with dithiophosphorus acids reacts directly to reduce the sulfur--sulfur bond of the disulfide in the absence of nascent or gaseous hydrogen. The metal itself is therefore oxidised to metal ions and the disulfide is transformed back into the metal loaded form of the dithiophosphorus acid, which is the end product of the reaction.
The presence of aqueous solution or water advantageously acts as an accelerating agent for the reaction. The amount of water required to accelerate the reaction is very small. Even the water entrained in the organic phase after a normal aqueous/organic phase separation in a solvent extraction circuit is sufficient. Alternatively, a separating agent such as water or aqueous solution can be added to the regeneration system to facilitate separation between the organic phase and unreacted metal. After agitation of the system ceases, unreacted metal settles in the water or aqueous phase to allow easy separation from the organic phase.
In regenerating dithiophosphinic acids, a metal powder reacts to form an intermediate of Bis(dithiophosphinato)-metal complex. Advantageously, the metal consists of a cobalt, iron, manganese, nickel or zinc powder or any metal which forms a complex with dithiophosphorus acids. The regeneration reaction proceeds under an air atmosphere, but since air is an oxidizing agent, an inert atmosphere advantageously improves the regeneration. Acceptable atmospheres include the Group VIII gases, CO 2 , N 2 and any other gases non-reactive with the process. The following illustrates the regeneration process for a dithiophosphinic extractant using nickel metal: ##STR2##
The Bis(dithiophosphinato)-nickel(II) complex product formed is similar to the product formed during the metal ion solvent extraction step--strong acids strip the metal to convert the complex back into its free extractant acid form. Thus, re-injecting this complex directly back into a nickel solvent extraction circuit allows regeneration without the requirement for additional vessels or reagents for stripping the metal and neutralizing effluent streams. In a nickel solvent extraction circuit for example, this Bis(dithiophosphinato)-nickel(II) complex releases its loaded nickel cation with a strong acid, providing free DTPA extractant for further loading, as follows: ##STR3##
The regeneration reaction occurs at about room temperature (20° C.) to 95° C. Increasing temperature to at least about 40° C. accelerates the reaction. To avoid volatilization of any diluent present with the organic phase, the reaction advantageously occurs at a temperature of less than about 80° C. Although it is most advantageous to have the reaction occur in the presence of a diluent, it is not considered essential that a diluent be present.
Since this process is a surface area dependent process, it is advantageous but not necessary to use metal in its powder form for increasing reaction efficiency. Advantageously, the powder has a specific surface area of at least about 0.001 m 2 /g. Most advantageously, the powder has at least about a 0.005 m 2 /g specific surface area. Furthermore, the use of excess metal advantageously promotes the reaction to proceed at an acceptable rate. However, the excess metal can be reused to treat additional batches of degraded organic solution, decreasing dramatically the overall metal consumption.
EXAMPLES
Example 1
A 15% (vol.) Cyanex 301, (bis(2,4,4trimethylpentyl) dithiophosphinic acid, a registered product of Cytec Industries Inc.), solution in Isopar M diluent (an aliphatic solvent from Imperial Oil), degraded to 58% of its original metal loading capacity, provided the test sample. A 1,000 mL heated vessel containing baffles and a 550 rpm down-draft agitating impeller provided the reactor. Introducing 250 mL of the test sample in the reactor established the regeneration mixture. The reaction proceeded with agitation under a CO 2 atmosphere and a temperature set point of 65° C. After reaching the temperature set point, adding 25 g of nickel-123 powder, a registered product of INCO Ltd (specific surface area of 0.34 to 0.44 m 2 /g) initiated the reaction. Organic samples were taken from the reactor at regular intervals. Stripping the regenerated nickel loaded organic samples with HCl 6N provided nickel(II) free organic samples. Analysing the organic samples for free DTPA by acid titration showed that the extractant capacity increased as a function of time from less than 60% to more
TABLE 1______________________________________ [DTPA]Time (h) (mole/L) Capacity (%)______________________________________0 0.190 58 3 0.262 79 6 0.289 86______________________________________ Note: Fresh 15% solution of Cyanex 301 has a free DTPA concentration of 0.33 mole/L.
Example 2
Effect of Addition of Water
This test operated with the conditions and equipment of Example 1, except that the organic solution had 55% loading capacity and the reactor contained an additional 25 mL of water. The assays of Table 2 show that the extractant capacity increased as a function of time from less than 60% to more than 95% after 4 hours.
TABLE 2______________________________________ [DTPA]Time (h) (mole/L) Capacity (%)______________________________________0 0.194 59 2 0.242 73 4 0.315 95 6 0.323 98______________________________________
EXAMPLE 3
Recycle of Nickel Powder
A solution of 15% (vol.) Cyanex 301 solution in Isopar M, degraded to 74% loading capacity provided the test sample. The organic contained 1.5 g/L of nickel(II). A 50 L fiberclass resin (FRP) reactor vessel with baffles, agitated with a down-draft impeller at 300 rpm, was used. A water jacket heated the test sample. Introducing 40 L of the degraded organic test sample and 5 L of water into the agitated reactor under a CO 2 atmosphere established the regeneration mixture. After reaching the temperature set point of 65° C., adding 4 kg of nickel-123 powder initiated the reaction. Organic samples were taken from the reactor at regular intervals. Stripping the regenerated nickel loaded organic samples with HCl 6N provided nickel(II) free organic samples. Stopping the agitation after 10 h allowed the aqueous solution and solids to settle to the bottom of the reactor. After one hour of settling, the organic solution was removed from the reactor without disturbing the solids settled in an aqueous layer.
Pouring a second batch of 40 L degraded organic (at 65° C.) into the reactor re-established the regeneration reaction without adding additional nickel powder. Repeating this procedure for seven successive batches (with the same nickel powder) regenerated each batch of degraded extractant. Stripping the regenerated Ni loaded organic samples with HCl 6N provided nickel(II) free organic samples and the data of FIG. 1.
The assays of FIG. 1 demonstrate that the extractant capacity increased as a function of time from less than 75% to more than 88% after 5 hours in all successive batches that used recycled nickel powder.
EXAMPLE 4
Effect of Temperature
A second series of seven batches followed the procedure described in Example 3 at various temperature set points: Batch Nos. 8, 9 and 14 at 65° C.; Batch Nos. 10 and 11 at 50° C. and Batch Nos. 12 and 13 at 40° C. The assays of FIGS. 2 and 3 show that the extractant metal loading capacity increased at different rates as a function of the temperature. The activation energy [--RΔ(Ln k)/Δ(1/T)] equaled 69 KJ/mol.
EXAMPLE 5
Continuous Regeneration
In this test, the test sample of Examples 3 and 4 was regenerated in a continuous process. The equipment consisted of a 22 L, stirred, water-jacketed, reaction chamber and a 12 L settling tank; both of them held under a CO 2 atmosphere. A down-draft impeller, at 250 rpm, provided agitation in the reaction chamber. The reactor was initially filled with the degraded organic. After reaching the 65° C. temperature set point, introducing 2.5 kg of nickel-123 powder initiated the regeneration reaction. After 6 h of batch-type reaction, a continuous supply of degraded organic was started. The 65° C. water-jacketed reaction vessel was fed with degraded organic at a rate of 4.2 L/h. Adding 250 g of nickel 123 powder on a daily basis supplied the reactor vessel with a fresh supply of nickel. Stripping and analysing samples every four hours for free DTPA as before proved the continuous regeneration. The assays plotted in FIG. 4 show that the extractant metal loading capacity of the product increased to an average of 88% from an initial 73% metal loading capacity. The average product contained 0.29 mol/L DTPA with a total of 4.75 mole DTPA produced each day. The reaction consumed 3.75 kg of nickel during the entire several day test to regenerate 625 liters of feed solution.
EXAMPLE 6
Zinc Powder
A 15% (vol.) Cyanex 301 solution in Isopar M, degraded to 49% of its original metal loading capacity, provided the test sample. The equipment and procedure was similar to that of Example 1 except that it relied upon 25 g of fine zinc powder (4 μm) to regenerate the DTPA. Removing organic samples every 1.5 h provided assays for testing in accordance with the procedure of example 1. The assays in Table 3 showed that the extractant capacity increased as a function of time from less than 50% to 75% after 6 hours.
TABLE 3______________________________________ [DTPA]Time (h) (mole/L) Capacity (%)______________________________________0 0.163 49 1.5 0.207 63 3 0.215 65 4.56 0.230 70 6 0.249 75______________________________________
EXAMPLE 7
Iron Powder
A 15% (vol.) Cyanex 301 solution in Isopar M, degraded to 57% of its original metal loading capacity, provided the test sample. The equipment and procedure was similar to that of Example 1, excepted that it relied upon 50 g of iron powder (-250 μm, Domfer MP-61) to regenerate the DTPA. Removing organic samples every one hour provided assays for testing in accordance with the procedure of Example 1. The assays in Table 4 showed that the extractant capacity increased as a function of time from less than 60% to almost 90% after 2 hours.
TABLE 4______________________________________ [DTPA]Time (h) (mole/L) Capacity (%)______________________________________0 0.187 57 1 0.253 77 2 0.290 88 4.5 0.288 87 6 0.249 75______________________________________
For a nickel solvent extraction circuit, the degraded organic solution of 15% vol. DTPA in an aliphatic diluent most advantageously reacts in the presence of water with 100 g of nickel-123 powder per litre of organic solution--it is most advantageous to match the metal powder with an end-product of a solvent extraction circuit. This reaction most advantageously occurs at a temperature of 65° C., with an organic to aqueous ratio of 10 to 20 and under a protective CO 2 atmosphere. This reaction forms a nickel complex in 4 to 6 hours depending on the level of degradation of the organic reagent. Recycling any remaining nickel powder in the reactor limits adding of fresh nickel to the previous regeneration's consumption.
This process operates effectively in a batch or a continuous mode. In the batch process, after the reaction, the bulk of remaining nickel powder settles quickly in an aqueous solution to allow the filtration of entrained micron-size metallic particles before the re-introduction of the regenerated organic extractant solution into the solvent extraction circuit. In the continuous process, adjusting flow rates and reaction time of the organic with a metal powder can achieve steady-state extractant concentrations in solvent extraction circuits.
This process has several advantages over the earlier method for regenerating dithiophosphorus acids. First, this process avoids the generation of large quantities of hydrogen. Second, this process does not require the addition or disposal of acidic reagents. Third, this process allows matching of a solvent extraction circuit's product with the sacrificial metal used. Fourth, this process more efficiently regenerates the dithiophosphorus acids, than the nascent hydrogen processes. Finally, the process can use a solvent extraction circuit's stripping stage to form the dithiophosphorus acid from the cation-loaded organic.
In accordance with the provisions of the statute, this specification illustrates and describes specific embodiments of the invention. Those skilled in the art will understand that the claims cover changes in the form of the invention and that certain features of the invention may operate advantageously without a corresponding use of the other features. | This is a method of regenerating dithiophosphorus acids from disulfides containing sulfur--sulfur bonds, formed by oxidation of dithiophosphorus acids, such as sulfur--sulfur bonding of dithiophosphoric, dithiophosphonic and dithiophosphinic acids, in a solvent extraction organic phase in which the dithiophosphorus acid is dissolved in a diluent. This process reacts metal directly with the organic solution containing the disulfide to produce a metal loaded complex form of the regenerated dithiophosphorus extractant in the organic solution. This metal complex forms by direct reaction of the metal with the disulfides without requiring the presence or the formation of nascent or gaseous hydrogen. The organic solution containing the regenerated dithiophosphorus extractant can be either directly recycled into a solvent extraction circuit or recycled after the loaded metal is stripped. | 2 |
STATEMENT OF RELATED APPLICATIONS
This patent application claims foreign priority on German Patent Application No. DE 10 2013 016 075.8 having a filing date of 27 Sep. 2013 and German Patent Application No. 10 2013 020 912.9 having a filing date of 12 Dec. 2013.
BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates to a method of folding items of laundry. The invention further relates to a method of mechanically folding items of laundry and/or stacking items of laundry, wherein the items of laundry are transported through at least one longitudinal-folding station, the items of laundry are folded longitudinally at least once in the longitudinal-folding station and preferably the folded items of laundry are stacked at a plurality of stacking locations. The invention additionally relates to a method of folding items of laundry, wherein the items of laundry are transported through a longitudinal-folding station having at least one folding template and, in the longitudinal-folding station, the items of laundry are folded over on the at least one folding template by way of blowing air.
2. Prior Art
The operation of folding items of laundry automatically takes place in folding machines having at least one longitudinal-folding station. The items of laundry are conveyed individually through the longitudinal-folding station and folded longitudinally in the process. During the longitudinal-folding operation, the items of laundry are provided with at least one folding line running in the longitudinal direction of the longitudinal-folding station.
It is usually the case that items of laundry of different sizes are folded one after the other. All the items of laundry—regardless of size—are thereby transported through the longitudinal-folding station at the same speed. This means that it is only possible for relatively small items of laundry, but not larger items of laundry, to be folded during uninterrupted onward transportation through the longitudinal-folding station. As a result, the onward transportation of larger items of laundry through the longitudinal-folding station is interrupted for longitudinal-folding purposes. This results in the cycle time being extended.
It is also known for the items of laundry to be folded by way of blowing air with the aid of folding templates of the longitudinal-folding station. The blowing air acts on the items of laundry which are to be folded until it can be assumed with a degree of certainty that items of laundry of any size, but also of any width and any desired materials, have been definitively folded. As a result, the blowing-time duration is adapted to items of laundry of maximum length. In the case of shorter items of laundry, the blowing duration is unnecessarily long. This may result in definitively folded items of laundry still having blowing air acting on them as they are transported away, and some folding may become undone again as a result. Moreover, an unnecessary long blowing duration results in an increased consumption of compressed air and in an unnecessary amount of noise being caused by compressed air exiting from compressed-air nozzles.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to provide a method of automatically folding items of laundry which has an enhanced folding performance and/or a shortened blowing time.
A method for achieving this object is a method of mechanically folding items of laundry and/or stacking items of laundry, wherein the items of laundry are transported through at least one longitudinal-folding station, the items of laundry are folded longitudinally at least once in the longitudinal-folding station and preferably the folded items of laundry are stacked at a plurality of stacking locations, characterized in that the items of laundry are transported through the longitudinal-folding station at a transporting speed adapted to their size, wherein the transporting speed is adjusted such that relatively small items of laundry are transported through the longitudinal-folding station more quickly than larger items of laundry. In the case of this method, provision is made for the items of laundry to be transported through the longitudinal-folding station at a transporting speed adapted at least to their size, in particular length. Length of the items of laundry means that direction of extent of the same which runs in the direction in which the items of laundry are transported through the longitudinal-folding station. In the case of this method according to the invention, less time is lost, in comparison with the conventional method, when small and large items of laundry are to be folded randomly, that is to say in a mixed-together state.
The speed at which the items of laundry are transported through the longitudinal-folding station is preferably adjusted such that the longitudinal-folding operation has been completed when the leading transverse edge of the respective item of laundry is located in the region of an outlet end of the longitudinal-folding station, that is to say is located at the outlet end or just upstream thereof. This means that items of laundry of any type and size, to be precise large items of laundry and small items of laundry, are transported as quickly as possible through the longitudinal-folding station, wherein the speed is selected such that the duration over which the items of laundry are transported through the longitudinal-folding station is sufficient for each item of laundry to be folded longitudinally in full at least once. Accordingly, relatively large items of laundry are transported through the longitudinal-folding station more slowly than smaller items of laundry.
Adapting the speed at which the items of laundry are transported through the longitudinal-folding station, on the one hand, avoids interruption in the onward transportation of relatively large items of laundry through the longitudinal-folding station and, on the other hand, means that, with smaller items of laundry being transported more quickly through the longitudinal-folding station, it is also the case that small items of laundry have at least more or less reached the outlet end of the longitudinal-folding station once the longitudinal-folding operation has taken place. It is only when very large items of laundry of a length corresponding approximately to the length of the longitudinal-folding station have to be folded that it is also necessary to provide a brief interruption in the onward transportation of the item of laundry in order for the latter to be folded in the longitudinal-folding station.
Provision is preferably made for the speed at which short or small items of laundry are transported through the longitudinal-folding station to be selected to be greater than for longer or larger items of laundry and/or for short or small items of laundry to be accelerated in the longitudinal-folding station and for larger, in particular longer, items of laundry to be slowed down. This provides for individual adaptation of the speed at which the items of laundry are transported through the longitudinal-folding station. It is also possible here for relatively large items of laundry—provided they are not items of laundry which take up the entire length of the longitudinal-folding station—to be folded without any interruption in their onward transportation and for smaller items of laundry to be transported through the longitudinal-folding station at a greater transporting speed, and therefore the operation of folding items of laundry of different sizes takes place over at least most of the length of the longitudinal-folding station. This eliminates standstill periods in the longitudinal-folding station and periods for transporting the already definitively folded small item of laundry to the outlet end of the longitudinal-folding station.
A preferred configuration of the method provides for the speed at which the items of laundry are transported through the longitudinal-folding station to be adapted individually and preferably continuously at least to the length of the item of laundry which is to be folded in each case and to be adjusted accordingly. The speed at which the items of laundry are transported in the longitudinal-folding station is preferably adapted individually to the amount of time required for the longitudinal-folding operation, which is smaller for relatively short items of laundry than it is for longer items of laundry. This adaptation takes place such that, during the amount of time required for the longitudinal-folding operation, the item of laundry has been transported throughout the entire longitudinal-folding station, and therefore, at the completion of each longitudinal-folding operation or of all the longitudinal-folding operations of the respective item of laundry, the leading (front) transverse edge of the same, to be precise both of large items of laundry and of small items of laundry, is located at the outlet end, or in the vicinity of the outlet end, of the longitudinal-folding station. As a result of this method, all the items of laundry, irrespective of their size or length, pass through the longitudinal-folding station in an extremely short amount of time and the at least one longitudinal-folding operation is completed in full in the process.
According to an advantageous development of the method, provision is made for the speed at which the items of laundry are supplied to the longitudinal-folding station to be adapted to the speed at which the items of laundry are transported through the longitudinal-folding station. This ensures that, in the case of small items of laundry, which are transported quickly through the longitudinal-folding station, next-following items of laundry are supplied to the longitudinal-folding station at the smallest possible distance apart from the preceding item of laundry. Conversely, in the case of large items of laundry, which are transported slowly through the longitudinal-folding station, the operation of feeding following items of laundry to the longitudinal-folding station is slowed down, in order that the situation where successive items of laundry run over one another or overlap in the longitudinal-folding station does not arise.
Provision is preferably made for the speed at which the items of laundry are supplied to the longitudinal-folding station to be adjusted such that the items of laundry run into the longitudinal-folding station closely one after the other and/or the next item of laundry is transported into the longitudinal-folding station as soon as the longitudinal-folding operation of the preceding item of laundry has been completed. This reduces idling times of the longitudinal-folding station to a minimum.
A particularly advantageous configuration of the method provides for the sizes of the items of laundry, that is to say the dimensions of the items of laundry in the transporting direction through the longitudinal-folding station, to be determined in good time before the beginning of the longitudinal-folding operation or of the first longitudinal-folding operation. The length of the respective item of laundry, to be precise preferably of the item of laundry which is the next to be folded, is preferably determined upstream of the longitudinal-folding station and/or during transportation to the longitudinal-folding station. Determination of length can take place by means of at least one sensor. This may be, for example, such a sensor as determines the duration between the front transverse edge of a respective item of laundry running past the sensor and the rear transverse edge thereof running past the same. As the transporting speed of the item of laundry is known, this means that the length of the item of laundry can be calculated. It is also conceivable, however, to use a displacement sensor by means of which the length of the item of laundry transported past it is sensed in a contactless manner or in contact with the item of laundry.
Another advantageous configuration of the method provides for the folded items of laundry to be transported from the final folding station to different stacking locations downstream of the final folding station at different supply speeds. Since the stacking locations, which are arranged one beside the other or one behind the other, necessarily have to be at different distances from the final folding station, the different supply speeds mean that the folded items of laundry require approximately the same amount of time to reach the stacking stations at different distances from the final folding station. In particular when the items of laundry are transported through the longitudinal-folding station at a transporting speed adapted to their size, and therefore the longitudinal-folding duration is approximately the same for each item of laundry, it can thus be ensured that it is also the case that the operation of stacking the items of laundry takes place in approximately the same amount of time and there is therefore no need to wait until items of laundry which are to be stacked at remote stacking locations have reached said remote stacking locations.
As an alternative, it is conceivable for relatively small items of laundry, which are transported at a relatively great transporting speed through the longitudinal-folding station, to be stacked at stacking locations which are remote from the final folding station, whereas longer items of laundry, which require a lower transporting speed through the longitudinal-folding station, are stacked at stacking stations which are closer to the final folding station. This can effect a kind of synchronization between the amounts of time required for folding and the amounts of time required for stacking, preferably in dependence on the dimensions of the respective item of laundry.
A further method for achieving the object mentioned in the introduction, it also being possible for this method to be a preferred development of the method described above, is a method of folding items of laundry, wherein the items of laundry are transported through a longitudinal-folding station having at least one folding template and, in the longitudinal-folding station, the items of laundry are folded over on the at least one folding template by way of blowing air, characterized in that, during the longitudinal-folding operation, an upper region of a folding region or blowing space above the at least one folding template is monitored as to whether there is still at least part of the respectively folded item of laundry located in the upper region of the folding region or blowing space, and the at least one folding operation and/or the supply of blowing air are/is controlled correspondingly. In the case of this method, provision is made, during the longitudinal-folding operation, for an upper region of a folding zone, in particular of a blowing space, located above the folding templates to be monitored as to whether there is still at least part of the item of laundry located in said monitored upper region. It is established here whether the item of laundry, or a part of the same which is to be folded longitudinally in each case, has left the monitored upper region. This is an indication of the termination of the respective longitudinal-folding operation. This method makes it possible to determine the duration of the respective longitudinal-folding operation and, in particular, to establish when the longitudinal-folding operation, which will last for different periods of time depending on the size of the item of laundry, has terminated.
Provision is preferably made for the supply of the blowing air which is necessary for folding purposes to be interrupted or terminated when it has been established that the relevant folding operation of the item of laundry currently located in the longitudinal-folding station, in particular a part of the same, has terminated. Preferably then, at the same time, the supply of blowing air to the following longitudinal-folding operation of the same item of laundry is started or released. It is thus possible for the blowing-air duration to be adapted to the duration of the respective longitudinal-folding operation and to achieve the situation where the blowing air acts on the item of laundry which is to be folded longitudinally only until the respective longitudinal-folding operation has taken place.
In the case of an advantageous development of the method, provision is made for only such an upper region of the folding or blowing zone or of the blowing space as has its lower plane located at a distance, preferably at a parallel distance, above the folding templates to be monitored. This distance is selected, in particular, such that said upper region is located above a main-extent surface area of the item of laundry which is located in the longitudinal-folding station in each case. On the one hand, the main-extent surface area of the item of laundry is that surface area which runs through the highest point of the as yet non-folded item of laundry located in the longitudinal-folding station. This is based on the finding that the non-folded item of laundry is located in a somewhat undulating state, rather than completely smoothly, in the longitudinal-folding station, and therefore the main-extent surface area is that surface area which does not go beyond the item of laundry located, possibly in a puckered state, in the longitudinal-folding station. On the other hand, the main-extent surface area is that surface area which is located closely above the highest point of the longitudinally folded item of laundry. Monitoring just the upper region of the folding zone or of the blowing space above the folding templates, said upper region being located above the main-extent surface areas, means that monitoring is provided for specifically that region through which, during the longitudinal-folding operation, at least part of the item of laundry which is to be folded longitudinally in each case is moved as it is folded over by the blowing air. Once the preferably outer parts of the item of laundry have been folded over in a longitudinally directed manner one after the other around the folding templates by the blowing air, the respectively longitudinally folded part, following each longitudinal-folding operation, leaves the upper region of the folding or blowing zone again, which is detected by the monitoring and thus indicates the end of the respective folding operation. This reliably provides the correct point in time for terminating the supply of blowing air, and the supply of blowing air for the longitudinal-folding operation which has taken place is terminated specifically.
According to an advantageous configuration of the method, at least one line through the lower plane of the upper region of the folding zone or of the blowing space is monitored. This can be done by way of at least one light barrier or the like extending preferably transversely, but possibly also longitudinally, via the longitudinal-folding station. It is also conceivable, however, for the lower plane of the upper region of the folding zone to be monitored by a plurality of parallel longitudinally and/or transversely running light barriers or the like which are located in said plane, and follow one after the other in particular along the longitudinal extent of the longitudinal-folding station. It is also conceivable for image-forming means to monitor the entire upper region of the blowing space or of the folding zone three-dimensionally for the presence of part of an item of laundry in said region. The linear, two-dimensional or three-dimensional options outlined for monitoring the upper region or the lower plane of the upper region can reliably determine whether there is still part of an item of laundry located in the upper region above the blowing or folding zone. In particular, it is thus possible to determine the point in time, corresponding to the end of the respective folding operation, at which the final point of the item of laundry which is to be folded longitudinally in each case has left the monitored upper region of the blowing or folding zone.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred exemplary embodiments of the invention will be explained in more detail hereinbelow with reference to the drawing, in which:
FIG. 1 shows a schematic view of an apparatus for folding and stacking items of laundry,
FIG. 2 shows a schematic plan view of a longitudinal-folding station of the apparatus from FIG. 1 , with small items of laundry,
FIG. 3 shows a schematic plan view of the longitudinal-folding station analogous to FIG. 2 , with a large item of laundry,
FIG. 4 shows a schematic cross section through the longitudinal-folding station of the apparatus from FIGS. 1 to 3 , with an as yet non-folded item of laundry,
FIG. 5 shows a view analogous to FIG. 4 during the longitudinal-folding operation of a right-hand part of the item of laundry,
FIG. 6 shows a view analogous to FIGS. 4 and 5 following the longitudinal-folding operation of the right-hand part of the item of laundry, and
FIG. 7 shows a schematic cross section (analogous to FIG. 5 ) through the longitudinal-folding station of an apparatus according to another exemplary embodiment of the invention, during the longitudinal-folding operation of a right-hand part of the item of laundry.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The apparatus shown in FIG. 1 serves for automatically folding items of laundry 10 and for simultaneously stacking folded items of laundry 10 . The items of laundry 10 may be of any desired type, preferably so-called flat textile products such as sheets, blankets, pillowcases, tablecloths, napkins or the like, but also towels, including those made of terry cloth. The invention also relates to apparatuses which serve for folding and/or stacking other items of laundry, for example items of clothing, so-called shaped items. The invention further relates to apparatuses which serve only for folding items of laundry 10 .
The apparatus has, on the left-hand side in FIG. 1 , an infeed table 11 with at least one circulating infeed conveying belt. A spread-out item of laundry 10 which is to be folded in each case is transported in the transporting direction 12 from the infeed table 11 to a longitudinal-folding station 13 . In the longitudinal-folding station 13 , the respective item of laundry 10 is folded longitudinally at least once. In the case of the exemplary embodiment shown, two longitudinal-folding operations take place one after the other from opposite longitudinal sides of the item of laundry 10 . This gives the item of laundry 10 two parallel folding lines running in the transporting direction 12 , that is to say longitudinally in relation to the longitudinal-folding station 13 , on opposite sides of the centre of the item of laundry, as seen in the transporting direction 12 .
The respective item of laundry 10 is transported from the longitudinal-folding station 13 into a cross-folding station 14 of the apparatus shown here. In the cross-folding station 14 , the respective item of laundry 10 is folded transversely at least once. The folded item of laundry 10 is transported by a lower delivery conveyor 15 , counter to the transporting direction 12 of the longitudinal-folding station 13 , to a stacking device 16 , which is located beneath and/or alongside the longitudinal-folding station 13 .
The stacking device 16 has a conveyor 17 which runs parallel to the longitudinal-folding station 13 and, in the exemplary embodiment shown, is assigned four stackers following one after the other in the transporting direction 12 , for example lifting trucks 18 , 19 , 20 and 21 , which are shown in FIG. 1 . The lifting trucks 18 to 21 are at different distances from the delivery conveyor 15 of the cross-folding station 14 , and therefore the conveying routes to the individual lifting trucks 18 to 21 are of different lengths. The shortest conveying route leads to the lifting truck 18 and the longest conveying route leads to the furthest-away lifting truck 21 . The conveyor 17 is assigned, on each lifting truck 18 to 21 , stacking plates, which each deposit a folded item of laundry 10 on the relevant lifting truck 18 , 19 , 20 and 21 or on the stack of folded items of laundry 10 already formed thereon.
In the case of the apparatus shown here, a length-measuring device 35 is provided upstream of the longitudinal-folding station 13 . The length-measuring device 22 may also be provided at the end of the infeed table 11 or at the start of the longitudinal-folding station 13 . The length-measuring device 35 may be a sensor which determines the length of the item of laundry 10 in the transporting direction 12 , that is to say in the longitudinal direction of the longitudinal-folding station 13 , in a contactless manner. The contactlessly operating sensor determines the amount of time which the respective item of laundry 10 requires in order to be transported past it. The length of the item of laundry 10 , (as seen in the transporting direction 12 ) can be calculated from this amount of time in conjunction with the known constant speed at which the item of laundry 10 is transported along the sensor. It is also conceivable, however, to have a displacement sensor rolling on the item of laundry 10 and, in the process, determining the distance between the front transverse edge and the rear transverse edge of the item of laundry 10 as it butts against the item of laundry 10 , this distance being a direct indication of the length of the item of laundry 10 .
The longitudinal-folding station 13 has a longitudinal conveyor 22 , which is continuous over the entire width and length of the longitudinal-folding station. The longitudinal conveyor 22 transports the item of laundry 10 through the longitudinal-folding station 13 in the transporting direction 12 . The longitudinal conveyor 22 has a circulating conveying belt which is continuous over the entire width of the longitudinal-folding station 13 or has a plurality of narrow conveying belts located one beside the other. The item of laundry 10 is spread out in the as yet non-folded state on the at least one conveying belt of the longitudinal conveyor 22 ( FIG. 4 ).
In the exemplary embodiment shown, two elongate folding templates 23 are provided at a small distance above the upper strand of the at least one circulating belt of the longitudinal conveyor 22 . The elongate, strip-like folding templates 23 extend parallel to one another in the longitudinal direction of the longitudinal-folding station 13 . In the exemplary embodiment shown, the folding templates 23 , spaced apart parallel to one another, are assigned to different halves of the longitudinal conveyor 22 . The folding templates 23 can be spaced apart differently from one another for adaptation to items of laundry 10 of different sizes, in particular of different widths. Apart from this, the folding templates 23 are arranged in a fixed position at a small distance above the longitudinal conveyor 22 . Outer sub-regions of the item of laundry 10 are folded over one after the other first of all around the one folding template 23 and then around the other folding template 23 and, as a result, two longitudinal-folding operations are carried out one after the other in order to fold the item of laundry 10 in thirds in relation to the width of the same.
The longitudinal-folding operation of the item of laundry 10 takes place pneumatically by way of compressed air in the longitudinal-folding station 13 shown here. For this purpose, blowing tubes 25 , 26 are arranged along each of the opposite, parallel longitudinal peripheries 24 of the longitudinal-folding station 13 . In the exemplary embodiment shown, the elongate, blowing tubes 25 , 26 running parallel to one another are arranged in a plane which is located some way above the folding templates 23 ( FIG. 5 ). Each blowing tube 25 , 26 serves for carrying out a longitudinal-folding operation of the item of laundry 10 . It is preferably the case that the identically designed blowing tubes 25 , 26 are provided, on their side which is oriented towards the center of the longitudinal-folding station 13 , with in each case at least one row of blowing nozzles, from which compressed-air jets exit. It is possible for the blowing nozzles to generate a cylindrical compressed-air jet, but also a slightly conical one. It is also conceivable for the blowing tubes 25 , 26 to be rotatable to some extent, for example to be rotatable back and forth in opposite directions, about their longitudinal axes in order to fold the item of laundry 10 .
At least one light barrier 27 is provided above the blowing tubes 25 , 26 . A light barrier 27 which runs horizontally transversely to the transporting direction 12 is illustrated symbolically in FIGS. 4 to 6 . The light barrier 27 has at least one light source 28 (on the right in FIGS. 4 to 6 ) and a reflector 29 (arranged above the left-hand blowing tube 26 in FIGS. 4 to 6 ) located opposite. The light barrier 27 —when interrupted—generates a horizontal sensor line 30 , which is symbolized by a row of spots of light in FIGS. 4 to 6 . The light source 28 and the reflector 29 are arranged at a small distance above the blowing tubes 25 , 26 , and therefore the sensor line 30 of the light barrier 27 is located at a parallel distance above a horizontal line/plane of connection between the blowing tubes 25 , 26 . This sensor line 30 constitutes a lower boundary of an upper region 31 which is symbolized by a grid of lines in FIGS. 4 to 6 and forms part of a folding space, namely a blowing space 32 , of the longitudinal-folding station 13 , said space being located above the folding templates 23 . The sensor line 30 thus subdivides the blowing space 32 into the upper region 31 and a lower region 33 , which is located between the sensor line 30 and the folding templates 23 . The height of the lower region 33 is selected such that a main-extent surface area of the folded and also non-folded or merely partially folded item of laundry 10 is located in it, that is to say each definitively folded item of laundry 10 , once the right-hand and left-hand peripheral regions have been folded over around the folding templates 23 , occupies only the lower region 33 , but not the upper region 31 , and therefore each definitively folded item of laundry 10 is located beneath the sensor line 30 .
Since the elongate blowing tubes 25 , 26 give rise to each side part of an item of laundry 10 being folded over uniformly around the respective folding template 23 , as seen in the longitudinal direction of the longitudinal-folding station 13 , it is sufficient for a single light barrier 27 with a sensor line 30 running transversely to the transporting direction 12 to be provided above the plane of the blowing tubes 25 , 26 . It is also conceivable, however, for a plurality of light barriers 27 , distributed at more or less large intervals over the length of the longitudinal-folding station 13 , with parallel, horizontal sensor lines 30 to be provided. It is then possible for the lower plane of the upper region 31 of the blowing space 32 to be sensed in a contactless manner over the surface area.
It is also conceivable for image-forming means, for example cameras, to monitor the entire upper region 31 of the blowing space 32 three-dimensionally.
The apparatus has a control means and/or circuit (not shown), to which the measured length of the item of laundry 10 supplied to the longitudinal-folding station 13 in each case is made available. The speed of the longitudinal conveyor 22 of the longitudinal-folding station 13 is then altered, in particular adapted, with reference to the length of the respective item of laundry 10 , to be precise such that a front transverse edge 36 of the respective item of laundry 10 , following completion of the longitudinal-folding operation, has been transported as closely as possible up to an outlet end 34 at the front transverse edge of the longitudinal-folding station 13 .
The same control means or circuit, or a separate control means or circuit, receives a signal from the light barrier 27 when a peripheral region of the item of laundry 10 which is to be folded over around the folding templates 23 by the air jets of the blowing tubes 25 , 26 is no longer located in the upper region 31 of the blowing space 32 .
The circuit or control means for adapting the transporting speed of the longitudinal conveyor 22 of the longitudinal-folding station 13 to the length of the item of laundry 10 can also be used to determine on which of the lifting trucks 18 to 21 located at different distances from the delivery conveyor 15 the respectively folded item of laundry 10 is deposited. The control means registers the size of the respective item of laundry 10 and the speed at which it has been transported through the longitudinal-folding station 13 and, accordingly, deposits an item of laundry 10 which has been transported relatively quickly through the longitudinal-folding station 13 onto the rearmost lifting truck 21 . Relatively large items of laundry 10 are deposited on the front lifting truck or trucks 18 or 19 .
The exemplary embodiment of FIG. 7 differs from the previously described exemplary embodiment only by the fact of at least one longitudinally running light barrier being provided instead of the light barrier 27 (of the exemplary embodiment of FIGS. 4 to 6 ) running transversely to the transporting direction 12 . The exemplary embodiment of FIG. 7 provides two parallel longitudinally directed light barriers 37 , 38 , to be precise one light barrier 37 , 38 , for each half of the longitudinal-folding station 13 . The two light barriers 37 , 38 are located in a common horizontal plane some way above the horizontal plane of connection between the blowing tubes 25 , 26 . The horizontal plane in which the light barriers 37 , 38 line is located between an upper region 31 and a lower region 33 of the blowing space 32 , that is to say still above the plane of the blowing tubes 25 , 26 above the folding templates 23 . The distance between the two light barriers 37 , 38 is larger than the distance between the outer longitudinal edges of the folding templates 23 . This means that the longitudinally directed light barriers 37 , 38 are located in a region through which it is necessary to move the outer peripheral strips of the respective item of laundry 10 , said outer peripheral strips having to be folded over around the folding templates 23 by blowing air. This allows the longitudinally directed light barriers 37 and 38 to determine reliably whether the longitudinal-folding operation of the respective outer peripheral region of the item of laundry 10 has taken place at least predominantly or not at all.
The method used by the abovedescribed apparatus for folding and stacking items of laundry 10 will be described in more detail hereinbelow in conjunction with the exemplary embodiment of FIGS. 1 to 6 .
The longitudinal-folding operation of the items of laundry 10 takes place in dependence on at least the size, preferably length and/or width, of the same, with different transporting speeds for each item of laundry 10 through the longitudinal-folding station 13 in the transporting direction 12 . The speed of the longitudinal conveyor 22 in the longitudinal-folding station 13 is adapted here to the size, and possibly the material, of the item of laundry 10 which is to be folded in each case. In particular short items of laundry 10 , in other words those of which the lengths are comparatively small as seen in the transporting direction 12 or longitudinal direction of the longitudinal-folding station 13 , are transported through the longitudinal-folding station 13 more quickly than longer items of laundry 10 . In other words, short items of laundry 10 are accelerated by the longitudinal conveyor 22 in the longitudinal-folding station 13 and longer items of laundry 10 are slowed down by virtue of the longitudinal conveyor 22 of the longitudinal-folding station 13 being braked correspondingly.
The length-measuring device 35 , which is arranged at the start, or upstream, of the longitudinal-folding station 13 , determines whether the item of laundry 10 is small or large, in particular short or long. The length of the item of laundry 10 is thus known before the beginning of the first longitudinal-folding operation of said item of laundry 10 in the longitudinal-folding station 13 . With reference to the previously established size or length of the item of laundry 10 , the control means of the longitudinal-folding station 13 determines the speed of the longitudinal conveyor 22 and drives the longitudinal conveyor 22 correspondingly. This means that it is possible for large and small items of laundry 10 , during continuous onward transportation through the longitudinal-folding station 13 , to be folded longitudinally two times one after the other, to be precise, in the exemplary embodiments of FIGS. 2 and 3 , in the first instance a right-hand peripheral region is folded around the right-hand folding template 23 and then a left-hand peripheral region is folded around the left-hand folding template 23 . It is also possible for the longitudinal-folding operation to be carried out for relatively large or relatively long items of laundry 10 without any interruption in the onward transportation of the item of laundry through the longitudinal-folding station 13 . It is only when the item of laundry 10 which is to be folded in the longitudinal-folding station 13 is large enough to take up virtually the entire length of the longitudinal-folding station 13 that the onward transportation of said very long item of laundry 10 through the longitudinal-folding station 13 has to be stopped briefly for longitudinal-folding purposes.
Adaptation of the transporting speed of the longitudinal conveyor 22 of the longitudinal-folding station 13 to the length of the item of laundry 10 which is to be folded longitudinally in each case takes place such that, at the conclusion of the final longitudinal-folding operation in the longitudinal-folding station 13 , a front transverse edge 36 of the definitively folded item of laundry 10 is located right at the outlet end 34 , that is to say a front transverse edge, of the longitudinal-folding station 13 or right at the front ends of the folding templates 23 ( FIG. 2 ). If at least one short item of laundry 10 ( FIG. 2 ) is followed by a longer item of laundry 10 ( FIG. 3 ), then the speed of the longitudinal conveyor 22 is reduced to the extent where the front transverse edge 36 of the longer item of laundry 10 , at the completion of the longitudinal-folding operation in the longitudinal-folding station 13 , is located at the front outlet end 34 of said station or in the vicinity of the front outlet end 34 and/or the front ends of the folding templates 23 .
As a result of the method described above, items of laundry 10 of different sizes (with the exception of extra-large items of laundry 10 corresponding approximately to the length of the longitudinal-folding station 13 ) can be folded longitudinally during uninterrupted, continuous onward transportation through the longitudinal-folding station 13 . In addition, as a result of the transporting speed of the longitudinal conveyor 22 being adapted in dependence on the length of the items of laundry 10 determined beforehand by the length-measuring device 35 , both short and long items of laundry 10 , following termination of the longitudinal-folding operation in the longitudinal-folding station 13 , have their front transverse edge 36 located at the outlet end 34 , or in the vicinity of the outlet end 34 , of the longitudinal-folding station 13 and/or at the ends of the folding templates 23 .
The method described reduces to a minimum the amount of time required for the items of laundry 10 to pass through the longitudinal-folding station 13 in that, irrespective of their size, in particular length, the items of laundry 10 , once folded longitudinally, are located immediately upstream of the outlet end 34 of the longitudinal-folding station 13 and thus, irrespective of their size, all the items of laundry 10 , following termination of the final longitudinal-folding operation, can be immediately transported out of the longitudinal-folding station 13 via the outlet end 34 .
Provision is preferably also made for the folded items of laundry 10 to be stacked specifically on the lifting trucks 18 to 21 . For this purpose, relatively small items of laundry 10 , which have been transported through the longitudinal-folding station 13 at a relatively great conveying speed of the longitudinal conveyor 22 , and of which the residence time in the longitudinal-folding station 13 is thus shorter than that of larger items of laundry 10 , are stacked on lifting trucks 21 or 20 , which are respectively furthest away or relatively far away from the delivery conveyor 15 of the cross-folding station 14 . In contrast, longer items of laundry 10 , which are transported through the longitudinal-folding station 13 more slowly, are deposited on the lifting trucks 18 or 19 , which are closer to the delivery conveyor 15 . It is therefore the case that relatively long transporting routes taken by folded items of laundry 10 to the rear lifting trucks 20 , 21 are combined with relatively short amounts of time required for passage through the longitudinal-folding station 13 . In contrast, larger items of laundry 10 , which require longer amounts of time for folding in the longitudinal-folding station 13 , are deposited on front lifting trucks 18 or 19 , which require shorter supply routes. As a result, the amounts of time required for relatively large items of laundry 10 and relatively small items of laundry 10 to pass through the longitudinal-folding station 13 and the stacking device 16 are more or less the same.
As an alternative, it is also conceivable for the conveyor 17 , which leads to the lifting trucks 18 to 21 , to be driven at such alternating speeds that folded items of laundry 10 are passed to the lifting trucks 18 to 21 within approximately the same amount of time. In this case, the folded items of laundry 10 are transported to the rearmost lifting truck 21 at the greatest transporting speed and to the front lifting truck 18 at the lowest conveying speed. There is no particular need here for the transporting speed of the conveyor 17 to be geared to the size of the folded items of laundry 10 ; rather, it can be adapted to the conveying route irrespective of the size of the items of laundry 10 .
The method also provides for the blowing duration of the blowing tubes 25 , 26 to be adapted to the duration of the respective longitudinal-folding operation. This means that the action of the compressed air exiting from the blowing tubes 25 and 26 is terminated as soon as the respective longitudinal-folding operation has been completed. This results in blowing-time regulation which is dependent at least on the length of the items of laundry 10 . It is also preferably the case, however, that the amount of blowing time required is determined in accordance with the width and/or the material, in particular where terry cloth is concerned, of the items of laundry 10 .
For the purpose of blowing-time regulation, monitoring is carried out as to whether there is still part of the item of laundry 10 located in the upper region 31 of the blowing space 32 . For this purpose, the lower, preferably horizontal, plane of the upper region 31 , said plane being located at a parallel distance above the folding templates 23 and blowing tubes 25 , 26 and having the sensor line 30 running through it, is monitored by the at least one transversely directed light barrier 27 . If the sensor line 30 between the light source 28 and the reflector 29 of the light barrier 27 , said sensor line being located in the lower plane of the upper region 31 , is interrupted ( FIG. 5 ), there is still part of the item of laundry 10 which is currently to be folded longitudinally located in the upper region 31 of the blowing space 32 . This signals that the folding operation, which also requires a compressed-air jet exiting from the nozzles of the blowing tube 25 or 26 , is still underway. As soon as a first (right-hand) peripheral region of the item of laundry 10 , said first peripheral region having been folded over around the right-hand folding template 23 by the compressed-air jets from the right-hand blowing tube 25 in FIG. 6 , has left the upper region 31 and the sensor line 30 is thus freed, the action of air exiting from the right-hand blowing tube 25 is interrupted and the operation of folding over the second peripheral region of the item of laundry 10 (the left-hand peripheral region in FIG. 6 ) around the left-hand folding template 23 can begin, by the compressed-air supply of the left-hand blowing tube 26 then being released. The compressed-air jet exiting from the left-hand blowing tube 26 then folds over the left-hand peripheral region of the item of laundry 10 around the left-hand folding template 23 onto the previously folded right-hand peripheral region of the item of laundry 10 . The light barrier 27 detects, in turn, the completion of the folding operation of the left-hand peripheral region of the item of laundry 10 when the latter has left the upper region 31 of the blowing space 32 and is located beneath the sensor line 30 of the light barrier 27 , in the lower region 33 of the blowing space 32 . The longitudinal-folding operation of the item of laundry 10 in the longitudinal-folding station 13 has then been completed, and the compressed-air supply of the left-hand blowing tube 26 is also interrupted.
Following the longitudinal-folding operation of one item of laundry 10 , the longitudinal-folding operation of the following item of laundry 10 can begin with the opening of the compressed-air supply of the right-hand blowing tube 25 , which first of all folds over the right-hand peripheral region of the item of laundry 10 around the right-hand folding template 23 . Thereafter, the folding operation of the left-hand peripheral region of the item of laundry 10 takes place in the previously described manner by virtue of the compressed-air supply of the blowing tubes 25 and 26 being changed over correspondingly and the compressed-air supply of the two blowing tubes 25 , 26 being terminated following the second longitudinal-folding operation of the left-hand peripheral region of the item of laundry 10 on the previously folded right-hand peripheral region of the same.
Monitoring the upper region 31 of the blowing space 32 for the presence or absence of part of the item of laundry 10 makes it possible for the duration over which air exits from each of the blowing tubes 25 , 26 to be controlled individually. Therefore, the one blowing tube 25 is still supplied with compressed air for as much time as is required by said blowing tube 25 in order to carry out the first longitudinal-folding operation of the relevant part of the item of laundry 10 . The termination of the supply of compressed air to the blowing tube 25 for the first longitudinal-folding operation is accompanied at the same time, or slightly later, by the supply of compressed air to the other blowing tube 26 for the second longitudinal-folding operation of the other part of the item of laundry 10 being released, that is to say the compressed-air supply of the one blowing tube 25 or the other 26 is changed over automatically. In other words, the method according to the invention supplies each blowing tube 25 , 26 with compressed air only for such a period of time as corresponds to the amount of time required for the respective longitudinal-folding operation. Moreover, the method according to the invention controls the beginning of the second transverse-folding operation, which takes place following the first transverse-folding operation.
According to the exemplary embodiment of FIG. 7 , the longitudinal-folding operation of items of laundry 10 takes place basically by the same method described above in conjunction with the first exemplary embodiment ( FIGS. 4 to 6 ). The only difference is that here the lower horizontal plane of the upper region 31 of the blowing space 32 is monitored by two light barriers 37 , 38 which run longitudinally directed in the transporting direction 12 .
