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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] A combination structure of a cinerary urn comprises an inner jug, an outer jug and locking keys. The outer jug can be separated. The inner jug can be put into the separated outer jug and the separated outer jug can be closed by means of several locking keys so as to achieve the object of easily getting access to and encapsulating the bone ash.
[0003] 2. Description of the Related Art
[0004] Cinerary/bone ash urns are well-known in prior art, and typically have a lid, a jug body and an inner jug. The main purposes of the structure of the known cinerary urns are to keep the cinerary urns from being humidified, fire, separating, falling on the ground due to accidents such as earthquake.
[0005] For example, Taiwan utility model patent No. 304331, entitled “improved structure of cinerary urn,” discloses a cinerary urn has an inner jug and an outer jug is made of glass fiber material so as to prevent the jug body from breaking. However, there is not any effort to keep the bone ash from being humidified or to easily get access to the bone ash.
[0006] Further, Taiwan utility model patent No. 284370, entitled “combination structure of cinerary urn,” discloses a cinerary urn has an inner jug. A flange on a lid of the inner jug is used to be snapped with protrusions and snapping supporters on the inner wall of the inner jug so as to seal the inner jug and to prevent the inner jug from being separated. However, it is laborious to close or open the inner jug, and it is not easy to get access to the bone ash.
[0007] Still further, Taiwan utility model patent No. 279335, entitled “improved structure of cinerary urn,” discloses a cinerary urn has an outer jug, an outer lid, an inner jug and an inner lid. The inner lid has a plurality of uneven bend flanges to serve as shock absorbers. The inner lip is laterally rotated to be firmly attached to the inner jug by mean of slope so as to seal the inner jug and to prevent the inner jug from being separated. However, it is laborious to close or open the inner jug, and it is not easy to get access to the bone ash.
SUMMARY OF THE INVENTION
[0008] With the trend of few-children and aged society, more and more people treat pets as one member of their family member. The raisers of those pets have a deep relationship with their pets. Particularly, a lot of people have pets, but the lifetime of the pets is most likely shorter than that of their raisers. The situation of the aged population structure is getting severe more and more. For sustainable development of the earth for the future of our progeny, the existing requirement of the environment protection is getting severe more and more. Therefore, cremation is the first consideration for the dead body of humans or pets.
[0009] Founding on piety and love, people usually keep the bone ash of the forerunners or the pets, and elaborate on completely protecting and preserving the bone ash of the forerunners and the pets. In order to keep the treasured affect and relationship between the pets and the raisers in the long term, there is a present need to provide a device for safely and closely keeping the bone ash which is meaningful to those raisers and those progeny.
[0010] The first object of the present invention is to provide a cinerary urn comprising a bone ash jug left portion, a bone ash jug right portion, and a bone ash inner jug. The bone ash jug left portion comprises a bone ash jug room and magnet rods. The bone ash jug right portion comprises a bone ash jug room and magnet bars. The bone ash inner jug comprises an inner jug left portion and an inner jug right portion which are engaged with each other by threads. The magnet rods of the bone ash jug left portion and the magnet bars of the bone ash jug right portion are attracted by each other so as to easily close the cinerary urn
[0011] The second object of the present invention is to provide the cinerary urn in which one of the magnet rod and the magnet bar is replaced by one of an iron plate and a steel plate.
[0012] The third object of the present invention is to provide the cinerary urn comprising a bone ash jug left portion, a bone ash jug right portion, and a bone ash inner jug. The bone ash jug left portion comprises a bone ash jug room and magnet rods. The bone ash jug right portion comprises a bone ash jug room and locking components each having a same polarity magnet bar and a different polarity magnet bar. The bone ash inner jug comprises an inner jug left portion and an inner jug right portion which are engaged with each other by threads. The different polarity magnet bar of the locking component of the bone ash jug right portion and the magnet rods of the bone ash jug left portion are attracted by each other so as to easily close the cinerary urn.
[0013] The fourth object of the present invention is to provide the cinerary urn in which the same polarity magnet bar and the different polarity magnet bar of the locking component are capable of moving up and down.
[0014] The fifth object of the present invention is to provide the cinerary urn in which the same polarity magnet bar and the different polarity magnet bar of the locking component are capable of rotation.
[0015] The sixth object of the present invention is to provide the cinerary urn in which the same polarity magnet bar of the locking component is made of non-ferromagnetic materials.
[0016] Due to the drawbacks in prior art and the need in the modern society, the present invention provides a cinerary urn for sealing the bone ash as well as for easily getting access to the bone ash. The invention may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic exploded perspective view showing a cinerary urn according to an embodiment of the present invention.
[0018] FIG. 2 is a schematic partially-sectional perspective view showing a cinerary urn according to an embodiment of the present invention.
[0019] FIG. 2-1 is another schematic partially-sectional perspective view showing a cinerary urn according to an embodiment of the present invention.
[0020] FIG. 3 is a schematic exploded perspective view showing a locking component according to an embodiment of the present invention in detail.
[0021] FIG. 4 is a schematic exploded perspective view showing another locking component according to another embodiment of the present invention in detail.
DETAILED DESCRIPTION OF THE INVENTION
Embodiment 1
[0022] Referring to FIG. 1 , a cinerary/bone ash urn according to the present invention comprises a bone ash inner jug, a bone ash jug and locking structure. The bone ash inner jug 30 is made of plastic material, such PE, PP, ABS, PS, PC, fireproof plastic material, and so on, and comprises a bone ash inner jug right portion 34 and a bone ash inner jug left portion 33 . The bone ash inner jug right portion 34 and the bone ash inner jug left portion 33 both are capsule-like in shape, and comprise bone ash cavity 35 for receiving bone ash 32 . The bone ash inner jug right portion 34 is longer than the bone ash inner jug left portion 33 and has an external thread 31 so as to be engaged with an internal thread 35 of the bone ash inner jug left portion 33 and then to encapsulate the bone ash 32 . The bone ash inner jug right portion 34 and the bone ash inner jug left portion 33 can be engaged with each other by snapping.
[0023] Referring to FIG. 1 and FIG. 2 , the bone ash jug 1 according to the present invention comprises a bone ash jug left portion 10 and a bone ash jug right portion 20 . The bone ash jug left portion 10 and the bone ash jug right portion 20 respectively have a bone ash jug left room 11 and a bone ash jug right room 21 for receiving the bone ash inner jug 30 which encapsulates the bone ash 35 . In addition, the rear end 16 of the bone ash jug left portion 10 have a pair of right magnet rods 12 with exposed cathodes and a pair of left magnet rods 13 with exposed cathodes, which are located on the both sides of the rear end 16 of the bone ash jug left portion 10 . The front end 26 of the bone ash jug left portion 20 have a pair of left magnet bars 22 with exposed anodes and a pair of right magnet bars 23 with exposed anodes, which are located on the both sides of the front end 26 of the bone ash jug right portion 20 corresponding to the right and left magnet rods 12 and 13 .
[0024] Then, the bone ash inner jug 30 which is in capsulate-like shape and contains the bone ash 32 is put into the bone ash jug right room 21 of the bone ash jug right portion 20 . Moreover, the right and left magnet rods 12 and 13 with the exposed cathodes which is located near the four corners of the rear end 16 of the bone ash jug left portion 10 will be moved or approached to the left and right magnet bars 22 and 23 with the exposed anodes which is located near the four corners of the front end 26 of the bone ash jug left portion 20 . The magnetic forces between the left and right magnet bars 22 and 23 with the exposed anodes and the right and left magnet rods 12 and 13 with the exposed cathodes will force the bone ash jug left portion 10 and the bone ash jug left portion 20 to be firmly attached to each other.
[0025] When the cinerary urn 1 needs to be opened, the bone ash jug left portion 10 and the bone ash jug right portion 20 need to be pivoted in relation to each other on the rear combination line 90 in horizontal direction so as to separate the front combination line 91 of the bone ash jug 1 . Then, the angle between the bone ash jug left portion 10 and the bone ash jug right portion 20 on the axis of the rear combination line 90 is increased, and the bone ash jug left portion 10 and the bone ash jug right portion 20 will be separated such that the inner jug 30 can be put into or took out from the bone ash jug 1 .
[0026] Further, the bone ash jug 1 also can be opened on the axis of the front combination line 91 , and the similar method can be used to open the bone ash jug 1 on the axis of an upper combination line 92 or a lower combination line 93 . In addition, ferromagnetic materials can be used in place of the magnet bars 22 and 23 with the exposed anodes or the magnet rods 12 and 13 with the exposed cathodes, and only one side is kept the same and the other is replaced with ferromagnetic materials, such as iron plates or steel plates.
Embodiment 2
[0027] Referring to FIG. 2-1 and FIG. 3 , two locking component 50 are installed on the both sides of the bone ash jug right portion 20 corresponding to the right magnet rods 12 and the left magnet rods 13 on the four corners of the rear end 16 of the bone ash jug left portion 10 . The locking component 50 comprises a pressing bottom 51 , a rotator 52 , locking control blocks 53 , a component supporter 54 , and a compression spring 55 . The rotator 52 comprises a receiving hole 522 and a rotating rod 524 . The locking control block 53 comprises a controller guiding rod 534 , an open and close controller 530 , a plate compression spring 535 and internal grooves 533 .
[0028] The compression spring 55 is horizontally put on the rotating rod 524 of the rotator 52 , and the rotating rod 524 of the rotator 52 is put into the component supporter 54 . Further, a pressing bottom shaft 510 of the pressing bottom 51 is installed into the receiving 522 of the rotator 52 , and then the pair of the locking control blocks 53 is located above and below the rotator 52 .
[0029] When the bone ash jug 1 need to be opened, the pressing bottom 51 will be pressed and a protrusion 511 located on the front of the pressing bottom 51 will contact a slant 523 of the rotator 52 such that a torque generated by the horizontal force between the pressing bottom 51 and the slant 523 rotates the rotator 52 . A tongue 520 of the rotator 52 is rotated following the rotation of the rotator 52 so as to push the controller guiding rod 534 out of a positioning trough 525 of the tongue 520 . Then, the controller guiding rod 534 slides alone by a curved slant 526 until the controller guiding rod 534 is moved to a positioning trough 521 of the tongue 520 . At the same time, the compression spring 55 located between the rotator 52 and the component supporter 54 horizontally pushes the rotator 52 and the pressing bottom 51 back to the original location after the rotator 52 is rotated by 90 degrees. When the controller guiding rod 534 is in the positioning trough 521 of the tongue 520 , the open and close controllers 530 of the locking control blocks 53 will be move up and down due to the spring force of the plate compression spring 535 and due to the gap between the tongue 520 and the positioning trough 521 , and then will be located in a lower position. A positive magnet plate 531 and a negative magnet plate 532 of the open and close controllers 530 is moved downward in the internal grooves 533 such that the negative magnet plate 532 of the open and close controllers 530 is positioned corresponding to the right and left magnet rods 12 and 13 with the exposed cathodes around the four corners of the rear end 16 of the bone ash jug left portion 10 .
[0030] In this case, the magnetic repulsive force between the same polarities separates the bone ash jug left portion 10 and the bone ash jug right portion 20 so as to open the bone ash jug 1 .
[0031] When the bone ash jug 1 need to be closed, the controller guiding rod 534 in the positioning trough 525 of the tongue 520 is pushed outward and slides alone by the curved slant 526 of the tongue 520 until the controller guiding rod 534 is moved to the lower position in the positioning trough 521 of the tongue 520 . The pressing bottom 51 is pressed again, the above mentioned movement will be repeated and the controller guiding rod 534 in the positioning trough 521 of the tongue 520 is pushed upward and slides alone by the curved slant 526 of the tongue 520 until the controller guiding rod 534 is moved to the higher position in the positioning trough 525 of the tongue 520 . The positive magnet plate 531 and the negative magnet plate 532 of the open and close controllers 530 is moved upward in the internal grooves 533 such that the positive magnet plate 532 of the open and close controllers 530 is positioned corresponding to the right and left magnet rods 12 and 13 with the exposed cathodes around the four corners of the rear end 16 of the bone ash jug left portion 10 .
[0032] In this case, the magnetic attractive force between the different polarities combines the bone ash jug left portion 10 and the bone ash jug right portion 20 together so as to close the bone ash jug 1 . Further, the negative magnet plate 532 of the open and close controllers 530 can be replaced by the non-ferromagnetic materials, such as plastic materials, non-ferrous metal materials, and so on.
Embodiment 3
[0033] Referring to FIG. 2-1 and FIG. 4 , two locking component 60 according to another embodiment of the present invention are installed on both sides of the bone ash jug right portion 20 corresponding to the right and left magnet rods 12 and 13 with the exposed cathodes around the four corners of the rear end 16 of the bone ash jug left portion 10 . The locking component 60 comprises a pressing key 64 , a rotating switch shaft 62 , a close controller paddle 61 , and a curved transfer supporter 63 . The pressing key 64 comprises a key 640 and a rear compression spring 645 . The curved transfer supporter 63 comprises an arc switch supporter 630 and a back compression spring 632 .
[0034] The close controller paddle 61 is installed on a front core shaft 620 of the rotating switch shaft 62 , and a stop key 626 is inserted into the front core shaft 620 and a key way 610 of the close controller paddle 61 so as to keep the close controller paddle 61 from rotating in relation to the switch shaft 62 . Then, the curved transfer supporter 63 is attached to the rotating switch shaft 62 from the rear side of the rotating switch shaft 62 , and the pressing key 64 is laterally installed to the locking component assembly 600 .
[0035] When the bone ash jug 1 need to be opened, the pressing key 64 will be pressed frontward such that two fin protrusions 641 on the upper and the lower sides of the shaft body 644 of the pressing key 64 is moved against a fin 621 of the rotating switch shaft 62 to push forward the rotating switch shaft 62 . An arc protrusion 622 installed on the rear portion of the rotating switch shaft 62 has an arc slant 623 which is against the curved transfer supporter 63 , rises alone by a curved slant 634 of the curved transfer supporter 63 through a high point 631 of the curved transfer supporter 63 , and falls to a low point 635 . As thus, the curved transfer supporter 63 is rotated by 180 degrees and a positive magnet bar 611 (also known as a different polarity magnet bar) is rotated to the downside and a negative magnet bar 612 (also known as a same polarity magnet bar) is rotated to the upside, the position of which is corresponding to the right and left magnet rods 12 and 13 with the exposed cathodes around the four corners of the rear end 16 of the bone ash jug left portion 10 , so as to generate the magnetic repulsive force between the same polarities and to open the bone ash jug 1 .
[0036] When the pressing key 64 is released, the spring force of the rear compression spring 645 will push the pressing key 64 back to the original position through a guiding slope 642 of the fin protrusions 641
[0037] When the bone ash jug 1 need to be closed, only the pressing key 64 need to be pressed again and the curved transfer supporter 63 rotates as the way mentioned above such that the positive magnet bar 611 is rotated to the upside and the negative magnet bar 612 is rotated to the downside, the position of which is corresponding to the right and left magnet rods 12 and 13 with the exposed cathodes around the four corners of the rear end 16 of the bone ash jug left portion 10 . The magnetic attractive force between the different polarities is generated and the bone ash jug 1 is closed. The negative magnet bar 612 on the close controller paddle 61 can be replaced by the non-ferromagnetic materials, such as plastic materials, non-ferrous metal materials, and so on.
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A combination structure of a cinerary urn comprises an inner jug, an outer jug and locking keys. The outer jug can be separated. The inner jug can be put into the separated outer jug and the separated outer jug can be closed by means of several locking keys so as to achieve the object of easily getting access to and encapsulating the bone ash.
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BACKGROUND OF THE INVENTION
This invention relates to improvements in rotary tobacco treatment cylinders and is particularly concerned with the geometry of internal paddles or flights in such cylinders, which are provided to optimize the treatment of tobacco in the cylinder.
In the pre-treatment of tobacco before manufacture within cigarettes, it is necessary to subject it to drying, mixing processes, or conditioning with the addition of fluid; and these are often carried out in a rotary treatment cylinder which is arranged to rotate about a generally horizontal or slightly inclined axis. Such treatment cylinders are provided with internal paddles to provide transport of the tobacco product through the cylinder. In the cases of drying and conditioning it is necessary to maintain the transport time through the cylinder; not only should the average time of the mass of tobacco be maintained but also the time for each individual particle.
Furthermore, the tumbling of tobacco within such a cylinder tends to cause degradation. This degradation is very dependent upon moisture content and increases rapidly with reduction of moisture content below normal cigarette moisture contents of some 13-14%. Thus variation in moisture content in the output from a drying cylinder can be a major contribution to tobacco degradation.
There are several factors which can affect the transport time such as paddle loading, cylinder inclination, drop height, that is to say the height within the cylinder from which the material drops from a paddle to fall back to the wall of the cylinder during the tumbling operation, and the number of drops. However a factor which has been generally overlooked is the consistency which is determined by the release point and which is particularly important in the case of drying.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an arrangement in which the release position can be precisely predetermined.
A further object of the invention is to provide a consistent rapid release of the tobacco from the paddle i.e. a sharply defined release point, instead of a slow sliding or tumbling off action.
According to the present invention there is provided a rotary tobacco treatment cylinder comprising an elongate hollow cylinder arranged to rotate about its longitudinal axis and disposed substantially horizontally or inclined by a small angle to the horizontal, a series of elongate paddles extending longitudinally within the cylinder and extending generally towards the longitudinal axis from the inside surface of the cylinder, the paddles serving to convey material to be treated from a lower position within the conveyor and around one side to an upper discharge position, the paddles having a proximal portion extending at a first angle being a right angle to the tangent at the root of the proximal portion or an angle less than a right angle at the loaded side of the paddle, and a distal portion which is inclined to the proximal portion at a second angle, which is less than the first angle, to form a tip, a major part of the tip considered longitudinally being of a length (viewed axially of the cylinder) less than half the length of the proximal portion, characterised in that the cross-sectional area of the material to be treated which is loaded onto a paddle, is less than or equal to the area enclosed by the paddle and a line from the paddle tip to the cylinder wall at the angle of repose of the material to be treated, when the paddle in question is at a predetermined release point around the cylinder.
Further according to the invention the angle of the tip of each paddle to the tangent at the root of the proximal portion is such that at a predetermined release point the tip is at the angle of sliding, the surface of the tobacco charge just contained by the tip being at the angle of repose.
Preferably the proximal portion of the paddle is radially disposed.
Another aspect of the invention is that the tip is inclined relative to the proximal portion at an angle substantially greater than the difference between the angle of repose and the angle of sliding, the paddles being suitable for light loading.
Yet another aspect of the invention is that the tip is inclined relative to the proximal portion at an angle substantially equal to the difference between the angle of repose and the angle of sliding, the angle of repose being parallel to the proximal portion of the paddle.
Further according to the invention the tip is inclined relative to the proximal portion at an angle substantially less than the difference between the angle of repose and the angle of sliding, the paddles being suitable for heavy loading.
Preferably, for a drying application, the arrangement of such paddles is such that as the cylinder rotates, material carried by the paddles leaves the paddles at substantially the same release point around the arc of the cylinder disposed substantially at the highest part of the cylinder.
For the application of a fluid treatment, the arrangement of paddles is such that as the cylinder rotates the tobacco carried by the paddles leaves the paddles from a chosen initial early release point at one end gradually changing to a late release point at the other end of the cylinder such as to cause the material to be treated to fall from the paddles in a curtain extending obliquely of the cylinder axis, at an acute angle to the axis of the cylinder.