The invention has been described above in conjunction with an apparatus for the combined folding of items of laundry 10 and stacking of folded items of laundry 10 . The invention is also suitable for apparatuses which serve only for folding items of laundry 10 , in particular for folding them at least longitudinally, or apparatuses by which folded items of laundry 10 are deposited merely on different lifting trucks 18 to 21 .
It is also the case that the invention is not restricted to apparatuses for combined longitudinal-folding and transverse-folding operations. The invention is also suitable for apparatuses which serve only for folding items of laundry 10 longitudinally at least once. It is also the case that the invention is not restricted to apparatuses which have four lifting trucks 18 to 21 , according to the exemplary embodiment shown in the figures. The invention is also suitable for apparatuses having more or fewer than four lifting trucks 18 to 21 .
LIST OF DESIGNATIONS
10 Item of laundry
11 Infeed table
12 Transporting direction
13 Longitudinal-folding station
14 Cross-folding station
15 Delivery conveyor
16 Stacking device
17 Conveyor
18 Lifting truck
19 Lifting truck
20 Lifting truck
21 Lifting truck
22 Longitudinal conveyor
23 Folding template
24 Longitudinal periphery
25 Blowing tube
26 Blowing tube
27 Light barrier
28 Light source
29 Reflector
30 Sensor line
31 Upper region
32 Blowing space
33 Lower region
34 Outlet end
35 Length-measuring device
36 Front transverse edge
37 Light barrier
38 Light barrier | In apparatuses for automatically folding items of laundry, items of laundry of different lengths usually are folded in an irregular sequence, resulting in idling and/or delays in particular in the longitudinal-folding station ( 13 ). The invention provides for determining the length of each item of laundry ( 10 ) upstream of the longitudinal-folding station ( 13 ) and for accelerating short items of laundry as they are transported through the longitudinal-folding station ( 13 ), whereas larger items of laundry are slowed down in the longitudinal-folding station ( 13 ). Following completion of the longitudinal-folding operation, the respectively folded item of laundry is located at the end of the longitudinal-folding station ( 13 ) and, immediately following completion of the longitudinal folding, is transported away out of the longitudinal-folding station ( 13 ). This avoids unnecessary idling times, and for relatively long items of laundry to be folded longitudinally during continuous, relatively slow onward transportation through the longitudinal-folding station ( 13 ). | 1 |
[0001] Presently many efforts are being made to convert and store energy so that electricity can be made available at a time and place when and where it is required. The drive to fight climate change is resulting in many new innovations and methods of generating renewable energy. Devices for generating electricity from different forms of renewable energy are being developed every day, but the intermittent nature of most renewable energy sources can be a problem when trying to match generation with demand, especially at times of peak demand. Therefore, a need exists for a cost effective and safe method of storing energy so that electricity can be made available at times of demand for consumers at different levels, namely domestic, commercial and industrial. There also exists a need to store and make energy available in large amounts to help with the balancing needs of the UK national electricity grid and the smart grids being developed in different cities around the world.
[0002] One method of energy storage presently being developed is flywheels. Flywheels can be very efficient and can store great amounts of energy in very confined spaces. One of the problems with storing great amounts of energy in very confined spaces is the health and safety implications.
[0003] If something goes wrong with a flywheel which is constructed of steel or highly compacted composite materials such as fibre glass or carbon fibre, then the dangers from debris can be considerable therefore in an effort to reduce any risk to life or property, steel or solid composite flywheels are usually encased in a strong steel tube and buried into the ground.
[0004] An alternative to this sort of flywheel is a flywheel containing fluid. In this sort of flywheel the flywheel is hollow and lightweight and may be driven up to its operating speed before fluid is added to thereby increase the mass of the flywheel. If energy is available to be stored in the flywheel the operating speed of the flywheel can be maintained while the addition of fluid increases the mass of the flywheel. One advantage of this sort of flywheel can be, in the event of a defect in the structure of the flywheel or a component such as a bearing if the flywheel breaks up the majority of the mass may be contained within a surrounding containment tank or bund, where the strength of the containment tank may be sufficient to contain the debris and avoid the necessity to bury the tank in to the ground. The containment tank may be provided with a vacuum pump in order to evacuate the tank of air, or to at least partially evacuate and/or reduce the amount of air contained within the tank. This results in lower air resistance and so the flywheel is able to rotate for longer.
[0005] The reduced health and safety risks of a flywheel containing fluid make them more suitable to domestic or commercial environments; they can also be used in many industrial applications.
[0006] A problem with a flywheel containing fluid is that during its operating cycle, the velocity and mass of the flywheel may change depending on how much fluid is present within the flywheel. This means that there will be different stresses and strains applied to the supporting bearings at different times during the operating cycle of the flywheel containing fluid.
[0007] A flywheel energy storage system may have its operating cycle broken down into three distinct operating periods of time.
[0008] There is, firstly, the period of time when the energy is transferred from one or more forms of energy such as, for example, electrical energy into the flywheel to be stored as kinetic energy which can then be seen as the rotation of the flywheel.
[0009] Secondly, there is the period of time when energy is not being transferred in to the flywheel and it is not being transferred out of the flywheel other than losses within the system.
[0010] Thirdly, there is the period of time when energy is being transferred out of the flywheel; this is when the energy is usually converted from kinetic energy into electrical energy for use by the consumer.
[0011] During these three periods of the operating cycle different forces stresses and strains may be set up within the flywheel energy storage system. These forces, stresses and strains may be transferred to and from the supporting bearings consequently these forces stresses and strains may reduce the efficiency and the operating life of the flywheel energy storage system.
[0012] This type of flywheel has many advantages due to the reduced health and safety risk but presently fluid filled flywheels consume some of their stored energy in maintaining power to the electromagnetic bearings and thereby reducing the energy storage capacity of a fluid filled flywheel.
[0013] To aid the balance, vibration and overall performance of a flywheel containing fluid there exists a need for a bearing and support mechanism that can adapt very quickly to the constantly changing loads. Furthermore, there exists a need for a bearing and support mechanism that can use the minimum amount of power in order to maintain the storage capacity of the flywheel.
[0014] As an energy storage system the flywheel containing fluid has many advantages over other forms of energy storage but because the technology has only recently been developed several problems exist. One such problem is that, the present methods of supporting a rotating flywheel containing fluid consumes some of the power being stored. This reduces the overall efficiency and the capacity of a flywheel based energy storage system.
[0015] Therefore, a need exists for a levitating magnetic bearing that can support a flywheel containing fluid and at the same time consume as little of the stored energy as possible.
[0016] The present invention is directed to a flywheel system and control mechanism as defines in the enclosed independent claims. Preferred features are set out in the sub-claims.
[0017] In one aspect of the present invention, there is provided a flywheel comprising a rotatable shaft, at least one end of the rotatable shaft being provided with a recess and two magnets, wherein the flywheel is provided with support means, the support means comprising:
[0018] a first arrangement of magnets for horizontal stabilization of the shaft; and
[0019] a second arrangement of magnets for vertical stabilization of the shaft;
[0020] and wherein the first of the two magnets of the shaft interacts with the first arrangement and the second of the two magnets interacts with the second arrangement.
[0021] The magnets may be arranged so that the two magnets on the shaft are attracted to, or repelled from, the respective first or second arrangement of magnets. Clearly, the attraction or repulsion depends on the orientation of the magnets with respect to the shaft and the arrangement employed.
[0022] Preferably, the first arrangement comprises a toroidal magnets and wherein the first shaft magnet is arranged coaxially with the magnet of the first arrangement and substantially therein, and more preferably, the first shaft magnet is toroidal and has a smaller diameter that the toroidal magnet of the first arrangement. The shaft magnet being smaller than the other magnet of the first arrangement allows for the shaft magnet to be positioned within the other magnet. This allows for any movement of the shaft magnet in a horizontal direction to be countered by the other magnet to keep the shaft centred.
[0023] Advantageously, the second arrangement comprises a toroidal magnet and the second shaft magnet is arranged coaxially with the magnet of the second arrangement and adjacent thereto, and more advantageously, the second shaft magnet is toroidal and has a diameter substantially the same as the toroidal magnet of the second arrangement and is positioned above the magnet of the second arrangement. Positioning one magnet above the other allows for vertical stabilization of the shaft because movement of one magnet will cause the magnetic fields and/or gravity to interfere with the field of the moved magnet, thereby providing vertical stabilization by the correction of movement in the fields to re-establish an equilibrium position.
[0024] The stabilisation arrangement in the form of support means allows for movement of the flywheel shaft in a vertical and horizontal direction to be controlled using two coaxial arrangements of magnets: the first comprising one on top of the other to allow the vertical position of the shaft to be controlled; and the second having one
[0025] In one arrangement both ends of the rotatable shaft comprise a two magnets and respective associated support means. This allows either or both end to be adjusted to keep the shaft stable.
[0026] Preferably, top and bottom pins are provided to be received within the recesses of the shaft. Positioning the pins within the recesses reduces the risk of the shaft falling and it allows for light touches between the inside of the shaft recesses and pins to assist with the stabilisation.
[0027] Advantageously, the pins are electrically conductive, which allows them to be used as switches for monitoring the position of the shaft relative to the pins.
[0028] In a preferred arrangement, the shaft further comprises magnetic bearings and a framework is provided with respective magnetic bearings to levitate the shaft from the framework. The framework provides a fixed location for the shaft to levitate relative to and the magnetic bearings reduce friction in the system, thereby allowing the flywheel to rotate for long periods of time.
[0029] In an advantageous embodiment, the vertical position of the support means can be adjusted to alter the vertical position of the shaft. This may include moving the pins accordingly so that they assist with the stabilisation of the shaft. By moving the vertical position of the shaft, the friction in the arrangement can be reduced and the flywheel can be more readily controlled.
[0030] A computer may be provided to monitor the position of the shaft and to adjust the support means to alter the vertical height of the shaft. Allowing a computer to monitor and adjust the position of the support means and the shaft of the flywheel allows for automated responses to changes in the shaft position and balance.
[0031] Preferably, the shaft is provided with an electrical contact in its recess, the method comprising the steps of monitoring the electrical flow through at least one pin and adjusting the vertical position of the shaft using a stepper motor until the flow ceases, and adjusting the vertical position of the shaft until the electrical contact is re-established. This allows the position of the shaft relative to the pins to be adjusted so that the frictional contact is reduced, thereby allowing for longer rotation of the flywheel. By continually disconnecting and reconnecting the connection between the pins and the shaft, the friction can be monitored and controlled to keep it relatively low. Alternatively, where necessary, the rotation of the shaft can be reduced by increasing the friction between the pins and the shaft.
[0032] It is therefore an object of the present invention to provide a computer controlled adjustable array of permanent magnets for supporting the rotating centre shaft of a flywheel containing fluid. The top and bottom of the vertically aligned rotating centre shaft may be supported by respective centralising pins; the centralising pins may act as a pair of switches to enable a computer control means to make accurate adjustments to the position of the array of permanent magnets and the position of the centralising pins. The top and bottom centralising pins may be constantly adjusted independently height-wise, or vertically, and almost simultaneously by the computer control means to apply a controlled pressure to both ends of the rotating centre shaft of a flywheel containing fluid to maintain stability and reduce undesirable vibrations in a flywheel containing fluid.
[0033] One object of the present invention is to provide a vertical array of permanent magnets for the support and stabilisation of a flywheel containing fluid, where the vertical array of permanent magnets is situated at or near to the top of a vertically aligned centre shaft of a flywheel containing fluid and at least one magnet of the said vertical array is vertically adjustable.
[0034] Another object of the present invention is to provide a vertical array of permanent magnets for the support and stabilisation of a flywheel containing fluid, where the vertical array of permanent magnets is situated at or near to the bottom of a vertically aligned centre shaft of a flywheel containing fluid and at least one magnet of the said vertical array is vertically adjustable.
[0035] Another object of the present invention is to provide a horizontal array of permanent magnets for the support and stabilisation of a flywheel containing fluid, where the said horizontal array of permanent magnets is situated at or near to the top and/or bottom of a vertically aligned centre shaft of a flywheel containing fluid and at least one magnet of the said horizontal array is vertically adjustable.
[0036] In another embodiment of the present invention it is an object of the present invention is to provide a horizontal array of permanent magnets for the support and stabilisation of a flywheel containing fluid, where the said horizontal array of permanent magnets is situated at or near to the top and/or bottom of a vertically aligned centre shaft of a flywheel containing fluid and at least one magnet of the said horizontal array is securely fixed and not adjustable.
[0037] Another object of the present invention is to provide a centralising pin for the support and stabilisation of a flywheel containing fluid, where the said centralising pin is situated at the top and/or bottom of a vertically aligned centre shaft of a flywheel containing fluid.
[0038] Another object of the present invention is to provide a centralising pin for the support and stabilisation of a flywheel containing fluid, where the said centralising pin may be shaped to a pointed cone at one end of the centralising pin.
[0039] Another object of the present invention is to provide a centralising pin for the support and stabilisation of a flywheel containing fluid, where the said centralising pin may be shaped with a radius at the tip of the pointed cone at one end of the centralising pin.
[0040] It is a further object of the present invention to provide a computer controlled adjustable support and stabilisation unit for the vertical positioning of at least one magnet which is part of a horizontal array of permanent magnets situated at or near to the top and/or bottom end of a vertically aligned rotating centre shaft of a flywheel containing fluid.
[0041] It is a further object of the present invention to provide a computer controlled adjustable support and stabilisation unit for the vertical positioning of at least one magnet which is part of a vertical array of permanent magnets situated at or near to the top and/or bottom end of a vertically aligned rotating centre shaft of a flywheel containing fluid.
[0042] It is a further object of the present invention to provide a computer controlled support and stabilisation unit for the coordinated control and vertical adjustment of a centralising pin situated at the top and/or bottom end of a vertically aligned rotating centre shaft of a flywheel containing fluid, furthermore the vertical adjustment of the said centralising pin may be along the central axis of rotation of the flywheel containing fluid.
[0043] The strength of all permanent magnets within the present invention is fixed and the strength of the interacting magnetic fields may be adjusted by adjusting the position of any or all of the magnetic supporting means and thereby adjusting the position of any or all of the magnets within any of the magnetic arrays of the present invention.
[0044] The strength of all permanent magnets within the present invention is fixed and the strength of the interacting magnetic fields may be adjusted by adjusting the position of any or all of the magnetic supporting means furthermore the position of any or all of the said supporting means may be controlled by the computer control means of the present invention.
[0045] Another object of the present invention is to provide a mechanical thrust bearing that may be separated in to two halves, where one half is securely attached to the vertically adjustable rotating centre shaft of the flywheel containing fluid and the other half is securely attached to a fixed means which is rigidly fixed into position.
[0046] It is a further object of the present invention to provide a computer control means to coordinate the lifting of the rotating centre shaft of a flywheel containing fluid by the vertical array of permanent magnets so that the two halves of the mechanical thrust bearing connect and disconnect in a controlled manner.
[0047] It is a further object of the present invention to provide a computer controlled adjustable bearing support means that may combine all of the features within the present invention with the simultaneous control of the lifting and lowering of the flywheel onto a plurality of mechanical bearings such as for example thrust bearings.
[0048] It is a further object of the present invention to provide a computer control means to coordinate a plurality of control signals to optimise the efficiency of a flywheel containing fluid.
[0049] In another embodiment of the present invention it is an object of the present invention to control the vertical adjustment of a vertical array of magnets combined with the vertical adjustment of a top and or bottom centralising pin and a horizontal array of permanent magnets where at least one permanent magnet is securely fixed and is not adjustable.
[0050] It is a further object of the present invention to provide a plurality of transducers at different positions within the present invention and thereby provide feedback signals to the computer control means so that the computer can calculate the present or changing state of all components within the present invention.
[0051] It is a further object of the present invention to provide a computer control means for the coordinated control and adjustment of all adjustable components within the present invention, furthermore in this way the computer controlled magnetic bearings and adjustable bearing support means and the adjustable centralising pins may be used to compensate for the changes in forces within the system at different times of the operating cycle of the flywheel containing fluid.
[0052] It is an object of the present invention to provide a rotating centre shaft that is securely attached to a flywheel that is substantially hollow and may contain fluid during operation.
[0053] It is an object of the present invention to provide an adjustable rotating centre shaft wherein the position of the rotating centre shaft may be vertically adjusted by the computer controlled adjustment of a vertical array of magnets wherein at least one magnet of the vertical array of magnets is securely attached to the rotating centre shaft.
[0054] It is an object of the present invention to provide a rotating centre shaft of a flywheel that can be filled with fluid, containing fluid wherein the said rotating centre shaft may have a recess at the top and/or bottom of the rotating centre shaft.
[0055] It is an object of the present invention to provide a rotating centre shaft wherein there is a recess at the top end and/or bottom end of the rotating centre shaft.
[0056] It is an object of the present invention to provide a rotating centre shaft wherein the recess at the top end and/or bottom end may be shaped to have an internal cone.
[0057] It is an object of the present invention to provide a rotating centre shaft wherein the internal cone has an internal tip shaped with a radius.
[0058] Preferably, during the operating cycle of the present invention, one or more surface areas of the internal cone of the recess of the rotating centre shaft may come into physical contact with the adjustable centralising pin.
[0059] It is an object of the present invention to provide a rotating centre shaft wherein there is a recess at the top end and or bottom end of the rotating centre shaft and the said recess may be shaped to allow the centralising pin of the present invention to be received within the said recess.
[0060] It is an object of the present invention to provide a rotating centre shaft wherein there is a recess to allow the centralising pin of the present invention to be received in, the recess and the centralising pin of the present invention may be vertically adjusted to make or break physical contact between the pin and the rotating centre shaft under the control of the computer control means of the present invention.
[0061] It is an object of the present invention to provide a rotating centre that may be constructed at least partially from an electrically conducting material.
[0062] It is an object of the present invention to provide a centralising pin that may be constructed at least partially from an electrically conducting material.
[0063] It is an object of the present invention to provide an adjustable rotating centre shaft and an adjustable centralising pin wherein the vertical adjustment of the centralising pin and or the vertical adjustment of the rotating centre shaft may make or break physical contact between the said rotating centre shaft and the said centralising pin and wherein the making and or breaking contact may be used to conduct or not conduct electricity to provide a switched signal to the computer control means.
[0064] It is an object of the present invention to provide an individual stepper motor that may be fitted to each individual adjustment means to enable accurate positioning of all adjustable support means within the present invention.
[0065] In another embodiment of the present invention an object of the present invention is to provide an adjustable rotating centre shaft and an adjustable centralising pin wherein the vertical adjustment of the centralising pin and or the vertical adjustment of the rotating centre shaft may make or break physical contact between the said rotating centre shaft and the said centralising pin and wherein the making and or breaking contact may be used to provide a pressure on pressure sensor that may provide a signal to the computer control means. The said pressure sensor may be for example a piezoelectric crystal transducer with an output signal proportional to the pressure being applied.
[0066] Fluid Feed System
[0067] It is an object of the present invention to provide a flywheel that may contain fluid, the flow of fluid into and out of the flywheel may be controlled by the computer control means of the present invention.
[0068] The operating cycle of the flywheel energy storage system may be divided into three distinct period of time.
[0069] There is firstly the period of time when the energy is transferred from one or more forms of energy such as, for example, electrical energy into the flywheel to be stored as kinetic energy which can then be seen as the rotation of the flywheel.
[0070] Secondly, there is the period of time when energy is not being transferred in to the flywheel and it is not being transferred out of the flywheel other than losses within the system.
[0071] Thirdly, there is the period of time when energy is being transferred out of the flywheel; this is when the energy is usually converted from kinetic energy into electrical energy for use by the consumer.
[0072] The computer control means is used to measure the speed and mass of the flywheel and measure the energy available to drive the motor and thereby drive the flywheel.
[0073] When it is determined by the computer control means that sufficient energy is available for the flywheel energy storage system to begin or continue its cycle energy is transferred to the drive motor and the speed of the flywheel may be increased until the flywheel reaches a predetermined speed. At the predetermined speed the computer control means provide control signals to allow the operation of the fluid pumping means to transfer fluid from an external reservoir to the peripheral reservoir chambers located in the periphery of the flywheel. When fluid is present in the inside reservoir the fluid transfer means transfers fluid from the inside reservoir to the inside of the flywheel.
[0074] The computer control means maintains the power to the drive motor and the fluid to the inside reservoir until the flywheel reaches a predetermined speed and mass.
[0075] The computer control means may monitor the availability of energy to be stored and the demand of energy as required by the consumer.
[0076] If it is determined that the flywheel has reached a predetermined speed and mass and energy is no longer required to be transferred into the flywheel or out of the flywheel then, in order to reduce frictional losses which may occur in the thrust bearings, the computer control means may adjust the position of the vertical array of permanent magnets in order to raise the rotating centre shaft and the flywheel, by raising the rotating centre shaft the rotating part and the non-rotating part of at least one thrust bearing may become disconnected, this is known as the second period of the operating cycle.
[0077] At this point in the operating cycle the computer control means may be used to precisely adjust the position of the top and bottom centralising pins so that both centralising pins may be just touching the rotating centre shaft. The pressure applied by both centralising pins to the rotating centre shaft may be adjusted and controlled by the computer control means.
[0078] The centralising pins may be used as switches to provide the computer control means with a signal to allow the computer control means to determine when the centralising pins are in contact with the rotating centre shaft.
[0079] The adjustment of the vertical array of magnets and the coordinated adjustment of the centralising pins may also be used to adjust the vertical position of the rotating centre shaft so that the rotating centre shaft is in the optimum position to take advantage of the horizontal array of permanent magnets and thereby reduce any horizontal movement in the rotating centre shaft.
[0080] Generally, but not exclusively, larger changes in forces within the flywheel supporting mechanism may be compensated for by the computer control means changing the position of the vertical array of magnets so that the rotating centre shaft may be lowered to enable the rotating part and the none rotating part of a one or more thrust bearings to be connected and thereby support the weight of the rotating centre shaft and the flywheel containing fluid.
DETAILED DESCRIPTION
[0081] Centralising Pin Support and Adjustment Means
[0082] The position of the centralising pins may be adjusted in a vertical direction
[0083] In one embodiment of the present invention the computer control means may be used to provide a plurality of electrical signals to drive a stepper motor in incremental steps, the stepper motor may be used to drive a series of timing belts and pulleys. The computer controlled adjustment of the stepper motor and pulleys may be used to accurately adjust the position of the centralising pins.
[0084] For a better understanding of the present invention and to show more clearly how it may be carried into effect, reference will now be made by way of example only, to the accompanying drawings in which like features are numbered accordingly and in which,
[0085] FIG. 1 shows how a flywheel containing fluid may be housed within a containment tank.
[0086] FIG. 2 shows how the different components of the present invention may be arranged.
[0087] FIG. 3 shows how a top centralising pin may be situated in relation to a top vertical array of magnets
[0088] FIG. 4 shows how a bottom centralising pin may be situated in relation to a vertical array of magnets
[0089] FIG. 5 shows how a vertical array of magnets and a horizontal array of magnets may be arranged
[0090] FIG. 6 shows how a horizontal array of magnets may be incorrectly aligned
[0091] FIG. 7 shows how a horizontal array of magnets may be correctly aligned
[0092] FIG. 8 shows how a horizontal array of magnets may be incorrectly aligned
[0093] FIG. 9 shows how a centralising pin may be used to provide a switched electrical input signal to the computer control means
[0094] FIG. 10 , shows how the magnetic poles of the magnets in a horizontal array of magnets within the present invention may be arranged.
[0095] FIG. 11 , shows how the magnetic poles of the magnets in a vertical array of magnets within the present invention may be arranged;
[0096] FIG. 12 shows an operating cycle of a flywheel according to the present invention; and
[0097] FIG. 13 shows a further embodiment of the present invention.
[0098] FIGS. 1 and 2 , show how there is provided a containment tank 1 , for housing one or more flywheels 6 . The said containment tank 1 , may be attached to a vacuum pump 11 to at least partially evacuate the containment tank 1 . The flywheel 6 , is provided with a cavity 49 , for retaining fluid, the said flywheel 6 , may be physically attached to a rotating centre shaft 7 , by a plurality of horizontal baffles 8 , the said horizontal baffles 8 , may he supported by vertical baffles 9 . The horizontal baffles 8 , may be provided with holes 52 , to allow fluid to pass freely from one compartment of the flywheel 6 , to another. The vertical baffles 9 , may be provided with holes 53 , to allow fluid to pass freely from one compartment of the flywheel 6 , to another.
[0099] FIG. 2 , shows how the rotating centre shaft 7 , may be securely connected to a top thrust bearing rotating part 25 , and a bottom thrust bearing rotating part 41 . FIG. 2 also shows how the bottom thrust bearing none-rotating part 42 , may be supported by a bottom thrust bearing support means 43 , and the top thrust bearing none-rotating part 26 , may be supported by a top thrust bearing support means 27 .
[0100] FIG. 2 shows how the top thrust bearing none-rotating part 26 , and the bottom thrust bearing none-rotating part 42 , may not be physically connected to the rotating centre shaft 7 .
[0101] FIG. 2 shows how a combined motor and or generator and or turbine unit 10 , may be connected to the rotating centre shaft 7 .
[0102] FIG. 2 shows how a fluid reservoir 45 , may be situated below the flywheel 6 , and a fluid transfer means 46 , may be attached to the flywheel 6 , the fluid transfer means 46 , may transfer fluid from the fluid reservoir 45 , into and out of the interior of the flywheel 6 .
[0103] FIG. 3 shows how a vertical array of permanent magnets may be situated at or near to the top end of the vertically aligned rotating centre shaft 7 , where the rotating magnet 15 , may be physically connected to the rotating centre shaft 7 , and supported by a magnet support means 16 .
[0104] FIG. 3 shows how a top vertical array of magnets may contain a non-rotating permanent magnet 17 , and the said non-rotating permanent magnet 17 , which may be supported by a vertically adjustable support means 18 .
[0105] FIG. 3 shows how a horizontal array of permanent magnets may be situated at or near to the top end of the rotating centre shaft 7 . The said horizontal array of permanent magnets may contain a rotating magnet 20 , and a none-rotating magnet 22 . In one embodiment of the present invention the said none-rotating magnet 22 , may be supported by a vertically adjustable magnet support means 23 . In another embodiment of the present invention the none-rotating magnet 22 , and the magnet support means 23 , may be fixed and not adjustable.
[0106] FIG. 3 shows how a top centralising pin 12 , may be situated at the top of the rotating centre shaft 7 . The conical, or tapered, tip 50 , of the centralising pin 12 , may be seated in the recess 51 , of the rotating centre shaft 7 .
[0107] Bottom
[0108] FIG. 4 also shows how a vertical array of permanent magnets may be situated at or near to the bottom end of the vertically aligned rotating centre shaft 7 , where the rotating magnet 31 , may be physically connected to the rotating centre shaft 7 , and supported by a magnet support means 32 .
[0109] FIG. 4 shows how a bottom vertical array of permanent magnets may contain a non-rotating magnet 33 , and the said magnet may be supported by a vertically adjustable support means 34 .
[0110] FIG. 4 , shows how a horizontal array of permanent magnets may be situated at or near to the bottom end of the rotating centre shaft 7 . The said horizontal array may consist of a rotating magnet 36 , and a none-rotating magnet 38 . The rotating magnet 36 , may be supported by a support means 37 , and the none-rotating magnet 38 may be supported by a support means 39 .
[0111] In one embodiment of the present invention the said non-rotating magnet 38 , may be supported by a vertically adjustable support means 39 . In another embodiment of the present invention the none-rotating magnet 38 , and the magnet support means 39 , may be fixed and not adjustable.
[0112] FIG. 4 shows how a bottom centralising pin 28 , may be situated at the bottom end of the rotating centre shaft 7 . The conical tip 50 , may be positioned to fit neatly into the recess 51 , of the rotating centre shaft 7 .
[0113] To Store Energy Within the Flywheel
[0114] FIG. 12 , shows the three periods of the operating cycle of a flywheel energy storage system.
[0115] When the operating cycle of a flywheel energy storage system begins, the computer control means 48 , of the present invention monitors the speed and mass of the flywheel 6 . During the first period 65 , of the operating cycle, in order to hold the rotating centre shaft in such a position as to allow the rotating part 25 , and the none-rotating parts 26 , of top thrust bearing 24 , to remain in contact with each other and the rotating part 41 , and the none-rotating parts 42 , of bottom thrust bearing 40 , to remain in contact with each other, the computer control means 48 , provides coordinated electrical signals to the top centralising pin adjustment means 13 , and the bottom centralising pin adjustment means 29 , and the top vertical array of magnets adjustment means 18 , and the bottom vertical array of magnets adjustment means 34 , and the top horizontal array of magnets adjustment means 23 , and the bottom horizontal array of magnets adjustment means 39 . In this way all of the moving parts and adjustment means may maintain the rotating centre shaft 7 , and the flywheel 6 in a stable position.
[0116] When the opening cycle of the flywheel energy storage system moves in to the second period 66 , fluid in the form of water, is pumped into the fluid reservoir inside tank 45 . From there the fluid is pumped into the flywheel 6 such that it enters into the cavity 49 , which is in the form of a peripheral reservoir.
[0117] As the cycle moves into the second period 66 of the operating cycle in order to lift the rotating centre shaft 7 , so that the rotating part 25 , and the non-rotating part 26 , of the top thrust bearing 24 , are not in contact with each other and the rotating part 41 , and the non-rotating part 42 of the bottom thrust bearing 40 are not in contact with each other, the computer control means provides coordinated electrical signals to the top centralising pin adjustment means 13 , the bottom centralising pin adjustment means 29 , the top vertical array of magnets adjustment means 18 , the bottom vertical array of magnets adjustment means 34 , the top horizontal array of magnets adjustment means 23 , and the bottom horizontal array of magnets adjustment means 39 . In this way all of the moving parts and adjustment means may move the rotating centre shaft into a position where the rotating centre shaft 7 and the flywheel 6 is arranged in a stable position.
[0118] For the coordinated control of the system, the computer control means 48 , using a plurality of sensors, measures the fluid flow into and out of the flywheel 6 . To compensate for the different amounts of fluid within the flywheel 6 , at any particular time, the computer control means 48 , vertically adjusts the position of the none-rotating magnets 17 , of the top vertical array of magnets and the none-rotating magnet 33 , of the bottom vertical array of magnets. As can be seen from FIG. 3 and FIG. 4 the permanent magnets of the top and bottom vertical array of magnets may be positioned so that like poles are facing each other, therefor when the top adjustment means 18 , lifts the none-rotating magnet 17 , and the bottom adjustment means 34 , lifts the non-rotating magnet 33 , vertically upwards the opposing magnetic field pushes the rotating magnet upwards and the supporting means 16 , and the support means 32 , then lifts the rotating centre shaft 7 , into a position calculated by the computer control means and corresponding to the amount of fluid within the flywheel.
[0119] When the opening cycle of the flywheel energy storage system moves in to the third period 67 , of the operating cycle in order to lower the rotating centre shaft 7 , so that the rotating part 25 , and the non-rotating part 26 , of the top and thrust bearing 24 , are reconnected with each other and the rotating part 41 , and the non-rotating part 42 , of the bottom thrust bearing 40 , are also reconnected with each other, the computer control means 48 , may provide coordinated electrical signals to the top centralising pin adjustment means 13 , the bottom centralising pin adjustment means 29 , the top vertical array of magnets adjustment means 18 , the bottom vertical array of magnets adjustment means 34 , the top horizontal array of magnets adjustment means 23 , and the bottom horizontal array of magnets adjustment means 39 . In this way all of the moving parts and adjustment means may maintain the rotating centre shaft 7 , and the flywheel 6 , in a stable position resting on the thrust bearings of the present invention.
[0120] The fluid in the cavity 49 may be allowed to drain back into the internal reservoir 45 to reduce the inertia of the flywheel 6 .
[0121] Centralising Pin Support and Adjustment Means
[0122] The position of the centralising pins of the present invention may be adjusted in a vertical direction.
[0123] FIG. 3 , shows how in one embodiment of the present invention the computer control means 48 , may be used to provide a plurality of electrical signals to drive a stepper motor 54 , the signals may be used to drive the said stepper motor in incremental steps, the stepper motor 54 , may be used to drive a series of timing belts 55 , and pulleys 56 , and 57 . The computer controlled adjustment of the stepper motor 54 , and pulleys 56 , and 57 , may be used to accurately adjust the vertical positioning of the top centralising pin.
[0124] FIG. 4 , shows how in one embodiment of the present invention the computer control means 48 , may be used to provide a plurality of electrical signals to drive a stepper motor 58 , the signals may be used to drive the said stepper motor in incremental steps, the stepper motor 58 , may be used to drive a series of timing belts 59 , and pulleys 62 , and 63 . The computer controlled adjustment of the stepper motor 58 , and pulleys 62 , and 63 , may be used to accurately adjust the vertical positioning of the bottom centralising pin.
[0125] FIG. 9 , shows how a centralising pin 28 , and the centralising pin 12 , may be used to provide a switched signal to or from the computer control means 48 .
[0126] It is important to note that the vertical position of the top centralising pin 12 , and the vertical position of the bottom centralising pin 28 , may be adjusted by the top centralising pin adjustment means 13 , and the bottom centralising pin adjustment means 29 , and to aid in the accurate positioning of both the top and bottom centralising pins each pin may be used as separate switches to conduct electricity and provide signals back to the computer control means 48 . The switched feedback signals from the centralising pins may be used to accurately control the signals to the stepper motors so that a measured amount of pressure is placed upon the rotating centre shaft by the centralising pins.
[0127] Where the connection between the centralising pin 12 and/or 28 and the rotating centre shaft 7 is broken, the rotating centre shaft 7 can be vertically adjusted by moving the magnet arrangements to re-establish the connection.
[0128] It is an object of the present invention to provide an individual stepper motor which may be fitted to each individual adjustment means within the present invention to enable accurate positioning of all adjustable support means.
[0129] It is an object of the present invention to provide a horizontal array of permanent magnets the said horizontal array of permanent magnets may be situated at or near to the top and or bottom of a vertically aligned rotating centre shaft 7 .
[0130] FIG. 6 , shows how the horizontal array of the permanent magnets of the present invention may be misaligned with the centre line 69 , of the none-rotating magnet 38 , may be above the centre line 68 , of the rotating magnet 36 .
[0131] FIG. 8 , shows how the horizontal array of the permanent magnets of the present invention may be misaligned with the centre line 69 , of the none-rotating magnet 38 , may be below the centre line 68 , of the rotating magnet 36 .
[0132] FIG. 7 , shows how the horizontal array of the permanent magnets of the present invention may be correctly aligned with the centre line 69 , of the none-rotating magnet 38 , may be at the same vertical height as the centre line 68 , of the rotating magnet 36 .
[0133] To achieve the optimum performance and stability of the flywheel containing fluid it is important that the computer control means 48 , maintains the position of all of the adjustment means within the present invention so that the vertical positioning of the rotating centre shaft 7 , is such that the position of the horizontal array of permanent magnets is aligned as shown in FIG. 7 .
[0134] The flywheel of the present invention may be substantially hollow and during the operating cycle fluid may be transferred into or out of the flywheel to increase or decrease the; mass of the flywheel.
[0135] For the coordinated control of the of all of the adjustment means within the computer control means 48 , using a plurality of sensors, measures the volume and velocity of the fluid flow into and out of the flywheel 6 . To compensate for the different amounts of fluid within the flywheel 6 , at any particular time, the computer control means 48 , vertically adjusts the position of the none-rotating magnets 15 , of the top vertical array of magnets and the none-rotating magnet 33 , of the bottom vertical array of magnets.
[0136] FIG. 11 , shows how the rotating permanent magnets 31 , and the none-rotating permanent magnets 33 , of the bottom vertical array of magnets may be positioned so that like poles of the magnets are facing each other, therefor when the adjustment means 34 , is adjusted to lift the none-rotating magnets 33 , vertically upwards the opposing magnetic field pushes the rotating magnet 31 upwards and the supporting means 32 then lifts the rotating centre shaft 7 . into a position calculated by the computer control means and corresponding to the amount of fluid within the flywheel. Both the top and bottom vertical array of magnets operate in the same way in order to lift the rotating centre shaft 7 .
[0137] FIG. 9 , shows how a centralising pin may be used to provide a switched signal to or from the computer control means.
[0138] FIG. 13 shows an adjustment means, or adjustable magnetic support means, 101 , which is securely attached to one or more magnet securing means 18 . The magnet securing means 18 , is used to securely hold the magnet 17 so that it will move in a vertical axis when the adjustable magnetic support means 101 , is moved vertically. A magnet securing means 16 , is used to securely hold a magnet 15 . The magnets 15 , and 17 , are aligned so that the opposite poles of the magnet are facing each other and, thus, the magnets are attracted to one another and the pull towards each other. As a result of the attraction between magnets 15 and 17 , when the adjustment means 18 is moved upwards in a substantially vertical direction, the magnetic field interactions between magnets 15 and 17 cause magnet 17 to exert a force on magnet 15 , which will in turn force the rotating centre shaft 7 , to also move in an upward direction along the vertical axis. An insulator 100 , may be used to electrically insulate the centralising pin 12 from the adjustment means 101 .
[0139] It is important to note that the vertical position of the top centralising pin 12 , and the vertical position of the bottom centralising pin 28 , may be adjusted by the top centralising pin adjustment means 13 , and the bottom centralising pin adjustment means 29 , and to aid in the accurate positioning of both the top and bottom centralising pins each pin may be used as a switch to conduct electricity and provide a signal back to the computer control means 48 . The switched feedback signal from the centralising pin may be used to accurately control the signals to the stepper motor so that a measured amount of pressure is placed upon the rotating centre shaft by the centralising pins.
[0140] In another embodiment of the present invention all of the adjustment means within the present invention may be provided by a series of pistons and cylinders and a controlled hydraulic or pneumatic pressure to move all adjustment means. The computer control means may be used to adjust pressures to pistons and cylinders in order to accurately adjust the position of all adjustment means within the present invention. A plurality of sensors within the present invention may provide the computer control means with signals to aid the computer control means to determine how much pressure is needed in each cylinder to accurately position each adjustment means.
[0141] The flywheel may comprise a peripheral reservoir created by the cavities 49 .
[0142] The top and/or bottom pins may be moved in combination with the magnetic support and stabilisation means so that the pin(s) may act to stabilise the rotatable centre shaft. In a particularly advantageous method of operating the system, once the flywheel is rotating, the shaft is raised using the vertical support arrangement to reduce the friction. At the same time, the pin(s) may be raised to keep in contact with the shaft with the whole arrangement moving in combination. The contact should be minimal and the pin(s) should be just touching the shaft in order to keep the shaft in a stable, substantially vertical, alignment. Where the pins comprise an electrical contact, the overall contact between the pins and the shaft can be monitored by the computer to reduce the contact, and thus the frictional interference, preferably making this as low as possible. In an alternative arrangement, it might be desirable for the pins to be fixed relative to the shaft and the shaft adjusted vertically without the pin(s) moving in combination with the support.
[0143] The magnet supporting means may be brackets to which magnets are connected.
[0144] Below is a list of the components show in the attached drawings.
1 Containment Tank 2 Containment tank wall 3 Containment tank top lid 4 Containment tank bottom lid 5 Central axis of rotation 6 Flywheel 7 Rotating centre shaft 8 Flywheel horizontal baffles 9 Flywheel vertical baffles 10 Combined Motor/Generator/Turbine 11 Vacuumed pump 12 Top centralising pin 13 Top centralising pin support and adjustment means 14 Top vertical array of magnets 15 Rotating magnet 16 Rotating magnet support means 17 Non-rotating magnet 18 Non-rotating magnet support and adjustment means 19 Top horizontal array of magnets 20 Rotating magnet 21 Rotating magnet support means 22 Non-rotating magnet 23 Non rotating magnet support and adjustment means 24 Top Thrust bearing 25 Top thrust bearing rotating part 26 Top thrust bearing none-rotating part 27 Top thrust bearing none-rotating part support means 28 Bottom centralising pin 29 Bottom centralising pin support and adjustment means 30 Bottom vertical array of magnets 31 Rotating magnet 32 Rotating magnet support means 33 Non-rotating magnet 34 Non-rotating magnet support and adjustment means 35 Bottom horizontal array of magnets 36 Rotating magnet 37 Rotating magnet support means 38 Non-rotating magnet 39 Non rotating magnet support and adjustment means 40 Bottom Thrust bearing 41 Bottom thrust bearing rotating part 42 Bottom thrust bearing none-rotating part 43 Bottom thrust bearing none-rotating part support means 44 Fluid reservoir outside tank 45 Fluid reservoir inside tank 46 Fluid transfer means 47 Fluid pump 48 Computer control means 49 Cavity 50 Centralising pin coned tip 51 Rotating centre shaft recess 52 Holes in horizontal baffle 53 Holes in vertical baffle 54 Stepper motor 55 Timing belt 56 Pulley 1 57 Pulley 2 58 Stepper motor 59 Timing belt 60 Computer input terminal 61 Computer input terminal 62 Pulley 3 63 Pulley 4 64 Fluid 65 Operating cycle first period 66 Operating cycle second period 67 Operating cycle third period 68 Centre line 69 Centre line | A flywheel ( 6 ) is provided that comprises a rotatable shaft ( 7 ). At least one end of the rotatable shaft ( 7 ) is provided with a recess ( 51 ) and two magnets ( 15, 20, 31, 36 ). The flywheel ( 6 ) is provided with support means ( 18, 23, 34, 39 ) with the support means comprising: a first arrangement ( 18, 34 ) of magnets ( 17, 33 ) for vertical stabilization of the shaft ( 7 ); and a second arrangement ( 23, 39 ) of magnets ( 22, 38 ) for horizontal stabilization of the shaft ( 7 ). The first of the two magnets ( 15, 31 ) of the shaft ( 7 ) interacts with the first arrangement ( 18, 34 ) and the second of the two magnets ( 20, 36 ) interacts with the second arrangement ( 23, 39 ). | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to systems and methods for authenticating a power source.
BACKGROUND
[0002] A conventional wireless device typically utilizes a rechargeable battery as a power source when it is not coupled to a line voltage. If the battery is not completely charged when a user intends to use the device, the user may swap the battery for a different, fully charged battery. While the battery intended for use with the device may be interchangeable with similar batteries (e.g., same model), the different battery may be intended for use with a different device or have different settings/properties incompatible with the device, which may cause structural and/or electrical damage to the device. For example, if the different battery is not capable of receiving the same charging voltage and charging rate from the device as the original battery, the different battery may explode, irreparably damaging the device and potentially causing harm to the user. Thus, there is a need to ensure authenticity of a power source provided for use with the device.
SUMMARY OF THE INVENTION
[0003] The present invention relates to a system and method for authenticating a power source. The system comprises a battery including a first encryption engine storing a first key and a computing device including a microcontroller and a second encryption engine storing a second key. When the microcontroller detects a coupling of the battery to the computing device, the microcontroller issues a challenge to the first encryption engine and the second encryption engine. The first encryption engine generates the first response as a function of the challenge, the first key and a predefined algorithm, and the second encryption engine generates the second response as a function of the challenge, the second key and the predefined algorithm. The microcontroller compares the first and second responses to authenticate the battery.
DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 shows an exemplary embodiment of a system for authenticating a power source according to the present invention.
[0005] FIG. 2 shows an exemplary embodiment of a method for authenticating a power source according to the present invention.
[0006] FIG. 3 shows an exemplary embodiment of a battery according to the present invention.
DETAILED DESCRIPTION
[0007] The present invention may be further understood with reference to the following description and the appended drawings, wherein like elements are referred to with the same reference numerals. The present invention describes a system and method for authenticating a power source. While the exemplary embodiments of the present invention will be described with reference to the power source of a wireless device, those of skill in the art will understand that the present invention may be utilized by any device which utilizes a battery at least as a contingent source of power, e.g., the device uses a line voltage as a primary power source and uses the battery when the line voltage is removed/terminated.
[0008] FIG. 1 shows an exemplary embodiment of a system 5 according to the present invention in which the system 5 is implemented in a mobile computing device 8 such as, for example, a laser-/imager-based scanner, an RFID reader, a mobile phone, a PDA, a tablet, a laptop, a portable media player, etc. The device 8 utilizes a rechargeable battery 10 as its primary power source when it does not receive power from an external power source, e.g., a line voltage, a USB port/hub, a solar cell, etc. As understood by those of skill in the art, when the device is coupled to, for example, the line voltage, the line voltage is used as the primary power source of the device 8 and for charging the battery 10 . While the exemplary embodiments will be described with reference to the rechargeable battery 10 , those of skill in the art will understand that the present invention may be similarly implemented for a single-use battery (e.g., an alkaline battery).
[0009] In the exemplary embodiments, the battery 10 , as shown in FIG. 3 , may be a smart battery which utilizes an integrated circuit to report and/or make available battery data to the device 8 . The battery 10 may include a microcontroller 305 and an encryption engine 310 . As will be described further below, the encryption engine 310 executed a predetermined algorithm on a stored battery key in response to a request from the device 8 to authenticate the battery 10 . The battery data may include, but is not limited to, a battery type, a model number, a serial number, a manufacturer identifier, a discharge rate, a predicted remaining capacity, a temperature and a voltage. The battery 10 may also provide an almost-discharged alarm when the battery 10 is almost completely discharged, allowing the device 8 to execute a proper shutdown procedure to prevent loss and/or corruption of data stored on the device 8 .
[0010] The device 8 includes a conventional primary processor (not shown) which executes applications and interfaces with components of the device 8 (e.g., a memory, a radio transceiver, a display screen, a keypad, a speaker, a microphone, etc.). As known by those of skill in the art, the primary processor typically consumes a significant amount of power from the battery 10 , and, as such, may be powered down at predetermined times to conserve power. When the primary processor is powered down, the device 8 is in a power-save mode, but a secondary processor 15 remains powered, maintaining selected operations of the device 8 while consuming substantially less power from the battery 10 . In the exemplary embodiments, the secondary processor 15 is a small processor which remains powered whether the primary processor is powered or the device 8 is in the power-save mode.
[0011] The secondary processor 15 may perform various functions on the device 8 including, for example, receiving and processing the battery data from the battery 10 . The secondary processor 15 may communicate with the battery 10 on a serial bus, e.g., an I 2 C bus 20 . As is known in the art, the I 2 C bus 20 is useful for coupling low-speed peripherals (e.g., the battery 10 ) to a motherboard and/or embedded system (e.g., the secondary processor 15 ). The I 2 C bus 20 allows the secondary processor 15 to read the battery data from hardware monitors, sensors, memory, etc. on the battery 10 . As will be described further below, the secondary processor 15 interfaces with the battery 10 over the I 2 C bus 20 during the authentication process.
[0012] Those of skill in the art will understand that the primary processor (or any other microprocessor or controller) may implement the present invention.
[0013] In the exemplary embodiment, the device 8 further includes a microcontroller 25 and an encryption engine 30 . As will be described further below, the microcontroller 25 and the encryption engine 30 are used to authenticate the battery 10 . The device 8 further includes a charger 35 which, when the device 8 is coupled to the line voltage, charges the battery 10 .
[0014] FIG. 2 shows an exemplary embodiment of a method 200 for authenticating the battery 10 according to the present invention. In step 205 , the device 8 detects a presence of the battery 10 by, for example, detecting closure of a battery compartment door and/or latch which secures the battery 10 to the device 8 . A switch may be deposed on a battery compartment so that when the battery compartment door is closed or the latch secures the battery 10 to a housing of the device 8 , a coupling signal is sent to the secondary processor 15 and the microcontroller 25 . The presence of the battery 10 may also be detected by monitoring signals on electrical contacts between the device 8 and the battery 10 . Those of skill in the art will understand that any mechanical, electrical, optical, etc. means may be used to detect the coupling of the battery 10 to the device 8 .