Preferably the arrangement of the paddles is such as to cause the formation of a second such curtain following the first curtain axially along the cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example with references to the accompanying drawings in which:
FIG. 1 is a schematic side elevation of a typical treatment cylinder to which the invention relates,
FIG. 2 is a schematic view of a typical cross section of the cylinder of FIG. 1,
FIG. 3 is a similar cross section to FIG. 2 of an embodiment of the invention,
FIG. 4 shows a schematic cross-section of a typical known cylinder used for fluid application,
FIG. 5 shows a plan view of the cylinder of FIG. 4,
FIG. 6A is a cross-sectional view taken in the direction of line 6A--6A of FIG. 1;
FIG. 6B is a cross-sectional view taken in the direction of line 6B--6B of FIG. 1;
FIG. 6C is a cross-sectional view taken in the direction of line 6C--6C of FIG. 1;
FIG. 7 shows a plan view of the cylinder of FIG. 6,
FIG. 8 shows a plan view of a further arrangement of the cylinder of FIGS. 6 and 7,
FIG. 9 shows a plan view of a yet further arrangement of the cylinder of FIGS. 6 and 7, and
FIG. 10 is a schematic diagram showing a series of radial paddles representing a range of angles of the tip relative to the proximal portion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show a typical treatment cylinder 10 arranged on supports 11 to rotate about an axis 12 which is inclined at an angle a to the horizontal. The cylinder is, as shown in FIG. 2, fitted with a series of elongate internal paddles 13 extending longitudinally within the cylinder, which paddles assist, in conventional manner, in the tumbling action of the tobacco passing from an inlet at the upper end of the cylinder to an outlet at the lower end of the cylinder.
In FIG. 1 there is shown schematically a height L from which any particular paddle may drop tobacco carried from the bottom of the cylinder, back to the bottom of the cylinder thus, taking account of the angle α, advancing the material an approximate distance B along the cylinder. Thus it can be seen that for a consistent transit time of tobacco through the cylinder it is desirable that each increment B is identical and controlled and thus the release height L should also be controlled.
In FIG. 2 tobacco material is shown schematically on the wall of the cylinder between the paddles 13 as indicated at 14. It can be seen that as the cylinder rotates the surface of the material 14 presented to the interior of the cylinder will assume the angle of repose (R) for the material within each pocket formed between the paddles. In this specification the angle of repose (R) is interpreted to refer to the angle of the edge surface that the material will freely assume in a heap, relative to a horizontal plane. Eventually as a particular parcel of tobacco material progresses with the cylinder on the paddle 13, there will come a time when the paddle 13 is at the angle of sliding (S) relative to the horizontal which in this specification is intended to refer to that angle of the paddle to the horizontal at which the tobacco material will slide off it irrespective of the angle of repose. Thus it can be seen that with the conventional radial paddles as shown in FIG. 2 the tobacco material will effect a sliding movement across the edge of the paddle tip as the paddle surface exceeds the angle of repose (R) and will eventually slide off the paddle as the angle of the paddle (P) exceeds the angle of sliding (S). With conventional cylinders with radial paddles, this takes place over an arc indicated at 15 which is often indeterminate and invariably at a low elevation relative to the axis of the cylinder.
For tobacco products the angle of repose (R) is typically between 60 and 90 degrees and is for one exemplary type of cut tobacco material approximately 85 degrees. For such cut tobacco products the angle of sliding (S) is typically between 30 and 60 degrees to the horizontal on a typical metal surface paddle.
It can be seen that with the prior arrangement of FIG. 2, firstly the tobacco material has contact with only a small area of the wall of the cylinder and of the paddles and thus has little opportunity to take up heat from those items when they are heated in a drying process. Secondly the material has a short path to fall back to the bottom since it barely reaches a point above the horizontal before it slides or falls off the paddles, thus in the drying process can have little opportunity to give up its moisture to the interior of the cylinder. Thirdly because the material leaves the paddles over an arc, the residence time and the fall or drop distance are variable. This again results in variation in the treatment of any particular portion of the tobacco.
Again in some instances, particularly when the pockets between the paddles are over filled, because the tobacco falls back to the bottom in the extreme right hand corner of the cylinder as viewed in FIG. 2, in some circumstances it can become formed into a roll-like filament in an area indicated generally at 16 in FIG. 2. This again results in a poor treatment of the material in that area, which may be likened to the situation with no paddles, often referred to as kilning.
FIG. 3 shows an embodiment of the invention which alleviates these problems. Each paddle 13 comprises a proximal portion 20 extending at a first angle being a right angle to the tangent at the root of the proximal portion or an angle less than a right angle at the loaded side of the paddle, and a distal portion 22, which is inclined to the proximal portion at a second angle, which is less than the first angle, to form a tip. The tip is of a length, viewed axially of the cylinder, not exceeding half the length of the proximal portion. Preferably, the tip is one third the length of the portion 20.
In this embodiment the paddle tips 22 are inclined to a radius passing through the tip at a paddle angle indicated generally at β. The angle β is chosen to be approximately equal to the difference between the angle of repose (R) for the material being treated and the sliding angle (S) for that material as defined above.
With this arrangement which is particularly suitable for drying and conditioning as discussed below, it can be seen that the material is lifted by the paddles to be released only at a much higher point round the arc of the cylinder as indicated at 21 and that no material will leave the paddles until this point is reached. To ensure this mode of operation care must be taken to ensure that the pockets between the paddles are not over filled. The degree of filling of any pocket which is suitable for a material drying operation is when the cross-sectional area of the material to be dried which is loaded into a space between a paddle and a paddle preceding it in rotation of the cylinder, is less than or equal to the area enclosed by the paddle and a line from the paddle tip to the cylinder wall at the angle of repose of the material, when that paddle is at the chosen release point around the cylinder. This means that more of the paddles are brought into use at any one moment so that the area of the cylinder and paddles in contact with the material is increased to the maximum and the drop through the interior space of the cylinder is also increased to the maximum resulting in the optimum treatment. Further the point at which the material leaves the paddles is accurately controlled and is therefore consistent, resulting in consistent treatment. Until the point 21 is reached neither the angle of repose or the sliding angle is exceeded.
When the slide angle is reached with a normal radial paddle (see FIG. 2), the remaining product which has not previously tumbled off, starts to slide down the paddle with increasing acceleration as the paddle increasingly exceeds the slide angle. It can take 20° to 30° of cylinder rotation before all the product has released.
In the present invention the tobacco is held by the tip until the tip exceeds the slide angle. The main portion of the paddle is then well beyond the slide angle. The product has only to slide down a relatively short tip to be released and under the influence of the accumulated acceleration of the main portion; a sort of avalanche. Hence the tip is generally not more than one third the length of the main portion of the paddle.
The construction results in maximized utilization of the heated surface and minimized variation in the release point.
The arrangement shown in FIG. 3 may be adapted for use in a situation where mixing is required. In such an arrangement the tips are less inclined to the radius through their tip as those in FIG. 3 but in operation the pockets between them are filled to a greater extent. The degree of filling of any pocket which is suitable for a material mixing operation is when the cross-sectional area of the material loaded onto a paddle, is greater than the area enclosed by the paddle and a line from the paddle tip to the cylinder wall at the angle of repose of the material to be treated, when the paddle in question is at the chosen initial release point around the cylinder, and less than the cross-sectional area enclosed between two adjacent paddles and the wall of the cylinder. This results in the material being released from the paddles over a considerable arc indicated at 31 extending from approximately the low point of release of the prior art arrangement of FIG. 2 to the high optimized release point of the embodiments of the invention shown in FIG. 3.
With this arrangement, as the paddles progress through the arc 31, the material thereon gradually exceeds its angle of repose so that material falls off the face of the pocket of material until such time as it reached the top of the arc when the angle of sliding is reached and the remainder falls off.
Mixing is enhanced if particles of material to be treated are dropped at different points across the width and length of the cylinder. This is achieved by the spread over an arc of the release of material from the paddles; and the different drop heights across the width will result in slightly different instantaneous rates of travel down the length of the cylinder which further enhances the mixing.
In some cases, the release arc can be extended over center to a position as indicated at 32 in FIG. 3, particularly when the paddles have more inclined tips, and when the material to be mixed is of a more tacky nature to bind to itself and to the paddle.
When such a cylinder is used to treat or condition tobacco, with a liquid treatment for instance, major changes in the properties can occur. Such conditioning or treatment can embrace the application of water and/or other fluids and/or heat and steam, and thus applies to other materials than tobacco.
For example in the direct cylinder conditioning method used in the tobacco industry, the tobacco at the input could be at 10% moisture and at 25% moisture at output from the cylinder. At input the tobacco may be in compressed blocks, while at output individual pieces of tobacco can be separate and distinct leaves or lamina.
Typical properties for a tobacco type are tabulated:
______________________________________ INPUT OUTPUT______________________________________Moisture 10-14 18-28%Density 400 kg/m.sup.3 40 kg/m.sup.3Repose Angle 90 + 40-60 (1) degreesTerminal Velocity -- 1-3 meters/secondAngle of Sliding -- 20-35 (2) degreesAngle of Repose -- 60-80 (3) degrees______________________________________ Note: (1) As a result of free fall from 300 mm (2) On smooth metal plate (3) Material on material within one body
The magnitude of these changes is very significant, and in the past has required that two cylinders should be used in series. In that case the second cylinder should be larger than the first and designed for a greater volumetric throughput. (See Patent GB 8408413--W. H. Dickinson).
In a drying system discussed above, it is desirable to achieve a uniform presentation of product to the heated surfaces and to the airstream. Within a cylinder for the conditioning function, heat may be supplied via a recirculating airflow, and fluids may be applied by vaporization/micro-droplets into the airflow or by direct spray onto the product. Direct fluid spray is more commonly used than micro-droplets.
The design criteria for fluid application becomes uniform presentation of the material to the airstream and to the applied fluid droplets. The criteria of controllability and low degradation also remain important.
A typical fluid application arrangement with conventional paddles is shown in FIGS. 4 and 5 which show a schematic cross-section and plan view of a cylinder respectively. Product in region 42 is presented to the spray 43 and has a good opportunity to receive fluid. Lower layers of product have less opportunity with region 41 having little or no opportunity to receive fluid from the sprays.
The product is concentrated over a low arc of the cylinder 10 leaving the remainder of the circular cross section free of material and open to the airflow. Consequently pick-up by the product of heat and moisture from the air is limited and occurs predominantly at the product surface 42 and most of the airflow bypasses the product.
This conventional method is degradation prone and ineffective in achieving the process objectiveness.
In a further embodiment of the invention the internal cylinder geometry is adapted to improve the product presentation to both sprays and airstream, to remove the risk of degradation and to allow for changes in the material density/volume occurring during conditioning. This requires different geometry at different positions along the length of the cylinder in that the angle and length of the tip varies along the axial length of the cylinder. Ideally the variation is gradual or stepped.
A cylinder of this further embodiment is described with reference to FIGS. 6A, 6B, 6C and 7, which show schematic cross-sections and a plan view of a cylinder respectively.
FIGS. 6A, 6B and 6C show diagrammatically the release and collection points at three axially displaced positions 51, 52 and 53, respectively along the length of the cylinder. Only a single paddle is shown at each illustrated cross-section for simplicity. Position 51 is near the start of the conditioning treatment zone from a spray 54 in the cylinder 10 while position 53 is near the end of the treatment zone. The treatment zone may be preceded by a material receiving or entry zone and followed by a material discharge zone.
In order to achieve the progression of the release point over the top arc of the cylinder, with the distance along the cylinder, each paddle is shaped at position 51 with a relatively long radial portion 51a and short tip 51b inclined to the portion 51a, at position 52 with a shorter radial portion 52a and longer inclined tip 52b, and at position 53 with the radial portion 53a just larger than the inclined tip 53b. The general criteria for the geometry of the paddles is similar to that discussed above for a drying operation with the exception that the release point is at a different position over the top arc of the cylinder progressively along the length of the cylinder. The criteria for filling the pockets between the paddles is again similar to that discussed above for a drying operation.
The progressive change in the release points creates the situation in FIGS. 6A, 6B, 6C and 7 and establish a falling curtain of material indicated at 55 disposed diagonally across the length of the cylinder. This increases the face area presented, on to which fluid can be sprayed and creates a situation where each material particle has a near equal opportunity to contact fluid droplets. The falling curtain also substantially covers the circular cross-section of the cylinder so that airflow along the cylinder has to pass through the curtain, so that each particle of product in the curtain has a near equal opportunity to receive heat and micro-droplets from the airstream.
The general procedure for relating product release and collection points to product properties has been discussed. In this further embodiment, the product specific volume increases during the process, and this must also be taken into account in determining the physical size and hence carrying capacity of the paddles along the length of the cylinder. Paddles at position 51 are designed to have a lower release point and to carry less volume of product than are paddles at position 53.
To increase the presentation of the product to the airstream further it may be desirable to create the situation shown in the schematic plan of FIG. 8 and generate a second curtain 56 following on from the curtain 55 discussed above, and a further spray (not shown) may be provided for that second curtain.
There are, however, instances where substantial changes in product volume do not occur during fluid application. Such an instance is the application of top flavours to tobacco in which case an alternative curtain shade as shown in the schematic plat of FIG. 9, may be applicable. This would enable a good fluid application over the portion C to B of the curtain 57, but at the same time the geometry between points A and B of the curtain could be arranged to give a mixing function.
FIG. 10 is a schematic diagram showing a succession of radial paddles representing a range from a paddle having a greater tip angle β 1 for lighter loads to a lesser angle β 2 for heavy loads, the slide angle and repose angles being assumed typically 45° and 75° respectively. For light loads, the tip is inclined relative to the proximal portion preferably at an angle of from about 30° up to 50°. For heavy loads, the tip angle is preferably between about 10° and 30°. Therefore, the angle formed between the tip and proximal portion is preferably between about 10° and 50°, depending on the relative weight of the load. The preferred example (P) shows the angle of repose on the equal to the angle of the main portion of the paddle.
Generally, for light paddle loads, the tip of the blades is inclined relative to the proximal portion at an angle substantially equal to the difference between the angle of repose (R) and the angle of sliding (S) and should be an angle greater than 30° up to 50°. In other instances, the tip should be inclined relative to the approximate portion at an angle substantially equal to the difference between the angle of repose (R) and the angle of sliding (S) or approximately 30°. With heavier loads, the tip should be inclined relative to the proximal portion at an angle substantially less than the difference between the angle of repose (R) and the angle of sliding (S) and should be at an angle less than 30° to approximately 10°.
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A rotary tobacco treatment cylinder includes an elongate hollow cylinder arranged to rotate about its longitudinal axis and disposed substantially horizontally or inclined by a small angle to the horizontal, a series of elongate paddles extending longitudinally within the cylinder and extending generally towards the longitudinal axis from the inside surface of the cylinder, the paddles serving to convey material to be treated from a lower position within the conveyor and around one side to an upper discharge position. Each of the paddies has a proximal portion extending at a first angle being a right angle to the tangent at the root of the proximal portion or an angle less than a right angle at the loaded side of the paddle, and a distal portion which is inclined to the proximal portion at a second angle, which is less than the first angle, to form a tip. A major part of the tip considered longitudinally is of a length (viewed axially of the cylinder) less than half the length of the proximal portion. The angle of the tip of each paddle to the tangent at the root of the proximal portion is such that at a predetermined release point the tip is at the angle of sliding, the surface of the tobacco charge just contained by the top being at the angle of repose.
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BACKGROUND OF THE INVENTION
This invention relates to a railroad car trash compactor and method for using same.
The handling and transporting of waste materials has involved in some situations the use of rail transport. It is therefore desirable to have a convenient railroad car which is capable of carrying waste materials and which is capable of facilitating the ease of handling of those waste materials both before and after transporting.
Therefore, a primary object of the present invention is the provision of an improved railroad car trash compactor and method for using same.
A further object of the present invention is the provision of a trash compactor which includes a blade therein which is movable from one end of the car to the other to compress the trash material and ultimately to expel the trash material from the car.
A further object of the present invention is the provision of a railroad car trash compactor and method for using same which provides a simple and easy manner in which to clean the car after it has been used.
A further object of the present invention is the provision of an improved rail car trash compactor which includes drain means for draining waste water from the car both during and after use.
A further object of the present invention is the provision of a railroad car trash compactor and method for using same which provides means for easily loading the car with waste materials.
A further object of the present invention is the provision of an improved railroad car trash compactor which is economical to use, efficient in operation, and durable throughout extended use.
SUMMARY OF THE INVENTION
The present invention utilizes an elongated railway car having a box forming a container therein. Within the container is a compaction blade which is mounted for longitudinal movement from the forward end of the container to the rear. The compactor blade includes upper rollers and lower rollers which are guided within tracks to facilitate movement of the blade from the forward end of the container to the rear. Chain drives are mounted both above and below the comparator blade and are attached to the compactor blade for causing the blade to move from its forward to its rear positions.
The rear end of the car includes openable doors so that the compactor blade can force the trash outwardly through the rear end of the car for emptying the car. Steam jets are provided along the length of the interior of the car, and are connected to a source of pressurized steam. The steam jets can be used to clean the interior of the car after the trash has been expelled from the car.
A drain is provided in the floor of the car for draining away the condensed steam and also for draining away any waste water which is within the trash. The drain is connected to a waste water storage tank mounted on the underside of the railway car.
A plurality of doors are provided in the upper wall of the railway car and can be opened to permit the depositing of trash into the car at various points along the length of the car.
In operation, the compactor blade is moved to the forward end of the car. The trash is deposited in the car through the openings in the upper wall thereof. The compactor blade is then used to move against the trash and compress the trash between the compactor blade and the rear wall of the car. The compactor blade is capable of providing pressures of approximately 800 pounds per square inch.
When the car is full, it is used to transport the trash to the desired location. At the deposit site, the rear doors of the railway car are opened, and the compactor blade is moved to the rear end of the car so as to force the trash outwardly through the rear opening.
DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIG. 1 is a perspective view of the railway car trash compactor of the present invention.
FIG. 2 is a schematic view showing the drive train for operating the chains to move the compactor blade.
FIG. 3 is a longitudinal sectional view taken along line 3--3 of FIG. 1.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is an enlarged detailed view taken along line 5--5 of FIG. 4.
FIG. 6 is a partial perspective view of the rear end of the railway car.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the numeral 10 generally designates a railroad car trash compactor of the present invention.
Car 10 includes a top wall 12, a bottom wall 14, end walls 16, 18, and sidewalls 20, 22. The top wall 12 is comprised of an upper panel 24 and a lower panel 26, and the bottom wall 14 is comprised of an upper panel 28 and a lower panel 30. Between upper panels 24, 26 is an upper space 32, and between lower panels 28, 30 is a lower space 34.
Top wall 12 is provided with a plurality of inlet doors 36 along its length which can be opened to provide access to the interior of the car. Sidewall 18 includes a pair of side doors 38. The railway car 10 includes a support frame 40 under which are mounted conventional railway wheel assemblies 42, each having a coupler 44 connected thereto.
The front end wall 16 includes a front outer panel 46 and an inner panel 48 which define a front space 50 therebetween. The rear wall 18 includes a discharge opening 52 therein over which are provided a pair of discharge doors 54 which are moveable from a closed position closing off the discharge opening 52 to an open position such as shown in FIG. 6 exposing the discharge opening and permitting the contents of the trash compartment 56 to be emptied.