[0015] In step 210 , the microcontroller 25 determines whether it has received an authentication request from the secondary processor 15 within a predetermined time of detecting the presence of the battery 10 . When the microcontroller 25 receives the coupling signal, it initiates a count for the predetermined time during which it expects to receive the authentication request from the secondary processor 15 . The microcontroller 25 may not receive the authentication request when, for example, the secondary processor 15 determines that the battery 10 is not intended to be used with the device 8 , e.g., the initialization handshake fails.
[0016] If the microcontroller 25 does not receive the authentication request in the predetermined time, the microcontroller 25 may execute a predetermined action to impair a link between the device and the battery 10 , as shown in step 215 . For example, the microcontroller 25 may lock the I 2 C bus 20 preventing the secondary processor 15 from receiving any further battery data, e.g., the battery data described above, battery fuel gauge information, current state of charge, etc. The microcontroller 25 may also disable or selectively impair the charger 35 . If the charger 35 is disabled, the battery 10 will not charge when the device 8 is coupled to the external power source. If the charger 35 is selectively impaired, the charger 35 may supply power to the battery 10 at a predetermined charge rate which is selected so that the battery 10 never becomes fully charged, rendering it useless as a power source for the device 8 . Alternatively, the predetermined charge rate (e.g., a charge current level) may be selected to ensure that the battery 10 does not explode, i.e., a very slow charge rate. In addition, the microcontroller 25 or the secondary processor 15 may cause the battery 10 to be partially or completely ejected from the device 8 .
[0017] In optional step 220 , an authentication failure message (e.g., text on the display screen, LED color change/blink sequence, audible signal, etc.) may be output by the device 8 to indicate to the user that the battery 10 was not authenticated. The authentication failure message may prompt the user to replace the battery 10 . When the battery door is opened and then re-closed, the method 200 will repeat itself.
[0018] When the microcontroller 25 receives the authentication request from the secondary processor 15 within the predetermined time, the microcontroller 25 generates a challenge to obtain a device response from the encryption engine 30 and a battery response from the encryption engine 310 in the battery 10 , as shown in step 225 . For example, the encryption engine 30 stores a device key, and, when instructed to do so by the microcontroller 25 , generates the device response based on the challenge, a predefined algorithm (e.g., CRC, SHA-1, etc.) and the device key. In the exemplary embodiments, the predefined algorithm is publicly known and the device key is secret. The device response is strongly influenced by the device key and the challenge, but it would be mathematically impossible to discover the device key even with knowledge of the device response, the challenge and the predefined algorithm.
[0019] In step 230 , the microcontroller 25 receives the device response from the encryption engine 30 and the battery response from the battery 10 . The encryption engine 310 in the battery 10 generates the battery response based on the challenge, the predefined algorithm and a battery key. The predefined algorithm may be the same publicly known algorithm used by the encryption engine 30 to generate the device response. As described above with reference to the device response, the battery response may be strongly influenced by the battery key and the challenge, but it would be mathematically impossible to discover the battery key even with knowledge of the battery response, the challenge and the predefined algorithm.
[0020] In step 235 , the microcontroller 25 determines whether the battery response is identical to the device response. When the responses are not identical, the microcontroller 25 may execute the predetermined action on the link between the device 8 and the battery 10 , as described above with reference to step 220 . When the responses are identical, the microcontroller 25 may assume (without ever expressly knowing) that the battery key is identical to the device key and authenticate the battery 10 , as shown in step 240 .
[0021] In the exemplary embodiment, the encryption engine 30 generates a single device response based on a single device key which is compared to a single battery response based on a single battery key. In other exemplary embodiments, the device response may be used to authenticate a plurality of batteries. For example, the device 8 may be capable of utilizing a plurality of batteries having a same model number. In this embodiment, the encryption engine 30 may store a plurality of device keys and select a particular device key based on, for example, the battery data (e.g., a model number of the battery 10 ), the battery response, etc. The resultant device response may be used to authenticate any battery with the model number. Those of skill in the art will understand that various modifications may be made to the response generation/encryption and/or response matching processes which would not depart from the overall scope of authenticating the battery 10 by the device 8 according to the present invention.
[0022] It will be apparent to those skilled in the art that various modifications may be made in the present invention, without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | Described is a system and method for authenticating a power source. The system comprises a battery including a first encryption engine storing a first key and a computing device including a microcontroller and a second encryption engine storing a second key. When the microcontroller detects a coupling of the battery to the computing device, the microcontroller issues a challenge to the first encryption engine and the second encryption engine. The first encryption engine generates the first response as a function of the challenge, the first key and a predefined algorithm, and the second encryption engine generates the second response as a function of the challenge, the second key and the predefined algorithm. The microcontroller compares the first and second responses to authenticate the battery. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for manufacturing a light-emitting device, and more particularly to a method for manufacturing an integrally formed multi-layer light-emitting device.
[0003] 2. The Prior Arts
[0004] The light-emitting theory of LED takes advantage of the intrinsic properties of semiconductors, which is different from the theory of electric discharging, heat and light-emitting of an incandescent light tube. Because light is emitted when electric current forward flowed across the PN junction of a semiconductor, the LED is also called cold light. The LED has the features of high durability, long service life, light weight, low power consumption, and being free of toxic substances like mercury, and thereby it can be widely used in the industry of the light-emitting device, and the LEDs are often arranged in an array and often used in such as electric bulletin board or traffic sign.
[0005] Taiwanese Utility Model Patent No. M387375 disclosed a package structure of an array type multi-layer LED, which included a metal substrate, a package module, a lead frame, and a mask, wherein the metal substrate was disposed on the bottom of the package structure, and the package module was used for encapsulating and fixing the lead frame over the metal substrate. The LED dies were arranged in an array on the metal substrate. The lead frames were electrically connected with the LED dies. The mask covered the package module.
[0006] However, the conventional LED package structure includes a package module which is usually made of plastic resin. The heat-dissipation efficiency of the plastic resin is much less than that of metal. If the heat-dissipation efficiency is low, the lifetime and the light-emitting efficiency of the LED package structure will be decreased. Another problem existing in the prior art is that the metal substrate is not integrally formed with the package module, and thereby the manufacturing process is complicated. Accordingly, it is desirable to provide a light-emitting device capable of solving the problems existing in the conventional LED package structure, such as low heat-dissipation efficiency, high consumption of package material, etc.
SUMMARY OF THE INVENTION
[0007] An objective of the present invention is to provide a method for manufacturing an integrally formed multi-layer light-emitting device. The method of the present invention comprises the following steps: preparing a seat including a central main body and a plurality of heat dissipation fins, a central portion of the central main body having two through holes longitudinally formed therein; milling a bottom of the central main body to form a first chamber having an accommodating space concaved inwardly, a top of the central main body being milled to form a second chamber having an accommodating space concaved inwardly, the second chamber including a bottom and an inclined inner sidewall, the two through holes each being milled to form a step at one end near the second chamber; arranging two connection pieces in the two through holes, respectively, each connection piece including a conductive rod and a sleeve for inserting the conductive rod therein, two ends of each conductive rod being extended out of the sleeve, each conductive rod having a flange on one end near the chamber, the flange being placed on the step; arranging two fixing pieces in the two through holes, respectively, so that the two connection pieces are fixed in the seat; selectively electroplating a first reflective layer onto an area of the seat; arranging a plurality of light-emitting elements on the bottom; electrically connecting the light-emitting elements with one ends of the two connection pieces by wire-bonding with use of metal wires; and arranging a lens mask on the second chamber so that the seat is sealed by the lens mask.
[0008] The seat is integrally formed in such a manner that the light-emitting elements can fit in the chamber which is formed on the top of the central main body. In other words, the light-emitting elements can be directly disposed in the chamber on the top of the central main body. The seat is made of a metal having good thermal conductivity, and thereby the seat can effectively absorb the heat generated from the light emitting elements in operation, and rapidly transmit the heat to the surrounding environment. Therefore, the package module is not needed to be used in the present invention so that the consumption of the package material is reduced, and the manufacturing process is simplified.
[0009] According to one embodiment of the present invention, the integrally formed multi-layer light-emitting device can further includes a lens mask which is tightly engaged with the seat so that the lens mask covers and seals the top of the chamber formed on the top of the central main body. Therefore, the moisture and fine particles in air cannot enter the chamber, and thereby the light-emitting elements and the optical elements can be protected from deterioration of their properties.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will be apparent to those skilled in the art by reading the following detailed description of a preferred embodiment thereof, with reference to the attached drawings, in which:
[0011] FIG. 1 is a flowchart showing a method for manufacturing an integrally formed multi-layer light-emitting device according to the present invention;
[0012] FIG. 2 is a schematic perspective view showing the seat of the integrally formed multi-layer light-emitting device according to the present invention;
[0013] FIG. 3 a is a schematic perspective view showing the milling of the seat of the integrally formed multi-layer light-emitting device according to one embodiment of the present invention;
[0014] FIG. 3 b is a schematic perspective view showing the milling of the seat of the integrally formed multi-layer light-emitting device according to another embodiment of the present invention;
[0015] FIG. 4 a is a schematic perspective view showing a conductive rod of a connection piece according to one embodiment of the present invention;
[0016] FIG. 4 b is a schematic perspective view showing the connection piece of the integrally formed multi-layer light-emitting device according to one embodiment of the present invention;
[0017] FIG. 5 is a schematic view showing the arrangement of the connection pieces of the integrally formed multi-layer light-emitting device according to one embodiment of the present invention;
[0018] FIG. 6 is a schematic view showing that two connection pieces are fixed in the seat according to one embodiment of the present invention;
[0019] FIG. 6 a is a schematic view showing that a plug is inserted into each through hole according to one embodiment of the present invention;
[0020] FIG. 7 is a schematic view showing that a first reflective layer is selectively electroplated according to one embodiment of the present invention;
[0021] FIG. 8 is a schematic view showing that the light-emitting elements are arranged on the first reflective layer according to one embodiment of the present invention;
[0022] FIG. 9 is a schematic view showing that the light-emitting elements are arrange on the bottom by wire-bonding according to one embodiment of the present invention;
[0023] FIG. 10 is a schematic view showing that a lens mask is arranged on the chamber according to one embodiment of the present invention; and
[0024] FIG. 11 is a schematic view showing that the integrally formed multi-layer light-emitting device according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0026] FIG. 1 is a flowchart showing a method for manufacturing an integrally formed multi-layer light-emitting device according to the present invention. FIG. 2 is a schematic perspective view showing the seat of the integrally formed multi-layer light-emitting device according to the present invention.
[0027] In step S 10 , a seat 1 is prepared. As shown in FIG. 2 , the seat 1 includes a central main body 11 and a plurality of heat dissipation fins 13 . The seat is formed by squeezing and injecting of a metal, and the seat is made of aluminum, copper, or carbon. The heat dissipation fins 13 are extended radially outward from the cylindrical wall of the central main body 11 . These heat dissipation fins 13 are spaced around the circumference of the central main body 11 . Two sides of the heat dissipation fins 13 are designed to have a corrugated shape. The central portion of the central main body 11 has two through holes 111 longitudinally formed therein.
[0028] In step S 20 , the bottom of the central main body 11 is milled by a cutter on its central portion to form a chamber 113 having an accommodating space concaved inwardly from the opening. The chamber 113 can be communicated with the two through holes 111 , as shown in FIG. 3 a . The tops of the heat dissipation fins 13 can be milled so that a portion of the central main body 11 can be exposed and protruded, as shown in FIG. 3 b . The shape of the outer lateral sides of the heat dissipation fins 13 can be milled into a bent arc-like shape. The reason for that is that the lower portions of the heat dissipation fins 13 receive heat slower than the upper portions of the heat dissipation fins 13 do, but the widths of the lower portions of the heat dissipation fins 13 are smaller than the widths of the upper portions of the heat dissipation fins 13 , and thereby the heat can be simultaneously dissipated to the surrounding environment through the lower portions and the upper portions of the heat dissipation fins 13 due to the shorter heat transfer path of the lower portions of the heat dissipation fins 13 , and thereby the heat dissipation efficiency is greatly increased.
[0029] The top of the central main body 11 can be milled by a cutter to form a chamber 115 having an accommodating space concaved inwardly from the opening, and the chamber 115 includes a bottom 115 a and an inclined inner sidewall 115 b , as shown in FIG. 3 b.
[0030] Furthermore, the two through holes 111 each can be milled to form a step 1111 at their sides near the chamber 115 .
[0031] FIG. 4 a is a schematic perspective view showing a conductive rod of a connection piece according to the present invention. FIG. 4 b is a schematic perspective view showing the connection piece of the integrally formed multi-layer light-emitting device according to the present invention. FIG. 5 is a schematic view showing the arrangement of the connection pieces of the integrally formed multi-layer light-emitting device according to the present invention.
[0032] In step S 30 , the two connection pieces 3 are respectively arranged in the two through holes 111 , as shown in FIG. 5 .
[0033] The connection piece 3 includes a conductive rod 31 and a sleeve 33 for inserting the conductive rod 31 therein. The two ends of the conductive rod 31 are extended out of the sleeve 33 . The conductive rod 31 has a flange 331 on one end near the chamber 115 . The flange 331 can be placed on the step 1111 so that the two connection pieces 3 can be respectively fixed in the two through holes 111 . The sleeve 33 can be made of liquid crystalline polyester resin.
[0034] In step S 40 , the two fixing pieces 5 are respectively disposed in the two through holes 111 so that the two connection pieces 3 can be fixed in the seat 1 , as shown in FIG. 6 . The connection pieces 3 can be held by the fixing pieces 5 , and the space of the two through holes 111 can be occupied by the fixing pieces 5 . A plug 6 can be inserted into the opening of each through hole 111 at its end near the chamber 115 , as shown in FIG. 6 a , so that the connection pieces 3 can be firmly fixed, and the moisture in air can be prevented from entering the two through holes 111 .
[0035] In step S 50 , a first reflective layer 7 can be selectively electroplated onto an area of the seat 1 , for example, the bottom 115 a and/or the inner sidewall 115 b , as shown in FIG. 7 . A second reflective layer (not shown in the figures) can be electroplated onto the first reflective layer 7 . The first reflective layer 7 and the second reflective layer can be made of chromium, silver, or any other suitable metals.
[0036] In step S 60 , the light-emitting elements 8 are directly arranged on the first reflective layer 7 or the second reflective layer formed on the bottom 115 a , as shown in FIG. 8 .
[0037] In step S 70 , the light-emitting elements 8 can be arranged in an array on the bottom 115 a , and electrically connected with one ends of the two connection pieces 3 by wire-bonding with the use of the metal wires 9 , as shown in FIG. 9 . The light-emitting elements are, for example, a plurality of LED dies. Another ends of the two connection pieces 3 are respectively electrically connected with the negative end and the positive end of the electrical power source (not shown in the figures). Thus, the electrical power source, the two connection pieces 3 , the metal wires 9 , and the light-emitting elements 8 are electrically connected together to form a circuit. The light-emitting elements 8 can emit light when the electrical power source is turned on. The metal wires 9 can be made of gold, copper, or any other suitable metals. A connection pad (not shown in the figures) can be disposed on the top of the conductive rod 31 for wire-bonding of the light-emitting elements 8 .
[0038] In step S 80 , the integrally formed multi-layer light-emitting device can further includes a lens mask 10 arranged on the chamber 115 so that the seat 1 can be sealed by the lens mask 10 , and the moisture and fine particles in air can be prevented from entering the chamber 115 .
[0039] FIG. 11 is a schematic view showing the integrally formed multi-layer light-emitting device according to one embodiment of the present invention. Referring to FIG. 11 , a phosphor layer 100 used for light mixing, and a silica gel protection layer 200 used for protecting the phosphor layer 100 can be sequentially formed on the light-emitting elements 8 .
[0040] The chamber 113 can be used for accommodating the power connector, the power supply module, and the wireless transfer module. The chamber 113 is hollow so that the seat 1 is lightweight, and the heat cannot be directly transferred to the power supply module and the wireless transfer module, and also the chamber 113 can have the heat-dissipation function.
[0041] Although the present invention has been described with reference to the preferred embodiments thereof, it is apparent to those skilled in the art that a variety of modifications and changes may be made without departing from the scope of the present invention which is intended to be defined by the appended claims. | A method for manufacturing an integrally formed multi-layer light-emitting device is provided, in which a seat is integrally formed in such a manner that the light-emitting elements can be directly disposed in the chamber. The lens mask is used to seal the light-emitting elements in the chamber of the seat so that some packaging steps can be omitted, and the manufacturing process is simplified. The seat is made of metal having good thermal conductivity instead of plastic materials. The consumption of the package material is reduced, and the heat-dissipation efficiency is increased in the present invention. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a fuel supply system for internal combustion engines, and more particularly, to a fuel supply system that has a pump for drawing in and discharging fuel from a tank, and a filter for catching foreign substances in the fuel.
Generally, internal combustion engines have injectors in the air intake passage. The fuel from the injectors and the air flowing through the air intake passage are mixed. Then, the mixed air is burned in the combustion chambers to produce driving power. Accordingly, internal combustion engines have a fuel supply system (fuel supplier) for the injectors.
The fuel supplier includes a fuel reservoir tank, a fuel suction pump, and a fuel supply passage from the pump to the injector, filter is usually provided in the fuel supply passage to catch foreign substances in the fuel, because the injectors can be clogged when fuel containing foreign substances is supplied to the injectors.
International Publication Number WO96/23967 describes such a fuel supplier. In the fuel supplier shown in FIGS. 4 and 5, a pump 110 and a filter 120 are assembled integrally to a lid 104 enclosing an opening 102 of a tank 100.
A lower housing 126 of the filter 120 is fixed under the lid 104. As shown in FIG. 5, the lower housing 126 is C-shaped and accommodates a filter element 124 in its internal space 123. An inset pipe 134 is integrally formed on the upper internal surface of the lower housing 126 and is connected to a discharging conduit 112 of the pump 110.
An upper space 160 and a lower space 162 are formed on the upper and lower portion of the filter element 124 in the internal space 123. The fuel discharged from the discharge conduit 112 flows into the upper space 160 through the inlet pipe 134. On the other hand, the lower space 162 is connected to a discharge duct 132 on the lid 104 by way of a duct 136.
The fuel that has flowed into the upper space 160 from the pump 110 then flows into the lower apace 162 through the filter element 124. Foreign matter in the fuel is caught by the filter element 124 The fuel in the lower space 162 is supplied to the injectors of the engine (not shown) through the ducts 136 and 132.
The pump 110 usually has an electric motor and an impeller fixed on the drive shaft of the motor (both not shown). The rotation of the impeller discharges the fuel. The pressure of the discharged fuel fluctuates continually. For this reason, when the fuel goes through the space 123, the lower housing 126 vibrates due to the pressure pulsation of the fuel. The vibration and noise are transmitted outside through the housing 126 and the lid 104.
SUMMARY OF THE INVENTION
Accordingly, it is an objective of the present invention to provide a fuel supplier that produces less vibration and noise.
To achieve the above objection, the present invention provides a fuel supply apparatus having a pump for drawing and discharging fuel from a tank and a filter for filtering out foreign matter from the fuel. The apparatus includes a housing for supporting the pump, the housing having an inner wall and a fuel outlet. The pump has a suction port for drawing the fuel and discharge port for discharging the fuel. A fuel passage is provided within the housing for connecting the fuel outlet to the discharge port. The filter is located in the fuel passage. The filter includes a filter case and a filter element located within the filter case. The filter case is located within the housing to be apart from the inner wall of the housing by a predetermined distance.
Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a sectional view showing a fuel supplier in an embodiment according to the present invention;
FIG. 2 is a sectional view taken on line 2--2 of FIG. 1;
FIG. 3 is a sectional view taken on line 3--3 of FIG. 1;
FIG. 4 is a sectional view showing a conventional fuel supplier; and
FIG. 5 is a plan view showing the fuel supplier of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A fuel supplier for fuel injectors for gasoline vehicle engines will now be described by reference to FIGS. 1 to 3.
As shown in FIG. 1, a fuel supplier 10 includes a pump 12 for drawing in and discharging the fuel in a tank 11, a filter 13 for catching foreign matter in the fuel, and a housing 14 for supporting the pump 12 and the filter 13 in the tank 11. The pump 12 has a generally columnar shape.
The housing 14 is made of resin material and includes the upper housing 14a and the lower housing 14b. The upper housing 14a includes a disc portion 15 and a cylinder portion 16. The cylinder portion 16 is inserted in the tank 11 through a circular hole 17 formed on the tank 11.
The disk portion 15 is installed on the tank 11 by a fixing plate 18 to cover the hole 17. The fixing plate 18 is bolted by bolts 20, which are located on the periphery of the plate 18. A seal ring or gasket 21, is located between the disk portion 15 and the tank 11 to seal about the hole 17.
A downwardly extending fitting 22 is formed integrally on the disk portion 15. A through hole 23 having a step is formed inside the fitting 22. The lower portion of a fuel supply pipe 25 is inserted and fixed in the upper portion of the through hole 23. The fuel supply pipe 25 has an internal L-shaped passage 24. The upper portion of the fuel supply pipe 25 is connected to a delivery pipe (not shown) of the engine (not shown) by way of a hose 26. The fuel in the delivery pipe is distributed to injectors installed to the delivery pipe.
The lower housing 14b is generally cylindrical. The cylinder portion 16 of the upper housing 14a is inserted in an upper opening of the lower housing 14b. Apertures 27 are formed on the upper portion of the lower housing 14b. Flexible lock fingers 28 are formed on the lower portion of the cylinder portion 16. The lower housing 14b is detachably engaged with the upper housing 14a by snap-fitting each finger 28 to the corresponding aperture 27.
A generally cylindrical holding portion 30 is integrally formed on the lower portion of the lower housing 14b. A bracket 31 made of resin material is attached on the holding portion 30. The bracket 31 is detachably installed on the holding portion 30 by snap-fitting apertures 32 of the bracket 31 to flexible lock fingers 33 of the holding portion 30. The lower portion of the pump 12 is inserted in the holding portion 30 and is supported by the bracket 31. In this configuration, the pump 12 is not in direct contact with the bracket 31. That is, a supporter 34 is fixed to the bracket 31 and is interposed between the lower portion of the pump 12 and the bracket 31. Fuel-resistant rubber is employed as the rubber material for the supporter 34 in this embodiment.
A fuel intake port 36a is located on the lower portion of the pump 12, and a discharge port 37a is located on the upper portion. Furthermore, the pump 12 has an intake pipe 36, a discharge pipe 37, a terminal 38, and an electric motor (not shown). The intake pipe 36 is connected to the intake port 36a and extends laterally. The discharge pipe 37 is connected to the discharge port 37a and extends upward.
A strainer 39 is attached to the intake pipe 36. When the fuel in the tank 11 is drawn in through the intake pipe 36, the strainer 39 blocks relatively large foreign particles. A disk-like impeller having grooves on its periphery (not shown) is connected to the electric motor. Furthermore, the electric motor is connected to a battery and a controller (both not shown), which are provided outside the tank 11, by lead wires (not shown).
In the pump 12, the electric motor rotates the impeller in accordance with the voltage applied by the controller The fuel in the tank 11 is drawn in from the intake pipe 36 through the strainer 39 and is discharged through the discharge pipe 37 at a predetermined discharge pressure.
When the tank 11 contains fuel, the pump 12 and the lower portion of the lower housing 14b are immersed in the fuel.
The filter 13 is provided in the lower housing 14b. As shown in FIG. 2, the filter 13 includes a filter case 40, which has a C-shaped section, and a filter element 41.
The filter case 40 is electrically conductive and made of material that contains resin material mixed with carbon fiber or conductive material such as carbon powder. The fuel discharged from the pump 12 flows through the filter element 41 accommodated in the filter case 40, and friction between the fuel and the element 41 generates a negative electric charge in the element 41. However, the filter case 40 is conductive and the electric charge in the element is discharged outside, thus preventing the accumulation or an electric charge in the element 41.
A filter chamber 42 is formed in the filter case 40 for accommodating the filter element 41. An upper passage 43 and lower passage 44 are formed respectively at the upper and lower sides of the element 41 in the filter chamber 42.
A space 45 connected to the tank 11 is formed between the filter case 40 and the housing 14. An arcuate space 46 is formed between the inner side of the filter case 40 and the pump 12, which is also connected to the tank 11. Accordingly, these spaces 45 and 46 are usually filled with the fuel.
An inlet pipe 47 and outlet pipe 48 are integrally formed on the filter case 40, respectively. The vices 47, 48 have stepped bores 50 and 51, respectively. The inlet pipe 47 is connected to the fuel discharge pipe 37. The outlet pipe 48 is connected to the lower portion of the fitting 22.
The inlet pipe 47 and the fuel discharge pipe 37 are not in direct contact with each other, that is, the fuel discharge pipe 37 is covered with a gasket, or cap 52 made of fuel-resistant rubber. The inlet pipe 47 is detachably fitted on the cap 52 to connect the members 37 and 47.
The outlet pipe 48 is also not in direct contact with the joint 22. That is, an O ring 53a and a gasket, or cap 53b, both made of rubber, are attached to the lower potion of the fitting 22. The outlet pipe 48 is detachably fitted to the members 53a, 53b to connect the fitting 22 and the pipe 47.
As shown in FIG. 3, an internal passage 55 is partitioned by a wall 54 in the filter case 40. The upper portion of the passage 55 is connected to the outlet pipe 48, and the lower portion is connected to a lower passage 44 through a communication passage 56 formed under the wall 54.
A support leg 60 is formed on the disk portion 15 and extends downward. A foot 61, which is made of fuel-resistant rubber NBR (acrylonitrile butadiene copolymer), is fixed to the lower portion of the support leg 60. A concave retainer 63 made of NBR is also fixed on a step 62 of the lower housing 14b. The foot 61 contacts the top of the inlet pipe 47, and the retainer 63 holds the bottom of the filter case 40. Accordingly, the filter case is supported by the housing 14 at three points: its bottom, the inlet pipe 47, and the outlet pipe 48, with no direct contact with the housing 14. The retainer 63 is also in contact with the side of the pump 12 as shown in FIG. 1.
As shown in FIG. 2, a level gauge 72 having a float 70 and a sensor 71 is provided outside the lower housing 14b. The level gage 72 detects the left fuel amount. A pressure regulator (not shown) is provided in the lower housing 14b. The pressure regulator returns some fuel to the tank 11 when the fuel pressure in the lower passage 44 goes higher than a predetermined value. A connector (not shown) is formed integrally on the upper housing 14a to electrically connect the terminal 38, the level gauge 72, and the controller.
The fuel flow from the tank 11 to the delivery pipe will now be described.
When the pump 12 is operated, the fuel in the tank 11 is drawn into the pump 12 through the strainer 39 and the intake pipe 36 and is discharged through the discharge pipe 37. Then, the fuel flows into the upper passage 43 through the bore 50 of the inlet pipe 47. As shown by an arrow A in FIG. 1, the fuel in the upper passage 43 flows into the lower passage 44 through the filter element 41 in the filter chamber 42 and then flows into the passage 55 through the communication passage 56. Foreign matter in the fuel is caught by the filter element 41.
As shown by an arrow B in FIG. 1, the fuel then flows upward through the passage 55. The fuel then flows into the hose 26 through the passage 24 of the supply pipe 25 and is then supplied to the delivery pipe.
As explained above, the fuel from the pump 12 goes through the filter case 40, that is, the upper passage 43, the filter chamber 42, the lower passage 44, the communication passage 56, and the passage 55. When the fuel goes through the filter case 40, the pressure pulsation of the fuel discharged from the pump 12 causes vibration. If the vitiation of the filter case 40 were transmitted to the housing 14, it would generate vibration and noise outside, especially through the disk 15 of the upper housing 14a, which is exposed to the exterior.
In this embodiment, the filter case 40 and the housing 14 are independent, and the filter case 40 is accommodated in the housing 14 with a space 45 between the case 40 and the housing 14. This prevents the transmission of vibration from the filter case 40 to the housing 14. When vibration is transmitted to the fuel, it is reduced, or dampened by the fuel. Therefore, in the fuel supplier 10 of this embodiment, the vibration and noise of the housing 14 is reduced.
Furthermore, in this embodiment, the filter case 40 is not in direct contact with the housing 14. Elastomeric supporting elements, that is, the foot 61, the retainer 63, and the cap 53b, are located between the case 40 and the housing 14. Accordingly, most of the vibration energy of the filter came 40 is converted into heat energy generated by the elastic deformation of the cap 53b, the foot 61, and the retainer 63.
As a result, vibration transmitted from the filter case 40 to the housing 14 is reduced, thus restraining the vibration and the noise of the housing 14. The amount of vibration energy converted to heat energy can be maximized by varying the elastic modulus and the damping rate of the supporting elements 61, 63, in accordance with the material quality and the shape of the elements 61, 63.
Vibration of the filter case 40 can also be caused by vibration of the pump 12 itself, in addition to the pressure pulsation of the fuel. In this embodiment, the inlet pipe 47 of the filter case 40 and the fuel discharge pipe 37 of the pump 12 are not in direct contact with each other, since the cap 52 separates them. Accordingly, most of the vibration energy of the pump 12 is converted to heat energy by the deformation of the cap 52. This minimizes the vibration transmitted to the filter case 40.
Furthermore, in this embodiment, the arcuate space 46 is formed between the inner side of the filter case 40 and the pump 12. The vibration transmitted to the filter case 40 is very small, since the fuel in the space 46 acts as a damper.
Still further, the retainer 63 contacts the side of the pump 12, in addition to supporting the filter case 40. Accordingly, the position of the pump 12 relative to the filter case 40 is set by the retainer 63 to form the apace is 46. As a result, the pump 12 and the filter case 40 are not in direct contact with each other, thus reducing the transmission of vibration from the pump 12 to the filter case 40.
As described above, the vibration and noise transmitted outward from the fuel supplier 10 or this embodiment is reduced by suppressing the vibration of the filter case 40 itself and the housing 14.
Furthermore, the elastomeric supporter 34 is located between the bottom of the pump 12 and the bracket 31. This reduces the transmission of vibration from the pump 12 itself to the housing 14, which further reduces vibration and note of the housing 14.
Further, in this embodiment, the filter came 40, which is required to be sealed and pressurized, and the housing 14b, which fixes the filter case 40 and the pump 12 to the tank 11, are independent. Accordingly, there is no need to pressurize and seal the housing 14. As a result, in this embodiment, there is no need to strengthen the assembly between the upper housing 14a and the lower housing 14b to form a seal. It is also not necessary to provide a seal ring between the members 14a and 14b.
In the prior art as shown in FIG. 4, the space 123 that accommodates the filter element 55 is formed in the lower a housing 126, and there is a need to weld the lid 104 (corresponding to the upper housing 14a) to the lower housing 126 (corresponding to the lower housing 14b), so that the fuel cannot leak from the housing 126. However, when the lid 104 and the lower housing 126 are welded to each other, it is difficult to replace the filter element 124, which makes maintenance more costly.
It is also possible to snap-fit the lid 104 of the prior art device to the lower housing 126 without welding, as in the present embodiment. However, in this case, it becomes necessary to increase the assembly strength and to provide a seal between the members 104 and 126 so that a predetermined pressure can be maintained inside the housing 126.
In the present embodiment, there is no need to weld the lower housing 14b to the upper housing 14a, and the lower housing 14b is detachably fitted to the upper housing 14a without a costly sealed coupling. Furthermore, since the filter case 40 is detachable from the pump 12 and the housing 14a, the filter element 41 is easily replaced together with the filter case 40 by detaching the upper housing 14a from the lower housing 14b and then detaching the filter case 40 from the pump 12. This improves maintenance and lowers costs.
Further, in this embodiment, since the filter case 40 of the filter 13 and the housing 14 are independent, the filter 13 may be used in other types of fuel suppliers, for example, chose with different pumps. This permits common parts to be used and lowers the total manufacturing costs of the fuel supplier 10.
The fingers 28 of the upper housing 14a are snap-fitted to the apertures 27 of the lower housing 14b, to make the lower housing 14b detachable from the upper housing 14a. This snap-coupling facilitates the attachment and detachment of the housing 14a and 14b. This permits some slight updown movement of the lower housing 14b with respect to the upper housing 14a. However, in this embodiment, the foot 61, the filter case 40, and the retainer 63 are located between the upper housing 14a and the lower housing 14b, 80 that the upper housing 14a and the lower housing 14b are constantly urged away from each other (in the vertical direction in FIG. 1) by the compression reaction force of the lactomeric elements 61, 62. Accordingly, rattling between the housing parts 14a, 14b is prevented.
As mentioned already, the filter case 40 must be conductive to prevent the accumulation of electric charge in the filter element 41. Accordingly, in the prior art shown in FIG. 4, it is necessary to make the lower housing, which accommodates the filter element 124, with conductive resin. On the other hand, the lid 104 is preferably formed by non-conductive resin, because the lid 104 has to integrally form the electric connector 127 as shown in FIG. 5. In the prior art, the lid 104 is welded to the lower housing 126 to ensure sealing.
However, when the lid 104 and the lower housing 126 are formed by different kinds of resin materials, stress is generated by the thermal expansion difference between these materials. This lowers the durability of the fuel supplier. In this embodiment, since the filter case 40 and the housing 14 are independent, there is no need to weld different types of resin materials together as in the prior art. Accordingly, this problem is avoided.
The summarized advantages of this embodiment will be listed below.
The vibration and noise of the fuel supplier 10 is reduced.
The lower housing 14b is detachable with respect to the upper housing 14a without a costly sealed coupling.
The filter element is easily replaced together with the filter case 40, thus facilitating maintenance.
The manufacturing cost of fuel supplier 10 is lowered by permitting the use of common parts.
Rattling of the lower housing 14b, which usually occurs when snap-fitting is employed, is prevented.
The durability of the fuel supplier 10 is improved.
The above embodiment may be varied as follows, while keeping substantially the same advantages.
In the illustrated embodiment the elastomeric elements 61, 63 are made of NBR rubber, however, other rubber material such as highly saturated nitrile rubber may be also employed, as long as it is fuel-resistant. Instead of rubber materials, leaf springs and coil springs may be employed for the elements 34, 61, and 63.
In the illustrated embodiment, the fuel supplier 10 is provided in the tank 10, however, the fuel supplier 10 may also be provided outside the tank 11.
The present examples and embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalence of the appended claims. | A fuel supply system having a pump for drawing and discharging fuel from a tank and a filter for catching foreign matter in the fuel. A housing has a fuel outlet and supports the pump. The pump has a fuel intake port and a fuel discharge port. A fuel passage is located in the housing and connects the fuel outlet with the discharge port The filter is located in the fuel passage. The filter has a filter case and a filter element therein. The filter case is located in the housing spaced from the inner wall thereof. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/014,254, filed Dec. 17, 2007, the entire disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to arthroscopic surgical methods and instruments and, more specifically, to an articulating hook elevator for arthroscopy.
BACKGROUND OF THE INVENTION
[0003] Arthroscopic surgery involves the insertion of an arthroscope into a joint region, such as the knee, elbow or shoulder, to allow a surgeon to view the internal condition of the joint. Examples of such arthroscopic procedures are partial meniscectomies and ligament reconstructions in the knee, shoulder acromioplasties and rotator cuff debridements, and elbow synovectomies.
[0004] During arthroscopic surgery, a small incision is made in the skin covering the arthroscopic site or joint so that surgical instruments may be placed in the joint and manipulated through arthroscopic visualization. A very small incision is highly desirable as it has an obvious cosmetic advantage, and low complication rates with a very low incidence of infection.
[0005] Because only a very small incision is made during arthroscopic surgery, it is often difficult to grab small regions of tissue and to subsequently apply a desired tension on the tissue within the joint capsule, either in a direction toward or away from the arthroscopic portal. In addition, it is also difficult to handle instruments within the joint capsule, where visibility and access to the structures of the joint capsule is minimal.
[0006] Accordingly, a need exists for a surgical instrument that allows improved handling of instrumentation within a joint capsule, for example the elbow capsule, during athroscopic surgery. A need also exists for a surgical instrument that is stable during elbow arthroscopy and that allows the secure lifting and/or retracting orientation desired by the surgeon, without accidental slipping or shifting and with minimal soft tissue edema to the patient.
SUMMARY OF THE INVENTION
[0007] The present invention provides an articulating hook elevator having a shaft, a proximal end, and a distal end provided with an articulating hook. The hook is configured to allow secure engagement and retraction of anatomical structures (such as neurovascular structures) during arthroscopic surgery. The hook may be actuated by a switch and can articulate into a standard tip for traditional manipulation of tissue, or into a rotated or articulated position.
[0008] Other features and advantages of the present invention will become apparent from the following description of the invention, which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of an articulating hook elevator according to an embodiment of the present invention.
[0010] FIG. 2 is a top view of the articulating hook elevator of FIG. 1 .
[0011] FIG. 3 is a cross-sectional view of the articulating hook elevator of FIG. 1 and in an articulating position.
[0012] FIG. 4( a ) is an enlarged view of the distal end of the articulating hook elevator of FIG. 1 and in a non-articulating position.
[0013] FIG. 4( b ) is an enlarged view of the switching mechanism of the articulating hook elevator of FIG. 1 and in a non-articulating position.
[0014] FIG. 5 is a partial cross-sectional view of the articulating hook elevator of FIG. 1 and in a non-articulating position.
[0015] FIG. 6( a ) is enlarged view of the distal end of the articulating hook elevator of FIG. 1 and in an articulating position.
[0016] FIG. 6( b ) is an enlarged view of the switching mechanism of the articulating hook elevator of FIG. 1 and in an articulating position.
[0017] FIG. 7 is a partial cross-sectional view of the articulating hook elevator of FIG. 1 and in an articulating position.
[0018] FIG. 8 is a lateral view of an elbow joint undergoing arthroscopy and with the articulating hook elevator of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] In the following detailed description, reference is made to various specific embodiments in which the invention may be practiced. These embodiments are described with sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be employed, and that structural and logical changes may be made without departing from the spirit or scope of the present invention.
[0020] The present invention provides an articulating hook elevator having a shaft, a proximal end, and a distal end provided with an articulating hook. The hook is configured to allow secure engagement and retraction of anatomical structures (such as neurovascular structures) during arthroscopic surgery.
[0021] The hook may be actuated by a switch and can articulate into a standard tip for traditional manipulation of tissue, or into a rotated or articulated position. The switch mechanism (in the form of a mechanical cam) actuates the tip of an articulating hook elevator to a rotated or “bent tip” position, in the manner described in U.S. Patent Application Publication No. 2005/0203345, entitled “Articulating Paddle Elevator and Arthroscopic Method for Using Same,” the disclosure of which is hereby incorporated by reference in its entirety.
[0022] Referring now to the drawings, where like elements are designated by like reference numerals, FIGS. 1-7 illustrate an articulating hook elevator 100 of the present invention. The articulating hook elevator 100 of FIGS. 1-7 may be used to manipulate and palpate tissue during arthroscopic surgery (for example, elbow arthroscopy) and to lift and/or retract tissue while maintaining capsular distention without damaging adjacent structures such as neurovascular structures, for example. The hook of the articulating instrument allows engagement and retraction of neurovascular structures without the risk of sliding off and subsequent injury of such structures during surgery. Thus, the hook elevator of the present invention allows more controlled arthroscopic engagement and secure lifting and/or retracting orientation desired by the surgeon, without accidental slipping or shifting and with minimal soft tissue edema to the patient.
[0023] As illustrated in FIG. 1 , the hook elevator 100 includes a shaft 20 provided in the shape of a cylinder and having a distal end 21 and a proximal end 22 . A handle 10 is disposed at the proximal end 22 of the shaft 20 , and an actuating tip or hook 50 is located at the distal end 21 of the shaft 20 . The actuating hook 50 has a configuration that allows it to securely engage (to hook) additional tissue structures (such as neurovascular structures, for example) and to retract these structures, without accidental slipping or shifting and with minimal tissue edema to the patient. The actuating hook 50 may be additionally used for manipulating and palpating tissue.
[0024] As illustrated in FIGS. 2 , 3 and 4 ( a ), for example, the articulating or actuating hook 50 comprises a main body region 50 a (in the form of a paddle) that is integral to a curved, hooked region 50 b positioned at the most distal end of the main body region 50 a. When the instrument is in a non-articulating position (such as the one illustrated in FIG. 5 , for example), a longitudinal axis (including a main paddle surface) of the main body region 50 a is about parallel to the longitudinal axis of the instrument. When the instrument is in an articulating position (such as the one illustrated in FIG. 7 , for example), the longitudinal axis (including the main paddle surface) of the main body region 50 a is about non-parallel to the longitudinal axis of the instrument.
[0025] An actuator 40 is located at the proximal end of the shaft 20 and connected to the handle 10 . The actuator 40 comprises a lever or thumb trigger 44 , a link 42 , a cam 11 and an actuator 25 connected to the link 42 and the trigger 44 . As shown in FIG. 3 , the actuator 40 also comprises a set screw 58 and a plurality of handle pins 53 . The actuator 40 is designed to cause the actuating hook 50 of the hook elevator 100 to be angled, for example at about 40°, when actuated. The actuating hook 50 is connected to actuator 25 by a plurality of pins 52 ( FIG. 3 ).
[0026] FIGS. 4-7 illustrate the mechanics of the articulating hook elevator 100 of the present invention. FIG. 5 illustrates the articulating hook elevator 100 disposed in the straight or “unlocked” position, while FIG. 7 illustrates the hook elevator 100 disposed in the articulating or “bent tip” position and locked. FIGS. 4( a )-( b ) and FIGS. 6( a )-( b ) are enlarged views of the articulating hook and switch mechanism corresponding to the straight and articulating positions of the articulating hook elevator 100 of FIGS. 5 and 7 , respectively.
[0027] The articulating hook 50 , which rotates to an angle of about 40° (in the embodiment shown in FIGS. 3 and 7 ) to about 120°, is connected to the actuator 40 which comprises the lever or trigger 44 , link 42 , cam 11 and actuator 25 connected to the hook 50 at the distal end. The switch mechanism 40 is mechanically connected to the hook 50 and, when actuated, causes the hook 50 to rotate to a 40° position, for example, as shown in FIGS. 3 and 7 . In the straight position shown in FIG. 5 , the trigger 44 is pushed in the direction of arrow A ( FIG. 4( b )) and disposed in a front or “unlocked” position. This causes the actuator 25 to be biased towards the distal end of articulating hook elevator 100 .
[0028] FIG. 7 illustrates the articulating hook elevator 100 in the “bent tip” or “locked” position, in which the articulating hook 50 is disposed in a 40° position. To rotate the articulating hook to the 40° position, trigger 44 is pushed backward in the direction of arrow B of FIG. 6( b ). Trigger 44 includes a cam 11 which pushes the actuator 25 backward or towards the proximal end of the actuator when trigger 44 is moved backward. This mechanical action causes the hook 50 to rotate 40° as shown.
[0029] The articulating hook elevator 100 of the present invention described above with reference to FIGS. 1-7 may be employed in various surgical medical procedures for manipulating body tissue and neurovascular structures during surgical procedures. For example, the articulating hook elevator 100 may be employed in endoscopic and arthroscopic procedures, including but not limited to elbow arthroscopy, knee arthroscopy, shoulder arthroscopy, and other arthroscopic procedures that require handling and manipulation (lifting and/or retracting) of tissue while maintaining capsular distention without damaging adjacent structures such as neurovascular structures, for example.
[0030] To better illustrate an exemplary surgical procedure conducted with the articulating hook elevator 100 of the present invention, reference is now made to FIG. 8 , which illustrate a side schematic view of a surgical site 90 of elbow joint 300 . A surgeon advances articulating hook elevator 100 in the “straight” or closed configuration into elbow joint 300 , as shown in FIG. 8 , optionally through a small cannula or portal, for example. The “straight” configuration allows the surgeon to gently insert instrument 100 into the elbow capsule and out of adjacent vital neurovascular structures, such as the brachial artery, the median nerve and the radial nerve, for example.
[0031] Once the articulating hook elevator 100 is inserted into the elbow joint, the surgeon then articulates hook 50 to a desired angle, for example to approximately 40° or 120°. The surgeon may also gradually increase or decrease the angle of the hook (for example, from a first position to a second position), as desired and in accordance with the characteristics of the surgical site. The hook of the articulating instrument 100 allows engagement and retraction of neurovascular structures (such as the ulnar nerve, for example) without the risk of sliding off and subsequent injury of such structures during surgery. The hook elevator of the present invention allows a more controlled arthroscopic engagement and secure lifting and/or retracting orientation desired by the surgeon, without accidental slipping or shifting and with minimal soft tissue edema to the patient.
[0032] Although the present invention has been described in relation to particular embodiments, many other variations and modifications and other uses will become apparent to those skilled in the art.
[0033] Although the present invention has been described in connection with preferred embodiments, many modifications and variations will become apparent to those skilled in the art. While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Accordingly, it is not intended that the present invention be limited to the illustrated embodiments, but only by the appended claims. | An articulating hook elevator for manipulating tissue during arthroscopic procedures. The articulating hook elevator comprises a shaft, a proximal end, and a distal end provided with an articulating paddle. The hook may be actuated by a switch and can articulate into a standard tip for traditional manipulation of tissue, or into a rotated or articulated position. In this manner, effective manipulation and retraction of tissue from the surgical site without tissue collapse may be achieved, allowing a surgeon to better visualize the internal condition of the arthroscopic site and speed up the overall procedure. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to the field of coding devices. More particularly, this invention relates to a coding device which is secure against unauthorized attempts to operate the device by human intervention.
Code operated devices are used for a variety of applications. One important application for code operated devices is for SAFE and ARM mechanisms for various kinds of missiles and other weapons. Such devices involve the use of codes to prevent arming of a weapon system unless a predetermined code has been satisfied. Coded SAFE and ARMING devices are particularly important for use with nuclear weapons, although their utility is by no means limited to such weapons.
A prior art electromagnetic code operated device is described in U.S. Pat. No. 4,099,161 granted to the present inventor and assigned to the assignee hereof (the subject matter of which is incorporated herein by reference). The device of that prior patent is an effective code operated device for a weapon or other system. In the environment of a weapon system, it operates to effect a change from a SAFE state to an ARMED state in response to receipt of a predetermined code in an appropriate signal input sequence. In the event an improper code is received, the device of that prior patent will lock to a DUD state, and the device will not advance further toward the ARMED state.
While effective for its intended purposes, the feature of the system of the U.S. Pat. No. 4,099,161 wherein it locks to a DUD state in response to receipt of an improper code can, if sufficient time is available, be used by a knowledgeable individual to work through the code to unlock and gain unauthorized access to the system. The system of the prior patent operates on a code of binary "0" and "1" inputs. If the proper code is delivered, the device will "unlock" to permit operation of the protected mechanism (missile, weapon, etc.); but the code wheel locks if an improper code sequence is delivered. Thus, if a "1" is inputted at the place in the code where an "0" is the proper input (or vice versa), the device will lock to the DUD state. However, while this locking prevents any further advance to the unlocked state, it will tell a knowledgeable person that the wrong binary signal was used at the place in the input signal string. Thus, a knowledgeable person will know that there is always a 50-50 chance of correctly guessing each succeeding bit in a code; and if the system locks because of an incorrect input, that person will know that the lock state can be avoided at this place in the input signal string by using the complementary binary input at that place. Thus, it may be possible to work through the code and unlock the device by
(1) inputting a string of binary signals until the device locks,
(2) resetting the device to the start position and repeating the previous string of input signals with the last one (i.e. the one that caused the system to lock) being changed to the opposite binary state,
(3) continuing to input signals until another lock state is encountered, and
(4) repeating steps (2) and (3) until the enter code is worked through and the device unlocks.
Thus, while the device of U.S. Pat. No. 4,099,161 is a coded safety device, it is not considered a secure device in the sense that it is protected against reasoned human intervention. With a binary code it is, of course, statistically possible that someone could randomly guess the correct code. While the probabilities of that happening are very low, there does not appear to be any way to make a device secure against that remote possibility. However, it is highly desirable to make coded safety devices secure in the sense of protecting them against attempts at reasoned human intervention.
SUMMARY OF THE PRESENT INVENTION
Although the device of the present invention will be described in connection with a SAFE and ARM device for weapons, it will be understood that its use is not limited to that application. In its broadest sense, the device of the present invention may be considered to be a secure coded locking device, and it may be used for any application which requires limitation to only authorized access or in which it is desired to unlock any mechanism or to generate an output signal such as mechanical movement in response to the receipt of an appropriate input signal code. Examples of uses other than weaponry include, but are not limited to, control of access to restricted areas, control of access to computer systems, control of operation of power plants. Regardless of the application, the operation of the device and its output may be viewed as generating an output or signal when the proper code is inputted to the device. In the context of the present invention, a secure coded device will be understood to be one which does not provide information to an attempted intervenor which can be used to further the attempt to gain access to the system.
In accordance with the present invention, a drive mechanism operates through coded sensors to provide an output signal (which may be to unlock a previously locked mechanism) upon receipt of a predetermined unique coded input signal. The device is made secure by means of "0" and "1" input code cams and a pair of input control cams which are each connected to and drive separate code and control output cams. Each operating signal, whether in the correct code or not, will cause the input control cam and its associated output cam to step or advance one unit. However, the input code cam and associated output cam will only advance if the properly coded signal has been delivered to operate the device; and they will not advance if the proper code signal has not been inputted. The output cams are each provided with operating means to unlock or otherwise provide an output signal if the cams are both moved synchronously to their actuating position with the operating means aligned or in other predetermined relationship (which occurs if the proper code sequence has been delivered to the device). Proper alignment (or other relationship) between the operating means defines an operating window. However, if the incorrect code is delivered to the device (on either the "0" input channel or the "1" input channel), the input code cam to which the incorrect signal has been delivered will not advance, but the associated input control cam will advance. This advance of the input control cam will cause the control output cam to advance and thus misalign or scramble the operating means on the two output cams; and that state of misalignment will continue to exist even if the remainder of the code inputted to the device is correct. This misalignment occurs in a single step i.e., in response to a single erroneous input. The misalignment of the operating means operates, in effect, to close the operating window of the device to prevent actuation of an unlocking device. Because of the misalignment and closure of the operating means in the two output cams, the output signal (e.g. unlocking of a locked device) will not occur. The operating means may e.g., be notches, other contours, electrical contact points, etc. on the output cams. The preferred system disclosed herein uses notches.
Unlike the device of prior U.S. Pat. No. 4,099,161 which locks when an erroneous signal is inputted, the device of the present invention is disabled from generating an output signal, but operation does not lock. Thus, the device of the present invention is secure against intentional unauthorized intervention because it does not give any signal to the intervenor that a wrong signal has been inputted. The intervenor does not learn when a wrong signal has been inputted, so the intervenor cannot work through the system in a series of locking, resetting and unlocking steps. Rather, the intervenor will continue to deliver input signals to the device without knowing that a wrong signal has been delivered and that the required synchronism of the output cams has been scrambled.
Other features and advantages of the secure code operated device of present invention will be apparent to and understood by those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several figures:
FIG. 1a shows a first version of the secure code operated device of the present invention
FIG. 1b is an illustration of the relationship of input and output cams of the device of FIG. 1a
FIG. 1c illustrates relative rotation senses of input and output cams
FIG. 2a is an illustration similar to FIG. 1a of a second version of the invention
FIG. 2b is an illustration of the relationship of input and output cams of the device of FIG. 2a
FIG. 3 is an isometric view of the device illustrated in FIGS. 2a and 2b
FIG. 4a is a view similar to FIG. 1a of a third version of the invention
FIG. 4b is an illustration of input and output cams of the device of FIG. 4a
FIG. 5 is an isometric view of the device shown in FIGS. 4a and 4b
FIG. 6 shows an enlarged detail of resettable or programmable teeth on a code cam.
FIG. 7 is a view along line 7--7 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1a, 1b and 1c, a first embodiment of the secure code operated device of the present invention is shown. Although not all supporting framework is shown, it will be understood that the device of the present invention is enclosed and suitably supported in a housing and is, preferably, environmentally sealed. In this first embodiment, first driver solenoid 10 drives a first rotatable shaft 12, and a second driver solenoid 14 drives a second shaft 16. Solenoid 10 and its shaft 12 are in the "0" bit channel, and solenoid 14 and shaft 16 are in the "1" bit channel of a binary code input. A pawl driver arm 18 is fixed to shaft 12 to move about the axis of shaft 12 when shaft 12 is rotated, and a pawl driver arm 20 is fixed to shaft 16 to move about the axis of shaft 16 when shaft 16 is rotated. A "0" bit drive pawl 22 is pivotally connected to arm 18, and a "1" bit drive pawl 24 is pivotally connected to arm 20. The shafts 12 and 16 and the pawl arms 18 and 20 will rotate by a set amount for each input to their respective solenoid drives 10 and 14.
A pair of cams is rotatably mounted on each of shafts 12 and 14. A control cam 26 and a "0" bit input code cam 28 are rotatably mounted on bearings about shaft 12, and a control cam 30 and a "1" bit input code cam 32 are rotatably mounted on bearings about shaft 16. Code cams 28, 32 (e.g. which function as mechanical means of storing the code) are shown partly broken away in FIG. 1b for convenience of illustration. Each of control cams 26 and 30 has a series of ratchet teeth 34 and 36 spaced equally about the entire periphery of cams 26 and 30. The number and spacing of teeth 34 and 36 will depend on the desired number of bits in the operating code and the resolution of the output cams (i.e., the ability of the mechanism to recognize and find the unlocking notches). While full cams of ratchet teeth 34, 36 may preferably be employed, it is not necessary that the ratchet teeth extend around the entire control cams 26, 30; but the ratchet teeth 34 and 36 must be equally spaced apart on the periphery of control cams 26 and 30 for whatever span they occupy and they must occupy corresponding coordinated spans on the respective control cams. Each of the input code cams 28 and 32 also has ratchet teeth 38 and 40, respectively, spaced about the periphery of the code cams. However, these code teeth are not equally spaced about the entire periphery of the code cams. Rather, these code teeth are spaced apart about the periphery of their respective code cams so as to be commensurate with the code for which the device is set to operate. Since the system operates on a binary code, at each corresponding position of the code cams 28 and 32 the ratchet tooth state is complementary. That is, if there is a ratchet tooth present at a particular position on the "0" bit code cam, then there will be no ratchet tooth at the corresponding position on the "1" bit code cam, and vice versa. Pawls 22 and 24 span their respective control and code cams 26, 28 and 30, 32 to contact the ratchet teeth 34, 38 and 36, 40 and incrementally drive both cams (assuming the code input is correct).
Since the control cams have teeth around their entire peripheries, each control cam will always advance one step for each cycling of its respective pawl driver and pawl (i.e. in response to either a "0" input signal to solenoid 10 or a "1" input signal to solenoid 14). However, the "0" bit input code cam 28 will advance only if there is ratchet tooth present at the position of the code cam when the pawl and pawl drive are cycled in response to an input signal to "0" bit solenoid 10; and, similarly, the "1" bit input code cam 32 will advance only if there is a ratchet tooth present at the position of the code cam when the pawl and pawl drive are cycled in response to an input signal to "1" bit solenoid 14. The fact the control cams advance for each cycling but the code cams do not is an important feature in making the device of the present invention a secure coded device.
Gears 42 and 44 are secured, respectively, to reduced diameter hub sections of control cam 26 and code cam 28; and gears 46 and 48 are secured, respectively, to reduced diameter hub sections of control cam 30 and code cam 32. Gears 42 and 46 mesh with and drive an output gear 50 which is secured to and drives an output shaft 52. Shaft 52 is supported by bearings 54 and 56. A control output cam 58 is also secured to and rotates with output shaft 52. Since shaft 52 and output cam 58 are drivingly connected to both of the control cams 26 and 30, and since one or the other of those control cams will be advanced one step for either a "0" or a "1" bit input signal, shaft 52 and output cam 58 will always rotate one step for a signal bit input, regardless of the digital state of the input signal bit.
Gears 44 and 48 mesh with a gear 60 which is supported on shaft 52 by a bearing 62, gear 60 being free to rotate relative to shaft 52. A code output cam 64 is also rotatably mounted on shaft 52 by a bearing 66, and output cam 64 ,is pinned or otherwise locked to gear 60 as at pin 67 so that gear 60 and output cam 64 rotate in unison. Because gear 60 is drivingly connected to code cams 28 and 32, gear 60 and output cam 64 will each advance one step whenever a "0" input signal is delivered to solenoid 10 or a "1" input signal is delivered to solenoid 14. Each pulse to a solenoid driver causes a fixed advance step rotation of its associated pawl driver and pawl. The amount of angular rotation is determined by the number of ratchet teeth on the code and control cams. For example, with 48 teeth spaced evenly about the entire periphery of each control cam (and the teeth on the code cams being spaced accordingly), each step advance would be 7.5°. Upon completion of each advance step, a return spring resets the input shaft 12, 16, associated pawl driver and pawl to its original position for another advance stroke; and a backstop pawl associated with each control cam and each code cam prevents reverse rotation of the control and code cams. In the embodiment of FIG. 1a, the return springs 72 and 74 are mounted, respectively, between ground locations and shafts 12 and 16. Representative spring loaded backstop pawls 76 and 78 are shown in FIG. 1b. Return stops 80 and 82 limit the return movement of pawl drivers 18 and 20 to ensure that the pawl units are properly reset for the next forward or advance stroke.
Output cams 58 and 64 have unlock or actuation notches or contours 68 and 70, respectively, in the periphery of the cams. The notches are similarly sized and shaped. Notches 68 and 70 are aligned when the unit is initially set or reset to the SAFE (locked) state (sometimes referred to as "home"); and the notches will remain aligned as the unit advances from the SAFE to the ARMED (unlocked) state as long as the correct code is delivered in the correct sequence to go from the SAFE to the ARMED state. However, if an incorrect code signal is delivered to the unit at any place in the code sequence between the SAFE and ARMED states, the notches will be moved out of alignment so that unlocking or other activation cannot occur.
The maintenance or loss of the state of alignment between the notches occurs as the result of movement and interaction of the input control cams 26, 30 and the input code cams 28, 32. A string of coded "0" and "1" bit digital signals is used to move the device from a starting SAFE state to an ARMED state. The "0" signals in the string are delivered as pulses to operate solenoid driver 10, and the "1" signals are delivered as pulses to operate solenoid driver 14. If the correct code string is delivered to the system, each "0" bit will advance both the control cam 26 and the "0" bit code cam 28; and, each "1" bit will advance both control cam 30 and "1" bit code cam 32. Each step advance of a control cam will cause a step advance rotation of output gear 50 and output cam 58; and each step advance of either code cam 28 or code cam 32 will cause a step advance rotation of output gear 60 and output cam 64. Thus, for each inputted code bit (whether a "0" or a "1" bit and whether or not it is a correct bit for the code), control output cam 58 will advance one step; and for each correct "0" or "1" bit, code output cam 64 will also advance one rotational step. Thus, if the correct code is inputted, the output cams 58 and 64 will advance in unison, and the notches 68 and 70 will remain aligned or synchronized. Then, upon inputting of the complete correct code, the output cams 58, 64 will rotate to a position where the notches 68, 70 are aligned with a mechanism such as a roller 84, and the roller will be permitted to move into notches 68, 70. As illustrated in FIG. 1b, the roller mechanism 84 is normally (i.e. in the SAFE condition) engaged and retained by the outer surface of output cams 58, 64 in a notch 86 in a part 88 of a device or system to be operated, to thus lock the part 88 against movement or activation. However, when both notches 68, 70 align with roller 84 and notch 86, roller 84 is permitted to move out of notch 86 and into notches 68, 70. Thus, roller 84 disengages from part 88, whereby part 88 is unlocked and is free to move, to operate a weapon or other system, i.e. the part 88 and its associated weapon or system are switched to an ARMED state.
It should be noted that each step rotary advance of either "0" code cam 28 or "1" code cam 32 will, through the gears 44, 60 and 48, cause a step rotary advance of the other code wheel. Thus, both code cams advance with each correct code input signal so that the ratchet teeth on the code cam are always properly positioned to receive a next correct input signal, as long as the input signal string is in the correct code sequence.
If an incorrect code is delivered to the system, the above described sequence will not occur, and unlocking to switch from a SAFE to an ARMED state will not occur. To illustrate this point, assume that a "0" bit is delivered to the system at a point in the code string where a "1" is correct. The erroneous "0" will operate solenoid 10 and effect a one step rotary advance of shaft 12, pawl arm 18 and "0" bit pawl 22. This one step advance or cycling of pawl 22 will cause a one step advance of "0" control cam 26 (because the pawl will be engaged with a ratchet tooth 34 on cam 26). Accordingly, as described above, there will also be a one step rotary advance of control output cam 58. However, since there will be no ratchet tooth on "0" code cam 28 at this position on the code cam, the advance or cycling of pawl 22 will not effect a step advance of code cam 28. Since code cam 28 does not advance, both gear 60 and code output cam 64 will remain stationary. As a result, control output cam 58 rotates relative to code output cam 64 to misalign or desynchronize the unlock notches 68, 70. Since the notches 68, 70 are now out of alignment, continued rotations of the output cams 58, 64 in step fashion in response to further code input signals will not result in unlocking of part 88, because notches 68, 70 will not be aligned to receive unlock roller 84.
An important point to be noted is that the presence of an incorrect code bit does not provide any feedback to indicate that an incorrect code input has been made. At and after the input of an incorrect code bit, the system continues to advance in step rotary increments, but with the unlock notches misaligned. If an intruder is attempting to effect unauthorized operation of the system, the intruder will not be informed when an erroneous bit has been inputted. Thus, the intruder will not be able to work through the system by repeating previous inputs and correcting an erroneous input when it occurs, because the intruder will not be informed when an erroneous bit has been inputted.
The code and control cams all rotate in the same direction for advancing steps, and the output cams rotate in the opposite direction to that of the input cams. The same sense of rotation of the code and control cams makes it possible to connect the cams through output gears 50 and 60. This is important to ensure that the code cams remain properly synchronized.
While a reset mechanism can be provided to reset the entire system to the start position, a reset mechanism has not been shown in FIG. 1a to simplify the showing and explanation of the system. However, suitable reset mechanisms are shown in FIGS. 2 through 5
Referring now to FIGS. 2a, 2b and 3, a second embodiment of the secure code operated device of the present invention is shown. The primary differences between this second embodiment and that of the first embodiment are:
(1) the presence of ratchet wheels 90, 92 with peripheral teeth on the output gears 50 and 60; and
(2) a pair of backstop pawls 94, 96 (only one of which is shown in FIG. 2b), operatively associated, respectively, with the ratchet wheels 90, 92.
(3) a reset solenoid 98 operable to release the backstop pawls 94, 96 to permit the unit to be reset to a starting position
(4) a return spring 100 which, when reset solenoid 98 is activated to withdraw the backstop pawls 94, 96, is effective to return all input and output control and code cams to their starting position (wherein unlock notches 68, 70 are aligned)
(5) return stops 102 and 104 on gears 50 and 60 which will contact a grounded stop element 106 when the cams have all returned to their starting positions
(6) a spring loaded unlock lever 108 with finger 108a instead of roller 84
(7) resettable or programmable ratchet teeth 110 on code cams 28 and 32 and ratchet tooth resetting solenoids 112a, 112b (all of which will be described in more detail in connection with FIGS. 6 and 7).
It will be noted that in this second embodiment, shafts 12 and 16 are each split into two independent segments 12a, 12b, 16a and 16b. The pawl arms 18 and 20 are connected to shaft segments 12a and 16a, but the control and code cams 26, 28, 30, and 32 are mounted on separate shaft segments 12b and 16b. The drive pawls are split into segments 22a, 22b on a common shaft which drive control cam 26 and code cam 28 in unison (assuming a correct code), and segments 24a, 24b on a common shaft which drive control 30 and code cam 32 in unison (assuming a correct code). The control cams 26, 30 are fixed to shaft segments 12b and 16b, while the code cams 28, 32 are rotatably mounted on the shaft segments.
Except for the resetting function and the programmable ratchet teeth, the embodiment FIGS. 2a, 2b and 3 operates in the same manner as the first embodiment of FIGS. 1a, 1b and 1c. A correct "0" bit input to driver solenoid 10 will cause step movement of drive pawls 22a and 22b to step advance control cam 26 and code cam 28. Similarly, a correct "1" bit input to driver solenoid 14 will cause step movement of drive pawls 24a and 24b to step advance control cam 30 and code cam 32. If the correct coded sequence of "0" and "1" inputs is delivered to the unit, the output gears 50, 60 and the control and code output cams 58 and 64 will rotate in synchronism to keep output control cam notch 68 and the output code cam notch 70 in alignment. Delivery of the complete correct code will rotate the control and code output cams 58, 64 to the position where finger 108a of output lever 108 moves into the aligned notches 68, 70 to unlock the locked device 88. However, if an incorrect "0" or "1" bit is inputted, output gear 50 and output control cam 58 will rotate, but output gear 60 and output code cam 64 will not rotate, thus desynchronizing notches 68 and 70 to prevent actuation of lever 108 and prevent unlocking of device 88.
As with the unit of FIGS. 1a and 1b, the intruder who entered the erroneous code will not receive any feedback of the error. At and after the input of the incorrect code bit, the system continues to advance in step rotary increments, but with the unlock notches misaligned and with the occurrence of the misalignment unknown to the intruder. The system may be reset to the start or home position for code input by operating reset solenoid 98 which disengages backstop pawls 94, 96 from ratchet wheels 90, 92, whereby return spring then drives the gears and cams in the reverse direction to reset everything to the start position to await input of the correct coded sequence.
It will be noted that drive pawls 22a, 22b, 24a, 24b are all pivotal on their respective pawl drivers 18, 20; and they are spring loaded so that they rotate inwardly into position to engage the cam teeth when the pawl drivers advance. Each drive pawl has a lever segment 23 which engages a stop 25 when the pawl driver is returned to its rest position to rotate the drive pawl outwardly beyond the cam teeth. This enables the code and control cams to be rotated in the reverse direction by return spring 100 if reset solenoid 98 is activated.
Referring now to FIGS. 4a, 4b and 5, a third embodiment is shown. This embodiment differs from the second embodiment in that
(1) A single common input control cam 114 is mounted directly on and fixed to output shaft 52. This single input control cam has ratchet teeth 116 which are engaged by pawls 22a and 24a. Backstop pawl 94 interacts with a ring of ratchet teeth on a reduced diameter part of the control cam.
(2) Input code cams 28 and 32 are combined in a single cam body which is mounted directly on and is rotatable on output shaft 52. Code cam 28 is driven by pawl 22b, and code cam 32 is driven by pawl 24b. Backstop pawl 96 interacts with a ring of ratchet teeth 120 on a reduced diameter part of the control cam.
(3) Code output cam 64 is formed as an integral part of the united code cam 28, 32.
The system of FIG. 5 mounts the input cams directly on the output shaft 52, and eliminates the gearing of the first and second embodiments. The single input control cam is fastened to shaft 52, while the code cams 28, 32 are rotatable on shaft 52. Code output cam 64 is rotatable on shaft 52, and control output cam 58 is fastened to shaft 52.
The system of the third embodiment operates in the same way as the system of the first and second embodiments. However, it will be understood that all control inputs, whether accompanying a "0" code input or a "1" code input, are delivered to, and drive, the single control input cam 114.
Referring now to FIGS. 6 and 7, enlarged partial details are shown of the resettable or programmable ratchet teeth 110 on the code cams. Programmable teeth 110 are made up of tooth segments 122, 124, both of which are secured on and rotate simultaneously with a shaft 126. Each tooth segment 122, 124 is generally diamond shaped and extends from a cylindrical body portion 127. The body portions 127 are secured to shaft 126 by any convenient means. Shaft 126 is pivotally supported in spaced disc members 128, 130 on the outer periphery of a code cam, e.g., cam 28. The lower or inner end of each tooth segment has a "V" notch 132 which receives one end of a toggle or overcenter leaf spring 134. The other end of spring 134 is retained in a V notch 136 in an inner peripheral surface 138 of the code cam. Spring 134 functions to keep a tooth 110 in either the full or dashed line position shown in FIG. 7 after the tooth has been moved to the selected position by setting fingers 140, 142 which are actuated by the code setting solenoids 112a and 112b. The dashed line position of the tooth 110 in FIG. 7 corresponds to the "up" or "set" position of the tooth where it is in the position to be engaged by a pawl driver to advance the associated code cam; the solid line position corresponds to the "down" or "recessed" position where the tooth 110 is positioned so that the pawl driver will pass over the tooth without engaging the tooth and without advancing the code wheel. A programmable tooth 110 is switched from the full line position of FIG. 7 to the dashed line position by actuating finger 142 to engage tooth segment 124 to rotate tooth 110 clockwise to the dashed line position. Conversely, a tooth 110 is moved from the dashed position to the full line position by actuating finger 140 to engage tooth segment 122 to rotate tooth 110 counterclockwise to the full line position. When a tooth is moved to either the "up" or "down" position, it is stopped on the cylindrical surface of the adjacent tooth and held in position by the over-center spring 134. For convenience of illustration, only one full tooth is shown in FIG. 7, and only the cylindrical portions 127 and shafts 126 of the adjacent teeth are shown. Also, it will be understood that while only three tooth positions are shown in FIG. 7, the teeth will extend around the full periphery of the cam (or an arc segment thereof if only part of the cam has coded teeth).
It will be understood that when a programmable tooth on one code cam (e.g., the "1" cam) is set to the "up" position, the corresponding or complementary tooth on the other cam (e.g., the "0" cam) must be in the "down" position. The actuating solenoids 112a, 112b are programmed to receive the appropriate actuating signals to establish and maintain the desired relationship among the programmable teeth.
As an alternative to the leaf spring toggle mechanism shown in FIGS. 6 and 7, an over center ball detent mechanism, or any other suitable toggle mechanism, can be employed to hold the teeth in the "up" or "down" positions. When the programmable teeth are used, the pawl driver which engage the "up" teeth must be sized to be of a width (i.e., in the axial direction of the code cam) just equal to the width of the tooth segment in the "up" position. Also, when programmable teeth are used, access to the code setting solenoids 112a, 112b should, preferably, be protected or restricted by a secure coding device of the present invention to prevent an intruder from gaining access to the system to set his own code.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto 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 illustrations and not limitation. | A secure coding device is presented that requires a multi-bit binary code to rotate a locking cam to an unlock position. The device is secure against unauthorized human intervention because it does not provide information to an attempted intervenor which can be used to further attempt to gain access to the system. | 4 |
TECHNICAL FIELD
This disclosure relates generally to pressure-relieving systems. More specifically, this disclosure relates to an injection system or other system with an anti-thermal lockdown mechanism and related method.
BACKGROUND
Injection systems are used in a wide variety of industries to inject a specified amount of one material in another material. For example, injection systems are routinely used to inject one or more additives into a stream of fuel. Often times, these injection systems need to be highly accurate so that the amount of injected material can be precisely controlled. To support this, an injection system often includes a diverter valve and a test port. The diverter valve can be used to divert the injected material to the test port, where the amount of injected material can be accurately measured. In this way, it is possible to determine whether the injection system is injecting the proper amount of material.
In many injection systems, the test port itself often includes a valve, which is usually closed when the test port is not in use. It is therefore possible for material to become trapped between the diverter valve and the test port valve. If the temperature of the injection system increases, this can cause the trapped material to expand. This expansion can actually rupture a seal in one or more of the valves, allowing material to leak from the injection system. As a particular example, this could occur if the material is trapped during the nighttime hours and the trapped material is later heated during the daytime hours.
Conventional injection systems typically deal with this problem using check valves that divert excess pressure. Unfortunately, this increases the complexity and cost of the injection systems. This also provides additional locations where leaks can form in the injection systems.
SUMMARY
This disclosure provides an injection or other system with an anti-thermal lockdown mechanism and related method.
In a first embodiment, an apparatus includes a first valve configured to selectively direct material to first and second outlets and a second valve configured to block the second outlet. The first and second valves define a dead space that has a volume between the first and second valves. The apparatus also includes a pressure compensation unit configured to dynamically provide an additional volume for material trapped in the dead space when the trapped material expands.
In a second embodiment, a method includes operating first and second valves, where material is trapped in a dead space defined by the first and second valves during operation of the valves. The method also includes, as the trapped material expands, dynamically providing an additional volume for the trapped material to enter in order to maintain a pressure in the dead space below a threshold.
In a third embodiment, an apparatus includes a dead space that has a volume in which material becomes trapped. The apparatus also includes a pressure compensation unit having a piston configured to move within a space of the pressure compensation unit. The pressure compensation unit is configured such that increased pressure in the dead space causes the trapped material to push against the piston in order to provide an additional volume for the trapped material.
Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates an example injection system with an anti-thermal lockdown mechanism according to this disclosure;
FIG. 2 illustrates an example fuel processing system that includes an injection system with an anti-thermal lockdown mechanism according to this disclosure; and
FIG. 3 illustrates an example method for anti-thermal lockdown in an injection system or other system according to this disclosure.
DETAILED DESCRIPTION
FIGS. 1 through 3 , discussed below, and the various embodiments used to describe the principles of the present invention in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the invention. Those skilled in the art will understand that the principles of the invention may be implemented in any type of suitably arranged device or system.
FIG. 1 illustrates an example injection system 100 with an anti-thermal lockdown mechanism according to this disclosure. The embodiment of the injection system 100 shown in FIG. 1 is for illustration only. Other embodiments of the injection system 100 could be used without departing from the scope of this disclosure.
As shown in FIG. 1 , the injection system 100 receives material to be injected through an inlet 102 . The inlet 102 includes any suitable structure through which one or more materials can flow to the injection system 100 , such as a pipe or tube. Also, the material to be injected could include any suitable material(s), such as one or more fuel additives.
An inlet block valve 104 can be used to allow or block the flow of material into the injection system 100 . For example, the inlet block valve 104 could be closed to prevent material from entering the injection system 100 during cleaning or replacement of other components in the system 100 or during times when the system 100 is not in use. The inlet block valve 104 includes any suitable structure for blocking or allowing the flow of material into the injection system 100 . The inlet block valve 104 could, for example, represent a manually-operated valve.
A streamer 106 receives material flowing through the valve 104 and filters the material. For example, the streamer 106 can help to remove particles or other undesirable contaminants from the incoming material. Among other things, this can help to protect the other components of the injection system 100 . The streamer 106 includes any suitable filtering structure, such as a strain basket.
A dosing valve 108 controls the amount of filtered material that is injected by the injection system 100 , and a dosing controller 110 controls the operation of the dosing valve 108 . For example, the dosing valve 108 can be opened more or opened more often (when a solenoid valve is used) by the dosing controller 110 when more material needs to be injected. The dosing valve 108 can be closed more or closed more often by the dosing controller 110 when less material needs to be injected. The dosing valve 108 can also be completely closed to stop the injection of the material. The dosing valve 108 includes any suitable structure for controlling a flow of material, such as a solenoid-operated valve. The dosing controller 110 includes any suitable structure for controlling a dosing valve, such as a load computer, a programmable logic controller (PLC), or other computing or control device.
A flow meter 112 measures the amount of material provided by the dosing valve 108 . The flow meter 112 can then provide these measurements back to the dosing controller 110 . In this way, the dosing controller 110 receives feedback from the flow meter 112 and can adjust operation of the dosing valve 108 so that, for instance, an appropriate amount of material is being provided by the dosing valve 108 . The flow meter 112 includes any suitable structure for measuring a flow of material, such as an oval gear positive flow meter or other flow meter.
A diverter valve 114 controls where the material being injected actually exits the injection system 100 . During a first mode of operation, the diverter valve 114 can be set so that the material provided by the dosing valve 108 is provided to a check valve 116 and a first outlet 118 . During a second mode of operation (such as a testing mode), the diverter valve 114 can be set to redirect the material provided by the dosing valve 108 to a test port 120 and a second outlet 122 . During a third mode of operation, the valve 104 can block the material, and the injection system 100 can be turned off.
The check valve 116 is located between the diverter valve 114 and the first outlet 118 of the injection system 100 . During the first mode of operation, the diverter valve 114 provides material to the check valve 116 , which passes the material to the first outlet 118 . The check valve 116 prevents “back flow” of the material when the outlet pressure exceeds the inlet pressure. The diverter valve 114 includes any suitable structure for controlling the flow of material, such as a manually-operated valve. The check valve 116 includes any suitable structure for substantially limiting the flow of material in one direction.
In this example, the injection system 100 injects the material out through the first outlet 118 . The outlet 118 includes any suitable structure through which one or more materials can flow out of the injection system 100 , such as a pipe or tube. The material flowing through the outlet 118 can be injected into any other material(s). As a specific example, the injection system 100 can receive one or more fuel additives through the inlet 102 and inject the fuel additive(s) through the outlet 118 into a base product, such as gasoline, diesel fuel, or jet fuel.
During the second mode of operation, the diverter valve 114 provides material to the test port 120 , which is located between the diverter valve 114 and the second outlet 122 . The test port 120 can be connected to a test device, which collects the material flowing through the second outlet 122 . The test port 120 includes any suitable structure for providing material to a testing device. The test port 120 typically includes a small valve that blocks the second outlet 122 when testing is not occurring. The second outlet 122 includes any suitable structure through which one or more materials can flow out of the injection system 100 , such as a pipe or tube.
In this example, material flowing out of the second outlet 122 is provided to a beaker 124 . The beaker 124 collects and accurately measures the amount of dispensed material. In this way, personnel can collect the dispensed material for a specified amount of time and then compare the collected amount of material to a target amount. This allows the personnel to test whether the injection system 100 is injecting an appropriate amount of material. Note that the use of a beaker 124 as part of the testing is for illustration only and that other techniques could be used to measure the amount of dispensed material or otherwise test the injection system 100 .
During the first mode of operation, the diverter valve 114 typically blocks the path to the test port 120 , and the valve in the test port 120 is typically closed. This can trap material within a dead space 126 of the injection system 100 . The dead space 126 generally denotes a volume in which material can become trapped when each exit from the space is sealed. As noted above, in conventional injection systems, material can expand when its temperature increases. This could conceivably burst a seal in the diverter valve 114 or in the test port 120 , causing leakage of the material.
In accordance with this disclosure, the injection system 100 includes a pressure compensation unit 128 , which can be used to relieve pressure in the dead space 126 of the injection system 100 . In this example, the compensation unit 128 includes a space 130 into which material from the dead space 126 can enter. The compensation unit 128 also includes a piston 132 that can move within the space 130 . The piston 132 is biased using a spring 134 , and the piston 132 is sealed against one or more edges of the space 130 using one or more seals 136 .
In one aspect of operation, the spring 134 biases the piston 132 in a forward direction (closer to the dead space 126 ). Material trapped in the dead space 126 can contact the piston 132 , but the seals 136 generally prevent the material from moving past the piston 132 and filling the portion of the space 130 on the left of the piston 132 in FIG. 1 . This effectively creates an air pocket in the left portion of the space 130 in FIG. 1 .
When the material in the dead space 126 is not expanding or contracting, the piston 132 may remain in a generally stable position. When the material in the dead space 126 heats up, the material can expand, causing the material to push against the piston 132 . This moves the piston 132 in a reverse direction (towards the spring 134 ), increasing the space that the trapped material can occupy and preventing a large pressure increase within the dead space 126 . When the material in the dead space 126 cools, the material can contract, and the spring 134 can push the piston 132 in the forward direction. Effectively, the pressure compensation unit 128 can be used to dynamically adjust a volume occupied by the trapped material, which adjusts the pressure in the dead space 126 .
In this way, the pressure compensation unit 128 can help to maintain the pressure within the dead space 126 below a threshold point where any seals might burst. This can help to reduce or prevent leakages in the injection system 100 caused by expansion of trapped material in the dead space 126 . Moreover, this compensation can be done without introducing additional leakage points and without interfering with the accuracy of test measurements taken when the test port 120 is used. In addition, this approach avoids the need to use a check valve to divert any excess pressure away from the dead space 126 , which eliminates an additional point where leakages could occur.
The pressure compensation unit 128 includes any suitable structure allowing material in a confined space to expand. In this example embodiment, the space 130 includes any suitable volume in which material can enter and other components of the compensation unit 128 can operate. The space 130 could, for example, represent a cylindrical volume. Note that the space 130 could join with the dead space 126 in any suitable manner. While FIG. 1 shows a small channel connecting these spaces, larger openings could be used. The piston 132 includes any suitable structure that moves within a space. The piston 132 could, for example, represent a cylindrical structure having a diameter less than or approximately equal to a diameter of the cylindrical space 130 .
The spring 134 includes any suitable structure for biasing the piston 132 . The spring 134 can be selected so that, at the lowest pressure during normal operating conditions, the spring 134 is not activated. Note that the spring 134 is only one example of a biasing mechanism that could be used in the pressure compensation unit 128 . In other embodiments, compressed or uncompressed gas or air could be used as the counter-force. The gas or air could be injected into the space 130 , and the piston 132 and seal 136 could trap the gas or air in the space 130 . This gas or air could then push against the piston 132 and bias the piston 132 in the forward direction.
Each seal 136 includes any suitable structure for substantially sealing a portion of the space 130 . Any number of seals 136 could be used. Each seal 136 could, for example, represent an O-ring. Note that the piston 132 and the seal(s) 136 could also be formed as a single integrated unit. For instance, the piston 132 and the seal(s) 136 could be formed from a single piece of polytetrafluoroethylene (PTFE).
In some embodiments, many of the components shown in FIG. 1 can be formed or used in an integrated or unibody structure. For example, a structure 138 could be machined or cast out of one piece of solid metal or other material(s). This unibody structure 138 could include many of the channels and spaces shown in FIG. 1 , along with areas where other components can be inserted into the structure 138 . After formation of this structure 138 , many of the components in the system 100 could be machined and inserted into the structure 138 . This can help to reduce or minimize the number of seals required in the system 100 , which can significantly reduce the number of possible leakage points in the system 100 .
Although FIG. 1 illustrates one example of an injection system 100 with an anti-thermal lockdown mechanism, various changes may be made to FIG. 1 . For example, the injection system 100 could have any other or additional components in any suitable arrangement. The pressure compensation unit 128 can generally be used in any injection system or other system in which pressure within a dead space needs to be controlled or relieved.
FIG. 2 illustrates an example fuel processing system 200 that includes an injection system 100 with an anti-thermal lockdown mechanism according to this disclosure. The embodiment of the fuel processing system 200 shown in FIG. 2 is for illustration only. Other embodiments of the fuel processing system 200 could be used without departing from the scope of this disclosure.
As shown in FIG. 2 , the fuel processing system 200 includes an inlet 202 , which receives fuel from storage (such as a storage tank). An isolation valve 204 controls the flow of fuel into the system 200 , and a strainer 206 filters the fuel entering the system 200 . Two isolation valves 208 a - 208 b control the flow of filtered fuel to two motor/pump units 210 a - 210 b , respectively. The motor/pump units 210 a - 210 b pump the filtered fuel through check valves 212 a - 212 b and isolation valves 214 a - 214 b , respectively. Each check valve 212 a - 212 b helps to ensure the filtered fuel flows substantially in one direction, and each isolation valve 214 a - 214 b controls the flow of filtered fuel to a pump outlet isolation valve 216 . The pump outlet isolation valve 216 generally controls or stops the flow of filtered fuel being pumped.
Various components are used to monitor, control, and relieve pressure of the pumped fuel. For example, a pressure gauge 218 connected to an isolation valve 220 can display a pressure of the pumped fuel. Also, a bypass relief valve 222 can provide the pumped fuel through an outlet 224 . This can be done, for example, to provide some of the pumped fuel back to storage when the pressure of the pumped fuel is too high. In addition, a pressure sensor 226 can measure the pressure of the pumped fuel and send the pressure measurements to a pressure controller 228 . The pressure controller 228 can use the pressure measurements to control a motor controller 230 , which can control operation of the motor/pump units 210 a - 210 b . For example, the pressure controller 228 can signal the motor controller 230 when the measured pressure exceeds a maximum pressure threshold or falls below a minimum pressure threshold. The motor controller 230 could then adjust operation of the motor/pump units 210 a - 210 b , such as by increasing or decreasing the pump rate or shutting down the motor/pump units 210 a - 210 b.
The pumped fuel flowing through the pump outlet isolation valve 216 is provided to a pump discharge bypass relief kit 232 , which includes a discharge check valve 234 and a thermal relief valve 236 . The fuel that passes through the discharge bypass relief kit 232 enters an overhead additive line 238 . The overhead additive line 238 is connected to a high point bleed with an isolation valve 240 and a plug 242 . The overhead additive line 238 feeds the fuel to an injection system 100 , which injects one or more materials (such as one or more additives) into the fuel. As noted above, the injection system 100 includes a pressure compensation unit 128 that can help to regulate the pressure within a dead space 126 of the injection system 100 . This can help to avoid leaks in the injection system 100 .
The fuel with the injected material is provided to an isolation valve 244 , which controls the flow to a check valve 246 . The check valve 246 provides the fuel with the injected material to any suitable destination, such as a tanker truck or other storage vehicle or storage structure.
Each of the components shown in FIG. 2 includes any suitable structure for performing the described function(s).
Although FIG. 2 illustrates one example of a fuel processing system 200 that includes an injection system 100 with an anti-thermal lockdown mechanism, various changes may be made to FIG. 2 . For example, FIG. 2 illustrates one example arrangement of a fuel processing system. Fuel could be processed in any other suitable manner. Material can be injected into fuel using any number of injection systems 100 at any number of locations within a larger fuel processing system. Also, the pressure compensation unit 128 shown in FIG. 1 and described above could be used in any suitable larger system, whether or not that system relates to fuel processing or injection. As particular examples, the injection system 100 could be used in marine applications to inject additives into fuel for marine vessels, aviation applications to inject de-icing or other additives into jet fuel, or biofuel applications to inject additives into biofuel or to inject biofuel into diesel or other fuel.
FIG. 3 illustrates an example method 300 for anti-thermal lockdown in an injection system or other system according to this disclosure. The embodiment of the method 300 shown in FIG. 3 is for illustration only. Other embodiments of the method 300 could be used without departing from the scope of this disclosure. Also, for ease of explanation, the method 300 is described with respect to the injection system 100 of FIG. 1 . However, the method 300 could be used with any other suitable system.
As shown in FIG. 3 , a valve is moved to a first position at step 302 , and material is sent to a first outlet at step 304 . The valve is moved to a second position at step 306 , and material is sent to a second outlet at step 308 . Material is trapped in a dead space when the valve is moved to the second position. As a particular example of this, these steps may include moving the diverter valve 114 in the injection system 100 to a test position and then moving the diverter valve 114 to a normal operating position. This can trap material in the dead space 126 of the injection system 100 .
The trapped material is heated at step 310 , which may occur for any number of reasons (such as an increase in ambient temperature). This causes the trapped material to expand into a pressure compensation unit at step 312 . This could include, for example, the trapped material pushing the piston 132 into the space 130 , allowing the trapped material to partially fill the space 130 . As a result, the pressure of the trapped material is maintained below a threshold at step 314 . More specifically, the trapped material can expand into the space 130 as needed to maintain the pressure within the dead space 126 below a pressure that might otherwise burst a seal in the injection system 100 .
Although FIG. 3 illustrates an example method 300 for anti-thermal lockdown in an injection system or other system, various changes may be made to FIG. 3 . For example, while FIG. 3 shows as a series of steps, various steps in the method 300 could overlap, occur in parallel, occur in a different order, or occur multiple times. Also, the same or similar method could be used in any system in which pressure within a dead space needs to be relieved.
It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or.
While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims. | An apparatus includes a first valve configured to selectively direct material to first and second outlets and a second valve configured to block the second outlet. The first and second valves define a dead space that has a volume between the first and second valves. The apparatus also includes a pressure compensation unit configured to dynamically provide an additional volume for material trapped in the dead space when the trapped material expands. The pressure compensation unit could include a piston configured to move within a space of the pressure compensation unit, where increased pressure in the dead space causes the trapped material to push against the piston in order to provide the additional volume for the trapped material. The pressure compensation unit could further include a spring configured to bias the piston and a seal configured to substantially prevent the trapped material from passing the piston and contacting the spring. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part (CIP) application of U.S. application Ser. No. 14/060,425, filed on Dec. 22, 2013, the disclosures of which are incorporated herein in their entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical assembly, and, more particularly, to a nonlinear optical assembly of an alert light.
2. Description of the Related Art
As having the advantages of being compact in size, low-power-consuming, and durable, light-emitting diodes (LED) have gradually replaced conventional light bulbs to become one of the major lighting sources, and have been extensively applied to all sorts of lighting applications and alert lights.
As far as the composition of a conventional LED alert light is concerned, the conventional LED alert light includes an LED module and an optical lens module. Depending on the number of LED in the LED module, the optical lens module is integrally formed with multiple lens units. The lens units are sequentially aligned in the form of a straight line. A light entrance end of each lens unit corresponds to an LED of the LED module to thereby constitute an LED alert light.
Although the conventional LED alert light can be applied to products with alert features, the optical lens module of the conventional LED alert light employs multiple integrally-formed lens units, and under the constraint of forming technique, each lens unit of the optical lens module takes the form of a cone with a cone apex angle approximately at 120 degrees. The conical shape of the lens units makes the integrally-formed optical lens module inflexible for significant changes and hard to adapt to the requirements of different forms of light projection. As a result, conventional alert lights can be designed to provide single-side straight-line light projection but fail to provide arced, wavy or annular light projection in response to the demand of diversified alert lights.
In spite of attempts of manufacturers in the related field to integrally form arcuate, wavy or annular optical assemblies, forming those nonlinear optical assemblies is a tough job to tackle. Thus, the molding and manufacturing requirements of the optical assemblies are rather high, rendering light projected therefrom non-uniform.
Moreover, concerns of light entering and exiting the nonlinear optical assemblies differ from those of linear optical assemblies. In view of different curvatures for nonlinear and linear optical assemblies, uniform light projected by the light exit portions of the nonlinear optical assemblies should be prioritized. However, corresponding in-depth development on conventional nonlinear optical assemblies is not available and the resulting uniformity of light exiting therefrom is not satisfactory.
U.S. Pat. No. 7,712,931, US 2006/0082999, and US 2011/0194279 involve linear optical assemblies. The present invention differs from the foregoing citations and further explores more different embodiments in continuation with the development of the nonlinear optical assembly of an alert light.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide a nonlinear optical assembly of an alert light for solving the problems of conventional alert lights, that is, optical lens elements are hard to adapt to different light form variations, such as arcuate, annular and wavy forms, because of their integrally-formed structure.
To achieve the foregoing objective, the nonlinear optical assembly of an alert light has two nonlinear optical halves obtained by symmetrically dividing the nonlinear optical assembly along an optical reference plane. Each nonlinear optical half has a base, a light entrance portion, and a light exit portion.
One side of the base corresponds to the optical reference plane and has a junction surface. The two nonlinear optical halves are assembled to form the nonlinear optical assembly with the junction surfaces of the two nonlinear optical halves attached to each other.
The light entrance portion is formed on one side of the base and adjoins the junction surface.
The light exit portion is formed on another side of the base and adjoins the junction surface.
Given the structure of the foregoing nonlinear optical assembly of alert light, the nonlinear optical assembly can be symmetrically divided into two separate optical halves along an optical reference plane. The divided optical halves are structurally simplified and therefore facilitate the molding thereof in production and the quality of the finished product. After reducing limitations upon molding specific optical halves, light form, light projection angle or product shape can be varied according to desired alert feature to make structural changes to the nonlinear optical assembly on its entirety. Additionally, because of the symmetrical shapes of the two optical halves, light emitted from an alert light having the nonlinear optical assembly passes through a center line of the light exit portion, thereby generating a uniform light effect.
Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a first embodiment of a nonlinear optical assembly of an alert light in accordance with the present invention;
FIG. 2 is an exploded perspective view of a second embodiment of a nonlinear optical assembly of an alert light in accordance with the present invention;
FIG. 3 is an enlarged partial cross-sectional view of the nonlinear optical assembly in FIG. 2 , shown combined;
FIG. 4 is a cross-sectional view of the combined nonlinear optical assembly in FIG. 2 applied to an alert light;
FIG. 5 is a cross-sectional view of the combined nonlinear optical assembly taken along line 5 - 5 in FIG. 4 ;
FIG. 6 is a cross-sectional view of two combined optical assemblies in FIG. 2 applied to an alert light;
FIG. 7 is an exploded perspective view of a third embodiment of a nonlinear optical assembly of an alert light in accordance with the present invention;
FIG. 8 is an enlarged partial cross-sectional view of the nonlinear optical assembly in FIG. 7 , shown combined;
FIG. 9 is a cross-sectional view of the combined nonlinear optical assembly in FIG. 7 ;
FIG. 10 is a cross-sectional view of two combined optical assemblies in FIG. 7 applied to an alert light;
FIG. 11 is an exploded perspective view of a fourth embodiment of a nonlinear optical assembly of an alert light in accordance with the present invention;
FIG. 12 is another exploded perspective view of the nonlinear optical assembly in FIG. 11 ;
FIG. 13 is a side view of four combined optical assemblies in FIG. 11 applied to an alert light;
FIG. 14 is a cross-sectional view of four combined optical assemblies in FIG. 11 applied to an alert light; and
FIG. 15 is an enlarged cross-sectional view of two combined optical assemblies in FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1, 2, 7 and 11 , four embodiments of a nonlinear optical assembly of an alert light in accordance with the present invention are shown and have common features as follows. Each of the embodiments of the nonlinear optical assembly 1 of an alert light has two separate nonlinear optical halves 10 A, 10 B. Each embodiment of the nonlinear optical assembly has a specific form. The nonlinear optical halves 10 A, 10 B are obtained by symmetrically dividing the nonlinear optical assembly 1 along an optical reference plane ‘P’ as shown in FIG. 3 . The optical reference plane corresponds to a virtual plane defined by center points of multiple light-emitting diodes (LEDs) in an LED module of the alert light. Each nonlinear optical half 10 A, 10 B has a base 11 , a light entrance portion 12 , and a light exit portion 13 . The base 11 takes a nonlinear and curved form and is integrally formed. One side of the base 11 corresponding to the optical reference plane has a junction surface 112 . The light entrance portion 12 is formed on one side of the base 11 and adjoins the junction surface 112 . The light exit portion 13 is formed on another side of the base 11 , adjoins the junction surface 112 , and is opposite to the light entrance portion 12 . The two optical halves 10 A, 10 B are made of a transparent material, which may be glass, polymethylmethacrylate (PMMA), and the like. The optical halves 10 A, 10 B respectively have at least one first jointing member 14 and at least one second jointing member 15 respectively formed on at least one position on the base 11 of the optical halve 10 A and on at least one position on the base 11 of the other optical half 10 B. The first jointing member 14 and the second jointing member 15 are respectively a raised portion and a recessed portion matching each other. The two optical halves 10 A, 10 B are assembled together by correspondingly engaging the at least one first jointing member 14 and the at least one second jointing member 15 with the junction surfaces 112 of the two optical halves 10 A, 10 B attached to each other for forming the nonlinear optical assembly 1 .