Within trash compartment 56 is a compactor blade 58 having a top edge 60, a bottom edge 62, and a pair of opposite side edges 64, 66. Extending upwardly from the top edge 60 are a pair of upper roller brackets 68, and extending downwardly from the bottom edge 62 are a pair of lower roller brackets 70. Brackets 68 extend through a pair of upper slots 72 in the lower panel 26 of top wall 12. The lower roller brackets 70 extend through a spaced apart pair of lower slots 74 in the upper panel 28 of bottom wall 14. Mounted on the upper ends of upper roller bracket 68 are a pair of upper rollers 76 which are rotatable about axles 78. Mounted within the lower space 46 between upper and lower panels 28, 30 of bottom wall 14 are a pair of lower rollers 80 which are rotatable about axles 82. Upper rollers 76 roll within upper tracks 84, and lower rollers 80 roll within lower tracks 86 so as to permit the compactor blade 58 to be moved from its fill position which is at the extreme left end of the car as viewed in FIG. 3 to its discharge position which is located at the extreme right end of the car shown in FIG. 3.
A drive system is provided for moving the compactor blade 58 from its fill position to its discharge position. The drive system comprises a pair of upper front sprockets 102 which are connected by an axle 103 and a pair of upper rear sprockets 104. Trained around the sprockets 102, 104 are a pair of chains 106 Sprockets 102, 104 and chain 106 are all located within the upper space 32 between upper and lower panels 24, 26 of top wall 12.
Located within the lower space 34 between upper and lower panels 28, 30 of bottom wall 14 are a pair of lower front sprockets 108 interconnected by an axle 107 and a pair of lower rear sprockets 110. Trained around sprockets 108, 110 are a pair of chains 112.
Located within front space 50 is a drive axle 114 which includes at one end an upper drive sprocket 116 having an upper drive chain 118 trained therearound and also trained around upper sprocket 102. Upper sprocket 102 is preferrably a dual sprocket capable of accommodating the upper drive chain 118 and the chain 106.
Connected to the other end of drive axle 114 is a lower drive sprocket 120 having a lower drive chain 122 connected thereto and trained around lower sprocket 108 which is a dual sprocket similar to upper sprocket 102. Interposed in the middle of drive axle 114 is a hydraulic drive motor 124 having dual output shafts 126, 128 which are connected to axle 114 by couplings 130. Actuation of the hydraulic cylinder 124 causes rotation of the drive axle 114 in the direction shown by the arrows, thereby causing similar rotation of the upper axle 103 and the lower axle 107.
The upper roller brackets 68 and the lower roller brackets 70 are attached to the upper runs of chains 106, 112 and, therefore, actuation of the hydraulic motor 124 causes the chains to move and causes corresponding movement of compactor blade 58 between its fill position and its discharge position. The motor 124 is reversible so as to be capable of reversing the rotational direction of drive axle 114 in a direction opposite from the arrows shown in FIG. 2.
In operation, the compactor blade is first moved to its fill position at the extreme left end of the car as shown in FIG. 3. The inlet doors 36 in the top wall 12 of rail car 10 are opened. These doors may be hinged, or they may be slidable in a horizontal direction without detracting from the invention. They are opened, and the trash to be disposed of is placed into the car through these openings. The trash is positioned between the compactor blade 58 and the closed discharge doors 54.
Periodically, during the time the material is being placed in the car, the compactor blade 58 can be moved towards its discharge position, thereby causing compaction of the trash materials within the container. The blade is then moved back to its fill position and further trash is added. When the car is full, the inlet doors 36 are closed, and the material is transported to its desired location.
At the desired location, the discharge doors 54 are opened as shown in FIG. 6, and the compactor blade 58 is moved to its discharge position. This causes the trash to be expelled from the discharge opening 52 of the car.
A steam system is provided for cleaning the interior of the trash compartment 56. The steam system includes one or more steam tanks 94 mounted on the undercarriage of the car. Lower steam lines 96 and upper steam lines 98 are connected to the steam tank, and also connected to a plurality of spray nozzles 100 which are located at the four corners of the trash compartment 56, and which are also located at spaced apart intervals along the length of trash compartment 56. Periodically, valves (not shown) may be opened to introduce steam to these spray openings 100 thereby causing the steam to be sprayed into the interior of the compartment for cleaning of the compartment. The bottom wall 14 of the compartment includes a drain 90 which is connected to a waste water tank 88 by means of a drain line 92. This permits the draining away of the waste water within the container 56 as well as the condensed water resulting from the spraying of steam nozzles 100.
Thus, after the car has been emptied, the compactor blade 58 can be returned to its fill position, the spray nozzles 100 can be opened so as to spray the interior of the tank and cause it to be cleaned. The drain 90 permits the draining away of the condensed water resulting from the steam.
Thus, it can be seen that the device accomplishes at least all of its stated objectives.
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A railroad car trash compactor includes an elongated box defining an elongated trash compartment therein. A compactor blade is movably mounted within the box and is movable from a fill position adjacent the forward end of the box to a discharge position adjacent the rear end of the box. Discharge doors are openable at the rear end of the box to permit the expelling of trash from the box by means of the trash compactor. Steam jets are provided within the compartment for cleaning the compartment.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 60/675,835, filed Apr. 28, 2005, incorporated herein by reference as if set forth in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with United States government support awarded by the following agency: NIH EY012492. The United States has certain rights in this invention.
BACKGROUND
Neuronal cell death is a final pathway common to a variety of diseases including neurodegenerative disorders and ophthalmological disorders, such as glaucoma, that involve injury to retinal ganglion cells (RGCs). In glaucoma, an increase in intraocular pressure (IOP) damages RGCs, causing them to undergo apoptosis. Consequently, vision is irreversibly lost.
The exact mechanism by which neuronal cells undergo apoptosis in various neurodegenerative and ophthalmological disorders has not been unequivocally established. In the case of axonal injury-induced RGC apoptosis, it is speculated that blockage of retrograde axonal transport of neutrophins and/or production of an injury signal are contributing factors.
There is considerable interest in the art in identifying/developing molecules that can reduce neuronal cell death. In this regard, tris-(2-carboxyethyl) phosphine (TCEP) has been reported to reduce axonal injury-induced RGC apoptosis. Geiger et al., Neuroscience 109:635-642 (2002).
BRIEF SUMMARY
In one aspect, the present invention is summarized in that a method for protecting neuronal cells from cell death includes the step of exposing one or more neuronal cells to an effective amount of one or more compounds having the formula:
wherein R 1 to R 3 are identical or different and represent a carbon chain of one to thirty carbons, preferably one to twenty or one to ten carbons, and most preferably one to eight, two to seven, or three to six carbons; the carbon chain can be saturated, unsaturated, linear, branched, cyclic or polycyclic, and can have heteroatoms, such as F, Cl, Br, I, O, S, P and N, and preferably O, attached as part of the chain or of a side group.
The above compounds also include pharmaceutically acceptable salts thereof. Specifically excluded from the method of the present invention is the use of TCEP.
In some embodiments, at least one of R 1 to R 3 of Formula I is an aryl group (e.g. a phenyl group) or a substituted aryl group (e.g. a substituted phenyl group), at least one of R 1 to R 3 is an alkyl ester group (R—C(O)—O—R′, either R or R′ can be attached to P), or both. In other embodiments, the aromatic ring of the aryl or substituted aryl group is directly linked to the phosphorus.
In preferred embodiments, the lone pair of electrons on the phosphorus of Formula I is protected by a removable protective group R 4 (Formula II) such as H or BH 3 . In more preferred embodiments, the lone pair of electrons is protected by BH 3 .
In other embodiments, R 1 to R 3 of Formula I are selected from an aryl group (e.g., a phenyl group), a substituted aryl group (e.g., a substituted phenyl group) and an alkyl ester group, wherein at least one of R 1 to R 3 is an aryl or substituted aryl group and at least one of R 1 to R 3 is an alkyl ester group. In preferred embodiments, the lone pair of electrons are protected by BH 3 . In more preferred embodiments, the compounds defined by Formula I are bis(3-propionic acid methyl ester)phenylphosphine borane comlex (PB1) and (3-propionic acid methyl ester)diphenylphosphine borane complex (PB2), described in detail below.
In some embodiments, the method of the present invention is employed to protect neuronal cells of a mammalian species such as human or rat neuronal cells. In preferred embodiments, a specific type of neuronal cells—RGCs—are protected
In a second aspect, the PB2 compound and a pharmaceutical composition comprising the compound and a pharmaceutically acceptable carrier are also within the scope of the present invention.
The previously described embodiments of the present invention have many advantages, including a first advantage that the compounds protect neuronal cells in vitro, as well as in vivo.
It is a second advantage that the methods and compounds are useful in enhancing survival and viability of neuronal tissue used in transplants.
It is a third advantage that the compounds may be applied topically.
It is a fourth advantage that the compounds possess anti-oxidant properties and may therefore be used to protect against oxidative damage.
These and other features, aspects and advantages of the present invention will become better understood from the description that follows. In the description, reference is made to the accompanying drawings, which form a part hereof and in which there is shown by way of illustration, not limitation, embodiments of the invention. The description of preferred embodiments is not intended to limit the invention to cover all modifications, equivalents and alternatives. Reference should therefore be made to the appended claims for interpreting the scope of the invention
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and features, aspects and advantages other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such detailed description makes reference to the following drawings, wherein:
FIG. 1 shows a PB1 synthesis pathway.
FIG. 2 shows a PB2 synthesis pathway.
FIG. 3 shows mild neuroprotection by three tri-phenylated phosphino compounds. A dose-response analysis of 2-(diphenylphosphino)benzoic acid (2DPBA) yielded significant protection at 1 μM and 100 μM (A). Likewise, 4-(diphenylphosphino)benzoic acid (4DPBA) produced neuroprotection at 1 and 100 μM (B). Of the three tri-phenylated phosphines, 3,3′,3″-phosphinidynetris(benzene-sulfonic acid) trisodium salt (3BSA) required the highest concentration (100 μM) to rescue RGCs from acute axotomy (C). RGCs were cultured at seventy-two hours in defined medium (see Example 1 below). All results were assessed at 72 hours using 4′,6-diamidino-2-phenylindole (DAPI) for retrograde RGC labeling and calcein-AM staining for viability. An asterisk indicates p<0.05.
FIG. 4 shows the structure of PB1 and PB2. A borane protects the phosphine from oxidation, and thus stabilizes the molecule (A). The phenyl group is nonpolar (which is likely to increase the molecule's cell permeability), delocalizes the electron pair of the phosphino group by resonance and provides minimal steric hindrance (B). The methyl esters are likely cleaved by cytosolic esterases, resulting in an anionic molecule that is unlikely to exit the cytosol (C).
FIG. 5 shows that PB1 is neuroprotective at lower concentrations than TCEP. A dose-response curve of TCEP (diamonds) and PB1 (squares) was determined at 72 hours in vitro. TCEP mildly rescued RGCs at 100 μM, whereas PB1 was highly effective at picomolar concentrations. An asterisk indicates p<0.05, and a double-asterisk indicates p<0.01.
FIG. 6 shows that PB1 and PB2 are highly neuroprotective for axotomized RGCs at nanomolar and at picomolar concentrations, respectively. RGCs were cultured for seventy-two hours in defined medium, following which DAPI-positive RGCs were identified and calcein-AM staining was used to assess viability. Dose response curves of PB1 and PB2 ranging from 1 pM to 100 μM were assessed at 72 hours. PB1 was neuroprotective for RGCs at ≧1 nM (A). PB2 was neuroprotective at ≧10 pM (B). An asterisk indicates p<0.05, a double-asterisk indicates p<0.01, and a triple-asterisk indicates p<0.001.
FIG. 7 is a schematic illustration of optic nerve injury and resultant protein modification via superoxide. RGC soma and axon are shown after injury (A 1 -A 4 ) and corresponding conformational states of a hypothetical signaling protein (B 1 -B 4 ) are also depicted. The inset displays a schematic drawing of the eye and of the optic nerve. A healthy RGC (A 1 ) contains a reduced signaling protein with free sulfhydryl groups (B1). Optic nerve injury or transection (A 2 ) initiates a rise in superoxide anion. Lievin et al., Invest. Ophthalmol. Vis. Sci. 47:1477-1485 (2006). Intracellular superoxide oxidizes the cysteine thiols of proteins (B 2 ). The concentration of superoxide increases over time within the RGC soma (A 3 ) and disulfide bonds are created as a result, inducing conformational changes and inducing apoptosis (B 3 ). The RGC will either undergo apoptosis (if untreated) or be rescued (if treated with thiol-reducing agents) (A 4 ). When a thiol-reducing agent, such as TCEP, PB1 or PB2, is administered, disulfide bonds are reduced, and the protein resumes normal conformation and function (B 4 ). Without the thiol-reducing agent, the signaling of apoptosis will continue.
The present invention is not intended to be limited to any particular operative theory; alternative or additional mechanisms of action, such as reducing other thiol modifications, scavenging of superoxide, and reducing other molecules, are certainly possible.
DESCRIPTION OF PREFERRED EMBODIMENTS
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. Although any methods and materials similar to or equivalent to those described herein can be used in the practice or in the testing of the present invention, the preferred methods and materials are now described
As used herein, the term “neuronal cells” encompasses any differentiated neuronal cells such as neurons (e.g. RGCs) or glial cells (e.g., astrocytes and oligodendrocytes) of either the central or the peripheral nervous system. The term also encompasses neuronal stem cells and neuronal progenitor cells. Neuronal cells encompassed by the term can assume any form such as the form of a tissue or dissociated neuronal cells (e.g. in a cell suspension).
As used herein, the term “cell death” encompasses apoptosis, necrosis and other types of cell death, such as mixed type of cell death.
As used herein, an “effective amount” of one or more compounds means an amount effective to protect neuronal cells from cell death. For the purpose of the present invention, the protective effect of a compound can be measured, for example, by a longer cell survival time, a decrease in the percentage of cells that die within a particular period of time or both in compound-treated cells in comparison to control cells. Of course, what constitutes the effective amount will depend on a variety of factors, including, for example, the size, the age and the condition of the individual, as well as on the mode of delivery. It is well within the ability of one of ordinary skill in the art to determine the effective amount.
The compounds of the present invention can protect neuronal cells both in vitro (e.g. in cultured cells) and in vivo (e.g. in a human or in a non-human animal). For example, protective compounds may be used with cultured neuronal cells or with tissue maintained ex vivo for purposes of transplantation into one or more sites in the eye of a patient suffering from an optic neuropathy. In this instance, the protective compound would enhance survival and viability of the neural tissue and increase the chances of a successful graft. Use of protective compounds in this context can be achieved with any of the available culturing or grafting procedures.
For in vivo applications, the compounds of the present invention are used to treat a subject (e.g., a patient) who is experiencing a neuronal cell death-related disease or condition. The compounds can also be used to prevent the disease or the condition (including partial prevention such as delay and minimizing symptoms at onset of disease or condition) in an at-risk individual not yet showing signs of the disease or the condition. In these applications, one or more compounds of the present invention are administered to a subject in an effective amount to treat or to prevent the disease or the condition.
Examples of neuronal cell death-related diseases or conditions that can be treated or can be prevented include, but are not limited to various neurodegenerative disorders (e.g. Alzheimer's disease, Huntington's Disease, prion diseases, Parkinson's Disease, amyotrophic lateral sclerosis, ataxia telangiectasia, spinobulbar atrophy, age-related reduction in number or in function, macular degeneration, retinal degeneration, dominant optic atrophy and Leber's hereditary optic neuropathy), diseases and conditions induced under various conditions of ischemia and/or excitotoxicity (e.g. ischemic stroke, hemorrhagic stroke and ischemic optic neuropathy), diseases due to nervous system trauma (e.g. spinal cord injury or traumatic optic neuropathy), diseases due to inflammation (e.g. optic neuritis or multiple sclerosis), diseases due to infection (e.g. meningitis and toxoplasmosis optic neuropathy), diseases and conditions induced by certain medications or irrigating solutions (e.g. optic neuropathy induced by ethambutol or methanol), and diseases due to other etiologies (e.g. glaucoma).
When the compounds of the present invention are used to protect neuronal cells in a subject in vivo, the compounds can be provided in a pharmaceutically acceptable carrier and can be administered to the subject via a topical or a systemic route, such as those described below.
In an exemplary embodiment, the compounds of the present invention are used to treat or to prevent a disorder related to neuronal cell death, including, but not limited to, glaucomatous optic neuropathy, ischemic optic neuropathy, inflammatory optic neuropathy, compressive optic neuropathy and traumatic optic neuropathy. In a preferred embodiment, the compounds of the present invention are used to treat or to prevent glaucoma.
It is reasonable to expect that the more neuronal cells that a protective compound contacts, the more pronounced its protective effect. Preferably, the method of the present invention allows a protective compound to contact at least about 25%, 50% or even as many as 95% or 100% of the cells.
Preferably, contacting the neuronal cells with one or more compounds of the present invention will reduce cell death by at least about 50% when compared to untreated cells. However, it is expected a reduction of cell death of 25%, 10% or 5% will extend the vision of the treated subject. In a human subject, a reduction in cell death may be estimated by extrapolation from functional and structural assays.
Functional assays involve evaluating changes in visual function over time, specifically, visual acuity and visual fields. It is reasonably expected that a reduction in the rate of neuronal cell death following initiation of treatment may be correlated with a reduction in the rate of loss of visual function over time. Structural assays involve visualizing or measuring the optic nerve head or the retinal nerve fiber layer with an ophthalmoscope or other device to assess optic disc atrophy, disc cupping or loss of nerve fibers.
A protective compound can be made to target a neuronal cell, such as a RGC, by linking it to an antibody or other molecule that can bind a cell surface antigen, such as Thy-1, which is a major RCG cell surface protein. For example, a protective compound can be covalently linked to a cell-specific aptamer. The Systematic Evolution of Ligands by EXponential enrichment (SELEX) procedure can be used to produce RNA molecules that bind to Thy-1. See Tuerk C & Gold L, Science 249:505-510 (1990), incorporated herein by reference as if set forth in its entirety. A library of RNA molecules can be generated by in vitro transcription from a commercially generated DNA library of sequences having a combinatorially rich random nucleotides core flanked by primer binding sequences (e.g., FFFFFFFFFFFFFFFFFNNNNNNNNNNNRRRRRRRRRRRRRR, wherein FFFFFFFFFFFFFFFFF represents a binding site for a forward primer, wherein RRRRRRRRRRRRRR represents a binding site for a reverse primer, and wherein NNNNNNNNNNN is twenty-four to thirty-six combinatorially rich random nucleotides). Purified Thy-1 can then be attached to sepharose beads, the RNA molecules allowed to bind, the beads washed, and the bound RNA eluted. The eluted RNAs are molecules with increased affinity for Thy-1. They can then be reverse transcribed and amplified in a PCR reaction (using the forward and the reverse primers that bind to all of the molecules). The amplimers will then be transcribed, and the process repeated. The optimal RNA sequences are then synthesized with resistant nucleotides and covalently attached to a protective compound.