With reference to FIG. 1 , a first embodiment of a nonlinear optical assembly 1 in accordance with the present invention takes a wavy and elongated form and has two nonlinear optical halves 10 A, 10 B. The base 11 has multiple light entry recesses 121 formed in the light entrance portion 12 and spaced apart from each other by gaps. Each light entry recess 121 takes the form of a semi-cylindrical hole, and has a semicircular opening 123 and a quadra-spherical lens portion 122 . The semicircular opening 123 corresponds to an inner opening of the light entry recess 121 . The quadra-spherical lens portion 122 is formed on an inner wall of the light entry recess 121 opposite to the semicircular opening 123 . The light exit portion 13 has multiple bumps 132 juxtaposedly formed on the light exit portion 13 in a wavy manner, and each bump 132 has an arcuate profile, protrudes outwards from the light exit portion 13 , and is aligned with one of the multiple light entry recesses 121 .
With reference to FIGS. 2 and 3 , a second embodiment of a nonlinear optical assembly 1 of an alert light in accordance with the present invention is shown. The base 11 of each optical half 10 A, 10 B takes an annular form. The light entrance portion 12 of the base 11 corresponds to an inner circumferential end surface of the base 11 , and has multiple light entry recesses 121 . The multiple light entry recesses 121 are annularly formed in the light entrance portion 12 and are mutually spaced apart by gaps. Each light entry recess 121 takes the form of an arcuate indentation. The light exit portion 13 of the base 11 corresponds to an outer circumferential end surface of the base 11 , and has an outer raised portion 133 . The outer raised portion 133 is annularly formed around a portion of the light exit portion 13 and is adjacent to the junction surface 112 of the base 11 . The base 11 further has an outer flange 113 and an inner bevel wall 114 . The outer flange 113 is annularly formed on and protrudes outwards from the outer raised portion 133 in a direction vertical to and away from the junction surface 112 . The inner bevel wall 114 is annularly formed on and protrudes inwards from an inner wall of the outer flange 113 , and reduces in thickness in a direction from the outer flange 113 to the light entry recesses 121 . The outer flange 113 can function as a light-exiting portion of the light exit portion 13 , and an inner end of the inner bevel wall 114 can function as a light entry portion of the light entrance portion 12 .
With reference to FIGS. 3 to 5 , the two nonlinear optical halves 10 A, 10 B of a nonlinear optical assembly in the present embodiment respectively have a lateral pin 16 and a lateral hole 17 respectively formed on and formed in two outer edges of the outer flanges 113 of the optical halves 10 A, 10 B that are opposite to the junction surface 112 . The lateral pin 16 and the lateral hole 17 are used for assembling the nonlinear optical assembly and a lamp holder 2 of the alert light together. With reference to FIG. 6 , when multiple nonlinear optical assemblies 1 are mounted inside the lamp holder 2 of an alert light in a juxtaposed manner, the lateral pins 16 and the lateral holes 17 of the bases 11 of the nonlinear optical assemblies 1 can be used to assemble the nonlinear optical assemblies 1 and the lamp holder 2 together.
With reference to FIGS. 2 to 6 , detailed description about assembly and operation of the nonlinear optical assembly in the present embodiment applied to an alert light is introduced as follows. The nonlinear optical assembly that is combined by assembling the two nonlinear optical halves 10 A, 10 B together is mounted inside the lamp holder 2 . The light exit portion 13 of the nonlinear optical assembly is exposed to an ambient environment. An LED module 3 is mounted inside the lamp holder 2 and is located inside the nonlinear optical assembly. Each LED 30 of the LED module 3 corresponds to the light entrance portions 12 of the two corresponding optical halves 10 A, 10 B. An annular alert light can be thus assembled. With reference to FIGS. 5 and 6 , when the LED module 3 is connected to a power source and the LEDs 30 are lighted up, light emitted from each LED 30 propagates through corresponding light entry recesses 121 and the bases 11 of the two optical halves 10 A, 10 B and is scattered out through the light exit portions 13 of the bases 11 , so that the alert light demonstrates the light effect of an annular alert light.
With reference to FIGS. 7 to 10 , a third embodiment of a nonlinear optical assembly 1 of an alert light in accordance with the present invention differs from the second embodiment in that instead of the outer raised portion 133 in the second embodiment, the present embodiment has multiple bulged projection portions 131 juxtaposedly formed around the light exit portion 13 . Each bulged projection portion 131 has an arcuate profile. Each light entry recess 121 corresponds to a number of bulged projection portions 131 adjacent to the light entry recess 121 , such that light that is emitted from each LED 30 and propagates through the nonlinear optical assembly 1 will pass through corresponding bulged projection portions 131 . Due to the arcuate profile of each bulged projection portion 131 , light passing through the bulged projection portions 131 is projected to different directions. Accordingly, luminance of light projected through the entire light exit portion 13 of the nonlinear optical assembly 1 can be substantially the same and uniform luminance of the alert light can be ensured.
With reference to FIGS. 11 to 15 , a fourth embodiment of a nonlinear optical assembly 1 of an alert light in accordance with the present invention takes an arcuate and elongated form. The base 11 is integrally formed and has multiple half LED cases 111 . The half LED cases 111 are juxtaposedly arranged along an arc on the light entrance portion 12 . Each half LED case 111 is formed in the light entrance portion 12 , and takes the form of a semicircular cone with diameters of cross sections of the half LED case 111 perpendicular to the junction surface 112 progressively increasing in a direction from the light entrance portion 12 to the light exit portion 13 . Each half LED case 111 has a light entry recess 121 formed in a portion of the light entrance portion 12 corresponding to the half LED case 111 . The light exit portion 13 has multiple bulged projection portions 131 juxtaposedly and arcuately formed on the light exit portion 13 . Each bulged projection portion 131 has an arcuate profile. Each light entry recess 121 corresponds to a number of bulged projection portions 131 adjacent to the light entry recess 121 , such that light that is emitted from each LED 30 and propagates through the nonlinear optical assembly 1 will pass through corresponding bulged projection portions 131 . Due to the arcuate profile of each bulged projection portion 131 , light passing through the bulged projection portions 131 is projected to different directions. Accordingly, luminance of light projected through the entire light exit portion 13 of the nonlinear optical assembly 1 can be substantially the same and uniform luminance of the alert light can be ensured. With further reference to FIGS. 13 to 15 , multiple nonlinear optical assemblies in the present embodiment are applied to an alert light.
Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only. Changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A nonlinear optical assembly of an alert light has two nonlinear optical halves obtained by symmetrically dividing the nonlinear optical assembly along an optical reference plane wherein each optical half has a base, which takes a nonlinear and curved form with one side thereof corresponding to the optical reference plane and having a junction surface, a light entrance portion and a light exit portion are on two opposite sides of the optical reference plane, and the two optical halves are assembled to form the nonlinear optical assembly with the junction surfaces therebetween. Given the light exit portions of the optical halves, each light entrance portion corresponds to multiple bulged portions for the nonlinear optical assembly to provide uniform lighting effect. The nonlinear optical assembly reduces molding and manufacturing requirements. | 5 |
BACKGROUND
Software used to run businesses may include data that corresponds to both materials to be sold, and process controls defining business processes corresponding to the materials. Master data is a collection of all of the process controls associated with a business. Due to the complexity of master data, it is often not possible to maintain all the data of all the process controls for one master datum correctly at any given time. Failed consistency checks in one process control may prevent other process controls from being used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a process control architecture according to an example embodiment.
FIG. 2 is a screen shot of a user interface to a process control having a status of in preparation according to an example embodiment.
FIG. 3 is a screen shot of a user interface to a process control having a status of active according to an example embodiment.
FIG. 4 is a block diagram of an example computer system for implementing various embodiments described.
DETAILED DESCRIPTION
In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural, logical and electrical changes may be made without departing from the scope of the present invention. The following description of example embodiments is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims.
The functions or algorithms described herein are implemented in software or a combination of software and human implemented procedures in one embodiment. The software may consist of computer executable instructions stored on computer readable media such as memory or other type of storage devices. The term “computer readable media” is also used to represent any means by which the computer readable instructions may be received by the computer, such as by different forms of wireless transmissions. Further, such functions correspond to modules, which are software, hardware, firmware or any combination thereof. Multiple functions are performed in one or more modules as desired, and the embodiments described are merely examples. The software is executed on a digital signal processor, ASIC, microprocessor, or other type of processor operating on a computer system, such as a personal computer, server or other computer system.
Master data processing enables a business organization to manage all master data that describes for example its tangible and intangible products and that is relevant to control its business processes, such as sales, purchasing, planning, production, and accounting processes.
Process controls are groups of attributes that execute software that automates a specific process involving a fundamental entity of a master data database. Fundamental entities are real world elements such as a bank, a terminal, a company, or a personal computer. Process controls are groups of attributes that are used to control a specific process step, and each process control offers a different view into an object. Process controls are used to model the master database, i.e., process controls define which attributes are relevant for a specific process step; the process control defines the set of attributes necessary to run a process. The process controls are defined to make the complexity of the database, which itself contains hundreds of attributes and in an embodiment many tables, more manageable. At a high level, process controls are defined according to an outside-in design approach along the lines of the processes it supports. That is, the process control is not concerned with what is in the database, but what the process control wants to retrieve for the outside world. In other words, a process control is designed for business reasons (what data a business organization wants to review) and not technical reasons (how should that data be retrieved from the database). In an embodiment, the process controls are defined at design time, and hence can be shipped to one or more customers. The process controls represent the process controlling business logic of a business system.
In one embodiment, some process controls are related to a material, such as a product to be sold, and a particular sales organization or distribution chain. If a process control is not usable, it is termed inactive. However, other process controls of the master data may be used, allowing business to continue. It should be noted that the terms material and product are just one form of master data used for illustration, and that master data relates to data for many different business processes. Further, references to a sales organization or distribution chain are also used as an example, and are not meant to be limiting.
In one embodiment, a status management module or process is used to manage the status of process controls. The status may be set by a user, or may be set by the a business system.
FIG. 1 is a block diagram representation 100 of the segmentation of process controls within a business management system. Master data is indicated at 110 , and in one example used for illustration, may be divided into product master data for business to business products 115 and for non business to business products 120 . Process control master data is maintained at 125 . In one example, a product may be a developer laptop device, and the data includes all data sufficient to identify the device.
Process control master data 125 may include relevant data for use in selling or transporting goods. It may include external dimensions of products, such as length, width, height, weight that are useful for transport of the products. Further, data used to execute a sale or replenishment durations, codes, material sold, planning information, grouping of materials supply planning, warranty information and other terms and conditions of sale may be included among other information. The information may be different for different countries or sales organizations as indicated at 130 .
Thus, each sales organization has a different instance of a process control for the sale of each product 135 or service 140 . For instance, a sales organization may have different internal material identification numbers, different value added propositions, such as rebates, or different terms and conditions depending on jurisdictional differences, which may be based on country, state, or local regulations or preferences. In one embodiment, the process controls are represented by software objects.
Once a process control 135 , 140 is finalized or otherwise ready for use, it may be used by product data processing 150 to actually sell products and services for the corresponding materials and service products for the corresponding organization.
In one embodiment, each process control is an object that has a current status. The status determines the actions that can be performed. The status may be set by a user or by the system. Various lifecycle statuses are one example. A status of “in preparation” means that the object is a preliminary version, for example, embodying the plans for a distribution channel to distribute material, such as a product or service. The object data may be incomplete and/or inconsistent. It would thus fail a consistency check. It is not possible to execute transactions on an object have an in preparation status.
A further status of a process control object is “active”. This status means that an object is currently usable, object data is complete and consistent, and it is possible to execute transactions. In other words, where master data is related to the example of a product or material, the sales organization may sell the material or service product corresponding to the control object. An object having a status of active may have a validity period, but the status may not be set on core level.
A further status include a “blocked status”. For the product or material example, this may be used for seasonal materials, or for materials currently experiencing a technical problem or for any other business reason where sales may not currently be desired. The status blocked means that an object is currently blocked and not usable, but may be used at a later time. It is not possible to execute new transactions on an object with a blocked status, but already existing transactions may be finalized. To have a blocked status, in one embodiment, all object data should be complete and consistent. This status may not be set on core level.
A still further status may include a “to be archived” status. This is meant to indicate that the object has been marked for archiving. It is not possible to execute new transactions on an object to be archived, but already existing transactions may be finalized. Once related business transactions are completed, the object may be archived. This status may only be set on core level.
When modifying process control objects with a status of in preparation, inconsistencies in the process control data may be presented as warnings. Using the limited example of master data related to a product, product master data may also be saved. When the status is not equal to in preparation, which may itself be referred to as a status, inconsistencies in process control data are presented as errors. Master may not be saved and the status may not be set to in preparation if this status has already been saved, as data can be already used in transactions.
An example is provided where a material has an ID of MCF-0002 that is assigned to two different distribution chains. A first process control object is exists for a US Southern Region. In this example, the first process control object is still in preparation as illustrated in an example user interface screen shot shown in FIG. 2 . Multiple fields are provided for entering data, such as pricing, commissions, rebates, etc. An entry for the US Southern Region is shown at 210 and includes the status at 215 . Data may be inconsistent as indicated at 220 , where a minimum order quantity is negative. Inconsistencies are displayed as warning messages as indicated at 225 . The process control object in this status may not be used in a process, so the US Southern Region may not conduct transactions for material MCF-0002.
The user interface of FIG. 2 also illustrates that the example process controls for sales may be part of a larger business process system that includes purchasing, inventory, planning, production, delivery, financials, etc. It may also be a stand alone system in further embodiments.
In a US Northern Region, a second process control is already active as illustrated in an example user interface screen shot shown in FIG. 3 . This means that the data in it must be consistent. An entry for the US Northern Region is shown at 310 and includes the status at 315 . Any inconsistencies, such as in a minimum order field 320 showing a negative value for minimum order quantity, that are created by attempting to change the second process control object may be displayed as an error message 325 , preventing saving of the object.
A block diagram of a computer system that executes programming for performing the above algorithm is shown in FIG. 2 . A general computing device in the form of a computer 410 , may include a processing unit 402 , memory 404 , removable storage 412 , and non-removable storage 414 . Memory 404 may include volatile memory 406 and non-volatile memory 408 . Computer 410 may include—or have access to a computing environment that includes—a variety of computer-readable media, such as volatile memory 406 and non-volatile memory 408 , removable storage 412 and non-removable storage 414 . Computer storage includes random access memory (RAM), read only memory (ROM), erasable programmable read-only memory (EPROM) & electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, compact disc read-only memory (CD ROM), Digital Versatile Disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium capable of storing computer-readable instructions. Computer 410 may include or have access to a computing environment that includes input 416 , output 418 , and a communication connection 420 . The computer may operate in a networked environment using a communication connection to connect to one or more remote computers. The remote computer may include a personal computer (PC), server, router, network PC, a peer device or other common network node, or the like. The communication connection may include a Local Area Network (LAN), a Wide Area Network (WAN) or other networks.
Computer-readable instructions stored on a computer-readable medium are executable by the processing unit 402 of the computer 410 . A hard drive, CD-ROM, and RAM are some examples of articles including a computer-readable medium.
The Abstract is provided to comply with 37 C.F.R. §1.72(b) to allow the reader to quickly ascertain the nature and gist of the technical disclosure. The Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. | A method of controlling transactions includes segmenting master data into separate process control data for a particular business process of a business organization, such as for example, materials to be the subject of transactions. A status may be set for each process control data. The method includes controlling storing of the process control data into the master data as a function of the status. Transactions may be processed using process control data as a function of the status of the corresponding process control data status. | 6 |
RELATED APPLICATION
[0001] This application is related to application Ser. No. 12/843,624, (our file JHUI1953) filed by co inventor, Wing-kin HUI, for A Power Head for Above Ground Pools, filed on Jul. 26, 2010. This application is specifically incorporated herein and is to be used for any and all purposes consistent with incorporation by reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to the field of automated pool products. More particularly, this invention relates to above ground pools having a facility for a return water flow head.
BACKGROUND OF THE INVENTION
[0003] In order to properly operate and maintain a pool and its contents, it is necessary to have a variety of electrical appliances. For example, a pool cleaner, which sweeps and cleans the pool water, requires electrical power. Additional electrical appliances, such as salt chlorinator generators and mineral sanitizing devices are used to maintain the proper pH levels in the pool.
[0004] Other electrical appliances are used to enhance the usability and the beauty of the swimming pool. For example, pool lights used to illuminate the pool at night to facilitate night swimming are powered by electricity. Additionally, a color wheel may be used as decoration to give the pool the special effects desired by the pool owner. Such a color wheel is likewise an electrical appliance.
[0005] Typically, the user now runs electrical lines or cords from the domestic residence to the site of the pool. This naturally would mean that electrical cords are spread out all over the area adjacent the pool. Naturally this is not a desirable condition. This condition is exacerbated when there is more than a single cord from the domestic residence to more than one electrical appliance. The likelihood of someone being injured by tripping on the cords increases exponentially. Obviously this creates a safety hazard and liability issues for the pool owner.
[0006] In addition to the likelihood of injury, the beauty and general attractiveness of the user's yard is dramatically and negatively affected by the messiness of having one or more cords lying around. It is quite clearly an unsightly and undesirable condition.
[0007] Additionally, each of the cords must be placed in storage after usage. First, the user must lay out the cord and then the user connects the cord to the electrical appliance desired to be used. The cords lay on the ground during usage and then upon completion of device usage, they must be disconnected from the electrical appliance and then stored.
[0008] Cleary having to do each of these steps, each and every time an electrical appliance is used becomes tiresome, if not downright tedious. There are certainly better ways for a pool owner to spend his/her time, for example enjoying his/her pool.
[0009] What is needed is the ability to exchange one pool appliance with the other easily. This means without have to drain the pool or substantial portions of the pool. Clearly, have to remove and then add water after draining is both expensive and time consuming.
[0010] Ideally, what is sought is the ability to make the exchange of one appliance for another without affecting the level of the pool in any way. This may mean that the exchange would need to take place underwater. Quick clearly, a new design for interconnection between pool power head and pool appliance would be required.
[0011] What is needed is a structure that allows the above ground pool user the ability to easily and efficiently connect one or more electrical appliances to a pool power head without affecting the level of the water. The exchange must be able to be made quickly and simply without requiring a pool owner to completely redesign his pool or his pool appliances.
SUMMARY OF THE INVENTION
[0012] A primary object of this invention is to create a user-friendly environment for exchanging on appliance for another in an above ground pool environment. By providing a receptacle member having quick release means for facilitating the quick exchange on the waterside or the interior of the above ground pool, a user can easily change one appliance for another without affecting the water level.
[0013] Thus, It is an object of the device in accordance with this invention is to provide a structure for facilitating the quick exchange of one pool appliance for another in an above ground pool environment.
[0014] It is another object of this invention to provide a device, which includes structure to allow a power head to be connected to such a device.
[0015] It s an additional object of this invention to provide such a device which releasably connects to a variety of different pool appliances for an above ground pool.
[0016] It s an additional object of this invention to provide such a device which releasably connects to a variety of different pool appliances for an above ground pool even where the connection to the appliance is made underwater and where the water level is not affected by the exchange of devices.
[0017] In accordance with the above objects of the invention as well as those discussed below as well as the advantages of the invention, one exemplary embodiment in accordance with the invention, includes, a device for facilitating the exchange of pool appliances for an above ground pool, the above ground pool have a pool wall separating the wet side from the dry side the device comprising:
[0018] a housing adapted for location proximate the pool wall, a portion of the housing extending into the dry side and a portion extending into the wet side
[0019] the portion of the housing extending into the dry side adapted to receive means for powering electrical pool appliances, the housing including means for transmitting electrical power from the dry side to the wet side;
[0020] the portion on the wet side defining a receptacle member and the receptacle member adapted to releasably accept various pool appliances requiring electrical power, and
[0021] structural means for fixing the housing on the pool wall.
[0022] In other exemplary embodiments, the receptacle is adapted to exchange the pool appliance underwater.
[0023] In another exemplary embodiment, the receptacle is adapted to exchange the pool appliance underwater using a snap connection.
[0024] In another exemplary embodiment, the receptacle is adapted to exchange the pool appliance underwater using a snap connection and additionally designed for quick release of the pool appliance.
[0025] It is an advantage of the device in accordance with this invention to provide a convenient means for exchanging one pool appliance for another.
[0026] It is an additional advantage of the device of the instant invention to provide such a device, which allows the user exchange one pool appliance for another underwater.
BRIEF DESCRIPTION OF THE DRAWING
[0027] For a further understanding of the objects and advantages of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawing, in which like parts are given like reference numerals and wherein:
[0028] FIG. 1 is a perspective view of an above ground pool in the prior art.
[0029] FIG. 2 is a perspective view illustrating the interior portion of the housing having the receptacle member.
[0030] FIGS. 3 & 4 illustrate in perspective view the exterior portion of housing on the dry side of an above ground pool, in accordance with this invention.
[0031] FIGS. 5 &6 illustrate attachment of one pool appliance, namely a light assembly to the receptacle in accordance with the invention.
[0032] FIG. 7 illustrates attachment of another pool appliance, namely a water feature to the receptacle in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] In order to appreciate the invention herein, one must appreciate the need in the art as set forth in the Background. Most importantly, the structure herein for resolving the long felt need to be able to quickly exchange one appliance for another, even under water in an above ground pool environment.
[0034] With particular reference to FIG. 1 , there is shown an above ground swimming pool. As seen, a pool wall 10 surrounds and encloses the pool defining an interior for holding the water 12 . As illustrated in FIG. 1 , pool wall 10 has an opening 14 defining an outlet and a second opening 16 defining an intake. A pump 18 includes conduit 20 between the intake and outlet. A power head 22 such as that described in application Ser. No. 12/843,524, is connected to the pump 18 . The power head 22 is connected to the residential power or A/C. The power head 22 converts the residential power into usable electrical power for various pool appliances.
[0035] In an exemplary embodiment of the invention, the device 50 is shown generally in FIGS. 2-6 . As seen the device 50 resides between the interior and exterior of the pool. In more advanced above ground pools, there is one opening in the pool wall and that serves as both the inlet and the outlet. In this embodiment, the device spans the interior and exterior of the pool and on the dry side includes connection to the power head and on the wet side includes a receptacle 50 for facilitating quick exchange of various electrical pool appliances, even under water.
[0036] The device 50 , as shown in FIG. 2 , illustrates the interior portion of the device connected to the pool wall 10 . The device 50 includes a housing 52 . On the interior side of the pool wall 10 when the housing 52 is connected. FIG. 2 illustrates the housing 52 having the receptacle member 54 in accordance with this invention.
[0037] The housing 52 has a central opening 56 , which in Fig. would span either the intake or outlet. In the more advanced above ground pool design, it would be the single opening in the pool wall 10 . The opening 56 defines a water channel. Water flows in and out of the water channel through the intake and outlet. Using structure and methods already known in the art, the dry side stays dry and the interior or pool side is freely submerged in the water. The receptacle member 54 does not interfere with the ability of the housing to carry out this function.
[0038] FIGS. 3 and 4 illustrate the exterior of the housing 52 . As noted above, the housing extends from the pool or interior or wet side through the pool wall opening and terminating at the dry side or exterior of the pool. On the exterior of the pool, the housing includes a power head adapter 58 sized and shaped for compatible mating fit with a pool power head of the kind earlier described with respect to application Ser. No. 12/843,624. The adapter 58 includes electrical connectors 60 , which electrically engage the power head electrical connectors.
[0039] The housing 52 also includes a nut fitting 62 and a washer 64 as well as a sleeve member 66 . The housing 52 includes threaded member 68 , which is inserted through the nut fitting 62 and washer 64 . The threaded member 68 mates compatibly by threading with the nut fitting 62 .
[0040] The interior portion of the housing 52 similarly includes electrical connectors 70 . Additionally, the interior portion of the housing 52 includes a threaded member 72 . As can be seen in FIG. 3 , each end of the sleeve member 66 is likewise threaded and is compatible with threaded mating connection of each of the threaded members 68 and 72 , respectively.
[0041] The electrical connectors 70 are male and the exterior electrical connectors have a matching female members (not shown). Upon threaded each of the threaded members 68 and 72 to the sleeve member 66 , a push fit electrical contact is made between the male electrical connectors 70 and the female portion of the electrical connectors 60 . Electrical connection is thereby carried from the residence through the power head, converted to usable power and made available at the electrical connectors 60 . Through connection of the exterior portion of the housing 52 to the interior portion and the electrical connectors 72 , usable electrical power is made available to a pool appliance at the receptacle 54 by connection thereto.
[0042] After connection of the interior and exterior portions of the housing 52 through the sleeve member 66 , the housing must be affixed in a semi-permanent position on the pool wall 10 at the pool opening. By rotating nut-fitting member 62 in the direction indicated in FIG. 4 , the housing is at least semi-permanently connected to the pool wall 10 .
[0043] In another embodiment of the device 50 in accordance with this invention, the sleeve member 66 has no threads whatsoever. The interior and exterior portions of the housing 52 , each have a central opening. The exterior circumference of the sleeve member 66 matches the interior circumference of the central openings of each of the interior and exterior portions in such a manner as to create a force fit between the portions of the housing 52 . The portions are aligned, including the electrical connectors 60 and 72 ( FIG. 3 ), and then force is applied to each portion, urging them against one another until a secure fit is made. As in the earlier described embodiment, the nut fitting 62 is then rotated is the manner shown in FIG. 4 until a semi-permanent connection is made.
[0044] FIGS. 5 & 6 illustrate a pool appliance, namely a lighting fixture, generally denoted by the numeral 90 , being connected to the receptacle member 54 in accordance with the present invention. The lighting fixture 90 is of the type discussed in Applicant's previously filed application, namely, application Ser. No. 13/013,459, which is specifically incorporated herein by reference.
[0045] The lighting fixture 90 has an electrical connector 92 , which mates with a force fit into the previous described electrical connection. In an alternative embodiment, the receptacle 54 includes no electrical connectors. The receptacle 54 , simply has an opening, which permits the electrical connectors 92 to directly engage and be electrically conductive with exterior portion electrical connectors 60 .
[0046] After aligning the light fixture 90 with the receptacle 54 , the components are pressed together into mating contact. Upon achieving mating contact, as seen in FIG. 6 , the components are rotated for a locking fit as described earlier with respect to FIG. 4 .
[0047] With respect to FIG. 7 , there is shown another appliance, namely, a water feature apparatus, generally shown by the numeral 100 , attached to the receptacle 54 in accordance with the invention. The water feature 100 snaps into the receptacle 54 in a manner discussed above.
[0048] First, the appliance already on the receptacle 54 is removed. This is done by reversing the twist shown in FIGS. 4 & 6 and the pulling the appliance from the receptacle, so as not to damage the electrical connections. As stated above, the act of removing and adding an appliance to the receptacle 54 is done either dry or wet. The pool water does not need to be removed or lowered in order to accomplish the exchange.
[0049] Once the earlier appliance is remove, the water feature 100 or whatever appliance desired, can be connected to the receptacle 54 . Of course, the water feature 100 attaches to the device, generally shown by the numeral 50 , in the manner described earlier and are similarly removed.
[0050] With respect to FIG. 8 , there is shown an additional appliance attached to the device 50 of the invention, a water game, generally denoted by the numeral 120 . The water game 120 includes an electrical motor 122 , which is connected to the device 50 using the electrical contacts of the device 50 . Thus, electrical power is supplied to this appliance by device 50 .
[0051] The motor is connected to a rod 124 , which rotates consistently with the rotation of the electrical motor 122 . A game 120 including a wheel 126 and a paddle 128 . Through a series of gears, such as those shown in FIG. 9 , the wheel 126 rotates, while paddle contact engages and disengages the electrical motor depending upon contact.
[0052] With respect to FIG. 9 , there is shown another appliance connected to the device 50 , a current creating device, generally denoted by the numeral 130 . The current creating device 130 includes a set of gears 132 for converting the rotation energy of the motor 124 into rotational energy of the rod 124 . The current creating device 130 includes a fan 134 also rotationally connected to the rod 124 . The gears 132 incrementally turn the wheel 126 . The gears 132 are likewise connected to the shutter member 138 , which depending upon the position of the switch 140 .
[0053] The rotational action of the fan, together with the up and down movement of the shutter member creates currents and wave that are tailored to the user's desire. The waveform and current are regulated and customized by the speed and period and frequency of the shutter member 138 and the fan 134 .
[0054] With respect to FIG. 10 , there is shown an additional appliance, an induction coil member, generally denoted by the numeral 140 . The induction coil member 140 attaches to member 50 (not shown in FIG. 10 ). An induction circuit is created by the induction coil 142 . A cleaner 150 is powered by the induction circuit. The cleaner 150 includes a male member 152 for insertion and connection with the induction coil 142 .
[0055] Thus, the inclusion of the induction member 140 allows the cleaner 150 to be connected with the induction circuit and thereby be powered by it. Thus, using the device 50 , the appliance connected is a induction-powered pool cleaner.
[0056] While the foregoing detailed description has described several embodiments of the power head for an above ground pool in accordance with this invention, it is to be understood that the above description is illustrative only and not limiting of the disclosed invention. Thus, the invention is to be limited only by the claims as set forth below. | Disclosed herein is a device for facilitating the quick exchange of one pool appliance for another. The device includes a housing, which spans the opening in the upstanding wall of an above ground pool. The opening is typically used by existing above ground pools for water intake and outlet, filtering, water leveling and the like. On the interior side of the pool, the waterside, the housing includes a quick release receptacle adapted to fit a variety of pool appliances. The receptacle includes means to conduct electricity usable for such pool appliances. On the exterior side of the pool, the housing includes an adapter designed to accept a pool power head. The power head connects to a residential or similar power source and is converted to a usable power supply for pool appliances. The receptacle allows exchange of appliances to be made even while the connective portion of the appliance is underwater. | 4 |
BACKGROUND OF THE INVENTION
The U.S. Government has a paid-License in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided by the terms of contract DAAD05-76-C-0758 awarded by the Department of the Army.
CROSS REFERENCE TO OTHER APPLICATION
This application is related in subject matter to concurrently filed application Ser. No. 748,922, filed 6/26/85, invented by Clifford E. Kristofferson, Donald G. Fisher, and Frank H. Bell and entitled "Solid Composite Bi-Nitramine Propellant and Method of Making Same." Said application Ser. No. 748,922, filed 6/26/85 is a continuation-in-part of application Ser. No. 731,440, filed May 6, 1985, and also entitled "Solid Composite Bi-Nitramine Propellant and Method of Making Same."
FIELD OF THE INVENTION
The invention relates to gun propellant preparations. More particularly the invention relates to a solventless procedure for the mixing of propellants for utilization in ammunition having a low vulnerability to undesired detonation. The invention also relates to storing propellants in an uncured state preparatory to making a finished extruded propellant grain.
DESCRIPTION OF RELEVANT ART
A continuing objective in the design of ammunition, particularly for military use is to provide ammunition that is energetic when used, but which displays low vulnerability to heat, flame, impact, friction, and chemical action. This is especially important in confined quarters such as tanks, ships, submarines, and the like. This low vulnerability ammunition is known by the acronym LOVA.
During the preparation of propellant compositions, it has been common practice to utilize a volatile processing solvent. The procedures of this invention eliminate the use of processing solvent for the compositions taught. Solvents which have been used in the past include ketones such as acetone, petroleum ethers, methylene chloride, and amyl acetate. Deformation of cast charges due to propellant solvent evaporation is prevented by this invention. Uneven evaporation of solvent from the surface or from the core of the propellant is also eliminated, and unpredictable acceleration or deceleration caused by solvent burning is avoided. This solventless procedure results in lower costs and less process steps than the solvent procedure of the prior art.
SUMMARY OF THE INVENTION
This invention includes a solventless method of producing a cured solid extruded propellant grain product that may contain either HMX or RDX as an oxidizer component. Both products of the invention have low vulnerability characteristics and are further characterized by having uniquely low (for the type of oxidizer employed in the formulation) burning rates and uniquely low burning rate exponents.
The method of producing HMX-containing LOVA propellants generally comprises the procedure set forth below, first, producing an uncured solventless propellant formulation consisting essentially of from about 68 to 80% of crystalline solid HMX oxidizer having a weight mean diameter of from about 1 to 14 microns; from about 5 to 22% polyol; and from about 4 to 18% polyisocyanate curative for the polyol, all percentages being weight percent based upon total propellant formulation weight, by blending the polyol and the curative to form an uncured binder and then blending said oxidizer into the uncured binder while maintaining a blending temperature below 110° F. so as to avoid reacting the binder and oxidizer and thereby creating an extended pot life, then deairing the uncured solventless formulation, then extruding the uncured solventless formulation to produce an extrusion, and then curing the extrusion so as to obtain a low vulnerability propellant grain having a low burning rate on the order of 0.652 inches per second at 10,000 psi and 70° F., and a low burning rate exponent on the order of 1.014.
The HMX-containing material generally comprises a solid cured extruded propellant grain product having low vulnerability characteristics, a low burning rate on the order of 0.652 inches per second at 10,000 psi and 70° F. and a low burning rate exponent on the order to 1.014. The product is made from a solvent-free composition consisting essentially of from 68 to 80% of crystalline solid HMX oxidizer having a weight mean diameter of from about 1 to 14 microns; from about 5 to 22% polyol; and from about 4 to 18% polyisocyanate curative for the polyol, all percentages being weight percent based upon total propellant weight.
The method of producing RDX-containing LOVA propellants generally comprises first, producing an uncured solventless propellant formulation consisting essentially of from about 68 to 80% of crystalline solid RDX oxidizer having a weight mean diameter of from about 1 to 14 microns; from about 5 to 22% polyol; and from about 4 to 18% polyisocyanate curative for the polyol, all percentages being weight percent based upon total propellant formulation weight, by blending the polyol and the curative to form an uncured binder and then blending the oxidizer into the uncured binder while maintaining a blending temperature below 110° F. so as to avoid reacting the binder and oxidizer and thereby creating an extended pot life, then deairing the uncured solventless formulation, then extruding the uncured solventless formulation to produce an extrusion, and then curing the extrusion so as to obtain a low vulnerability propellant grain having a low burning rate on the order of 0.714 inches per second at 10,000 psi and 70° F., and a low burning rate exponent on the order of 0.939.
The RDX-containing material generally comprises a solid cured extruded propellant grain product having low vulnerability characteristics, a low burning rate on the order of 0.714 inches per second at 10,000 psi and 70° F. and a low burning rate exponent on the order to 0.939. The product is made from a solvent-free composition consisting essentially of from 68 to 80% of crystalline solid RDX oxidizer having a weight mean diameter of from about 1 to 14 microns; from about 5 to 22% polyol; and from about 4 to 18% polyisocyanate curative for the polyol, all percentages being weight percent based upon total propellant weight.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A method for preparing a propellant formulation is disclosed. The formulation itself includes an oxidizer, and a binder. When the propellant is cured the binder serves as a matrix for the oxidizer. This oxidizer-binder matrix is generally termed, the propellant.
Suitable oxidiers for LOVA ammunition are cyclotetramethylene tetranitramine (HMX) or cyclotrimethylene trinitramine (RDX).
For the compositions taught in the Examples, it is preferred that either oxidizer have a weight mean diameter of from about 2.3 to 2.8 microns because of the particularly beneficial burn characteristics provided by oxidizer particles size. However, size parameters can be adjusted to suit the needs of the propellant formulator and generally oxidizer having a weight mean diameter of from about 1.0 to 14 is acceptable.
Bimodal, trimodal, and polymodal oxidizers may be used. However, unimodal oxidizers provide satisfactory results. Thus the necessity of experimenting with various modalities is obviated. Generally, it is desirable to include as much oxidizer as possible in the propellant composition in order to maximize thrust. Due to the increase in vicosity of the uncured propellant as the amount of oxidizer increases, as a practical matter, no more than about 80 weight percent oxidizer may be incorporated; generally about 75 weight percent oxidizer will be incorporated. As a practical matter, RDX contains up to 10 weight percent HMX as an impurity and HMX contains up to 2 weight percent RDX as an impurity. However, other than as an impurity, mixtures of the oxidizers are not contemplated in this invention.
Preferably, a polyurethane binder is utilized that is the reaction product of a polyisocyanate and at least one polyol. In a preferred embodiment two polyols are utilized. One polyol is the diol Pluronic L-35. Pluronic L-35 is the trademark of the Wyandotte Chemical Company for a diol which is the polyoxyalkylene derivative of propylene glycol. The other polyol is the triol trimethylol propane which is also known as TMP.
Other suitable diols include, but are not limited to, hydroxyterminated polybutadiene such as R-45, a trademark of Arco, Inc., for a hydroxyterminated polybutadiene, and R-18, a Hooker Chemical Company, Inc., trademark for a diol. Other diols may be utilized. The most preferred diols are highly fluid and readily wet the solid oxidizer.
Other suitable diols include, but are not limited to ethylene oxide glycidol, LHT 112, a very fluid glycol, polycaprolactone-260, a trademark of Union Carbide for a waxy solid caprolactone, and like reactants.
The preferred polyisocyanate is isophorone diisocyanate (also known as IPDI). Other suitable diisocyanates include, but are not limited to, toluene diisocyanate, hexane diisocyanate; and the like. Tri and higher functional isocyanate may also be used.
In curing the above composition, a cure catalyst is preferably utilized. A metal oxide cure catalyst such as titanyl acetyl acetonate (TiO(AA) 2 ) is preferred. Other cure catalysts which may be utlized include dibutyl tin diacetate, dibutylin dilaurate, ferric acetyl acetonate, and other reasonable catalysts. When a cure catalyst is utilized a cure effective amount is about 0.0125 weight percent. That percentage can be adjusted.
In addition to the above components, the composition may include as optional ingredients, those ingredients used by those who practice this art to achieve certain propellant properties. Such optional ingredients include, but are not limited to, oxamide coolant, fire retardant phosphorous compounds, and stiffeners such as CAB-O-SIL, a trademark of the Cabot Corporation for fumed silica. Generally, these optional ingredients are kept to a minimum so as not to detract from the energetic nature of the propellant.
Plasticizers such as nitroglycerin and the like may be optionally present in the composition of the invention. However, metallic fuels such as aluminum should not be present in amounts greater than about 1 weight percent so as to preclude scoring of gun barrels when gun propellants are employed.
In a preferred embodiment a diol, e.g. Pluronic L-35, is used as a chain extender and a triol, e.g. TMP, is utilized as a cross linker.
In practice, the chain extender and the cross linker are mixed together and blended until all the cross linker is dissolved. Generally, blending and dissolving are better achieved at elevated temperatures. For Pluronic L-35 and TMP, a blending temperature of 145° F.±10° F. is preferred because it optimizes blending while maintaining temperatures sufficiently low to avoid undesired chemical activity.
After the cross linker has been dissolved, the resultant polyol blend is cooled preferably to a temperature of from about 80°-100° F. Then a curative, e.g. IPDI, and a catalyst, e.g. TiO(AA 2 ), are added while mixing within the 80°-100° F. temperature range. Because of the chain extension reaction between the polyisocyanate and the diol and the potential for extensive cross linking with the triol, positive efforts must be taken to control the temperature in order for reaction to occur in a desirably controlled manner. Generally a temperature below 100° F. is preferred.
To this mixture finely divided oxidizer, e.g. HMX or RDX, is added. Generally mixing occurs at a temperature that is sufficiently high to keep the viscosity low enough to facilitate efficient oxidizer wetting of the binder that is formed from the above diol-triol-isocyanate. But the temperature is kept sufficiently low to avoid chemically reacting the oxidizer with the binder and thereby creating an extended pot life. For the IPDI-TMP-Pluronic L-35 binder just described a temperature less than about 110° F. is desired during oxidizer addition.
Less than about 110° F. is also desired for mixing these specific components because this temperature is also sufficiently low to avoid complete cross linking of the binder. Complete cross linking or curing of the binder is to be avoided prior to the extrusion of the uncured propellant into a desired propellant grain.
In order to facilitate blending at this reduced temperature of less than about 110° F., the oxidizer may be added in stages.
The mixture is then packaged and cooled to a cure arresting temperature; preferably a temperature of about -50° F. or lower.
When a propellant is to be produced, the cure arrested mixture is thawed and extruded at normal extrusion temperatures. Normal extrusion temperatures are those temperatures at which extrusion can be reasonably practiced. Preferably, those temperatures fall within the range of 120°-160° F. Most preferably extrusion temperatures of from 130°-150° F. will be used for the compositions embodied in the Examples.
After extrusion, cross linking will be completed at a cure temperature. Preferably a temperature of about 150° F. will be utilized. However, since cure is to a certain extent both time and temperature dependent, lower cure temperatures can be utilized. Although cure could be accomplished at room temperature, as a practical matter, temperatures falling within the range 130°-150° are preferred because this provide a more practical cure rate.
It should be pointed out that cure arresting cooling is an optional step. It is feasible to prepare, extrude, and cure the propellant composition without using the cure arresting procedure.
The above prepared blend is containerized, as a whole or in portions, in polyethylene film bags or other suitable containers, and stored at -50° F.
When extrusion is desired, the package mix is thawed, the mix removed from the container and then extruded to form a propellant grain. It is believed that storage at the cure arresting temperature of -50° F. is suitable to maintain pot life for up to 2 months before thawing and subsequent extrusion. High, cure arresting temperatures are available and can be determined without undue experimentation. But generally temperatures below -40° F. are preferred and temperatures below -50° F. are most preferred because the lower temperatures tend to provide a more complete cure arrest and longer pot life.
The following Examples provide a few of the possible embodiments of this invention. The use of the term percent in relation to a specific indicates percent by weight of that specific component based on the weight of the entire propellant composition.
EXAMPLE 1
______________________________________ CompositionItem Material (wt. %)______________________________________1. Polyol, Pluronic L-35 11.72. Trimethylolpropane (TMP) 3.133. Isophorone diisocyanate (IPDI) 10.104. HMX (cyclotetramethylene tetranitramine) 75.00 Size may be 2.3-2.8 micron WMD (100%) 100.00 or a ratio of 2.8 micron WMD HMX and Class E HMX may be used.5. TiO (AA).sub.2 as catalyst 0.0125______________________________________
The following procedure was used:
Propellant mixing was accomplished in a heavy duty vertical mixer having blades utilizing a planetary motion. Particular attention was paid to time and temperature throughout the process.
The Pluronic L-35 polyol and the trimethylolpropane (TMP) were mixed and preheated at 145° F.±10° F. until all TMP solids were dissolved. The mixture was then cooled to fall within the range 90°-100° F. The Pluronic L-35 and TMP had added to them curative IPDI and catalyst TiO(AA) 2 . Mixing occured for 10 minutes at slow speed while maintaining a temperature below 100° F.
Finely divided HMX explosive was added in four portions. First, one half the total amount of allocated HMX was added to the above mixture, mixing for five minutes at slow speed while temperature was controlled to less than 110° F.
Then an additional 20% of the total allocated HMX was added and mixing continued for 15 minutes at slow speed while the temperature was maintained at less than 110° F.
An additional 20% of the total allocated HMX was added to the above mixture and mixing was continued for 15 minutes at slow speed. The temperature was again maintained at less than 110° F. during mixing.
The remaining 5% of the total HMX was added and the mixture mixed for 15 minutes at slow speed under vaccum. (0.5 inch Hg absolute) while the temperature was maintained at less than 110° F.
The resulting uncured propellant mixture was divided and packaged in polyethylene film bags.
The bags of propellant mixture were frozen at -50° F. and stored for two months.
At the end of two months, the uncured propellant mixture was thawed and extruded.
The extruded propellant was cured, and found to have the following properties:
Physical Properties:
Density: 0.064 lb/in 3 at 77° F.
Ballistic Properties for unimodal HMX:
Cured Strand R b at 10,000 psi and 70° F.: 0.652 in/sec
Burning Rate Exponent: 1.014
The uncured propellant mixture prepared from the above components was stored at a temperature of -50° F. for two months. At the end of two months, the mixture temperature was elevated sufficiently to allow extrusion and then the mixture was extruded to form a propellant grain. The propellant grain was cured and after curing had the following properties:
Physical Properties:
Density: 0.0615 16/in 3 at 77° F.
Balistic Properties for unimodal RDX:
Cured Strand R b at 10,000 psi and 70° F.: 0.714 in/sec
Burning Rate Exponent: 0.939 | A solventless method for the preparation and storage of uncured low vulnerability ammunition propellant (LOVA) includes blending from about 60 to 80 weight percent of either HMX or RDX oxidizer having a weight mean diameter from 1.0 to 14 microns with a polyurethane binder. A cure effecting amount of cure catalyst may also be included. These ingredients are blended at a temperature below about 110° F., deaired, and optionally stored at low temperatures at a pre-cured condition, extruded and subsequently cured. The products produced thereby have uniquely low burning rates as well as uniquely low burning rate exponents. | 2 |
This is a division, of Application Ser. No. 583,914, filed June 5, 1975, now U.S. Pat. No. 4,020,196.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present application relates to an apparatus for treating textile fibers.
2. Technical Considerations and Prior Art
For certain treatments of textile fibers, one uses either chambers of large size, which are bulky and require constant maintenance, or devices which are in contact with the yarns which increase in size with the length of the treatment time of the yarn.
The treatment performed in contact with a surface, which is generally hot, has two main disadvantages. Firstly, there is friction between the stretched yarn and the device (which may be, for example, a heating drum or a heating plate). Secondly, there is non-uniformity of the treatment of the yarn at any one instant, because only one face of the yarn is in contact with the device; the other face being in the surrounding atmosphere.
Prior art approaches which may be of interest, and over which the instant invention distinguishes, include U.S. Pat. Nos. 3,393,661; 3,422,796 and 3,511,730 and French Patent 1,357,993.
SUMMARY OF THE INVENTION
The present invention makes it possible to avoid the afore-mentioned disadvantages. According to the present invention, contact of the yarn with the treatment apparatus is avoided.
The present invention contemplates an apparatus for treating at least one moving yarn, characterized in that the yarn passes with minimal friction (fluid friction), through a treatment zone consisting of a groove which is pierced with at least one orifice, through which is introduced a fluid for treating the yarn and keeping the yarn suspended.
The present invention also contemplates an apparatus for the treatment of at least one moving yarn by a fluid, characterized in that it consists of at least one static hollow solid, having a surface which includes and defines at least one groove for the yarn to pass through. The bottom of this groove is pierced with at least one orifice through which a fluid under pressure passes from the interior to the exterior of the solid. At least one means is provided for supplying the fluid. The fluid, which is introduced under pressure, can be a gas, a liquid or a vapor. If it is a liquid, the liquid can be a dyestuff, a size, water or the like. The fluid may or may not contain a filler for sanding. The fluid may be supplied at a desired temperature, and may be heated inside the apparatus by suitable means. The groove into which the fluid is introduced, and which contains the yarn, can have any suitable profile. The groove may or may not be at right angles to the axis of the apparatus and the maximum depth of the groove is at least equal to the diameter of the yarn. The solid is preferably, but not necessarily, a volume of revolution such as a straight cylinder, truncated cone or prismatic cylinder. In this case, the solid includes at least one groove over at least a part or all of its circumference.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partial cross-section of a treating cylinder, according to the present invention, with a helically arranged groove therearound.
FIG. 2 is an enlarged cross-section of a portion of FIG. 1, showing a detailed view of the groove.
FIG. 3 is a cross-section of FIG. 1 taken along lines 3--3.
FIGS. 4 through 8 are enlarged cross-sections of the groove, showing various configurations for the groove.
FIG. 9 is an isometric view showing a pair of treatment cylinders treating yarn.
DETAILED DESCRIPTION
In FIG. 1, there is shown an apparatus 1 in the shape of a straight cylinder, having a groove 2 arranged in the form of a helix and executing seven turns. In the bottom of the groove 2, there are orifices 3 distributed uniformly over the circumference of the cylinder. The apparatus or cylinder 1 is hollow and forms a chamber 4 which receives a fluid under pressure through an orifice 5. The fluid comes from a source of supply which is not shown.