For treating a neuronal cell death-related disorder, protective compounds may be administered singly or in combinations of two or more protective compounds, with or without other active drugs, including without limitation, ocular hypotensive and other anti-glaucoma agents (e.g. prostaglandins or prostanoids, carbonic anhydrase inhibitors, beta-adrenergic agonists and antagonists, alpha-adrenergic agonists, N-acetyl cysteine, glutathione or other anti-glaucoma agents) known to those skilled in the art. Protective compounds may be delivered within any appropriate pharmaceutical formulation by topically (e.g. eye drops), transclerally, intravitreally, intraorbitally (e.g. retrobulbar or peribulbar injection), subconjunctivally, orally, intravenously, subcutaneously, intramuscularly, intraocularly, transdermally, bucally, intravaginally, rectally, nasally, intracerebrally, intraspinally or any of a variety of novel alternative drug delivery systems including those currently marketed, or any other means that is appropriate to the compound(s) in question.
For easy access to neuronal cells, protective compounds can be delivered through injection or depot injection in or around the vitreous, the retinal nerve fiber layer, the optic nerve fibers or the targets of neuronal cells within the brain. Topical ophthalmic compositions are employed when the compounds are to be dosed topically. Preferably, the topically dosed compounds are formulated for sustained release over a period of time. See Remington's Pharmaceutical Sciences (14th Ed. 1970); Joshi J, Ocul. Pharmacol. 10:29-45 (1994); McCalden et al., Experientia 46:713-715 (1990); Feist et al., J. Cataract Refract. Surg. 21:191-195 (1995); Cheng et al., Invest. Opthalmol. Vis. Sci. 36:442-453 (1995); and Chetoni et al., J. Ocul. Pharmacol. Ther. 129:245-252 (1996), each of which is incorporated herein by reference as if set forth in its entirety. Also preferably, the topically dosed compounds are formulated to increase penetration and to increase corneal contact time. See Meseguer et al., J. Ocular. Pharm. Ther. 12:481-488 (1996); and Nelson et al., J. Am. Optom. Assoc. 67:659-663 (1996), each of which is incorporated herein by reference as if set forth in its entirety.
The preparation of topical ophthalmic compositions is well known in the art. Generally, topical ophthalmic compositions useful in the present invention are in the form of a solution, a suspension, a gel or formulated as part of a device, such as a collagen shield or other bioerodible or non-bioerodible device.
Various excipients may be contained in the topical ophthalmic solutions, suspensions or gels of the present invention. For example, buffers (e.g. borate, carbonate and phosphate), tonicity agents (e.g. sodium chloride, potassium chloride and polyols), preservatives (e.g. polyquaterniums, polybiguanides and BAS), chelating agents (e.g. EDTA), viscosity enhancing agents (e.g. polyethoxylated glycols) and solubility agents (e.g. polyethoxylated castor oils, including polyoxl-35 castor oil, Polysorbate 20, 60 and 80; Pluronic® F-68, F-84 and P-103; or cyclodextrin) may be included in the topical ophthalmic compositions.
Likewise, a variety of gels may be useful in topical ophthalmic gel compositions of the present invention, including, but not limited to, carbomers, polyvinyl alcohol-borate complexes, xanthan, gellan or guar gums.
Topical ophthalmic bioerodible and non-bioerodible devices (e.g. conjunctival implant) may be used for topical administration of protective compounds. See Weiner A, “Polymeric Drug Delivery Systems For the Eye,” in Polymeric Site-Specific Pharmacotherapy, (A. J. Domb, Ed., John Wiley & Sons, pp. 316-327, 1994). Topical administration is suitable for facilitating the delivery of the protective compounds described herein to enable chronic treatment of the eye.
Protective compounds may also be delivered on a solid or a semisolid scaffold, wherein delivery is accomplished by placing the support in a region of the eye selected from the group consisting of an eyelid, a conjunctiva, a sclera, a vitreous, a retina, an optic nerve sheath, an intraocular location and an intraorbital location. Additionally, protective compounds may be delivered slowly over time to the eye through the use of contact lenses. This regimen is generally performed by first soaking the lenses in a protective compound and then applying the contact lenses to the eye.
When the protective compounds are administered during intraocular, intracerebral or intraspinal surgical procedures, such as through retrobulbar or periocular injection, intraocular perfusion or injection, or intraspinal or intracerebral injection or perfusion, the use of irrigating solutions as vehicles are most preferred. The most basic irrigating solutions generally comprise sterile saline or phosphate-buffered saline (PBS). More advanced irrigating solutions, however, are preferred. Also contemplated are sustained-release formulations.
As used herein, the term “physiologically balanced irrigating solution” refers to a solution adapted to maintain the physical structure and the function of tissues during invasive or noninvasive medical procedures. This type of solution typically contains electrolytes, such as sodium potassium, calcium, magnesium and/or chloride; an energy source, such as dextrose; and a bicarbonate buffer to maintain the pH of the solution at or near physiological levels. Various solutions of this type are known (e.g. Lactated Ringers Solution, BSS, RTM, BSS Plus RTM, Sterile Irrigating Solution and Sterile Intraocular Irrigating Solution).
Retrobulbar and periocular injections are useful techniques also known to those skilled in the art and are described in numerous publications including, for example, Ophthalmic Surgery: Principles of Practice, W. B. Sanders Co., Philadelphia, Pa., USA, pp. 85-87 (G. L. Spaeth, Ed., 1990).
Pharmaceutical compositions of the protective compounds can be formulated for systemic use using techniques well known in the art. Orally administered compositions are generally in the form of tablets, hard or soft gelatin capsules, suspension, granules, powders or other typical compositions and contain excipients typically present in such compositions. Methods for the preparation of such oral vehicles are well known by those skilled in the art. Parenterally administrated compositions are generally in the form of injectable solutions or suspensions. Methods for the preparation of such parenteral compositions are well-known by those skilled in the art.
It is appreciated that the compounds of the present invention are good electron donors (upon removal of the removable protective group if present), and thus have antioxidant activities. Accordingly, these compounds can be used to protect against oxidative damage to human or animal cells, tissues and organs in general. The role of reactive oxygen species (ROS) in the etiology of human diseases (e.g. cancer, atherosclerosis, rheumatoid arthritis, inflammatory bowel diseases, immune system dysfunctions, brain function decline and connective tissue dysfunction) is well-established.
Diseases and conditions caused by oxidative damage can be prevented or can be treated with the compounds of the present invention. The specifics on using these compounds for this purpose, such as the appropriate dosage and the route of administration, can be readily determined by a skilled artisan as described above in the context of protecting neuronal cell death-related diseases and conditions.
The invention will be more fully understood upon consideration of the following non-limiting examples.
EXAMPLES
Example 1
Neuroprotective Effects of Phosphine Compounds and Derivatives
Experimental Procedures
Animals: All experiments were performed in accordance with Association for Research in Vision and Ophthalmology (ARVO), institutional, federal and state guidelines regarding animal research.
Materials: Cell culture reagents were obtained from GIBCO (Grand Island, N.Y.). A retrograde fluorescent tracer, 4′,6-diamidino-2-phenylindole (DAPI), and a fluorescent viability agent, calcein-AM, were obtained from Molecular Probes (Eugene, Oreg.). Papain was obtained from Worthington Biochemical (Freehold, N.J.). TCEP analogues bis(3-propionic acid methyl ester)phenylphosphine borane complex (PB1) and (3-propionic acid methyl ester)diphenylphosphine borane complex (PB2) were synthesized as described below. Unless noted, all other reagents were obtained from Sigma-Aldrich (St. Louis, Mo.).
RGC Labeling and Culture: RGCs were retrogradely labeled by stereotactic injection of the fluorescent tracer DAPI dissolved in dimethylformamide into the superior colliculi of anesthetized postnatal days two to four Long-Evans rats. DAPI binds to nuclear DNA and fluoresces under UV light. At postnatal days eleven to thirteen, the animals were sacrificed by decapitation, the eyes enucleated, and the retinas dissected in Hank's balanced salt solution (HBSS). After two incubations in enzyme solution containing papain (3.7 U/ml), each for 30 minutes at 37° C., the retinas were gently triturated with a Pasteur pipette and plated on poly-L-lysine-coated 96-well flat-bottomed tissue culture plates (0.32 cm 2 surface area/well) at a density of approximately 2000 cells/mm 2 . The cells were cultured for 72 hours in Neurobasal-A, B27 supplement lacking antioxidants in a humidified 5% CO 2 incubator at 37° C.
Retinal Ganglion Cell Identification and Counting: RGCs were identified by the presence of DAPI, which appears blue when viewed with appropriate filters under epifluorescence. Cell viability was determined by metabolism of calcein-AM, which produces a green fluorescence when viewed with fluorescein filters. Cells were incubated in a 1 μM solution of calcein-AM in phosphate-buffered saline (PBS) for 30 minutes, after which the medium was replaced with fresh PBS. Wells were counted in duplicate or in triplicate.
Synthesis of PB1 and PB2: Chemicals and solvents were from Aldrich Chemical (Milwaukee, Wis.). Reactions were monitored by thin-layer chromatography and were visualized by ultraviolet light or staining with I 2 . NMR spectra were obtained with a Bruker AC-300 or Varian Inova-600 spectrometer. Phosphorus-31 NMR spectra were proton-decoupled and referenced against an external standard of deuterated phosphoric acid. Mass spectra were obtained with electrospray ionization (ESI) or matrix-assisted laser desorption/ionization (MALDI) techniques.
Synthesis of bis(3-propionic acid methyl ester)phenylphosphine Borane Complex (PB1) ( FIG. 1 ):
Phosphine 1: See Rampal et al., J Am. Chem. Soc. 103:2032-2036 (1981), incorporated herein by reference as if set forth in its entirety. Phenylphosphine (10 g, 90 mmol) was dissolved in acetonitrile (10 ml, degassed) in a flame-dried, round bottom flask under Ar(g). Potassium hydroxide (1.0 N, 1.0 ml) was added to this mixture, and the resulting solution was cooled to 0° C. Methyl acrylate (16.2 ml, 180 mmol) was added at a rate that maintained the reaction temperature below 35° C. Upon complete addition of methyl acrylate, the reaction was heated at 50° C. for 8 hours. The reaction mixture was then washed with brine (2×10 ml). The organic layer was dried over MgSO 4 (s), filtered, and concentrated en vacuo. The residue was purified by distillation with the desired product distilling at 160-170° C. (0.5 mm Hg). Phosphine 1 was isolated as a clear liquid (20.7 g, 73 mmol, 81% yield).