In FIG. 2, there is shown the channel of groove 2, the orifices 3 and a part of the apparatus 1 with the associated internal chamber 4.
Referring to FIG. 1, in carrying out the process a fluid is introduced under pressure into the chamber 4 of the apparatus 1, from where it escapes through the orifices 3 and channels into the groove 2, where it encounters a moving yarn. The fluid maintains the yarn in suspension, without friction against the walls of the groove 2 or surfaces defining the groove while treating the yarn. The number of orifices 3 can be varied, and the introduction of the fluid from the channel into the groove is either radial or tangential relative to the interior of the cylinder 1. For example, in FIG. 3, the cross-section of a groove with tangential introduction of the fluid relative to the interior wall of the cylinder 1 is shown. In this case, the fluid treats the yarn, keeps it in suspension and also assists its travel by having a tangential component relative to the groove 2. The diameter and shape of the orifices 3 can be varied from one groove to the other and within the same groove. If desired, it is possible to allow two different fluids or the same fluid at different temperatures to issue through two successive orifices. In addition, the interior of the apparatus can contain means for blocking certain orifices depending on the use to which the apparatus is put. As seen in FIG. 3, the groove 2 defines a helical path in that the groove surrounds the cylinder 1.
Depending on the desired treatment, one or more cylinders 1 can be used. The treatment by means of the apparatus including the cylinders 1 can be carried out alone or in combination with other treatments using other apparatuses (for example, false twist apparatus). The fluid is introduced at any desired pressure depending on the treatment to which the yarn is to be subjected. The speed of travel of the yarn also depends on the desired treatment.
By "yarn", it is to be understood to include any continuous filament, spun fiber yarn or sliver which may or may not be in a crimped or compressed form.
Among the treatments which can be carried out by means of the apparatus of the present invention, there may be included heat treatments to cause stalibization or relaxation, sizing, fixing or cooling treatments, spraying with particles or the like.
The apparatus of the instant invention permits heat treatment of long lengths of yarn within a limited space. Thus, as shown in FIG. 9, two cylinders 1 are used for heat treatment of the yarn 6 which passes through two sets of false twist nozzles 8. In this case, the orifices 3 in the internal faces of the grooves may be blocked. The two cylinders are mounted on a support 7. In operation the yarn is hooked up to a take-up or winding device and the fluid pressure in the chamber 4 is increased to suspend and advance the yarn. The take-up then winds the yarn in a conventional way as the yarn is advanced.
EXAMPLE
The present example describes the relaxation heat treatment of a multifilament yarn of 2,300 dtex/136 strands, texturized by the process described in U.S. Pat. No. 3,703,754, in which after texturizing, the compression effect is eliminated by subjecting the yarn to relative tension by passing it between two rollers. The treated yarn is then wound up on a bobbin. The yarn is used for the manufacture of needle-punched or tufted carpets, in which it is desirable for the loop formed by the pile to have good elasticity, good covering power, a high crimping bulk and low dimensional shrinkage so as to preserve a good definition of the pattern in use.
The yarn passes over a spirally groved cylinder 1, such as that shown in FIG. 1. The groove is arranged in the form of an endless screw. The speed of travel of the yarn in the groove is 900 meters/minute, the pressure of the steam introduced into the apparatus is 8 kg/cm 2 and the temperature of the steam introduced is 280° C; the spiral is located between two stations for subjecting the yarn to relative tension, and the yarn is thereafter wound up at about 850 meters/minute.
The table which follows gives a comparison of the results obtained on a texturized yarn with and without using the apparatus according to the instant invention. The amount of tension applied or stretch is 6% in both cases.
______________________________________ Without the apparatus With the apparatus______________________________________Yarn gauge 2870 dtex/136 strands 2900 dtex/136 strandsShrinkage in 1.4% 0.25%boiling waterShrinkage in 2.2% 0.67%steam at130° CContractionof crimp in 29.5% 14%water at 60° CFElting cap-acity)Elasticity 13% 16%Bulk 3.2 cm.sup.3 /g 3.77 cm.sup.3 /gCrimps, 1/2 7 10.3wave/cm______________________________________
The yarn treated with this apparatus satisfactorily exhibits the properties required for producing a tufted fabric, the design of which does not have a felted appearance and which will therefore retain good definition during use.
In as much as the present invention is subject to many variations, modifications and changes in detail, it is intended that all matter described above or shown in the accompanying drawing be interpreted as illustrative and not in a limiting sense. | Apparatus for treating filamentary products, such as yarn, includes advancing the yarn in a groove, which has orifices opening in the bottom thereof, and which communicate with a channel through which a fluid is expelled. The channel lies in the wall of a cylindrical static body and is tangent to the inner wall of said body. The fluid supports the strand so that the yarn does not touch the groove. In addition, the fluid treats the yarn and helps to advance the yarn. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Japanese Priority Document No. 2002-169419, filed on Jun. 11, 2002 with the Japanese Patent Office, which document is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is related to a bias circuit for a read MR (Magneto-Resistive) head applied to a magnetic recording and/or reproducing apparatus such as a HDD (Hard Disk Drive) or the like.
[0004] 2. Description of the Related Art
[0005] Conventionally, in a magnetic recording and/or reproducing apparatus such as a Hard Disk Drive for recording necessary data by magnetizing a magnetic layer formed on a rotating recording disk, a Magneto-Resistive head (MR head) is usually used to read out recorded data in case of reading the recorded data.
[0006] Such a MR head is positioned opposite to the recording disk, and is possible to carry out the reading of the recorded data by outputting a change of magnets in the magnetic layer of the recording disk as a change of resistive value of the MR head.
[0007] In this case, it is necessary to flow a bias current through the MR head using a bias circuit in advance, and the Voltage bias system which controls a voltage applied to the MR head is well-known as a bias system as one of such bias circuit.
[0008] As shown in FIG. 3, a bias circuit a of the Voltage bias system is comprised of a bias current output circuit 100 for outputting the bias current flowing through the MR head Rmr, and a feedback circuit 200 for controlling the output bias current from the bias current output circuit 100 , so that a voltage across the MR head Rmr is controlled to be a predetermined value by detecting the voltage variation across the MR head Rmr through which the bias current is flowing.
[0009] In the magnetic recording and/or reproducing apparatus having the MR head Rmr connected to the bias circuit a, not only the read MR head Rmr but a write inductive head 400 are provided in a head body 300 which is positioned opposite to a recording disk as shown FIG. 4, and it is so configured to operate either one of the MR head Rmr or the inductive head 400 .
[0010] Here-in-after, a mode where a playback of the recorded data is carried out from the recording disk by operating the MR head Rmr is called as a read (reproducing) mode, and a mode where a writing of the data is carried out to the recording disk by operating the inductive head 400 is called as a write (recording) mode.
[0011] The head body 300 is positioned opposite to the recording disk as mentioned above, and accordingly, the MR head Rmr and the bias circuit a are connected to each other by using a flexible printed circuit board 500 , the inductive head 400 is connected to the recording data amplifier circuit 600 , and the head body 300 is isolated from an amplifier circuit 700 which includes aforementioned bias circuit a and the recording data amplifier circuit 600 .
[0012] The flexible printed circuit board 500 has a bare essential substrate area in order to make the magnetic recording and/or reproducing apparatus as small and light-weighted as possible. Further a read signal wiring 800 for connecting the MR head Rmr and the bias circuit a, and a write signal wiring 900 for connecting the inductive head 400 and the recording data amplifier circuit 600 are positioned extremely close to each other.
[0013] For this purpose, when a writing signal flows through the write signal wiring 900 in the write mode, some cross-talk is, sometimes, generated in the read signal wiring 800 due to the writing signal, and there occurs a variation in the bias current flowing through the MR head Rmr due to the cross-talk. Accordingly, when the mode is changed from the write mode to the read mode, a recovery time is required for the bias current to be a predetermined bias current value for the read mode, so that, it takes a time to start the reading operation. Therefore in the write mode, it was usual to stop the flow of the bias current through the MR head Rmr by halting the operation of the bias circuit a.
[0014] Namely, in a change-over switch SW provided in the bias circuit a in FIG. 3, the change-over switch SW was made ON in the read mode, and the change-over switch SW was made OFF in the write mode.
[0015] In FIG. 4, a reference sign 710 designates a control signal line for transmitting control signals for transmitting the read mode for a read signal and for transmitting the write mode for a write signal to the bias circuit a, a read data amplifier 720 for amplifying the read data outputted from the bias circuit a, and further to the recording data amplifier circuit 600 . In this case, it is so configured that the control signal line 710 transmits the write signal when not in the read mode, and that the control signal line 710 transmits the read signal when not in the write mode.
[0016] However, when the operation of the bias circuit a was halted, following problems occurred.
[0017] Namely, when the operation of the bias circuit a is halted by setting the change-over switch SW to be OFF, there occur changes in an electrical state of the regulating circuit 110 provided in the bias current output circuit 100 that is prepared in order for the bias current output circuit 100 of the bias circuit a to operate in stable. Therefore, when the mode is changed from the write mode to the read mode, there requires a recovery time which is necessary for the regulating circuit 110 to comeback to a predetermined electrical state. Accordingly, it becomes difficult to carry out a stable conduction of the bias current during the recovery time, so that it is not able to start reading of the recorded data immediately after the mode is changed from the write mode to the read mode.
[0018] Here, the regulating circuit 110 includes an oscillation suppressing capacitor C 1 provided in the bias current output circuit 100 for the purpose of suppressing the oscillation of the circuit and noise elimination, and the oscillation suppressing capacitor is configured by one oscillation suppressing capacitor C 1 in FIG. 3.
[0019] If the operation of the bias circuit a is halted in the write mode, the power supply to the regulating circuit 110 is also halted, and thereby, there occurs voltage variation at the oscillation suppressing capacitor C 1 of the regulating circuit 110 , and the change-over switch SW is made ON, because the read signal is transmitted to the bias circuit a in this condition. Then, charging and discharging of the oscillation suppressing capacitor C 1 in the regulating circuit 110 occur at first, so that it becomes difficult to carry out a stable conduction of the bias current until the oscillation suppressing capacitor C 1 becomes to have a predetermined voltage.
[0020] Particularly, it is able to increase a noise reducing effect to use a capacitor having as large capacity as possible as the oscillation suppressing capacitor C 1 , so that there is a problem that it takes a long time for the voltage of the oscillation suppressing capacitor C 1 to comeback to the predetermined voltage.
SUMMARY OF THE INVENTION
[0021] In order to solve the above problems, a bias circuit for MR head of this invention includes a bias current output circuit for outputting a bias current flowing through the MR head, and a feedback circuit for controlling a bias current output from a bias current output circuit so that a voltage across the MR head is controlled to be a predetermined value by detecting the voltage across the MR head through which the bias current is flowing. Further, the bias circuit for MR head is so configured in which the bias current output circuit includes a regulating circuit for stably operating the bias current output circuit, and a control circuit for the regulating circuit for controlling the regulating circuit to be a predetermined state, and the control circuit for the regulating circuit is started to operate when not in the read mode of the MR head.
[0022] Further the regulating circuit is a circuit equipped with an oscillation suppressing capacitor and the control circuit for the regulating circuit is characterized to be the charging circuit for the oscillation suppressing capacitor.
[0023] Namely, when the MR head is in the read mode, the regulating circuit in the bias current output circuit is activated by activating the bias current output circuit, and on the contrary, when the MR head is made not in the read mode, namely made in the write mode, the regulating circuit is activated by activating the control circuit for regulating circuit so that the regulating circuit is always controlled and maintained to be a predetermined state.
[0024] Accordingly, the bias current output circuit can start the playback of the data by the MR head immediately after the mode is changed from the write mode to the read mode, because a read current is anytime ready for flowing, and therefore, the twitching time from the write mode to the read mode is able to be shortened.
[0025] Further, as a result, the recording disk of the magnetic recording and/or reproducing apparatus does not require a waiting interval corresponding to the recovery time of the regulating circuit, and it is able to carry out the recording of the data during the waiting interval so that it is also able to improve the recording density in the magnetic recording and/or reproducing apparatus.
[0026] In addition, the regulating circuit is a circuit having an oscillation suppressing capacitor, and the control circuit for the regulating circuit is able to simplify the construction of the bias current output circuit without complexity, and also is able to operate it stably when it is to be the charging circuit for the oscillation suppressing capacitor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In the accompanying drawings:
[0028] [0028]FIG. 1 is a circuit diagram of a bias circuit for a MR head of the present invention in a read mode;
[0029] [0029]FIG. 2 is a circuit diagram of a bias circuit for a MR head of the present invention in a write mode;
[0030] [0030]FIG. 3 is a circuit diagram of a conventional bias circuit for a MR head; and
[0031] [0031]FIG. 4 is a chart for explaining a configuration of a peripheral circuit in the conventional bias circuit for a MR head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Here-in-after, one embodiment of the present invention is described with reference to the accompanying drawings. FIG. 1 is a circuit diagram of a bias circuit for a MR head A, and is a circuit diagram illustrating the bias circuit for the MR head A particularly in a read mode. FIG. 2 is the bias circuit for MR head A in a write mode.
[0033] The bias circuit for MR head A is configured with a bias current output circuit 1 for outputting a bias current Ib flowing through the MR head Rmr, and a feedback circuit 2 which detects a voltage variation across the MR head Rmr by a voltage-current converting circuit gm, outputs a detecting result as a current, and controls the voltage across the MR head Rmr to be a predetermined value by controlling the bias current output circuit 1 based on the detected current.
[0034] The bias current output circuit 1 is a current mirror circuit, and is configured to include a first PNP transistor P 1 and a third PNP transistor P 3 , where emitters of the first PNP transistor P 1 and the third PNP transistor P 3 are connected to an upper-side voltage source V CC through resistors R 1 , R 3 , respectively, and bases thereof are connected to each other.
[0035] In the bias current output circuit 1 of the present embodiment, a collector of the first PNP transistor P 1 is connected to the MR head Rmr, and flows the bias current Ib through the MR head Rmr. A collector of the third PNP transistor P 3 is connected to a base of the first NPN transistor Q 1 , an emitter of the first NPN transistor Q 1 is connected to a base of the second PNP transistor P 2 , and an emitter of the second PNP transistor P 2 is not only connected to a base of the third PNP transistor P 3 but also to the upper-side voltage source Vcc through a resistor R 2 .
[0036] By the way, an emitter of the first NPN transistor Q 1 and a base of the second PNP transistor P 2 are connected to a second current source 12 by way of a second change-over switch SW 2 .
[0037] An operation control of the bias current output circuit 1 is carried out by the forth NPN transistor Q 4 a collector of which is connected to the base of the first NPN transistor Q 1 . Further, a collector of the forth NPN transistor Q 4 is connected to a first oscillation suppressing capacitor C 1 one terminal of which is connected to the upper-side voltage source V CC , and is configured to prevent oscillation of the bias current output circuit 1 by the first oscillation suppressing capacitor C 1 , and to eliminate noise. In the present embodiment, the regulating circuit 3 is configured with a single first oscillation suppressing capacitor C 1 . An emitter of the forth NPN transistor Q 4 is connected to the lower-side voltage source V EE by way of a resister R 8 .
[0038] Further in the bias current output circuit 1 , there is provided a control circuit 4 for regulating circuit to be operated by switching of a second change-over switch SW 2 not in the read mode of the MR head Rmr, namely in the write mode.
[0039] The control circuit 4 for the regulating circuit is served as a dummy current mirror circuit, and is configured to include a sixth PNP transistor P 6 , a fifth NPN transistor Q 5 , and a fifth PNP transistor P 5 . In this case, a collector of the sixth PNP transistor P 6 is connected to the collector of the forth NPN transistor Q 4 , a base of the fifth NPN transistor Q 5 is connected to a collector of the sixth PNP transistor P 6 , a collector of the fifth NPN transistor Q 5 is connected to the upper-side voltage source V CC , an emitter thereof is connected to a second current source I 2 by way of the second change-over switch SW 2 . In addition, a base of the fifth PNP transistor P 5 is connected to the emitter of the fifth NPN transistor Q 5 , and an emitter of the fifth PNP transistor P 5 is not only connected to the upper-side voltage source V CC through a resistor R 9 but also to the base of the the sixth PNP transistor P 6 .
[0040] An operation control of the forth NPN transistor Q 4 is carried out at the feedback circuit 2 , and the feedback circuit 2 is configured as follows.
[0041] Namely, the feedback circuit 2 comprises a reference voltage source V 1 for applying a reference voltage to the MR head Rmr, a voltage-current converting circuit gm for detecting voltage variation across the MR head Rmr to which the reference voltage, a seventh PNP transistor P 7 serving as a switch for operating the feedback circuit 2 based on the output from the voltage-current converting circuit gm, a forth PNP transistor P 4 serving as a switch for operating the bias current output circuit 1 , and a second NPN transistor Q 2 for controlling the flow of the bias current Ib to the MR head Rmr by connecting an emitter of the seventh PNP transistor P 7 .
[0042] A pair of registers R 4 and R 5 are connected to both end terminals of the MR head Rmr for setting a center point of the MR head Rmr to be the ground potential. Further an emitter of the second NPN transistor Q 2 is connected to the lower-side voltage source V EE through a resistor R 6 .
[0043] A second capacitor C 2 one of terminals of which is connected to the lower-side voltage source V EE is connected to a base of the seventh PNP transistor P 7 , and a cutoff frequency of the feedback circuit 2 is determined by the second capacitor C 2 .
[0044] An emitter of the seventh PNP transistor P 7 a base of which is connected to output of the voltage-current converting circuit gm is connected to the first current source I 1 by way of the first change-over switch SW 1 . A collector of the seventh PNP transistor P 7 is connected to the lower-side voltage source V EE .
[0045] Further, an emitter of the forth PNP transistor P 4 a base of which is connected to an output of the voltage-current converting circuit gm is connected not only to a third current source I 3 but also to a base of the forth NPN transistor Q 4 , and is configured to carry out the operation control for the bias current output circuit 1 . A collector of the forth PNP transistor P 4 is connected to the lower-side voltage source V EE .
[0046] In the read mode, namely when the first change-over switch SW 1 is ON state, and provided that R 1 =R 3 , and R 6 =R 8 , the transistors P 1 and P 3 have the same characteristics, and the transistors Q 2 and Q 4 have the same characteristics, and when the voltage Vmr of the MR head Rmr is less than the voltage V 1 of the reference voltage source V 1 , −terminal voltage of the voltage-current converting circuit gm is expressed as follows
(+terminal voltage of he voltage-current converting circuit gm)<(−terminal voltage of the voltage-current converting circuit gm)
[0047] Wherein the voltage of the −terminal voltage of the voltage-current converting circuit gm is ‘(+terminal voltage of he voltage-current converting circuit gm)+Vmr−V 1 ‘, and Vmr<V 1 .
[0048] In this case, in the feedback circuit 2 , in connection with the increase of the output current of the voltage-current converting circuit gm, the base potential of the seventh PNP transistor P 7 and the base potential of the forth PNP transistor P 4 are increased.
[0049] In connection with the increase in the base potential of the forth PNP transistor P 4 , the base potential of the forth PNP transistor P 4 increases, and the bias current Ib outputted from the bias current output circuit 1 is increased, and in addition, in connection with the rise in the base potential of the seventh PNP transistor P 7 , the base potential of the second NPN transistor Q 2 is increased, and also the bias current Ib flowing through the MR head Rmr is increased.
[0050] As a result, the voltage Vmr of the MR head Rmr increases, and when the voltage Vmr of the MR head Rmr becomes equal to the voltage V 1 of the reference voltage source V 1 , a feedback for stopping the output of the control current from the voltage-current converting circuit gm is activated.
[0051] Further in the read mode, the base potential of the forth NPN transistor Q 4 becomes Vc 2 +Vbe, provided that the potential of the second capacitor C 2 is Vc 2 , so that the forth NPN transistor Q 4 always keeps its ON state, and the charging is carried out to the first oscillation suppressing capacitor C 1 which is the regulating circuit 3 .
[0052] On the contrary in the write mode, namely in the mode where the first change-over switch SW 1 is OFF state and the second change-over switch SW 2 connects the second current source 12 and the control circuit 4 for regulating circuit, a base potential of the forth NPN transistor Q 4 becomes Vc 2 +Vbe, and accordingly, the forth NPN transistor Q 4 becomes ON state, so that the charging is carried out to the first oscillation suppressing capacitor C 1 which is the regulating circuit 3 .
[0053] The charging to the first oscillation suppressing capacitor C 1 is carried out, regardless of the read mode or the write mode, by setting the forth NPN transistor Q 4 to be ON state, the potential across the first oscillation suppressing capacitor C 1 is not changed when the mode is changed from the write mode to the read mode. Accordingly, it becomes possible to start the playback immediately after the mode is changed by flowing a predetermined bias current Ib through the MR head Rmr, and it is able to shorten the switching time from the write mode to the read mode.
[0054] In this case, in the present invention, the control circuit 4 for regulating circuit serves as a charging circuit for the first oscillation suppressing capacitor C 1 by carrying out the charging of the first oscillation suppressing capacitor C 1 in connection with the operation of the control circuit 4 for regulating circuit.
[0055] In the present embodiment, the regulating circuit 3 comprises of a single first oscillation suppressing capacitor C 1 , but the invention is not limited to this single first oscillation suppressing capacitor C 1 , and the regulating circuit 3 may comprises of a combination of necessary elements. | A bias circuit for a magneto-resistive head having a bias current output circuit for flowing a bias current through a magneto-resistive head, and a feedback circuit for controlling the bias current from a bias current output circuit by detecting voltage variation across the magneto-resistive head so as a voltage across the magneto-resistive head to be a predetermined value, comprises a regulating circuit for regulating an operation of the bias current output circuit in the bias current output circuit, a control circuit for the regulating circuit for controlling the regulating circuit to be in a predetermined condition, and a switching circuit for switching a read/write condition for activating the control circuit for the regulating circuit in a non-read condition of the magneto-resistive head. The regulating circuit includes an oscillation suppressing capacitor; and the control circuit for the regulating circuit is a charging circuit for the oscillation suppressing capacitor. | 6 |
BACKGROUND OF THE INVENTION AND INFORMATION DISCLOSURE STATEMENT
This invention relates generally to an electrophotographic copying apparatus, and more particularly, to the heat and pressure fixing of toner images formed on a copy substrate by direct contact with a heated fusing member.
In the process of xerography, a light image of an original to be copied is typically recorded in the form of a latent electrostatic image upon a photosensitive member with subsequent development of the latent image by the application of marking particles commonly referred to as toner. The visual toner image is typically transferred from the member to a copy substrate, such as a sheet of plain paper, with subsequent affixing of the image by one of several fusing techniques. A preferred fusing system applies both heat and pressure to the copy substrate.
In one prior art fusing system, a fuser roll is used which has an outer surface or covering of polytetrafluoroethylene or silicone rubber, the former being known by the trade name Teflon, to which a release agent such as silicone oil is applied, the thickness of the Teflon being on the order of several mils and the thickness of the oil being less than 1 micron. Silicone based oils which possess a relatively low surface energy, have been found to be materials that are suitable for use in a heated fuser roll environment where Teflon constitutes the outer surface of the fuser roll. In practice, a thin layer of silicone oil is applied to the surface of the heated roll to form an interface between the roll surface and the toner images carried on the support material. Thus, a low surface energy layer is presented to the toner as it passes through the fuser nip and thereby prevents toner from offsetting to the fuser roll surface. A fuser roll construction of this type is disclosed in U.S. Pat. No. 3,718,116 assigned to Xerox Corporation.
While heat and pressure fusers of the type discussed above are desirable because of their thermal efficiency, they possess some disadvantages because of their mechanical complexity, cost, long warm-up times and paper wrinkling. A second type of system is known in the prior art which reduces or eliminates these undesirable characteristics. This system utilizes a relatively low mass fuser roll member of the type disclosed, for example, in U.S. Pat. No. 4,689,471 assigned to Xerox Corporation. As disclosed in this patent, a low mass heated fuser roll cooperates with an elongated web member comprising a woven fabric to form an extended fusing area. One end of the pressure web is fixed while the other end is biased into pressure engagement with the fuser roll to form an entrance nip. The pressure web is an enabling feature of this type of system but its effectiveness depends upon several factors such as the type of copy substrate media being used and relative humidity conditions. As an example, certain types of copy media are as subject to stalling or jamming on the leading edge entrance of the fuser entrance nip. The pressure and location of the biasing means if therefore of critical importance. One improvement is disclosed in U.S. Pat. No. 4,860,047 in which a feed roller is introduced at the entrance nip which cooperates with the fuser roll to improve entrance of the copy sheet into the fusing area.
The present invention is directed to a still further improved system whereby a copy sheet entry into the fusing area is effected by causing the fuser web member to move in the direction of copy sheet movement at the critical moment of entry carrying the leading edge of the copy sheet into the entrance nip area. More particularly the invention relates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in section of a reproduction machine having the improved fuser system of the present invention.
FIG. 2 is an enlarged view of a first embodiment of the fuser system shown in FIG. 1.
FIG. 3 is an enlarged view of a second embodiment of the fusing system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawings there is shown a xerographic type reproduction machine 8 incorporating the present invention. Machine 8 has a suitable frame 12 on which the machine xerographic components are operatively supported. Briefly, as will be familiar to those skilled in the xerographic printing and copying arts, the xerographic components of the machine include a charge retentive recording member, shown here in the form a of a rotatable photoreceptor 14. In the exemplary arrangement shown, photoreceptor 14 comprises a drum having a photoconductive surface 16. Other photoreceptor types such as belt, web, etc. may instead be employed. Operatively disposed about the periphery of photoreceptor 14 are a charging station 18 with charge corotron 19 for placing a uniform charge on the photoconductive surface 16 of photoreceptor 14, exposure station 22 where the previously charge photoconductive surface 16 is exposed to image rays of a document 9 being copied or reproduced to thereby form a latent electrostatic image on the charge retentive surface; development station 24 where the latent electrostatic image created on photoconductive surface 16 is developed by toner; combination transfer and detack station 28 with transfer corotron 29 detack corotron 30 for sequentially transferring the developed image to a suitable copy substrate material such as a copy sheet 32 brought forward in timed relation with the developed image on photoconductive surface 16 and lessening the forces of attraction between the copy substrate and the charge retentive member; cleaning station 34 and discharge corotron 36 for removing leftover developer from photoconductive surface 16 and neutralizing residual charges thereon.
A copy sheet 32 is brought forward to transfer station 28 by feed roll pair 40. Sheet guides 42, 43, serve to guide the sheet through an approximately 180 degree turn prior to the copy substrate reaching the transfer station 28. Following transfer, the sheet 28 is carried forward to a fusing station 44 where the toner image is contacted by fusing roll 49 forming one member of a heat and pressure fuser. Fusing roll 49 is heated by a suitable heater such as quartz lamp 50 disposed within the interior of roll 49. After fusing, the copy sheet 32 is discharged from the machine.
A transparent platen 50 supports the document 9 as the document is moved past a scan area 52 by a constant velocity type transport 54. As will be understood, scan area 52 is in effect a scan line extending across the width of platen 50 at a desired point along platen 50 where the document is scanned line by line as the document is moved along platen 50 by transport 54. Transport 54 has input and output document feed roll pairs 55, 56 respectively on each side of scan area 52 for moving document 9 across platen 50 at scan area 52. The image rays from the document line scanned are transmitted by a gradient index fiber lens array 60 to exposure station 22 to expose the photoconductive surface 16 of the moving photoreceptor 14.
Developing station 24 includes a developer housing 65, the lower part of which forms a sump 66 for holding a quantity of developer 67. As will be understood by those skilled in the art, developer 67 comprises a mixture of larger carrier particles and smaller toner or ink particles. A rotatable magnetic brush developer roll 70 is disposed in a predetermined cooperative relation to the photoconductive surface 16 in developer housing 65, roll 70 serving to bring developer from sump 66 into developing relation with photoreceptor 14 to develop the latent electrostatic images formed on the photoconductive surface 16.
The fuser roll 49 comprises a thin-walled thermally conductive tube having a thin (i.e. approximately 0.005 inch (0.01 Centimeters)) coating of silicon rubber on the exterior surface thereof which contacts the toner images on the copy substrate to thereby affix the images to the substrate. A release agent management system, not shown, applies a thin layer of silicone oil to the surface of the fuser roll for the prevention of toner offset thereto as well as reducing the torque required to effect rotation of the fuser roll. In one operative embodiment of the fuser roll its diameter was 3.3 inches and had a length of 40 inches. This embodiment is typically used to fuse images on copy substrates that are 3 feet (0.91 meters) wide by 4 feet (1.22 meters) in length.
The fuser apparatus 44 also comprises a non-rotating, elongated pressure web member 72. As viewed in FIGS. 1 and 2, one end of web 72 is wrapped around reciprocating drive pulley 74. The opposite end of the web is biased into engagement with the fuser roll so that the fuser roll and the web cooperate to form an elongated nip 78 therebetween.
A pressure applying mechanism 80 creates a force between the roll and web so as to produce a frictional force therebetween that keeps the web in tension so it can provide suitable pressure to the surface of the fuser roll. Mechanism 80 encompasses a weighted rod 82 disposed in a loop 84 formed in web 72. A portion of the web intermediate the two ends thereof rides over a curved portion 86 of a web frame or support member 88. A biasing force is applied to the frame or support member 88 so that to thereby urge the web 72 into engagement with the fuser roll 49. The force, so applied, is just sufficient to keep the web biased against the roll in the fusing zone.
A blade member 90 has one end anchored in the frame structure 92 while its other end contacts the web at the nip area 93 to apply a load against the web and thereby cooperate with the pressure applying mechanism 80 to effect the required pressure in the nip for satisfactory operation. The area of contact between the web and the fuser roll forms the entrance to the nip area. The blade is preferably fabricated from thermally nonconductive material and is mounted such that in its free state it is flat and in its operative state the edge of the blade is deflected by the fuser roll to thereby cause it to function as a leaf spring, applying the aforementioned load against the web. Edge contact of the blade produces the highest possible pressure for a given force or lead the purpose of the blade is to control paper cockle caused by the rapid drying of high moisture content paper.
According to a first aspect of the invention, reciprocating pulley 74 is adapted to rotate in a counterclockwise direction when the leading edge of copy sheet 32 begins its entrance into nip area 93. Appropriate signals are generated from system controller 95 and sent to drive motor 98. Gear output shaft 100 cooperates with gear 102 to drive pulley 74 in the counterclockwise direction for a relatively short time duration. As the pulley rotates, web member 72, moving in the same direction as copy sheet 32, frictionally engages the copy sheet against the surface of fuser roll 49, carrying it into and just beyond the nip area. Weighted rod 80 descends slowly to maintain the biasing of web 72 to roller 49. The web member motion stops at that point and the copy sheet is moved along by fuser roll 49 rotation. The sheet progresses through the contact (fusing) area until it emerges from exit area 104. When the trailing edge clears exit area 104, controller 95 energizes motor 98 in a reverse drive causing drive roller 74 to rotate in a clockwise direction returning web member 72 to its original position.
FIG. 3 shows a second embodiment of the invention where the web member 72 is reciprocated between a take-up roller 110 and a feed roller 112. One end of the web is wound around take-up roller 110; the web rides over curved portion of web frame 88. The web biasing force is again supplied by a blade member 90. The other end of web member 72 is wound around feed roller 112. The copy sheet is maintained in a flat condition as it approaches the nip area by conveying the sheet along the top perforated surface 114 of vacuum chamber 116. The copy sheet rides on web member 72 which is porous enough to permit a vacuum force to engage and hold the copy sheet flat. The copy sheet is engaged at the time it leaves detack area 28.
For this embodiment, system controller 95 is programmed to provide signals causing roller 110 to rotate in a counterclockwise direction by means of a drive motor 99. As the leading edge of copy sheet 32 leaves the detack area 28, web 72 is moved so as to move at the same speed as the copy sheet as it leaves the detack area. The web motion is stopped when the leading edge of the copy sheet is past the nip area, but the rest of the sheet maintains its flat orientation along the vacuum surface until the entire sheet passes through the nip entrance 93. When the trailing edge of the sheet emerges from exit area 104, the system controller sends a reverse drive signal to drive motor 99 reversing rotation of take up roller 112, and causing web member 72 to rewind to its original position.
While the invention has been described with reference to the structure disclosed, it will be appreciated that numerous changes and modifications are likely to occur to those skilled in the art, and it is intended to cover all changes and modifications which fall within the true spirit and scope of the invention. | A low mass fuser roll fusing system incorporates a thin web member to maintain copy sheets in biased contact with a fuser roll during a fusing operation. The copy sheets are introduced to the fusing area at an entrance nip formed by a biasing assembly. The lead edge of the copy sheet is introduced into the entrance nip by a reciprocating mecahnism which moves, the web member and the copy sheet supported thereon into the entrance nip. The web member motion is then stopped and the copy sheet progresses through the fusing cycle until the copy sheet emerges from the fusing area, at which time the web member is returned to its original position. | 6 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to a system and method for a human powered vehicle. In particular, the present invention relates to a three-wheeled skateboard system and method.
2. Description of the Related Art
Over the years, conventional skateboards have become familiar to both children and adults. FIG. 1 is a perspective view diagram showing a general embodiment of a conventional skateboard of the prior art. Skateboard 100 includes a front truck assembly 102 and a rear truck assembly 104 . As illustrated, the truck assemblies each include an axle and two wheels.
As illustrated, the conventional skateboard is constructed of an elongate board having a set of axially coupled wheels mounted beneath the board at each end of the board. In the past, this conventional design has been altered only slightly. For example, each two wheel set always included two wheels, but the sets may have been sized differently. In addition, the axle for each set may have been extended, and the elongate board may have been shaped differently to give an alternative look. Further, many aesthetic variations of the design have been implemented over time. These variations in aesthetic design have created a popular market that provides lucrative rewards to manufacturers and aesthetic designers of conventional skateboards. However, recently the conventional design of the skateboard has been modified significantly.
The conventional design of the skateboard has been modified such that each set of axially mounted wheels has been removed. FIG. 2 is a perspective view diagram showing a general embodiment of a contemporary skateboard 200 of the prior art. Contemporary skateboard 200 is illustrated to show an example of the skateboard including a front footboard and caster assembly 202 and a rear footboard and caster assembly 204 . These two footboard/caster assemblies are mechanically coupled by means of a connecting element 206 which is often constructed of resilient and/or flexible material.
In contemporary skateboard designs, the conventional two wheel set at each end of the elongate board has been replaced with a single caster on each of two footboards. This single caster design has greatly enhanced a rider's enjoyment on a skateboard. This latest innovation in fundamental skateboard design has been well received throughout the world. As a result of the acceptance of the contemporary skateboard design, various manufacturers have begun competing for customers. At this point, businesses compete for consumers of the contemporary skateboard, again, mostly through altering aesthetics of the contemporary two caster skateboard design.
Aside from aesthetics, consumers appear to be drawn to the contemporary skateboard, at least in part, for the unusual riding techniques that are required to operate the contemporary skateboard. Unfortunately, as users seem to ignore, these unusual riding techniques that are required to operate the contemporary style of skateboard can be detrimental to skills that are learned in analogous winter or even water sports. For example, a sport such as snow boarding appears to be similar, but does not work the same muscle sets of a rider of the contemporary skateboard. Of note, when snow is unavailable, riders sometimes ill advisedly use the contemporary skateboard as a substitute for teaching/learning snow boarding skills. Riders seem to be unaware of the detrimental effects of the contemporary skateboards and, even if aware, seem to simply ignore the problem.
Further, riders/consumers may be confused by the similar look of the contemporary skateboard to a snow board. Still further, consumers may believe that they may improve their snow boarding skills by non-snow surface training on the contemporary skateboard. However, the unusual riding technique required by the contemporary skateboard, when the athlete uses the contemporary skateboard for snow board training, could actually reduce an athlete's snow board performance. In addition, the athlete simply seeking the feel of a snow board through the use of the contemporary skateboard when off the snow surface may be disappointed when discovering such deficiencies after purchasing the contemporary style skateboard.
Unfortunately, riders/consumers have mostly ignored these problems because of the new and exciting challenge associated with the contemporary skateboard. In fact, consumers that may not be familiar with snow board or surf board techniques have turned the contemporary skateboard market into a lucrative business, thereby discouraging manufacturers from changing the fundamental design of the contemporary skateboard. In addition, experienced snow board/surf board consumers do not look to the contemporary skateboard to meet their cross-training needs, but look to the contemporary skateboard for entertainment value. Therefore, manufacturers have not seen a need to change the fundamental skateboard design and have focused mostly on improving/changing skateboard aesthetics to capture market share.
From the foregoing discussion, what is unapparently needed, therefore, is a system and method for a skateboard that provides a user with a feel that is similar to a snow or surf board. Ironically, because contemporary skateboards are often considered unsafe for stability reasons, thrill seeking consumers often seek the contemporary skateboard exactly for these instability reasons and do not seek a more stable skateboard.
Recent advancements/alternatives in skateboard technology do not address this cross training aspect. In fact, the recent advancements even teach away from addressing cross training aspects. For example, some skateboard advancements fail to even slightly appear like a snow or surf board. Further, recent advancements often lead to a decrease in skateboard stability.
For example, “Caster Skate Apparatus” US 2007/0284835 A1 (Choi) addresses problems such as an inconvenient turning radius. Choi's solution to the inconvenient turning radius leads directly to creating more instability and absolutely no cross training benefits. Still further, cross training is ignored in “Two-wheeled Skateboard” U.S. Pat. No. 5,984,328 (Tipton) where the need for in-line skateboard skating is addressed. Of note, the in-line wheels preferred in Tipton also clearly teach away from increasing stability in a conventional skateboard.
In addition, “Skateboard With Direction Caster” U.S. Pat. No. 7,195,259 (Gang) addresses the steering aspect of skateboards by disclosing techniques to improve steering of a conventional skateboard. Among other things, Gang alters the wheel arrangement of conventional skateboards by including two or even three direction casters in place of the conventional two wheel set arrangements. Of note, even with the three wheel arrangement of Gang, the wheels are constructed such that less stability is offered with the three wheel arrangement.
Among all the different types of advancements in conventional skateboard technology, aside from the failure to address cross training appeal in a skateboard, stability appears to be an advancement that has actually been avoided. Apparently, stability has been intentionally avoided due to consumer choice.
Of note, neither conventional nor contemporary skateboard designs have addressed performance adaptations by means of providing subtle adjustments to truck, hanger (axle), or wheel position dimensions. Thus, skateboard adjustments to accommodate for both environmental conditions and the sometimes significant differences between experienced and inexperienced skateboard users have been ignored.
For example, skateboard changes such as the use of a reverse kingpin truck having a reverse kingpin have been reserved for more advanced skateboard designs such as high speed long-boards. As a result, inexperienced skateboard users are unable to perform minor adjustments to these more advanced skateboards that would make the more advanced skateboard conducive to use by the inexperienced skateboard user.
In addition, key spacing in both “wheelbase,” which is defined as the space between front and rear axles, and “clearance,” which is defined as the space between wheel axles and deck has not been made readily adjustable in skateboards of the past. Moreover, these adjustments differ on a traditional skateboard where front and rear wheels and trucks are essentially the same dimensions. Whereas, according to principles of the three-wheeled skateboard of the present invention, as will be understood by those of ordinary skill in the art upon review of the following disclosure, the predominantly one-directional design of the past makes these adjustments far more significant.
Also of note, as will be understood by those of ordinary skill in the art upon review of the instant application, a caster pin may also be referred to herein as a “caster kingpin” and vice-versa.
In view of the prior art, the effort to improve the conventional skateboard appears to have skateboard manufacturers focused on creating a more challenging and/or aesthetically pleasing skateboard. Apparently, the practical nature of stability and/or cross training has been completely and intentionally ignored in the prior art.
SUMMARY
It has been discovered that the aforementioned shortcomings are resolved using a system for a skateboard and method for propelling the skateboard.
In one embodiment, the skateboard system includes a board including a first end and a second end. The first end is offset from the second end, and the second end defines a board plane. The skateboard system includes a truck assembly attached near the first end. The truck assembly includes a shaft substantially perpendicular with the board. The shaft connects to an axle that supports a first wheel and a second wheel. Each of the first wheel and second wheel are freely rotatable about the axle.
In addition, the skateboard system includes a caster assembly attached near the second end. The caster assembly includes a caster pin that defines an angle with respect to the board plane. The caster pin angle is an adjustable angle with respect to the board plane. Thus, the caster pin is adjustably coupled relative to the board plane such that the caster pin angle is adjustable between forming a first acute angle with respect to the board plane and a substantially perpendicular angle with respect to the board plane.
The caster assembly also includes a caster fork supporting a caster wheel that is freely rotatable about a caster axle. The caster fork translates radially about the caster pin regardless of a selected caster pin angle.
In addition, the skateboard system may include a caster assembly that is removably coupled to the board. As will be appreciated by one of ordinary skill in the art when viewing the present disclosure, the removably coupled caster assembly may be removable by means such as a simple bolt and nut arrangement, a pin assembly coupling the caster assembly to the board, or other such apparatus to create a removable coupling that avoids welding or breaking the caster assembly.
Further, the skateboard may provide an adjustably coupled caster pin that is adjustable to certain fixed angular positions according to a mating selection of matching teeth within caster assembly to secure the caster pin.
Still further, the adjustably coupled caster pin may also be adjustable via an angle pin. The angle pin can be positioned to obtain a certain fixed angular position according to an angle pin location. The angle pin location is selected within caster assembly. In either of the adjustably coupled caster pin embodiments, in operation, the caster pin has a fixed angular position that is angular with respect to the board plane.
In another embodiment, the skateboard system may include a handlebar assembly that is coupled to the board. The handlebar assembly creates a scooter embodiment that includes a skateboard that is constructed according to principles of the present invention.
In yet another embodiment, a method of propelling a skateboard constructed according to principles of the present invention includes the following steps, not necessarily in the following order.
The method includes the step of applying a lateral force to a first side of a board. The board includes a first end and a second end. The first end is offset from the second end, and the second end defines a board plane. A truck assembly is attached near the first end, with the truck assembly including a shaft substantially perpendicular with the board. The shaft connects to a truck axle supporting a first wheel and a second wheel.
Each of the first wheel and second wheel is freely rotatable about the truck axle, and a caster assembly is attached near the second end with a caster pin defining a caster pin angle with respect to the board plane. The caster pin angle forms a first acute angle with respect to the board plane, and the caster assembly includes a caster fork that supports a caster wheel freely rotatable about a caster axle. The caster fork translates radially about the caster pin.
Another step of the method of propelling a skateboard constructed according to principles of the present invention includes transferring a force through the caster assembly. In addition, the method includes applying the transferred force to a surface, wherein the applied force is the product of the transferred force and the distance between the line perpendicular to the board plane and the caster axle. In yet another step, the method includes applying a lateral force to a second side of the board based on the application of the lateral force to the first side of the board.
The method may also include adjusting the caster pin angle relative to the board plane. The caster pin angle may be adjusted by relocating an angle pin. Thus, the adjustably coupled caster pin is adjustable via alternate settings of the angle pin to obtain certain fixed angular positions.
Another skateboard embodiment includes a board as in the previously described skateboard system. However, the instant skateboard embodiment also includes a caster assembly attached near the second end with a caster pin defining an adjustable caster pin angle with respect to the board plane wherein the caster pin is adjustably coupled relative to the board plane such that the caster pin angle is adjustable between forming a first acute angle with respect to the board plane and a substantially perpendicular angle with respect to the board plane. The caster pin has a caster block and lock nut arranged to secure a caster lock plate to hold caster pin at a selected caster pin angle.
As in the previous skateboard system embodiment, the caster assembly of the instant embodiment includes a caster fork supporting a caster wheel freely rotatable about a caster axle, wherein the caster fork translates radially about the caster pin regardless of the selected caster pin angle.
The instant skateboard may also include the caster block and lock nut being configured to engage caster lock plate within caster assembly by means of mechanically threading caster lock nut onto caster lock plate in a nut and bolt arrangement such that caster lock nut may be tightened using threads of caster lock plate by rotating caster lock nut upon corresponding threads of caster lock plate.
In this embodiment, caster block provides spacing beside caster lock nut within caster assembly in a washer ring style with a teeth arrangement of caster assembly being operative to secure caster lock plate when caster lock nut is tightened. When tightened, caster lock nut and caster block secure movement of caster pin. In other words, when caster lock nut is tightened, the selected caster pin angle remains unchanged during operation.
Upon viewing the present disclosure, one of ordinary skill in the art will appreciate that variations to the above disclosed system and method could be contemplated. For example, in one embodiment, the system may include a caster assembly further including at least one shim positioned to alter the caster angle. In addition, other examples of the method may include applying a shim to the caster assembly, the shim positioned to alter the caster angle.
The foregoing is a summary and thus contains, by necessity, simplifications, generalizations, and omissions of detail; consequently, those skilled in the art will appreciate that the summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the present invention, as defined solely by the claims, will become apparent in the non-limiting detailed description set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood, and its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
FIG. 1 is a perspective view diagram showing a general embodiment of a conventional skateboard of the prior art;
FIG. 2 is a perspective view diagram showing a general embodiment of a contemporary skateboard of the prior art;
FIG. 3A is a perspective view diagram showing a general embodiment of a skateboard constructed according to principles of the present invention;
FIG. 3B is a perspective view diagram showing another embodiment of a skateboard constructed according to principles of the present invention;
FIG. 3C is a perspective view diagram showing a scooter embodiment having a three-wheel arrangement constructed according to principles of the present invention;
FIGS. 4A-C are perspective view diagrams showing the caster assembly of FIG. 3A moving through different positions when the skateboard of FIG. 3A operates according to principles of the present invention;
FIG. 5 is a perspective view diagram showing a removable caster assembly that operates according to principles of the present invention;
FIG. 6A is a perspective view diagram showing an adjustable caster assembly embodiment that operates according to principles of the present invention;
FIG. 6B is a profile view diagram showing the adjustable caster assembly embodiment of FIG. 6A when moved through different angled positions;
FIG. 6C is a perspective view diagram showing the adjustable caster assembly embodiment disclosed in FIG. 6A wherein the adjustable caster assembly is combined with the removable caster assembly disclosed in FIG. 5 ; and
FIGS. 7A-C are perspective, profile, and cross-sectional view diagrams illustrating an alternative adjustable caster assembly embodiment when the caster assembly operates according to the embodiment disclosed in FIG. 3A .
DETAILED DESCRIPTION
The following is intended to provide a detailed description of examples of the invention and should not be taken to be limiting of the invention itself. Rather, any number of variations may fall within the scope of the invention, which is defined in the claims following the description.
FIG. 3A is a perspective view diagram showing a general embodiment of a skateboard 300 constructed according to principles of the present invention. Skateboard 300 includes a board 301 having a front caster assembly 302 , with caster fork 314 , caster wheel 316 , and caster axle 318 , and a rear truck assembly 304 , with truck mount 306 , truck axle 308 , first wheel 310 , and second wheel 312 , both assemblies being mounted on the underside of an elongate board or single deck. Advantageously, a rider of skateboard 300 does not have to leave skateboard 300 to propel the board.
In a preferred embodiment, skateboard 300 is designed such that drive is created with somewhat of a falling forward sensation that a rider may experience upon operating skateboard 300 . As illustrated, and as will be described in greater detail herein, front caster assembly 302 includes a caster with a caster pin at an angle with respect to a first end 303 of the elongate board. The caster pin allows the front, caster assembly 302 to freely pivot on skateboard 300 . Further, unlike prior art skateboards, the combination of front caster assembly 302 and rear truck assembly 304 , adjacent to second end 305 of board 301 , provides an unexpectedly stable skateboard with an unexpected snow board/surf board feel.
FIG. 3B is a perspective view diagram showing another general skateboard embodiment, skateboard 350 , constructed according to principles of the present invention. Unlike skateboard 300 , skateboard 350 includes a front truck assembly 352 and a rear caster assembly 354 , both assemblies being mounted on the underside of an elongate board. As illustrated and as will be described in greater detail herein, rear caster assembly 354 includes a caster at an angle that is free to pivot on skateboard 350 .
Regardless of which skateboard 300 , 350 is constructed, the skateboard includes a caster assembly that is mounted at an angle. Specifically, the caster mounting bolt (caster pin) is mounted at an angle and is not perpendicular or even required to be substantially perpendicular to the skateboard deck.
FIG. 3C is a perspective view diagram showing a scooter embodiment having a three-wheel arrangement constructed according to principles of the present invention. FIG. 3C illustrates skateboard 300 constructed according to principles of the present invention, however, skateboard 300 includes a handlebar 370 to create a scooter embodiment.
As understood by those of ordinary skill in the art when viewing FIG. 3C , the illustrated scooter embodiment may be constructed with many variations. For example, as discussed with regard to FIG. 3A , skateboard 300 could simply include a front caster assembly 302 and a rear truck assembly 304 , both assemblies being mounted on the underside of an elongate board or single deck. Handlebar 370 allows a rider greater stability upon operation of skateboard 300 .
FIGS. 4A-C are perspective view diagrams showing a caster assembly embodiment that moves through different positions when the caster assembly operates according to embodiments disclosed in FIGS. 3A , 3 B and 3 C. Illustrated in FIGS. 4A-C is front caster assembly 302 shown in three different pivot positions. FIG. 4A illustrates caster frame and fork 404 supporting caster wheel 402 freely rotatable about a caster axle.
As illustrated in the following FIGS. 4B-4C , caster fork 404 translates radially about a caster pin, the caster pin being mounted at an angle with a board plane. Further, caster fork 404 defines a caster angle, the caster angle defining an acute angle with respect to board plane. The caster angle may further define an acute angle with respect to the caster pin.
FIG. 5 is a perspective view diagram showing a removable caster assembly 500 that operates according to principles of the present invention. Removable caster assembly 500 includes, similar to front caster assembly 302 , a caster wheel 502 freely rotatable about a caster axle. In addition, removable caster assembly 500 includes a caster frame and fork 504 that allows caster wheel 502 to translate radially about a caster pin. Caster fork 504 defines a caster angle, the caster angle defining an acute angle with respect to a board plane. The caster angle may further define an acute angle with respect to the caster pin. As illustrated, the caster pin is at an angle with respect to the board plane.
In addition, caster frame and fork 504 includes a base arrangement 506 for easily removing or attaching removable caster assembly 500 . In the illustrated embodiment of FIG. 5 , removable caster assembly 500 is shown having apertures 508 spaced about base arrangement 506 . Apertures 508 are intended to receive bolts 510 which can be adapted to securely affix removable caster assembly 500 to the board plane by means of fastening nuts 512 .
Upon viewing FIG. 5 , it will be appreciated by those of ordinary skill in the art that other embodiments of removable caster assembly 500 such as a pin arrangement could be produced when skateboards of the invention such as skateboard 300 are studied.
FIG. 6A is a perspective view diagram showing an adjustable caster assembly 602 that operates according to principles of the present invention. Like the front caster assembly 302 of FIG. 3A , adjustable caster assembly 602 includes a caster wheel with caster frame and fork. A caster angle pin 604 when engaged with a base arrangement 606 is a preferred arrangement for securing the caster frame and fork into a particular angled position. As illustrated, angle pin 604 can be inserted at aperture 608 of base arrangement 606 in order to securely select a particular caster angle position. As will be appreciated by those of ordinary skill in the art upon viewing FIG. 6A , the different apertures of base arrangement 606 allow the caster wheel to be positioned at different angles with respect to the board plane.
FIG. 6B is a profile view diagram showing adjustable caster assembly 602 when moved through different positions. Adjustable caster assembly operates according to the embodiment disclosed in FIG. 6A . Three separate positions for the caster wheel/fork are illustrated in FIG. 6B . Each position is illustrated with a separate profile image in the drawing. Of course, upon viewing the present disclosure, other angled embodiments may be illustrated as appreciated by those of ordinary skill in the art.
FIG. 6C is a perspective view diagram showing adjustable caster assembly 602 as disclosed in FIG. 6A ; however, adjustable caster assembly 602 is combined with removable caster 500 disclosed in FIG. 5 . Specifically, base arrangement 606 is configured to allow the presence of apertures 508 spaced about base arrangement 606 for receiving bolts 510 which can be adapted to securely affix a now easily removable adjustable caster assembly 602 . Removable and adjustable caster assembly 602 is affixed to the board plane by means of fastening nuts 512 . It will be appreciated by those of ordinary skill in the art upon viewing FIG. 6C that other embodiments of a removable adjustable caster assembly 602 could be produced within the scope of the present invention while yet including other aspects according to principles of the presently disclosed invention.
FIGS. 7A-C are perspective, profile, and cross-sectional view diagrams illustrating different views of an adjustable caster assembly 700 when the caster assembly operates according to embodiments disclosed in FIG. 3A . Adjustable caster assembly 700 includes a caster fork supporting a caster wheel 702 , a caster plate 704 , and a caster base arrangement 706 . Caster base arrangement 706 is illustrated having apertures 708 which enable removable caster functionality. Caster base arrangement 706 is also shown having teeth 710 which enable the angle of caster assembly 700 to be securely adjustable when engaging caster lock plate 712 with caster assembly teeth 710 .
In operation, as illustrated by the two-way arrows of FIG. 7A , caster plate 704 enables the caster fork with caster wheel 702 to freely pivot on an axis. In addition, engaging caster assembly teeth 710 with caster lock plate 712 enables caster wheel 702 to be securely and seamlessly adjusted relative to the board plane such that a preferred caster angle may be selected by a rider of a skateboard incorporating adjustable caster assembly 700 .
FIG. 7B illustrates a profile view of adjustable caster assembly 700 . The profile view shows two positions that a rider may set caster wheel 702 . These two positions are shown in different line formats. One position is shown with solid lines, while a second position is shown with dashed lines; dashed lines are used in order to illustrate the second position that a rider of skateboard 300 may select for a skateboard constructed according to principles of the disclosed invention.
FIG. 7C illustrates a profile and cross-sectional view of an embodiment of an adjustability mechanism for adjustable caster assembly 700 . For clarification purposes, caster base arrangement 706 is illustrated showing multiple views and hence multiple label numbering. For example, in the profile portion of the drawing, caster base arrangement 706 is illustrated and in the cross-sectional view, caster assembly teeth 710 are illustrated on caster base arrangement 706 . Caster assembly teeth 710 are shown engaging with teeth of caster lock plate 712 .
Also shown in FIG. 7C is a detailed cross-sectional view of caster plate 704 and related hardware for implementing an embodiment of adjustable caster assembly 700 . Caster plate 704 is coupled to caster lock plate 712 by the tension of caster plate retaining bolt (aka., caster mounting bolt or caster pin) 722 threaded into said caster lock plate 712 . Caster plate 704 rotates freely due to caster retaining bolt 722 engaging caster radial bearing 718 on the inner race. Outer race of caster radial bearing 718 engages the caster plate 704 . Caster thrust bearing 720 suspends caster plate 704 above caster lock plate 712 .
As will be appreciated by those of ordinary skill in the art when viewing caster assembly 700 , caster block 714 may be secured with caster lock nut 716 to secure a caster pin angle when caster assembly 700 is configured to allow selection of a caster pin angle by a rider of skateboard 300 . Further, the caster fork may attach to caster plate 704 via simple welding, manufacturing caster plate 704 having forks included as a single part, or other similar attachment method.
The included functional descriptive material is information that imparts functionality to a machine. This functional descriptive material includes, but is not limited to, mechanical gearing of an apparatus such as adjustable caster assembly 700 .
While particular embodiments of the present invention have been shown and described, based upon the teachings herein, it will be appreciated by those skilled in the art that changes and modifications may be made without departing from the principles of this invention and its broader aspects. Therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of this invention. Furthermore, it is to be understood that the invention is defined by the appended claims. It will be understood by those with skill in the art that if a specific number of an introduced claim element is intended, such intent will be explicitly recited in the claim, and in the absence of such recitation no such limitation is present. For non-limiting example, as an aid to understanding, the following appended claims contain usage of the introductory phrases “at least one” and “one or more” to introduce claim elements. However, the use of such phrases should not be construed to imply that the introduction of a claim element by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an”; the same holds true for the use in the claims of definite articles. | A system and method for a skateboard and for propelling the skateboard. The skateboard system includes a board including a first end and a second end, the first end offset from the second end, and the second end defining a board plane. The skateboard system also includes a truck assembly attached near the first end of the board, and a caster assembly attached near the second end of the board. The caster assembly has a caster pin at an angle with respect to the board plane. Other embodiments are also disclosed. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a thin film magnetic head and more particularly to a thin film magnetic head having a multi-winding coil and a narrow gap depth, which is preferably adapted to a high density recording/reproducing.
In recent years, the high density recording in disk devices and the like has been eagerly demanded. In order to meet this demand, first, the recording density in a track width direction is increased. However, this leads to a problem of the reduction of a single reproduction output since the track width is reduced. To overcome this problem it is necessary to increase the number of windings of a conductor coil in a limited area. Further, to meet the above demand, the recording frequency is also increased to increase the line recording density. But, this also leads to the same problem. Moreover, the disk device, etc. are miniaturized. This also gives rise to the same problem since the relative speed between a recording medium and the head is reduced. Thus, now, the magnetic head having a more improved performance is required to obviate the reduction of a single reproduction output.
To prevent the reduction of a reproduction output resulting from the increase of the recording density, it is usual to give a larger coersive force to a recording medium. This requires a thin film magnetic head having such a structure as to increase the recording magnetic field. To obtain such a head, it has been proposed to increase the gap length and core thickness while decreasing the gap depth. When gap length and the core thickness are increased, however the reproduction output is inclined to be decreased in a high frequency range. This is not preferable. Thus, it is necessary to decrease the gap depth more greatly than before.
In order to prevent the reproduction signal output reduction resulting from the decrease of the relative speed between the recording medium and the magnetic head, it is also necessary to make many windings of a conductor coil in a limited area as in the case where the track width is reduced as mentioned above.
A previously known typical thin film magnetic head has eight windings of a substantially elliptical conductor coil for the purpose of a higher recording/reproduction as before. Such a thin film magnetic head is disclosed in JP-A-No. 55-840l9 corresponding to U.S. Pat. No. 4,190,872 filed in 1978 and JP-A-No. 55-84020 corresponding to U.S. Pat. No. 4,216,854 filed in 1978. However new problems posed by such a magnetic head, are not proposed in those patent applications.
The problems newly posed are follows.
In the case where many windings are wound in a single layer conductor (coil) structure in a limited area, the coil resistance is increased. To prevent this, the coil thickness must be increased and the coil intervals must be decreased. To provide the coil with an increased thickness, the photoresist used when they are formed must be also increased in its thickness. However, it is difficult to pattern the thick photoresist and so the thick coil with a high accuracy during the production process. The short-circuiting between the coil windings may frequently occur because of any alien substance mixed between the coil windings since the coil intervals are short. This leads to the reduction of a production yield of the head. Further, in the aforesaid case, the area of the region connecting the central portion of spiral windings with an external circuit must also be decreased. However, it is difficult to form such a connection region in a decreased area with less variation. Thus, the connection resistance may vary while the head is being used so that a stabilized recording/reproduction characteristic can not be provided. This is a serious problem in the reliability of the head.
One structure for making many windings of a conductor in a limited area is proposed in Japanese Patent Publication No. 49-33648. In this structure, many layers of a conductor having a wide width are stacked on a substrate through individual insulating, layers. However, a great many layers must be stacked in order to obtain a satisfactory characteristic of the head. This provides an undesired increase of the number of fabrication steps.
Another structure is a multi-layer multi-winding constructor structure as disclosed in JP-A-No. 56-8124. If the number of conductor layers is increased as in this structure, the plane where the coil windings are formed becomes higher. This makes it difficult to form the individual coil windings, with a high accuracy, on the entire surface of the substrate. Since a second magnetic member is formed at a higher step displacement portion in a subsequent step, the provision of a track width with a high accuracy is also made difficult. Further, the window within a magnetic yoke is heightened and the end point of the gap depth, which is determined by etching, at the side opposed to the medium, the insulator within the magnetic yoke, is formed with a decreased accuracy. This gives rise to the variations in the gap depth. The slope portion of the insulator on the side of the magnetic yoke is also difficult to manufacture so that it can have a predetermined angle of the slope and size between the conductor and the magnetic member because of the excess or shortage of etching. Thus, the desired recording characteristic and insulating property between the conductors and magnetic members may vary or can not be obtained. Therefore, the number of the conductor layers is required to be limited so that their many windings can be made without increasing the height of the window within the magnetic yoke.
Still another structure is a two-layer multi-winding conductor structure as shown in JP-A-No. 60-1335l6 corresponding to U.S. Pat. application Ser. No. 684,300 filed in 1984. This structure does not take into consideration the aforesaid problems and also the following problem posed when a small gap depth is intended to be provided with a high accuracy. More specifically, in order to obtain the head with a predetermined depth, the gap depth, which can be decided by machining the head surface opposed to the recording medium, must be measured through a thick protection film from the side where a head element is to be formed. Therefore, the gap depth of approx. 1 μm or less is difficult to measure with a high accuracy. Namely, the small gap depth is difficult to obtain and may vary, thus making it difficult to provide a stabilized and satisfactory electro-magnetic conversion characteristic.
Further, a method of manufacturing a thin film magnetic head with a small gap depth is disclosed in JP-A-No. 61-322l2 corresponding to U.S. Pat. No. 4,749,439 filed in 1985.
SUMMARY OF THE INVENTION
An object of this invention is to provide a magnetic thin film head which is capable of providing a stabilized high electro-magnetic conversion characteristic by making many windings of conductors in a magnetic yoke with a limited size without decreasing the production yield.
Another object of this invention is to provide a thin film magnetic head which is suited for a high density recording, has a highly reliable conductor structure and has a small and very accurate gap depth.
To attain these objects, in accordance with this invention, there is provided a thin film magnetic head comprising a structure consisting of two conductor layers which crosses a closed magnetic yoke or circuit consisting of a first and a second magnetic member, wherein said first and second magnetic member are connected with each other to form the closed magnetic yoke at its front portion which is opposite to a recording medium and at its rear portion which is not opposite thereto, and have portions which are opposite to each other over a length substantially equal to a gap depth, intervening a non-magnetic gap member therebetween, on a plane substantially parallel to a substrate surface at least at said front portion, and the edge of said gap member constitutes an aperture of the magnetic yoke.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a central sectional view of a thin film magnetic head according to one embodiment of this invention.
FIG. 2 is a central sectional view in a certain step of the process of fabricating a magnetic thin film head according to one embodiment of this invention.
FIG. 3 is a sectional view for explaining conductor coils.
FIGS. 4 and 5 are a graph and a sectional view for explaining the operation of this invention, respectively.
Prior to explaining the preferred embodiments of this invention, the operation of this invention having the construction mentioned above will be described. In accordance with this invention, the window height within a magnetic yoke can be prevented from being increased by arranging conductor members in a two-level multi-winding structure. Therefore, the aforesaid problems associated with the increase of the window height are minimized. Adequency of arranging the conductors in a two-layer multi-winding structure will be explained. Assuming that the width L where conductor windings 60 are to be inserted is fixed in FIG. 5, it is necessary to set the interval S between the conductor windings and the interval T between the conductor layers for predetermined sizes in order to assure a satisfactory production yield of heads through the fabrication process. The number of windings of the conductor that can be wound in a prescribed space, with their sectional area fixed, will be explained. Assuming that L≈80 μm, S≈1.5 μm, T≈1.5 μm and the window height in the magnetic yoke H≈9 μm, FIG. 4 shows characteristic curves of the number of windings which can be wound vs. their sectional area for respective conductor structures of one to three layers. In FIG. 4, A relates a single layer structure with the film thickness of approx. 5 μm; B relates to a two-layer structure with the film thickness of approx. 1.7 μm; C relates to a three-layer structure with the film thickness of approx. 0.7 μm; and D relates to a single layer structure of the film thickness of approx. 3 μm. As seen from the figure, if the conductor sectional area is the same, the two-layer structure B can make more windings than the three-layer structure C. The single layer structure A can make more windings than the two-layer structure B when the conductor sectional area is greater than approx. 8 μm. However, since this single layer structure has a film thickness as large as approx. 5 μm its fabrication is very difficult. On the other hand, when the single layer structure (D in FIG. 4) having a film thickness of approx. 3 μm which is a realizable upper limit is compared with the two-layer structure B, it can be seen that the latter structure can make more windings than the former structure. Further, even if the number of conductor layers is different, the conductor resistance is not substantially varied if the number of windings is fixed. Therefore, when the respective conductor structures having the same number of windings and the realizable film thickness are compared, it can be seen that the two-layer structure B can take the largest conductor sectional area. The same result can be provided (not shown) when the two-layer structure is compared with a structure having four or more conductor layers. However, using the structure having more conductor layers is not preferable since it requires so more steps of fabrication. Moreover, even when the values of L, S, T and H are varied to the extent allowed by the production yield of the magnetic heads, viewed from the magnetic circuit efficiency, conductor short-circuitings, etc. is not so seriously deteriorated because the relations among the characteristics shown in FIG. 4 are not almost varied. Accordingly, it should be understood that the two-layer conductor structure is a structure which is most suitable to assure the sectional area necessary for the reliability of the head and to make the desired number of windings of conductors.
In this invention, the center of each of the respective windings of a second conductor member 8 located in a magnetic yoke is located substantially just above each of the centers between the respective windings of a first conductor 6, and the angle θ 1 formed by the line connecting the upper surface edges of the first and second conductors and the plane substantially parallel to a substrate surface is made substantially equal to the angle θ 2 formed by a side slope of a second magnetic member 101 and the plane parallel to the substrate surface. Therefore, many windings of conductors can be effectively wound within a limited area of the magnetic yoke, and a third insulater 9 can be formed so that the smoothness of the surface thereof at the regions constituting the front portion and the rear portion of the magnetic yoke is prevented from being reduced and the slope angle thereof on the side of the magnetic yoke is stably set for a predetermined angle. Thus, there can be provided a magnetic head which has uniform sizes between the conductors and the second magnetic member, less variation of the insulating property between the conductor members and the second magnetic member, and stabilized recording property.
Moreover, in this invention, the first 30 and second 101 magnetic members have portions which are opposite to each other over a length substantially equal to a predetermined small magnetic gap depth provided by an intervening a gap member therebetween, at least on their sides opposite to a recording medium, and are connected with each other ahead of the above portions. Therefore, by monitoring the state of the connection portion from a machining side, the point where the connection portion is removed by machining and also the gap member is completely exposed can be defined as machining ending point, thus making it unnecessary to measure the gap depth from the side where a head element is to be formed. Accordingly, in accordance with this invention, a head structure which has a highly accurate and small-sized gap depth can be implemented.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to FIGS. 1 to 3, embodiments of this invention will be explained.
Embodiment 1
FIG. 1 shows a central section of a head element which has been completed in this embodiment. FIG. 2 shows a central section of the head element at the half-way step.
First referring to FIGS. 2 and 3 and thereafter FIG. 1, the fabrication process of the head element in accordance with this embodiment will be explained.
First, on a substrate 1 formed is an underlying film 2 of e.g. alumina which constitute a base on which a head element is to be formed.
A first magnetic member 30 of e.g. permalloy which is thinner at its medium opposing side 9b and thicker at its side reverse thereto 9a is formed on the underlying film 2. This first magnetic member 30 consists of a first layer 31 and a second layer 32 which are successively deposited on the underlying film 2 through e.g. a sputtering technique and thereafter etched through sputtering.
A non-magnetic gap member 4 of e.g. alumina which will be machined later to constitute a gap member is deposited on substantially the entire surface of the underlying film 2, including the first magnetic member 30, through e.g. the sputtering technique.
A first insulator member 5 is formed on the gap member 4 over the region having a larger area than the region where a first conductor member 6 is to be formed. This first insulator member 5 has a flat and smooth surface and is formed by applying an insulator of polyimide system resin, etc. on the gap member 4, patterning it and baking the patterned insulator.
A first conductor member 6 of e.g. copper is formed on the first insulator 5. Each of the windings of this first conductor member 6 has thin contact layers of e.g. chrome deposited on its lower surface 6a as shown in FIG. 3.
A second insulator member 7 is formed so that it covers the first insulator member 5 and the conductor member 6 and provides a connection part 7a electrically connecting the first conductor member 6 and a second conductor member 8. This second insulator 7 has a flat and smooth surface and is formed through the application of insulator of e.g. polyimide system resin, patterning and baking thereof.
A second conductor member 8 of e.g. copper is formed on the second insulator member 7. Each of the windings of this second conductor 8, like the first conductor member 6, has thin contact layers of e.g. chrome deposited on its lower surface 8a as shown in FIG. 3. Then, the second conductor member 8 is arranged so as to have the following positional relationship with the first conductor member 6. Namely, the center of each of the windings of the second conductor member 8 is located substantially just over the central position between the windings of the first conductor member 6 in a magnetic yoke, and also is located substantially just over the center of each of the windings of the first conductor member 6 in the part behind the connection portion 7a. Further, an angle θ 1 is made substantially equal to an angle θ 2 as seen from FIG. 2; the angle θ 1 is formed by the plane substantially parallel to the substrate surface and the line connecting the respective upper surface edges (6c and 8c) of the first and second oonductor members 6 and 8, at their side in proximity to a second magnetic member 100 (FIG. 1) in the magnetic yoke, and the angle θ 2 is formed by the plane substantially parallel to the substrate surface and the side slope of the second magnetic member 100 (the slope formed by simultaneously etching the first to third insulator members).
Thereafter, a third insulator member 9 is formed so that it covers the second conductor member 8. This third insulator member 9 is formed by applying insulator of e.g. polyimide resin onto the second conductor member 8; at the medium opposing side 9b and at the portion where the first magnetic member 30 is connected with the second magnetic member 100, etching the applied insulator together with both the first insulator member 5 and the second insulator member 7, and also at the back portion 9c, etching the applied insulator 9 so as to cover the second insulator 7; and hardening the etched insulator.
The gap member 4 is patterned using the third insulator 91 as a mask and this third insulator member 91 is also etched to form another third insulator member with the thickness reduced by size G in the horizontal direction. Then, the angle θ 2 of the aforesaid slope may preferably 30°-45° in view of the deposition state of the first layer 101 (FIG. 1) of the second magnetic member 100 on the slope and the magnetic property of the head.
Next, as seen from FIG. 1, a second magnetic member 100 consisting of a first layer 101 and second layer 102, which is thinner at its medium opposing side 9b and thicker at its side reverse thereto 9a, is formed on the third insulator member 91. This second magnetic member 100 is formed by successively depositing the first layer 101 of e.g. permalloy, an intermediate film l0a of e.g. alumina and the second layer 102 of e.g. permalloy through e.g. the sputtering technique and thereafter etching the second layer 102 and the first layer 101 in this sequence also through e.g. the sputtering technique. Then, the first layer 101 is formed so as to have a thickness larger than the second layer 32 of the first magnetic member 30. The etching of the first layer 101 is performed, when it is patterned, using, as a mask, non-magnetic material of e.g. alumina which doesn't pose any problem even if it is used as a head constituent in order to provide a precise track width at the step displacement portion. Namely the intermediate film 10a acts as an etching stopper for the first layer 101 of the second magnetic member so that it can prevent the first layer 101 from being excessively etched. Incidentally, when the magnetic members are deposited through the sputtering technique, the substrate must be heated at a higher temperature during the deposition in order to provide the magnetic members with a uniform and high performance so that the insulator members used in the fabrication process may be preferably resin of polyimide system which has an excellent heat resistance property.
A thick protection film (not shown) of e.g. alumina is formed on the second magnetic member 100 to provide input/output terminals for connection of an external circuit.
Finally, as shown in FIG. 1, the medium opposing side is removed by machining to provide a predetermined gap depth G D .
The magnetic head fabricated by the process mentioned above can provide a very accurate track width which is an effect peculiar to this embodiment. It has been confirmed that the thin film magnetic head in accordance with this invention has a high performance and high reliability and so can be suitably applied to a high density recording.
Embodiment 2
In Embodiment 1, the thin contact layers of e.g. chrome have been formed on the upper and lower surfaces of the first conductor member 6 and the second conductor member 8, as shown in FIG. 3. In accordance with Embodiment 2, the upper contact layer of the first conductor 6 is removed through e.g. the sputter-etching technique after an aperture which constitutes a connection part 7a of connecting the first conductor member 6 and the second conductor member 8 has been formed. In Embodiment 2, the contact layers are arranged on both upper and lower surfaces 6b and 6a of the first and second conductor members so that the reliability of the conductor members can be further enhanced. When the contact layer is removed from the upper surface 6b of the first conductor member 6 (at a connection part 7a), the time when the etching is to be terminated can be easily decided from the appearance of the upper surface of e.g. copper of the first conductor member.
It has been confirmed that the thin film magnetic head according to this embodiment has the same performance as in Embodiment 1.
Embodiment 3
In this embodiment, an inorganic film of e.g. SiO 2 is adopted for the first to third insulator members 5, 7 and 9 in Embodiment. This inorganic insulator film is formed so as to have a flat and smooth surface through several techniques of sputtering, lift-off, bias-sputtering, etc. Its shape having slopes of angle θ 2 is formed through techniques of reactive sputter-etching, plasma etching, etc. The inorganic insulater films according to this invention further enhances the reliability of the magnetic head of this invention since it has a high heat resistance.
It has been confirmed that the magnetic head in accordance with this embodiment has also the same performance as in Embodiments 1 and 2.
This invention has the following meritorious effects.
The multi-winding of conductor coils can be implemented in such a way that the resistance thereof is prevented from being increased without reducing the sectional area of each of the conductor coils, thereby enhancing of the reliability the resultant magnetic head, and preventing the reproduction output from being decreased.
Since the positional relationship between the windings of each conductor and the second magnetic member and the angle of each of the slopes on the sides of the magnetic yoke are stabilized, a magnetic head having good insulation between the conductor members and the magnetic members and an excellent recording property can be realized.
Since the small-sized gap depth G D can be provided with a high accuracy, the reduction of the reproduction output, which is associated with the increase of the recording frequency, is prevented, thereby making uniform the electro-magnetic characteristic of the magnetic head. Thus, the magnetic head having a high performance and reliability can be made with a high production yield. | A thin film magnetic head having two conductor layers provided within a magnetic circuit constituted by a first and a second magnetic member. The magnetic circuit has, at the side to which a recording medium is opposed, a portion where the first and second magnetic members are opposed to each other over a length substantially equal to a gap depth, intervening a non-magnetic gap member therebetween, and a portion ahead thereof where they are connected with each other. The edge of the gap member constitutes an aperture of the magnetic circuit. The thin film magnetic head arranged as above permits a high density recording without reducing its production yield. | 8 |
FIELD OF THE DISCLOSURE
[0001] This patent generally pertains to HVAC systems (heating, ventilating and air conditioning systems) and, more specifically, to under-floor air ducts.
BACKGROUND
[0002] To heat, cool, filter, dehumidify, ventilate or otherwise condition the indoor air of a comfort zone, such as a room or area in a building, the floor of some buildings have a supply air plenum between a subfloor and a matrix of floor panels that are elevated about one or two feet just above the subfloor. The floor panels, which are usually supported by a matrix of pedestals extending upward from the subfloor, provide the surface upon which the building occupants walk and furniture is set.
[0003] With an under-floor HVAC system, a supply air duct discharges fresh or conditioned supply air into the plenum, which in turn conveys the supply air to a series of supply air registers or openings in the floor panels. The registers release the supply air from within the plenum up into the comfort zone. The general goal is to have a sufficient number of properly placed registers such that the supply air rises evenly up through the comfort zone for the benefit of the occupants at floor level. As the supply air continues to rise above the occupants, the eventually used or less-than-fresh air approaches the ceiling to where one or more return air ducts extracts the air for reconditioning and/or exhausting outdoors.
[0004] One problem, however, is that if the air from the supply air duct has to travel a great distance to a remote register, the supply air might lose much of its desirable temperature by heat transfer with the subfloor, particularly if the subfloor is made of concrete with a high specific heat. Also, as the supply air travels radially from the supply air duct, the air expands and loses much of its velocity. Additional velocity is lost when less remote registers release air before that air can reach more distant registers. Thus, remote registers receiving lower pressure air tend to release disproportionately less air to the comfort zone than registers that are closer to the supply air duct.
[0005] To avoid these problems, some under-floor HVAC systems include a relatively rigid sheet metal air duct or a pliable tubular air duct that is installed under-floor in the plenum between the subfloor and the floor panels. Under-floor air ducts help channel supply air along a more directed route from the supply air duct to certain remote registers. A drawback of such installations, however, is that under-floor air ducts, particularly pliable ones, tend to retract and extend longitudinally in response to changes in duct pressure. The resulting sliding movement can create noise and abrade the duct material. Moreover, there are endless possible floor layouts with various supply airflow needs, thus it can be difficult and expensive to custom build numerous air duct systems to meet all those needs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a top view of an example of an under-floor air duct system with a plurality of floor panels omitted to show underlying features of the system.
[0007] FIG. 2 is a cross sectional view taken along line 2 - 2 of FIG. 3 .
[0008] FIG. 3 is a top view similar to FIG. 1 but with most of the floor panels installed.
[0009] FIG. 4 is an exploded top view illustrating an example of an under-floor method.
DETAILED DESCRIPTION
[0010] Certain examples are shown in the above-identified figures and described in detail below. In describing these examples, like or identical reference numbers are used to identify the same or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic for clarity and/or conciseness. Additionally, several examples have been described throughout this specification. Any features from any example may be included with, a replacement for, or otherwise combined with other features from other examples.
[0011] A building floor 10 , shown in FIGS. 1-3 , includes a plurality of generally rigid floor panels 12 supported by a matrix of pedestals 14 that extend upward from a subfloor 16 . The space between subfloor 16 and floor panels 12 provides a plenum 18 for conveying fresh supply air 20 from a supply air duct 22 to a series of supply air registers 24 in floor panels 12 . Supply air 20 discharging upward through air registers 24 helps condition or ventilate a comfort zone 26 that is just above floor panels 12 . Comfort zone 26 may be any designated zone supplied with air from a HVAC system, and that may be occupied by people.
[0012] To create an air duct system 28 that ensures supply air 20 is evenly distributed or properly apportioned across comfort zone 26 , a distribution air duct 30 is installed within plenum 18 . Distribution air duct 30 receives supply air 20 from a supply air chamber 32 fed by supply air duct 22 and conveys supply air 20 to wherever it is needed. Distribution air duct 30 is particularly useful for conveying supply air 20 to remote areas of comfort zone 26 that are quite distant from supply air chamber 32 .
[0013] For sake of example, distribution air duct 30 is shown to include two runs, a straight run 34 and a longer L-shaped run 36 ; however, any number of runs, shapes or branches of runs are well within the scope of the methods and apparatus described herein. Although the actual construction, assembly and installation of distribution air duct 30 may vary, example runs 34 and 36 are tubes of pliable material, thus distribution air duct 30 generally inflates when pressurized by supply air 20 and tends to collapse (i.e., sag or deflate) when supply air 20 is turned off. The pliable material of distribution air duct 30 can be cloth fabric, sheets of plastic or rubber, porous, nonporous, perforated, nonperforated, and various combinations thereof.
[0014] Run 34 of distribution air duct 30 comprises a pliable tubular inlet collar 38 at a proximal end 40 of run 34 , a first duct segment 42 that can be porous or nonporous, a second duct segment 44 that is preferably perforated although not necessarily so, and an end cap 46 at a distal end 48 of run 34 . To release more supply air 20 near distal end 48 , second duct segment 44 includes a series of discharge air perforations 50 . First and second duct segments 42 and 44 are examples of an upstream tubular wall section and a downstream tubular wall section, respectively, with first duct segment 42 being more air permeable than second duct segment 44 . Alternatively, or to release even more supply air 20 near distal end 48 , end cap 46 can be provided with a discharge opening 52 . The amount of supply air 20 discharged through end cap 46 can be adjusted by tightening or loosening a drawstring 54 at the throat of discharge opening 52 . An example of end cap 46 can be found in U.S. Pat. No. 6,558,250.
[0015] To assemble run 34 , a strap clamp 56 fastens inlet collar 38 to a rigid tubular flange 58 that conveys supply air 20 from supply air chamber 32 to the interior of run 34 . To balance or apportion the airflow between runs 34 and 36 , a conventional baffle (not shown) can be installed within tubular flange 58 . Inlet collar 38 , first and second duct segments 42 and 44 , and end cap 46 can be joined end-to-end via any suitable fastener 60 including, but not limited to, a zipper running circumferentially around the adjoining pieces. Once assembled, run 34 of distribution air duct 30 can simply rest upon subfloor 16 for vertical support.
[0016] For horizontal support, however, or to prevent run 34 from sliding around or repeatedly extending and retracting due to changes in air duct pressure, a fastener 62 preferably connects distal end 48 to one or more pedestals 14 . In some examples, fastener 62 comprises an elongate pliable member 64 (e.g., cable, strap, chain, rope, cord, wire, etc.) that connects a loop 66 (e.g., hook, snap connector, etc.) that is sewn or otherwise attached to one end of second duct segment 44 . To provide run 34 with horizontal support in two dimensions, elongate pliable member 64 can be attached to two or more pedestals 14 in a generally V-shaped layout as shown in FIG. 1 . In the V-shaped layout, fastener 62 can be two individual elongate members or a single elongate member with two legs.
[0017] To aid service personnel in maintaining or troubleshooting air duct system 28 , distribution air duct 30 preferably includes a series of decals 68 (e.g., label, tag, visual marker, sign, arrowhead, etc.) that are distributed along the upper surface of distribution air duct 30 . Decals 68 are best placed at intervals that correspond to the standard dimension of floor panels 12 so that whenever any floor panel 12 above distribution air duct 30 is lifted for service reasons, such as panel 12 ′ of FIG. 3 , at least one decal 68 is visible. Two feet is a common standard width 70 for floor panels 12 , thus the separation between decals 68 is preferably at most two-foot.
[0018] Run 36 is similar in construction to run 34 . Run 36 comprises inlet collar 38 at a proximal end 72 of run 36 , first duct segment 42 , a right-hand tubular elbow 74 made of a pliable material, a relatively long duct segment 76 that can be porous or nonporous, second duct segment 44 , and a closed end cap 78 . Similar to run 34 , strap clamp 56 fastens inlet collar 38 to tubular flange 58 , and the various pliable duct segments 42 , 44 and 76 , inlet collar 38 and elbow 74 can be joined end-to-end by way of zippers.
[0019] Run 36 includes a first distal end 80 at elbow 74 and a second distal end 82 at end cap 78 . Fastener 62 ′ and loop 66 anchors second distal end 82 to pedestals 14 a and 14 b, and fastener 62 ″ anchors elbow 74 to pedestals 14 c, 14 d and 14 e. Fasteners 62 ′ and 62 ″ each can be made of a single elongate member with multiple legs or multiple individual elongate members.
[0020] Since there are endless possible floor layouts with various supply airflow needs, it can be difficult and expensive to custom build numerous air duct systems to meet all those needs. To address this problem, air duct system 28 preferably is assembled from a predefined assortment of duct segments 83 , as shown in FIG. 4 . For sake of example, assortment 83 includes two predefined long duct segments 76 , seven predefined short first duct segments 42 , three predefined second duct segments 44 , one right-hand elbow 74 , two left-hand elbows 84 , three inlet collars 38 , two closed end caps 78 , three strap clamps 56 , and three open end caps 46 . The terms “long” and “short” as they relate to duct segments 42 and 76 , simply means that one segment of predefined length is longer than the other. It should be noted that right-hand elbow 74 and left-hand elbow 84 are unique and distinguishable from each other by virtue of the location of loop 66 and/or the orientation of their zippered joints.
[0021] To create the two-run distribution air duct 30 after defining assortment 83 , one strategically chooses a collection 88 of duct segments from assortment 83 , wherein collection 88 is depicted by the parts encircled by the dashed lines in FIG. 4 . Arrows 90 represents the assembling of collection 88 to create distribution air duct 30 , and arrow 92 represents installing of distribution air duct 30 . The assembling (arrow 90 ) of collection 88 and the installing (arrow 92 ) of air duct 30 do not have to be performed in any particular order. The assembling (arrow 90 ) of collection 88 and the installing (arrow 92 ) of air duct 30 can be done in any sequential order or done generally simultaneously. Arrows 94 and 96 each represent coupling proximal ends 40 and 72 to supply air duct 22 such that supply air 20 from supply air duct 22 can pass in series through, for example, proximal end 40 , toward distal end 48 , out from within distribution air duct 30 , into plenum 18 , up through supply air register 24 and into comfort zone 26 Once distribution air duct 30 is assembled, fasteners 62 being shown taut in FIGS. 1 and 2 illustrate pulling distribution air duct 30 in tension generally between supply air duct 22 and at least one pedestal 14 .
[0022] The just-described modular method of assembling a distribution air duct is best achieved when duct segments 42 , 44 and 76 are of predefined lengths that are substantially whole number multiples of standard width 70 . If, for instance, standard width 70 is two feet, predefined short first duct segment 42 can be two, four, six, eight, . . . 2n feet long. The same is true for predefined long duct segment 76 but with long duct segment 76 being longer than short first duct segment 42 .
[0023] At least some of the aforementioned examples include one or more features and/or benefits including, but not limited to, the following:
[0024] In some examples, an air duct system for a building comprises a collection of pliable tubular segments that are assembled end-to-end to create a distribution air duct that rests upon a subfloor below a plurality of removable floor panels. To help keep the distribution air duct from sliding freely along the subfloor, the air duct is held taut by anchoring a distal downstream end of the duct to at least one and preferable two or three pedestals that help support the floor panels above the subfloor.
[0025] In some examples, a distribution air duct is assembled from a collection of pliable tubular segments chosen from a predefined assortment of segments, wherein the assortment of segments are of discrete lengths based upon the width of a standard floor panel.
[0026] In some examples, a distribution air duct made of one or more pliable tubes rests directly upon a subfloor, thereby eliminating the need for any overhead mounting support, such as an overhead cable or track.
[0027] In some examples, a pliable distribution air duct includes a series of flow direction indicators that are distributed along the length of the duct at a spacing interval that corresponds to the width of a standard floor panel.
[0028] In some examples, an under-floor distribution air duct includes an end cap with an adjustable discharge opening.
[0029] 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. | An under-floor HVAC system for a building includes a pliable air duct lying upon a subfloor. A matrix of pedestals resting upon and extending upward from the subfloor supports a set of floor panels, which thus creates a plenum between the subfloor and the set of floor panels. The air duct extends through the plenum to convey conditioned air from a supply air duct to a series of registers in the floor panels. The registers disperse the conditioned air to a room or area just above the panels. To help keep the air duct from repeatedly extending, retracting, and otherwise sliding freely along the subfloor in response to changes in air duct pressure, the air duct is held taut by anchoring a distal downstream end of the duct to one or more of the floor-supporting pedestals. Various air duct configurations can be assembled from a predefined assortment of duct components. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to new and useful improvements in the design and fabrication of a brace or orthosis, referred to as a cuff or sleeve, which is to be used in the treatment of tennis elbow, either medial or lateral. Tennis elbow includes the painful condition known as epicondylitis and epicondylalgia.
Current methods of applying an external force to the lateral or medial area of the proximal forearm in order to relieve the stress imposed on the tender area of the muscle and/or the ligamentous attachment during activity, is to use a fabric band of approximately 2 inches in width which is circumferentially wrapped around the forearm and closed with a pressure sensitive fastener such as Velcro. Such bands are disclosed in J Bone Joint Surg 53A, page 183-184, 1971 by Froimson.
However such bands, although they often effect some relief, tend to dislocate on the forearm and may be foam rubber lined to prevent this. Such bands, in order to be effective, have to be relatively tight thereby tending to cause venous congestion and edema if worn too tightly or for too long. Therefore it is recommended that they are to be worn only for actual play or high stress producing situations.
Once present, the pain of tennis elbow can and often is present in all activities of daily living involving the use of the affected elbow. In such acute cases, the fabric band is often supplemented by anesthetic and steroid injections but these of course also have unfortunate side effects in certain patients.
SUMMARY OF THE INVENTION
The present invention overcomes disadvantages present with the use of relatively tight fabric band and in many instances avoid the use of injections.
This is because the invention does not apply a constrictive circumferential pressure but does apply a higher pressure to the required area. By having a semi-rigid or rigid plastic cuff shaped to the forearm with a U-shaped indentation, determined by the size and shape of the forearm, the required pressure can be readily applied to the localized area and maximized without constriction. This means that the cuff can be worn at all times if necessary and has not shown any need to be supplemented with injections or anesthetics in most test cases.
The pressure is applied over the proximal area of the forearm extensor muscle group and/or the proximal forearm flexor group without the application of a circumferential and equal pressure to the entire area with its associated complications and one aspect of the invention is to provide a cuff for the relief of tennis elbow and the like comprising a resilient, semi-rigid, split sleeve having a pair of longitudinally extending side edges defining an opening longitudinally of said sleeve, adjustable fastening means to detachably hold said sleeve in the closed position around the forearm of the patient, and an inwardly extending pressure pad formed in the wall of said cuff and situated to apply pressure over the proximal area of the forearm extensor muscle group and/or the proximal forearm flexor group of the patient.
Another aspect of the invention consists of the provision of a method of forming a cuff for the relief of tennis elbow and the like consisting of the steps of; applying a separator around the forearm of the patient, casting the forearm of the patient with a plaster of paris bandage or the like, indenting the bandage before same sets in a substantially triangular form on either side of the radial head and directly over the muscle belly overlying the radius, maintaining the pressure forming the indentations until the plaster of paris bandage has set, removing the cast and the separator by sliding same distally from the forearm, closing one end of the cast, inserting a hollow apertured metal pipe within said cast, filling the cast with a plaster of paris mix or the equivalent, removing the original cast and separator when the filling has set, carrying a U-shape to connect the indentations formed in the filling, to a depth of the indentations and smoothing off all edges to produce a gentle transition from the surface to the base of the U-shaped indentation, engaging a fabric sleeve over the cast and over the pipe, heating a synthetic plastic sheet of suitable dimensions, to a forming temperature, hand draping the hot sheet around the cast and the metal pipe, pinching off the sheet along the anterior and distal areas and around the pipe above the aperture therein, connecting said pipe to a vacuum pump and drawing the plastic sheet tightly to the cast, and then removing the formed hollow plastic sleeve from the cast and splitting same lengthwise along the anterior seam.
Another advantage of the invention is to provide a device of the character herewithin described which is simple in construction, economical in manufacture and otherwise well suited to the purpose for which it is designed.
With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the preferred typical embodiment of the principles of the present invention, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of the finished cuff.
FIG. 2 is an end view thereof along the line 2--2 of FIG. 1.
FIG. 3 is a side elevation of a cuff with a separate pressure pad.
FIG. 4 is an end view of FIG. 3 showing the separate pressure pad attached to the interior wall of the cuff.
FIG. 5 is a side view of the separate pressure pad per se.
FIG. 6 is a plan view of FIG. 5.
FIG. 7 is a fragmentary cross sectional view along the line 7--7 of FIG. 2.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
Proceeding therefore to describe the invention in detail, the cuff is preferably made from a polypropylene sheet of synthetic plastic. However it will be appreciated that any other suitable plastic can be used and that the finished cuff, due to the configuration thereof is relatively rigid so that the term "semi-rigid" is meant to embrace any mouldable material, which when in its finished shape, has a substantially rigid characteristic.
Dealing first with the preferred embodiment illustrated in FIGS. 1 and 2, the method of manufacture of the cuff 10 is as follows:
The patient's forearm (not illustrated) is cast with a plaster of paris bandage after the installation of a separator such as a cotton stockinette separator. The cast extends from four inches proximal to the olecranon, to approximately four inches distal to the olecranon.
During the casting process, the patient must have the forearm musculature relaxed with the elbow being flexed to approximately 90° and the hand pronated.
After the cast application but before same has set, the finger tips of the applicator's hand are pressed in triangular form so as to apply pressure on either side of the radial head and immediately distal to and directly over the muscle belly overlying the radius and this pressure is maintained until the cast has set.
Once set, the stockinette separator is reflected down over the cast and the cast and the separator removed by sliding same distally from the forearm.
Following removal of the cast, one end of the cast is closed and the cast is filled with a plaster of paris mixture or the equivalent. At this stage a hollow metal pipe is inserted into the plaster mix and the mix is allowed to harden.
Once hardened, the original plaster of paris bandage wrap is removed together with the separator and the resulting hardened cast is smoothed overall. A U-shape is carved in the cast connecting the three indentations made in the casting procedure and this carving is to a depth approximately the depth of the indentations. All edges are then smoothed off to provide a gentle transition from the normal arm shape to the base of the U-shaped indentation.
One or more small holes is now drilled in the hollow pipe as near to the cast as possible and a fabric such as a cotton stockinette or nylon stockinette is fitted over the cast snugly ensuring that this covers the drill hole or holes in the pipe.
A sheet of synthetic plastic of suitable dimension is heated and although many types of synthetic plastic can be used, it has been found that a polypropylene sheet of approximately 1/8 of an inch thickness is suitable. When heated to the forming temperature (which varies with the type of plastic sheet being used) the sheet is hand draped over the cast and the plastic is pinched together along the anterior and distal areas. It is also pinched off around the metal pipe above the drill hole with the drill hole then being connected to a vacuum pump (not illustrated) in order to draw the plastic tightly around the cast.
After the plastic sheet has cooled, the vacuum is removed and the plastic cylinder is removed from the cast. The plastic cylinder or cuff is split lengthwise along either side of the anterior seam and is then trimmed so that it is approximately 2 inches long anteriorly and 31/2 inches long posteriorly.
This produces a cuff as illustrated in FIGS. 1 and 2 with the inner end 11 being shaped as shown although this is not critical.
The result is a split sleeve of somewhat resilient material having a pair of longitudinally extending side edges 12 and 12A defining the slit 13 therebetween.
The pressure pad 14 is formed on the interior surface as illustrated due to the fact that the plastic sheet was drawn into configuration upon the cast, by the vacuum pump.
A flexible leather or plastic tongue 15 is secured as by adhesive to the underside of one edge 12A of the slit and underlies the opposite side when in the closed position illustrated in FIG. 2.
Fastening means are provided and preferably take the form of Velcro strap assemblies 16 secured by adhesive or other means to the outside of the sleeve and on either side of the slit 13 and these cooperate together to pull the sleeve around the forearm of the wearer to the required degree of tightness and permitting easy release of the sleeve when necessary.
The configuration of the inner end 11 defines the location of the sleeve upon the forearm of the wearer adjacent the upper end thereof with the U-shaped portion 14 of the pressure pad fitting directly over the proximal extensor or flexor muscle group on the lateral or medial side of the proximal forearm respectively. The central area 14A of the pad is not depressed thus preventing impingement upon the humeral epicondyle when installed. The amount of pressure exerted through the pad is adjustable through the Velcro closure straps 16 located across the anterior opening or slit 13 of the cuff. By forming the cuff precisely to the forearm shape with indentations where pressure is required to relieve muscle pull on the tender area, the pressure is applied more directly and effectively.
FIG. 13 shows a conventional forearm sleeve 17 such as that referred to in Froimson above "Treatment of Tennis Elbow with Forearm Support Band" J Bone Joint Surg 53A, page 183-184, 1971.
The use of this particular cuff can be improved by the application of a pressure pad separate from the cuff as indicated by reference character 18 and illustrated in FIGS. 5 and 6. This may take the form of a cylindrical base portion 19 with the pressure pad 20 formed thereon and this may be adhesively secured to the inner surface 21 of the cuff 17 as shown in FIG. 4. It should be noted that the upper or proximal portion is not intended therefore preventing impingement upon the humeral epicondyle.
Use of the pressure paid in this type of cuff provides added benefit to the device and the inserts 20 could be made of any semi-rigid or rigid material.
The cuff hereinbefore described is preferably made from a polypropylene sheet which is semi-rigid. However the inherent shape of the pad with the compound curves makes that particular area, rigid. And similar materials could be used for the separate pressure pads 18.
Finally, it should be noted that the position of the cuff on the forearm should be such that the cuff should not extend more than two inches distally from the anterior surface of the upper arm otherwise active muscle contraction will create severe discomfort.
Since various modifications can be made in my invention as hereinabove described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | A semi-rigid formed shape or cuff is provided with a substantially U-shaped inwardly extending projection so that when wrapped around the forearm adjacent the elbow crease, controlled application of pressure is provided over the proximal area of the forearm extensor muscle group and/or the proximal forearm flexor group without applying a circumferential and equal pressure to the entire area. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation application of U.S. application Ser. No. 09/512,304, filed Feb. 24, 2000, the disclosure of which is expressly incorporated by reference in its entirety, which is a continuation application of parent U.S. application Ser. No. 09/176,962, filed Oct. 22, 1998, now abandoned, the disclosure of which is expressly incorporated by reference in its entirety. The present application also claims priority under 35 U.S.C. § 119 of German Patent Application No. 197 47 091.2, filed Oct. 24, 1997, German Patent Application No. 198 23 739.1, filed May 27, 1998, German Patent Application No. 198 20 516.3, filed May 8, 1998, and German Application No. 297 23 289.4, filed May 6, 1998, the disclosures of which are expressly incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention concerns devices and processes for the direct or indirect application of a fluid or pasty medium on a fully formed but still wet material web, in particular made of paper or cardboard.
[0004] 2. Discussion of Background Material
[0005] From DE-OS 19 42 348, the disclosure of which is herein incorporated by reference in its entirety, a coating device is known, for example, wherein the coating medium is applied to a material web accommodated between two fourdrinier screens. Furthermore, suction devices which remove moisture from the still wet web are provided. Because of the relatively loose guidance of the web inherent to the fourdrinier screens in a direction perpendicular to the plane of the web, the web has a relatively loose structure in the region of the coating device. Consequently, the coating material applied to the material web tends to penetrate into the interior of the web and does not remain, as is actually desired, in the region of the surface of the material web. Thus, with the coating device known from DE-OS 19 42 348, the coating quality required in modern paper or cardboard production machines cannot be obtained.
[0006] In U.S. Pat. No. 5,152,872, the disclosure of which is herein incorporated by reference in its entirety, a coating device for a wet material web is described in which a fibrous web lies on a wire fabric. On the side of the fibrous web not in contact with the wire fabric—in the belt contact region of a supporting roll—an additional rotating roll transfers the coating medium to the surface of the fibrous web. A pair of rolls touches the generating line of the application roll. The coating medium is metered in the upper wedge of the pair of rolls. By rolling all three of these rolls, the coating medium is distributed on the surface of the application roll. A disadvantage of this design is the rapidly opening gap between the area of the supporting roll, which is looped by the wire fabric and the fibrous pulp web and the applicator roll after coating. This is caused by the radius of curvature of the application roll. Through the adhesion of the coating medium both on the surface of the fibrous web and on the surface of the application roll, there is flaking on the surface. A further disadvantage of this arrangement is the design consisting of three rolls. This makes the design expensive. Due to the three roll arrangement, space requirement is also significant since the coating device must be positioned directly on the path of the web.
[0007] In U.S. Pat. No. 4,793,899, the disclosure of which is herein incorporated by reference in its entirety, the application of a medium occurs in the press section of a paper machine. Here, the fibrous web likewise lies on a conveyor belt; in this case, a press felt. A coating device-described there as a “short-dwell coater”—applies the coating medium to a press roll surface which has no felt. In conjunction with another roll, this press roll forms a press nip. With the rolling of the press roll surface on the fibrous web, the coating medium is transferred to the surface and pressed into the fibrous strip. As the fibrous web leaves the press nip, there is again the above-described disadvantage of flaking with this design. The surface of a fibrous web which has been provided with a coating medium in the manner described above has a rough surface. This can lead to problems during coating. A significant cause of the flaking is found in the coating nip which opens too quickly. This opening speed becomes an increasingly greater problem the faster the paper machines run.
[0008] Moreover, with the coating device known from U.S. Pat. No. 4,793,899, the problems resulting from an excessively loose structure of the material web do not occur so much and do not affect coating quality so strongly; however, the coating medium is so intensely pressed into the material web in the gap formed between the two rolls that the objective expressly stated in U.S. Pat. No. 4,793,899 of keeping the coating material as near the surface of the web as possible is not achieved to the extent desired.
[0009] In addition to this, the coating device known from U.S. Pat. No. 4,793,899 has many guide and press rolls for the material web as well as for the wire fabrics guiding it and thus is expensive.
SUMMARY OF THE INVENTION
[0010] According to a first aspect of the invention, an object of the invention is to provide a coating device for the wet portion of a machine for the production of a material web, in particular, made of paper or cardboard, which enables keeping the coating medium applied to the web near its surface. Moreover, a second aspect of the invention is to avoid flaking in the application of the coating medium. Both of these aspects are made possible through the simple configuration of the coating device and process of the present invention.
[0011] Accordingly, the design of a device for the direct or indirect application of a fluid or pasty medium on a fully formed but still wet material web, in particular of paper or cardboard, is proposed. The device may include a roll, whereby the roll guides the web along a section of the its circumference in a belt contact region, and includes a coating mechanism for the application of the fluid or pasty medium onto the surface of the material web or the surface of the roll, and includes at least one screen or wire fabric belt carrying the material web, whereby the screen or wire fabric belt is positioned between the coating mechanism and the material web and the coating medium comes into contact with the material web in the belt contact region of the roll.
[0012] The mode of operation of the coating device according to the invention is based primarily on the combination of two characteristics, i.e., first, that the coating medium comes into contact with the material web in the belt contact region of the roll, and second, that the coating medium is always applied through a screen or wire fabric onto the material web, regardless of whether the coating medium is applied to the web from its inside out or from its outside in. In this regard, the terms “inside” and “outside” refer to the curved path of the material web in the belt contact region, i.e., “inside” means the side of the material web facing the roll, while “outside” means the side of the material web away from the roll.
[0013] If the coating mechanism is positioned on the outside of the web, the screen or wire fabric belt positioned between the material web and the coating mechanism results in a compacting of the fiber structure of the material web. Thus, the coating medium applied cannot penetrate into the interior of the material web and remains in the region of the outer surface of the material web. If, on the other hand, the coating mechanism and thus the screen or wire fabric belt as well are positioned on the inside of the material web, the material web is compacted as a result of the already existing cohesion of the fibrous structure of the material web, which in turn renders penetration of the coating medium into the interior of the material web difficult. At the same time, the screen or wire fabric belt acts as a pressure buffer for the hydrodynamic pressure which builds upon entry into the belt contact region. Thus, the pressure cannot reach a value which could enable the coating medium to penetrate through the compacted region into the interior of the material web. As a result, no mating roll is provided on the outside of the material web. Consequently, the material web can avoid pressure peaks of the coating medium being applied and thus prevent penetration of the coating medium into the interior of the material web. In addition, the coating device according to the invention has a simple structure since in its basic design, it requires only one contact roll, one screen or wire belt, and one coating mechanism.
[0014] Both in the case of placement of the coating mechanism on the outside of the material web and with its placement on the inside of the material web, it is advantageous to accommodate the material web between two screen or wire fabric belts. In the first case, the second web belt provided on the inside of the material web prevents direct contact of the material web with the roll surface, which prevents damage to the material web resulting from unwanted adhesion to the roll surface, especially at the end of the belt contact region. In the second case, the second screen or wire fabric belt provided on the outside of the material web contributes to compaction of the material web.
[0015] In the case of application from the outside of the material web in, the coating mechanism may, according to one embodiment, be in sliding contact with the screen or wire fabric belt. This embodiment makes it possible to ensure in a simple manner that the coating medium passes through the screen or wire fabric belt into contact with the material web. Here, the coating mechanism may have a coating chamber from which the coating medium comes out under pressure and is brought into contact with the material web through the screen or wire fabric belt. By means of suitable selection of the value of the pressure prevailing in the coating chamber, it is possible for the coating medium to be pressed into the material web to a desired depth.
[0016] According to an alternative embodiment, the coating mechanism may, however, also be positioned at a distance from the screen or wire fabric belt and be designed, for example, as an open-jet spray coating mechanism. Here, the coating medium passes only “gradually” through the screen or wire fabric belt and into contact with the material web.
[0017] In both embodiments, a removal device may be positioned downstream from the coating mechanism to remove excess coating medium from the material web. Especially in conjunction with the previously discussed first embodiment, the removal device may be positioned immediately downstream from the coating mechanism. To ensure the most uniform coating possible, an equalization device may additionally or alternatively be positioned downstream from the coating mechanism to equalize the coating medium and, if desired, to remove excess coating medium from the material web. This equalization device may, for example, include a scraper device or another known doctor knife element.
[0018] Also in the case of coating from the inside of the material web out, i.e., coating with involvement of the surface of the roll, the coating mechanism may, according to a first embodiment, be in sliding contact with the surface of the roll or, according to a second embodiment, be positioned at a distance from the surface of the roll.
[0019] In each of the aforementioned cases, it is advantageous if the roll has at least one suction zone extending over part of the belt contact region. In the case of coating from the outside of the material web in, the moisture present in the still wet material web is sucked to the roll, which makes anchoring of the coating medium in the region of the outer surface of the material web easier. In the case of coating from the inside of the material web out, it is possible to again remove excess coating medium by means of the suction zone.
[0020] As has already been indicated for one embodiment, the coating mechanism may have a coating chamber in which the coating material is under pressure. For example, a pressure of preferably between about 300 Pa and 10 kPa, more preferably between about 500 Pa and 5 kPa may prevail in the coating chamber. The exposure time may preferably be between about 1 and 10 milliseconds. To enable the most economical handling of the coating medium, it is further proposed that the coating mechanism be designed for metered delivery of the coating medium.
[0021] The radius of the roll may preferably be between about 200 mm and 1200 mm. And finally, the solids content of the paper web may preferably be between about 5 wt % and 50 wt %, more preferably between about 8 wt % and 17 wt %, and the solids content of the coating medium may preferably be between about 5 wt % and 50 wt %, more preferably between about 10 wt % and 30 wt %, whereby the coating medium may contain, for example, water, mineral fillers such as kaolin, CaCO 3 , TiO 2 , and the like, binders such as starch, latex, or the like, retention agents, and optical brighteners.
[0022] The invention also includes not using a roll as a coating element, but rather creating a slowly opening coating gap in another manner, wherein the transfer of the coating medium onto the material web occurs by means of a transfer belt slowly approaching the fibrous web and likewise slowly moving away from the fibrous web after coating. In particular, depending upon the speed of the material web, the angles formed by the material web and the transfer belt before and after the nip are preferably about 2° to 45°, more preferably about 10° to 15°.
[0023] This embodiment has several advantages: for one, the coating medium comes into contact with the material web before the press nip, which lengthens the exposure period of the coating medium on the material web. For another, the speed of separation of the transfer belt from the material downstream from the press nip is significantly reduced compared to roll coating. To prevent the entrained air boundary layer from presenting a disruptive barrier between the coating medium and the material web in this narrow coating wedge on the felts and the web, the transfer belt should be air permeable. Air permeability is also preferred when the transfer nip opens, so that the material web can separate from the transfer belt.
[0024] The coating medium may be applied to the transfer belt by means of an application roll. The coating medium in turn may be applied to the circumference of the application roll by means of a doctor knife device. The coating device according to the invention consists of a transfer belt and a coating mechanism. The coating mechanism may be implemented as an application roll. It is, however, also conceivable that a coating mechanism with an associated pair of rolls (three-roll system) be used to wet the transfer belt.
[0025] An additional advantage of the coating device described is that one part of the coating device—the transfer belt—is already present in most cases and thus there is no additional space requirement. The other part of the coating device—the coating mechanism—may be positioned at a greater distance from the web, where adequate space exists.
[0026] The coating device according to the invention can be installed at various locations in the region of the wet section and/or the press section of a paper machine.
[0027] One advantageous implementation location is at the beginning of the press section. The fibrous web arrives, drained by the screen section, with the help of a felt from the screen section to the first press nip of the press section. A second felt, which has been provided with the coating medium by the coating mechanism, runs together with the first felt into the first press nip in a wedge shape. Due to the still high water content of the fibrous web, penetration of the coating medium into the fibrous web is typical for this embodiment.
[0028] It may also be advantageous that additional draining of the fibrous web not occur until in the press section in the first press nip. Because of the changed properties of the fibrous web after the first press, application of coating medium with the device according to the invention in this region results in different fibrous web properties.
[0029] It is further advantageous that a fibrous web be provided with coating medium not only once on one side, but rather in two or even more coating stages. Here, the coating medium can be adjusted in consistency and/or composition from one application site to another.
[0030] According to the invention, the transfer belt does not have to be a press felt. A screen or wire fabric which has adequate absorption capacity for the coating medium and a fine enough mesh not to leave a mesh pattern on the fibrous web is also suitable as a transfer belt.
[0031] It may also be advantageous that the coating device according to the invention be implemented in the belt contact region of the suction roll of the screen section. For one thing, the fibrous web still has a very loose fiber bond there such that the coating medium can penetrate particularly intensively into the fiber bond. For another, the suction zone of the suction roll supports this effect.
[0032] In accordance with one aspect, the present invention is directed to a device for at least one of direct and indirect application of a coating medium on a fully formed but still wet material web, the coating medium being at least one of a fluid and pasty medium. The coating device includes a roll having a circumference and capable of guiding a material web along a part of the circumference in a belt contact region, a coating mechanism capable of applying a coating medium on at least one of a surface of the material web and the circumference of the roll, such that the coating medium comes into contact with the material web in the belt contact region of the roll, and at least one screen belt that contacts the roll in the belt contact region, the at least one screen being capable of supporting the material web.
[0033] In accordance with another aspect, the material web comprises a material selected from the group consisting of paper and cardboard.
[0034] In accordance with another aspect, the at least one screen belt is capable of being positioned between the coating mechanism and the material web.
[0035] In accordance with yet another aspect, the coating mechanism is capable of being positioned on a side of the material web opposite from the roll.
[0036] In accordance with still another aspect, the coating mechanism is in sliding contact with the at least one screen belt.
[0037] In accordance with another aspect, the coating mechanism is positioned at a distance from the at least one screen belt.
[0038] In accordance with still another aspect, the coating device further includes a removal device positioned downstream from the coating mechanism to remove excess coating medium from the material web. The removal device may be positioned immediately downstream from the coating mechanism. The removal device may comprise a suction device positioned on the paper side.
[0039] In accordance with another aspect, the coating device further includes an equalization device positioned downstream from the coating mechanism to equalize the coating medium. The equalization device may be capable of removing excess coating medium from the material web. The equalization device may include a scraper device.
[0040] In accordance with yet another aspect, the coating mechanism is capable of applying the coating medium on a surface of the roll. The coating mechanism may be in sliding contact with the surface of the roll. The coating mechanism may be positioned at a distance from the surface of the roll.
[0041] In accordance with another aspect, the roll has a suction zone over at least part of the belt contact region.
[0042] In accordance with another aspect, the coating mechanism has a coating chamber capable of holding coating medium under pressure. The coating chamber may be capable of holding the coating medium under a pressure of between about 300 Pa and 10 kPa, preferably between about 500 Pa and 5 kPa. The device may be capable of providing an exposure time of the material web to the coating medium at the coating chamber of between about 1 and 10 milliseconds.
[0043] In accordance with another aspect, the coating mechanism is capable of metered delivery of the coating medium.
[0044] In accordance with another aspect, the coating mechanism comprises an open-jet spray coating mechanism.
[0045] In accordance with still another aspect, the at least one screen belt comprises two screen belts which are capable of holding the material web therebetween.
[0046] In accordance with another aspect, the roll has a radius between about 200 mm and 1200 mm.
[0047] In accordance with yet another aspect, the material web has a solids content of between about 5 wt % and 50 wt %, preferably between about 8 wt % and 17 wt %.
[0048] In accordance with another aspect, the coating medium has a solids content of between about 5 wt % and 50 wt %, preferably between about 10 wt % and 30 wt %.
[0049] In accordance with one aspect, the present invention is directed to a paper machine with a device for application of a coating medium on a traveling material web of one of paper and cardboard with a wet section, a press section, and a drying section. The paper machine includes at least one transport device for a material web in a wet section, the at least one transport device comprising an endless, air-permeable carrier belt, and at least one coating mechanism capable of applying a coating medium, the at least one coating mechanism capable of being positioned on a side of the material web which is opposite to a side of the material web which contacts the at least one transport device, the at least one coating mechanism comprising an endless, air-permeable transfer belt, the endless, air-permeable transfer belt being capable of applying the coating material to the material web.
[0050] In accordance with another aspect, the at least one coating mechanism comprises a roll-coating mechanism capable of applying the coating medium on the endless, air-permeable transfer belt. The roll-coating mechanism may have a single roll or may comprise a plurality of rolls.
[0051] In accordance with still another aspect, the transfer belt may comprise a press felt.
[0052] In accordance with yet another aspect, the transfer belt may comprise a screen.
[0053] In accordance with one aspect, the present invention is directed to a process for application of a coating medium on a traveling material web comprising one of paper and cardboard, the coating medium comprising at least one of a pasty medium and a liquid medium. The process includes forming a material web in a wet section of a machine for one of paper and cardboard, and guiding the material web which is still wet with a traveling, endless, carrier belt during application of a coating medium, the application of the coating medium comprising transferring the coating medium from at least one transfer belt onto the still wet material web, the coating medium being transferred from a surface of the at least one transfer belt moving in a direction of travel of the material web, the at least one transfer belt being a traveling, endless, air-permeable transfer belt.
[0054] In accordance with another aspect, the carrier belt is air-permeable.
[0055] In accordance with another aspect, the material web lies on a screen of a screen section during application of the coating medium.
[0056] In accordance with another aspect, the material web lies on a felt of a press section during application of the coating medium.
[0057] In accordance with yet another aspect, the coating medium is applied to only one side of the material web.
[0058] In accordance with another aspect, the coating medium is applied to two sides of the material web.
[0059] In accordance with still another aspect, the coating medium is applied to the material web prior to at least one of a first press and a second press in a press section.
[0060] In accordance with another aspect, the coating medium is applied to the material web after a first press in a press section.
[0061] In accordance with yet another aspect, the coating medium is applied to the material web in a carrier belt contact region with a screen suctioning roll in a screen section.
[0062] In accordance with another aspect, the coating medium is applied to at least one side of the material web inside a wet section.
[0063] In accordance with another aspect, the coating medium is applied to the material web through both felts of a dual—felt press of a press section.
[0064] In accordance with another aspect, the coating medium comprises different coating media having different compositions which are applied at different locations.
[0065] It is understood that the aforementioned characteristics and those subsequently to be explained are applicable not only in the respective combination indicated, but also in other combinations or in isolation without leaving the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0066] The present invention is further described in the detailed description which follows, in reference to the noted plurality of non-limiting drawings, and wherein:
[0067] [0067]FIGS. 1 and 2 illustrate embodiments in which the coating medium is applied to the material web from its outside in;
[0068] [0068]FIGS. 3-5 illustrate embodiments in which the coating medium is applied to the material web from the its inside out;
[0069] [0069]FIG. 6 illustrates an enlarged depiction to explain the coating principle of the embodiment according to FIG. 1;
[0070] [0070]FIG. 7 illustrates a partial view of a paper machine at the transition between the wet section and the press section;
[0071] [0071]FIG. 8 illustrates a partial view of a paper machine from the end of the wet section to the beginning of the drying section;
[0072] [0072]FIG. 9 illustrates a partial view of a paper machine from the end of the wet section including the press section; and
[0073] [0073]FIG. 10 illustrates a partial view of a paper machine at the transition from the wet section to the press section with positioning of the coating device according to the invention in the region of the suction roll.
DETAILED DESCRIPTION OF THE INVENTION
[0074] The particulars shown herein are by way of example and for purposes of illustrative discussion of the various embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. All percent measurements in this application, unless otherwise stated, are measured by weight based upon 100% of a given sample weight. Thus, for example, 30% represents 30 weight parts out of every 100 weight parts of the sample.
[0075] Unless otherwise stated, a reference to a compound or component, includes the compound or component by itself, as well as in combination with other compounds or components, such as mixtures of compounds.
[0076] In FIG. 1, a first embodiment of the coating device according to the invention is collectively referenced by the number 10 . The coating device is positioned in the wet section of a machine for the production of a material web 12 , in particular made of paper or cardboard. As one may see in FIG. 1, the still wet material web 12 is accommodated between two screen or wire fabric belts 14 and 16 , which ensure the cohesion of the fiber structure of the material web 12 . In addition to the screen or wire fabric belts 14 and 16 , the material web 12 is guided around a roll 18 and in a belt contact region U lies against the surface 18 a of the roll 18 . The roll 18 is rotationally driven around its axis A in the direction of the arrow R such that the material web 12 engages with the surface 18 a of the roll 18 essentially slip-free upon its movement in the operating direction L.
[0077] On the outside of the material web 12 , i.e., on the side of the material web 12 facing away from the roll 18 , a coating mechanism 20 is positioned, the configuration and function of which are to be explained in detail below with reference to FIG. 6.
[0078] [0078]FIG. 6 again depicts the material web 12 accommodated by two screen or wire fabric belts 14 and 16 as well as the coating mechanism 20 . In the enlarged schematic cross-section depiction of FIG. 6, the coating mechanism 20 comprises an upstream boundary wall 20 a and downstream boundary wall 20 b , which are in sliding contact with the screen or wire fabric belt 14 . The two boundary walls 20 a and 20 b as well as side boundary walls (not depicted) surround a coating chamber 22 open on the screen or wire fabric belt 14 , to which coating medium 24 is added from the outside (arrow M). The distance d between the coating chamber walls 20 a and 20 b in the direction of travel L of the material web 12 is selected to yield a dwell time of the material web 12 in the region of the coating mechanism 20 of roughly about 1 to 10 milliseconds with the usual travel speeds of the material web 12 . In addition, the coating medium 24 in the coating chamber 22 is under a pressure p of preferably between about 300 Pa and 10 kPa, more preferably between about 500 Pa and 5 kPa. The pressure is selected such that, on the one hand, the coating medium 24 is pressed through the screen or wire fabric belt 14 into a region 12 a near the surface of the material web 12 during the dwell time of the material web 12 in the region of the coating mechanism 20 in sufficient quantity and is anchored there in its fiber structure, but, on the other hand, does not penetrate into the interior 12 b of the material web 12 .
[0079] As depicted in FIG. 1, the direction of travel L immediately connected with the coating mechanism 20 is provided with a suction device 26 by means of which the coating medium which has not adequately bonded with the material web 12 can again be removed from it. The quantity S of the coating medium sucked out may, after filtering out any fiber material sucked out with it, again be supplied to the coating mechanism 20 , whereby dilution of the coating medium by any moisture also removed can be compensated for, if desired, by addition of coating medium with appropriately high solids content. The boundary walls of the suction device 26 are preferably in sliding contact with the screen or wire fabric belt 14 , whereby the necessary sealing effect against the surroundings can be ensured.
[0080] The roll 18 may be equipped at least over a portion of belt contact region U with a suction zone 28 . Such rolls with suction zones are known such that it is unnecessary to describe their structure in detail at this point. The suction zone 28 serves primarily to remove moisture from the material web 12 , naturally causing the moisture present in the material web 12 to be sucked away from the surface area 12 a and through the screen or wire fabric belt 16 . Since the surface region 12 a thus becomes drier, the coating medium 24 can more readily penetrate into it and become anchored there in the fibrous structure of the material web 12 .
[0081] [0081]FIG. 2 depicts another embodiment of a coating device according to the invention, which corresponds essentially to that according to FIG. 1. Analogous parts are, consequently, identified by the same reference characters, but increased by the number 100 . The coating device 110 according to FIG. 2 is described below to the extent that it differs from the coating device 10 according to FIG. 1, whose description is otherwise hereby referred to.
[0082] The coating device 110 according to FIG. 2 differs from that according to FIG. 1 in that on the side of the material web 112 accommodated between screen or wire fabric belts 114 and 116 turned away from the roll 118 , an open-jet spray coating mechanism 120 is positioned, which is placed at a distance from the material web 112 or the screen or wire fabric belt 114 and applies the coating medium 124 premetered onto the material web 112 or the screen or wire fabric belt 114 . An equalization device 130 , which in the embodiment according to FIG. 2 comprises a scraper device 132 , but which may be designed in principle as any other known doctor knife or equalization device, is positioned downstream from the coating mechanism 120 . The equalization device 130 smooths the coating medium 124 applied and removes any excess coating medium 124 applied, to return it via an intermediate cleaning step to the feed flow M to the spray coating mechanism 120 . Corresponding to the embodiment of FIG. 1, the roll 118 also has a suction zone 128 .
[0083] [0083]FIG. 3 depicts another embodiment of a coating device according to the invention, which corresponds essentially to that of FIG. 1. Analogous parts are, consequently, identified in FIG. 3 by the same reference characters as in FIG. 1, but increased by the number 200 . The coating device 210 according to FIG. 3 is described below to the extent that it differs from the coating device 10 according to FIG. 1, whose description is otherwise hereby referred to.
[0084] The coating device 210 according to FIG. 3 differs from the embodiment according to FIG. 1 in particular in that the coating mechanism 220 is positioned on the side of the material web 212 facing the roll 218 . The coating mechanism 220 is in principle designed exactly as has been described for the coating mechanism 20 with reference to FIG. 6. However, the boundary walls of the coating mechanism 220 are in sliding contact with the surface 218 a of the roll 218 such that a layer of coating medium 224 is applied on surface 218 a . This coating layer is moved forward to the belt contact region U as a result of the rotation of the roll 218 around the axis A in the direction of the arrow R, with the coating medium 224 being brought into contact with the material web 212 . In particular, upon entry into the belt contact region U, the coating medium 224 is pressed into the material web 212 as a result of the hydrodynamic pressure developing between the roll surface 218 a and the material web 212 . The intermediate positioning of the screen or wire fabric belt 216 ensures that the pressure does not assume such high values that the coating medium 224 would be pressed into the interior 212 b of the material web 212 , but rather remains on the surface 212 a of the material web 212 . Furthermore, in the embodiment according to FIG. 3, no mating roll is provided on the side of the material web 212 facing away from the roll 218 , such that the development of hydrodynamic pressure is prevented and penetration of the coating medium 224 into the interior of the material web 212 is prevented.
[0085] In the embodiment according to FIG. 3, the suction zone 228 serves primarily to suction off excess coating medium 224 applied to the material web 212 and to return it after intermediate cleaning to the feed flow M to the coating mechanism 220 . In FIG. 3, a cleaning device 234 is also provided to clean the surface 218 a of the roll 218 . The cleaning device 234 comprises a delivery device 236 to apply a cleaning medium 238 , e.g., water, steam, anti-bonding agents, chemical barriers, and tensides, to the roll surface 218 a as well as a scraper knife 240 to remove contaminants from the surface 218 a.
[0086] [0086]FIG. 4 depicts another embodiment of a coating device according to the invention, which corresponds essentially to that according to FIG. 3. Analogous parts are, consequently, identified by the same reference characters as in FIG. 3, but increased by the number 100 , i.e., by the number 300 compared to FIG. 1. The coating device 310 according to FIG. 4 is described below to the extent that it differs from the coating device 210 according to FIG. 3, whose description is otherwise hereby referred to.
[0087] The coating device 310 according to FIG. 4 differs from the coating device 210 according to FIG. 3 to the extent that instead of the coating mechanism 220 , an open-jet spray coating mechanism 320 is provided, which meters the coating medium 324 onto the surface 318 a of the roll 318 . As a result of the rotation around the axis A in the direction of arrow R, the coating medium is forwarded to the material web 312 accommodated between the screen or wire fabric belts 314 and 316 . Otherwise, the embodiment according to FIG. 4 corresponds to the embodiment according to FIG. 3 including the provision of a suction zone 328 and a cleaning device 334 .
[0088] [0088]FIG. 5 depicts another embodiment of a coating device according to the invention, which corresponds essentially to that according to FIG. 3. Analogous parts are, consequently, provided in FIG. 5 with the same reference characters as in FIG. 3, but increased by the number 200 , i.e., by the number 400 compared to FIG. 1. The coating device 410 according to FIG. 5 is described below to the extent that it differs from the coating device 210 according to FIG. 3, whose description is otherwise hereby referred to.
[0089] The coating device 410 according to FIG. 5 differs from the coating device 210 according to FIG. 3 only in that the material web 412 is supported by a screen or wire fabric belt 416 only on the side facing the application roll 418 . Furthermore, the roll 418 has in the embodiment according to FIG. 5 no zone corresponding to the suction zone 228 . The roll 418 may thus, for example, be a simple guide roll for the material web 412 . With regard to the application of the coating medium 424 by means of the coating mechanism 420 on the roll surface 418 a and the forwarding of the coating medium 424 to the material web 412 , the embodiment according to FIG. 5 corresponds to that according to FIG. 3. And finally, a cleaning device 434 is provided.
[0090] As can be seen from the Figures, the coating mechanism may be positioned in one of: (1) a position below and adjacent to the roll to apply the coating medium to the roll, and (2) a position adjacent to the belt contact region to apply the coating medium directly onto the material web in the belt contact region.
[0091] Although only embodiments for one-sided coating of a fluid or pasty medium have been described above, it is understood that the coating device according to the invention may also be designed for two-sided coating. Any combination of the “outside” coating device according to FIGS. 1 and 2 with any of the “inside” coating devices according to FIGS. 3 and 4 is possible.
[0092] It should however be added that the solids content of the material web 12 in the region of the coating mechanism 20 may preferably be between about 5 wt % and 50 wt %, more preferably between about 8 wt % and 17 wt %, while the solids content of the coating medium 24 may preferably be between about 5 wt % and 50 wt %, more preferably between about 5 wt % and 30 wt %, even more preferably between about 10 wt % and 30 wt %. Here, the solids content of the material web is understood to mean the percent by mass of solid matter, for example, fibers, fillers, and the like, based on the total mass of the material web consisting of fibers, fillers, water, and the like. Moreover, the solids content of the coating medium means the percent by mass of solid matter, for example, mineral pigments, binders, auxiliary materials, and the like, based on the total mass of the coating medium containing additional fluid components, primarily water. The coating medium may, for example, be composed of water, mineral fillers, such as kaolin, CaCO 3 , TiO 2 , and the like, binders such as starch, latex, or the like, retention agents, e.g., available under the trade names “Nalco 74503”, “Percol” available from Ciba-Allied Colloids, “Polymin” available from BASF, “BMA” and “BMB” both available from Eka Chemicals, “Compozil System”, and optical brighteners, e.g., available under the trade names “Aphranil”, “Leukophor”, “Tinopal”, and “Blanchophor”.
[0093] It should also be added that the increase in mass due to the application of the fluid or coating medium per side amounts preferably to between about 1 g/m 2 and 10 g/m 2 .
[0094] The coating device according to the invention can, for example, be used in a dual-web former and, because of its design, can replace a film press, which increases the efficiency of the machine for the production of the material web.
[0095] Reference should again be made to the fact that the material web is compacted in the belt contact region such that the coating medium is uniformly distributed on its surface instead of soaking it completely, i.e., penetrating into the interior of the material web. Overall, it is thus possible to achieve with the coating device according to the invention a more uniform smooth coating with less coating weight.
[0096] In FIG. 7, the material web (fibrous material web) P moves in the indicated direction of the arrow 501 . The material web P runs—lying on the screen or wire fabric 502 —over suction roll 503 into the press section. In the deflection process on the suction roll 503 , the material web P is held by suction zone 504 on screen or wire fabric 502 . A first felt 505 of the press section picks up the material web P with the help of pickup roll 506 and its suction zone 507 from the screen or wire fabric 502 . A second felt 508 of the press section is wetted with coating medium by means of application roll 509 and an associated doctor knife device 510 (together they form coating mechanism 516 ). After deflection of the felt 508 on felt guide roll 51 1 , it runs along with the felt 505 into a press nip. The press nip is formed by press roll 512 and a flexible press roll 513 with a press shoe. The intake gap 514 is exaggerated in the drawing in its opening angle which, depending upon the speed of the material web, is preferably about 2° to 45°, more preferably about 10° to 15°. Thus, the distance from the roll 511 to the felt 505 can be only a few millimeters. In the press nip between the rolls 512 and 513 , the coating medium is transferred to the material web P under pressure and with a significantly longer exposure time than in a roll application system. After the material web P and the felts 505 and 508 have left the press nip, the felt 5
[0097] runs back to the coating mechanism 516 . The felt 505 and the material web P lying on it continue to run together through a press nip between rolls 512 and 515 . After this gap the material web P partially runs around the roll 515 and is either guided to another press nip or to a drying section.
[0098] Another embodiment of a coating mechanism according to the invention is depicted in FIG. 8. Here in FIG. 8, first upper felt 605 is wetted with a coating medium by means of a coating mechanism 617 on its surface which later comes into contact with material web P. Screen or wire fabric 602 , the felt 605 , and the material web P travel together on suction roll 603 . On a long stretch between the suction roll 603 and suction take-up roll 606 , the coating medium reacts on the material web P. After passing through the first press nip of rolls 612 , 613 , the web comes into contact with suction take-up roll 622 . This releases the material web P from the felt 605 and transfers it onto felt 619 . The felt 619 has been wetted with a coating medium by a coating mechanism 618 . On the felt 619 , the material web P now makes contact with the coating medium on its other surface. Another coating mechanism 621 wets felt 620 . Thus, as it travels through the subsequent press nip, the material web P is coated again on its upper side. When the material web P has left this press nip, it is guided—diverted along with the felt 619 by suction felt guide roll 623 —to dry suction roll 624 . Then, the material web P is dried in drying section 625 .
[0099] [0099]FIG. 9 depicts another embodiment of a coating device according to the invention. Similar to FIG. 8, in FIG. 9 material web P passes through two successive press roll pairs 712 , 713 and 731 , 732 . Both an angle a before the nip and an angle β after a nip are, depending upon the speed of the material web, preferably about 2° to 45°, more preferably about 10° to 15°. A coating mechanism 716 wets both felt 708 and the material web P on its bottom side. After the transfer of the material web P onto felt 719 by means of suction take-up roll 722 , the material web P is guided to the press nip of the rolls 731 , 732 . A felt 720 traveling in the material web P has been wetted with coating medium by coating mechanism 726 . In this press nip, the material web P is coated on its upper side. After leaving the press nip, the material web P—as already described for FIG. 8—is guided to a drying section (not shown). Although in FIG. 9 different press nip forms from those in FIG. 8 are seen, here again there is a sharp intake and opening angle which facilitates a long exposure time to the coating medium and the careful opening of the coating gap.
[0100] A special application case of another embodiment of a coating device according to the invention is depicted in FIG. 10. Here, by means of an additional screen loop or felt loop 827 and additional rolls 828 and 829 in the deflection region of suction roll 803 or its suction zone 804 , a coating medium is applied to the top side of the material web P, which lies on screen or wire fabric 802 . The loop 827 is wetted by coating mechanism 830 . This device can be useful if one wishes to use the properties of the material web P at this point of the suction roll 803 and the mode of action of the suction zone 804 . Because of the loose fiber bond, it is possible to apply a coating medium particularly well on and in the material web P. However, because the material web P is still very loose here, application of a medium which supports web stability may be useful.
[0101] While the invention has been described in connection with certain preferred embodiments so that aspects thereof may be more fully understood and appreciated, it is not intended to limit the invention to these particular embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the scope of the invention as defined by the appended claims. | Process for application of a coating medium on a traveling material web that is one of paper and cardboard, the coating medium including at least one of a pasty medium and a liquid medium, wherein the process includes forming a material web in a wet section of a machine for one of paper and cardboard and guiding the material web which is still wet with a traveling, endless, carrier belt during application of a coating medium. The application of the coating medium includes transferring the coating medium from a roll-coating mechanism to at least one transfer belt onto the still wet material web. The coating medium is transferred from a surface of the at least one transfer belt moving in a direction of travel of the material web. The at least one transfer belt is a traveling, endless, air-permeable transfer belt which is guided by rolls. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to the diagnostic imaging arts. It finds particular application in non-axial pediatric diagnosis using computed-tomography (CT) and will be described with particular reference thereto. However, it is to be appreciated that it is also applicable to non-pediatric applications and imaging scenarios, and is not limited to the aforementioned applications.
In a slice mode, CT scanners procure image data by taking a plurality of contiguous slices of a subject and reconstructing them into a volumetric representation. Typically this is done by taking axial or near axial slices, that is, taking slices that are substantially perpendicular to a longitudinal (head to toe) axis of a subject.
In a spiral mode, volume images are collected by moving the x-ray beam through a spiral trajectory around the longitudinal axis. Commonly, the source rotates continuously while the patient support moves longitudinally back and forth.
A limitation of present devices is that patients are inserted head-first or feet-first. Often, only a few slices along a major axis of an organ or tissue of interest are necessary. Organs and anatomical structures that have large longitudinal profiles such as the spine or lungs require many axial slices to generate a single longitudinal slice.
The generation of numerous axial slices is time consuming, plus penetrating radiation can be harmful to living cells. Not only is the tissue in the longitudinal slice of interest irradiated, all tissue in the axial planes around the longitudinal slice of interest are irradiated from many directions. In particular, cells that divide rapidly are more susceptible to radiation than slower dividing cells. In general, children are more susceptible to radiation damage than adults simply because they are growing and their cells are dividing faster. When using penetrating radiation to image children, it is desired to keep the dosage as low as possible and limit the irradiation, as much as possible, to the specific slices to be displayed. In addition, children tend to be more restless than adults. Thus, motion artifacts become problematic, especially in temporally longer scans. A more efficient method of imaging portions of the body with large axial profiles which lessens exposure and scan time is desirable.
Another problem with imaging children is that an attendant frequently remains close at hand to assist in keeping the child still, as well as to comfort the child. Although the attendant does not enter the imaging region, she still receives a nominal amount of scattered radiation. Over many scans of many different children, the received dosages of the attendant becomes problematic.
The present invention provides a new and improved method and apparatus that overcomes the above referenced problems and others.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a computed tomography apparatus is given. Radiation from a source is detected by an array of detectors and reconstructed into an image representation of a patient within the apparatus. A patient support that provides support for the patient in a seated position within the apparatus is located on a patient couch.
In accordance with another aspect of the present invention, a method of diagnostic imageing is given. A subject is positioned in a seated position within an imaging region of a CT scanner. A source emits radiation into the region and is detected after it traverses the region. The detected radiation is converted into corresponding electronic data and reconstructed into an image representation.
In accordance with another aspect of the present invention, a patient seat for use in conjunction with a third or fourth generation CT scanner is given. A back support that supports an upper torso of a patient in an upright position rests upon a base portion that supports the weight of a patient. The base portion and back support fit inside a bore of the CT scanner.
One of the advantages of the present invention resides in shorter scan times.
Another advantage resides in less received dose by the patient.
Another advantage resides in improved image quality.
Yet another advantage resides in the ability to procure non-axial image slices.
Still further benefits and advantages of the present invention will become apparent to those skilled in the art upon a reading and understanding of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.
FIG. 1 is a diagrammatic illustration of a CT scanner an patient support in accordance with the present invention;
FIG. 2 is a perspective view of the patient support.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a mobile patient couch 10 is disposed adjacent an aperture 12 of a computed tomography scanner. In the preferred embodiment, the aperture 12 is approximately 85 cm, larger than those of typical present day CT scanners. Optionally, smaller apertures such as 75 cm, are practical. Preferably, the CT scanner is a third or fourth generation machine. An x-ray source, disposed on a perimeter of the aperture 12 emits a fan or cone of x-rays into an imaging region. In a third generation machine, an array of detectors is disposed opposite to and rotates with the x-ray source to detect the radiation. The array moves in synchronization with the source, such that the center of the array is 180° around the perimeter from the source. In a fourth generation machine, the perimeter is lined with stationary detectors, and the source rotates about the perimeter.
In the preferred embodiment, a patient support and positioner 14 is supported on the patient couch 10 . The support 14 fits into the aperture 12 of a CT scanner gantry 16 . A large aperture 12 yields several advantages. One is that the patient feels less cramped, helping the patient relax. Another advantage is that it allows patients to sit upright or other non-prone positions during scans, as opposed to only lying flat.
The patient support and positioner 14 provides stability and secure stationary support for a child or small adult in a seated or other selected, non-axial imaging position on the patient couch 10 . Taller patients are supportable in partially reclined positions. With the patient in this position, coronal, and sagittal slices of the patient are collected.
In particular applications, organs and other bodily structures are imaged that are longitudinally elongated but have relatively small transverse profiles. Some examples are the lungs, spinal column, and kidneys. While it would take many slices to image the entire spinal column with axial slices, it takes but a few slices with a coronal orientation. By positioning the patient seated with the spine vertical, the coronal plane through the spine can be aligned with the plane of rotation of the x-ray beam. Coronal imaging captures the spine with only a few slices. Therefore, less of the body receives useless radiation. Moreover, the eyes and other radiation sensitive organs are positioned outside of the x-ray beam during data acquisition.
With reference to FIG. 2 and continuing reference to FIG. 1, the back support member 14 of the preferred embodiment is flanked by two side restraint panels 18 . The restraint panels have matching angle adjustment grooves 20 for an attendant or operator to select an angle of the back support member 14 with respect to a vertical axis. Thus, varying entry orientations can be achieved by manipulating the angle of the support member. To do this, the operator loosens two securing knobs 22 one on each side of the support member 14 . The operator grasps the support member 14 by a handle 24 or by the knobs 22 and lifts it from the angle adjustment grooves 20 . Pivot pins 26 received in elongated slots allow the support member 14 to be lifted sufficiently for the knobs 22 to clear the grooves 20 . The back support is tilted within the range of the adjustment grooves 20 . The operator lifts the back support 14 , selects one of the grooves 20 corresponding to a selected tilt, and lowers the support member 14 until the knobs are received in the selected groove. The knobs are tightened to help prevent the support member from shifting during an imaging process. In addition, the angle of the irradiated slice is varied by tilting the gantry 16 , as ghosted in FIG. 1 .
The side restraint panels 18 also serve as rigid restraints against lateral movement during imaging. As children tend to become restless when uncomfortable or nervous, the restraint panels 18 remind and arrest the child to remain still. Additional restraints, such as straps 30 with Velcro™ hook an loop connectors, a harness, or the like extend from the support member. The support member 14 is equipped with multiple strap holes 32 for securing the restraint straps 30 . A wide range of patient heights are accommodated. The operator chooses among the plurality of strap holes 32 to select ones that best fit the patient height or desired position in the apparatus. Additional supports and restraints such as foam wedges or cushions are contemplated.
In addition to improving image quality by reducing motion artifacts, the restraints also allow for less attendant interaction. While an attendant may remain in the room, the attendant will not remain as close to the CT scanner to attend to the child when the machine is in operation. The attendant may also wear more mobility constricting radiation shielding garments.
The base board 28 defines a seat where the patient sits during imaging. The base board 28 is temporarily attachable to the patient couch. The base board 28 has a convex shape that matches the concave shape of the patient couch 10 . The base board 28 is attached to the patient couch with radiolucent clamps 34 , straps, or other configurations that are designed to engage the couch
When the base board 28 is positioned and secured to the couch 10 for coronal imaging, the assembly is oriented such that the legs of the patient extend along the patient couch. During a slice imaging sequence, the back support and gantry are angled and the couch is moved longitudinally to align a slice of interest with the plane of the radiation beam. For spiral, volume imaging, the couch 10 translates into and out of the aperture 12 while the x-ray source is rotating.
Alternately, the base board 28 can be shaped such that it fits 90° rotated from the orientation previously described. This orientation facilitates sagittal imaging of the subject.
In the preferred embodiment, the back support member 14 , the side restraint panels 18 , the base board 22 , and the restraint straps 30 are all made of carbon fiber reinforced polymers, low density wood, or other radiolucent material which does not contribute negatively to the imaging process.
In the preferred embodiment, a removable telescopic head rest 40 is used for certain imaging procedures. The head rest is adjustable to varying heights. A height adjustment pin 42 is used to select the height of the headrest 40 depending on the size of the patient, desired position, etc. Varying heights are selected by removing the adjustment pin 42 sliding the upper section up or down on the lower section and reinserting the pin in a different hole. The headrest 40 is also removable entirely if it is not required. The upper section is shaped to receive the patient's forehead when it is desired to keep the head of the patient out of the scan region. The eyes, for example, are especially sensitive to the x-rays. Sometimes procedures are performed in which uncomfortable or contorted positions are held for the duration of the scan. The head rest 40 helps make such positions more bearable by providing a soft support for the head of the patient.
With further reference to FIG. 1, prior to the patient being inserted into the machine, the operator submits selected parameters 50 into the machine. Parameters such as slice thickness, number of slices, gantry tilt angle, scanning mode, and the like are selected. After the patient is disposed on the patient couch 10 in the selected position, the operator initiates the selected procedure. The source rotates around the gantry 16 emitting x-rays which are detected by the detectors opposite the source. The views of the x-ray detectors are stored in a pre-reconstruction data memory or buffer 52 . The view data is reconstructed in a reconstruction processor 54 . In an exemplary reconstruction, the views are convolved 54 a and backprojected 54 b to form a slice image. For a volume image, a plurality of slices are then reconstructed and stacked in a volumetric image memory 56 . Spiral and other reconstruction techniques are also contemplated. The operator then selects desired portions of the volume for viewing. An image processor 58 formats slice images, 3D renderings, and the like for display on a human readable display 60 such as a video monitor, liquid crystal display, active matrix monitor, or the like.
In an alternate embodiment, a cine mode is available. This mode is applicable to dynamic temporal scanning techniques. The x-ray source rotates about one slice or a small number of slices. Images are continuously reconstructed and viewed as new ones become available. In this manner, real time, or semi-real time images of the subject are acquired. Some possible applications are bolus tracking, digestive/respiratory tract studies, joint movement, etc.
The invention has been described with reference to the preferred embodiment. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | In pediatric diagnostic imaging, a patient is seated upright on a patient couch ( 1 0) of a large bore CT scanner. The patient is seated such that coronal or near coronal slices are taken as opposed to axial slices as in typical CT scanners. The patient is stationarily supported in this position during imaging. A back support member ( 14 ) supports the back and side restraint panels ( 18 ) limit lateral movement. Restraint straps ( 30 ) further secure selected parts of the patient. The angle of the support member ( 14 ) is adjusted to conform with a selected imaging region by angle adjustment grooves ( 20 ). A removable telescopic head rest ( 40 ) positions the patient leaning forward. The back support ( 14 ), the side restraint panels ( 18 ), and the headrest ( 40 ) are all constructed of radiolucent materials. | 0 |
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