Spectral data: 1 H NMR (300 MHz, CDCl 3 :CD 3 OD) δ 7.54-7.48 (m, 2H), 7.37-7.30 (m, 3H), 3.62 (s, 6H), 2.46-2.23 (m, 4H), 2.10-2.03 (m, 4H) ppm; 13 C NMR (75 MHz, THF-d 6 ) 173.25 (d, J=12.9 Hz), 133.51 (d, J=15.5 Hz), 132.28 (d, J=19.4 Hz), 129.22, 128.43 (d, J=7.2 Hz), 51.47, 30.22 (d, J=16.9 Hz), 22.63 (d, J=11.9 Hz) ppm; 31 P NMR (121 MHz, CDCl 3 :CD 3 OD) −23.06 ppm; MS (ESI) m/z 305.0905 (MNa + [C 14 H 19 O 4 PNa + ]=305.0919).
PB1: Phosphine 1 (20.7 g, 73 mmol) was dissolved in dry tetra hydro furan (THF) in a flame-dried round bottom flask under Ar(g). This solution was cooled to 0° C. and borane-THF (1.0 M in THF, 80.6 ml, 80.6 mmol) was added slowly. The reaction was stirred at 0° C. for 45 minutes and then was stirred at room temperature for an additional 1.5 hours. The solvent was removed under reduced pressure, and the residue was purified by flash chromatography (silica gel, 80% v/v methylene chloride in hexanes). PB1 was isolated as a clear oil (7.6 g, 25.6 mmol, 35% yield).
Spectral data: 1 H NMR (300 MHz, CDCl 3 :CD 3 OD) δ 7.78-7.70 (m, 2H), 7.57-7.47 (m, 3H), 3.64 (s, 6H), 2.70-2.56 (m, 2H), 2.41-2.19 (m, 6H), 0.68 (m, 3H) ppm; 13 C NMR (75 MHz, THF-d 6 ) 172.29 (d, J=19.1 Hz), 131.88 (d, J=13.5 Hz), 131.84, 128.93 (d, J=12.3 Hz), 126.11 (d, J=61.4 Hz), 51.83, 27.37, 20.71 (d, J=45.4 Hz) ppm; 31 P NMR (121 MHz, CDCl 3 :CD 3 OD) 17.34 (d, J=70.4 Hz) ppm; MS (ESI) m/z 318.1292 (MNa + [C 14 H 22 BO 4 PNa + ]=318.1283).
Synthesis of (3-propionic acid methyl ester)diphenylphosphine Borane Complex (PB2) ( FIG. 2 ):
PB2: See Imamoto et al., J. Am. Chem. Soc. 107:5301-5303 (1985), incorporated herein by reference as if set forth in its entirety. Borane-diphenylphosphine complex (0.190 g, 1.0 mmol) was dissolved in methanol (8 ml) in a flame-dried, round bottom flask under Ar(g) at room temperature. Potassium hydroxide (0.0028 g, 0.05 mmol) was added to this mixture, followed by the drop-wise addition of methyl acrylate (0.108 ml, 1.2 mmol). The reaction mixture was allowed to stir at room temperature for 6 hours, after which the methanol was removed en vacuo. The residue was taken up in dichloromethane (10 ml) and was washed with 0.5 N HCl (1×5 ml) and brine (1×5 ml). The aqueous layers were washed with dichloromethane (10 ml), and the combined organic layers were dried over MgSO 4 (s), filtered and concentrated en vacuo. The residue was purified by flash chromatography (silica gel, 30% v/v ethyl acetate in hexanes). PB2 was isolated as a pale yellow oil (0.219 g, 0.76 mmol, 76% yield).
Spectral data: 1 H NMR (300 MHz, CDCl 3 ) 7.72-7.65 (m, 5H), 7.51-7.45 (m, 5H), 3.64 (s, 3H), 2.55 (m, 4H), 0.96 (m, 3H) ppm; 13 C NMR (75 MHz, CDCl 3 ) 132.37 (d, J=9.20 Hz), 131.67, 129.17 (d, J=10.1 Hz), 128.84, 52.24, 28.01, 21.15 (d, J=39.5 Hz) ppm; 31 P NMR (121 MHz, CDCl 3 ) 16.26 (d, J=59.0 Hz); MS (ESI) m/z 309.1190 (MNa + [C 16 H 20 BO 2 PNa + ]=309.1192).
Statistical Analysis: All RGC viability calculations were normalized to the control (no treatment) condition by dividing the mean number of living RGCs in an experimental condition by the mean in controls. Comparisons were by unpaired t-test.
Results
Novel thiol-reducing agents PB1 and PB2 protect RGCs in vitro at very low concentrations: Previous studies have demonstrated that (1) a thiol-reducing agent, TCEP, potently prevented RGC death in vitro to a degree equivalent to the combined effect of brain-derived neurotrophic factor (BDNF) and ciliary neurotrophic factor (CNTF), and that (2) TCEP injected intravitreally into adult rats inhibited RGC death after optic nerve crush. The concentrations required for RGC neuroprotection with this molecule were on the order of 100 μM. The TCEP molecule, being highly polar, does not cross cell membranes well, and the extracellular stability of the compound is low.
We tested the effects of three other phosphino compounds in vitro by using a standard method for postnatal day eleven to thirteen RGC culture, a time after which development of RGC death has already completed in the rat. Geiger et al., Neuroscience 109:635-642 (2002). 2DPBA prevented RGC death at concentrations as low as 10 nM (216±18%) at 72 hours. Additionally, 4DPBA rescued RGCs at 1 μM (183±19%), and 100 μM 3BSA increased survival (206±6%) ( FIG. 3 ). The reduction potential of these phosphines prevents disulfide bond formation.
We further tested the neuroprotective effects of PB1 and PB2 ( FIG. 4 ) in vitro. These two molecules were synthesized and then characterized by NMR spectroscopy and by mass spectrometry. As shown in FIG. 5 , PB1 showed higher protection at lower concentrations than did TCEP at 72 hours after axotomy. Dose-response curves for PB1 and PB2 were generated over the range of 1 pM to 100 μM, and relative RGC survival (compared to control) was assayed at 72 hours after axotomy ( FIG. 6 ). All data points were in duplicate or in triplicate, and all experiments were performed two to five times. PB1 rescued RGCs at concentrations as low as 1 nM (174±12%) at 72 hours; whereas PB2 increased RGC viability at 10 pM (180±10%) at 72 hours.
In many optic neuropathies, injury to the nerve axon is believed to be the primary pathophysiological damage that initiates apoptosis ( FIG. 7 ). After axotomy, a rise in ROS occurs, which is thought to be sufficient to be the upstream signaling event that induces the apoptotic cascade signal. Though the source of ROS has not been determined, our recent findings suggest that it may be partly generated in the mitochondrial electron transport chain. ROS induce oxidative stress within the cell and transduce signals by oxidizing reduced sulfhydryls. Cross J & Templeton D, J. Cell Biochem. 93:104-111 (2004). Disulfide bond formation within a protein or with other proteins alters its configuration, which can then prevent it from performing specific functions or cause it to initiate new reactions. Ultimately, the rise in ROS causes the cell to undergo an irreversible death cascade. The RGC can survive axotomy, however, if treated with thiol-reducing agents.
Previous studies have shown that other thiol-reducing agents, such as dithiothreitol (DTT) and TCEP, were not effective at nanomolar concentrations. Because these molecules are polar, they do not easily cross cell membranes and therefore required high extracellular concentrations to show any significant survival effects.
We have herein identified a class of reducing compounds that have neuroprotective activities. In particular, we found that the TCEP analogues PB1 and PB2 were highly neuroprotective at nanomolar and picomolar concentrations, respectively. Additionally, they were significantly more protective at lower concentrations than their predecessor, TCEP. Less protected phosphines, 2DPBA, 4DPBA and 3BSA were less effective at rescuing RGCs from acute axotomy. By modifying TCEP so that (1) its phosphino group can be protected from reaction in the extracellular milieu; and that (2) its pendant carboxyethyl groups were either replaced with a nonpolar phenyl group or converted to esters that can be cleaved by endogenous esterases within the RGC, we markedly increased the effectiveness of these compounds. Passage of PB1 and PB2 across the cell membrane and cleavage of their protective groups would produce highly effective thiol-reducing compounds. Because deprotected PB1 and PB2 are polar and highly charged, they will be confined within the RGCs. Accordingly, the phosphines can protect biomolecules from oxidation by ROS during optic nerve injury.
Example 2
Preventing RGC Death Associated with Optic Nerve Crush In Vivo
Experimental Procedures
Optic Nerve Crush Surgery and Intravitreal Injections: Surgeries are conducted on adult (i.e. eight to twelve week old) rats that have previously received 1,1′-dioctadecyl-3,3,3′,3′-tetramethylindocarbocyanine (DiI) injections. All surgeries are done aseptically and are performed on the left eye only. Animals are anesthetized with a mixture of ketamine and xylazine. A limited lateral canthotomy is performed. The conjunctiva is then incised at the limbus and the subtenons space bluntly dissected posteriorly. Next, 4 μl of sterile drug (i.e. PB1 or PB2) or control (BSS) is slowly injected intravitreally just anterior to the pars plana using a 5 μl Hamilton syringe with a 33 gauge needle. Assuming the vitreous volume of an adult rat eye to be approximately 60 μl (Dureau et al., Curr. Eye Res. 22:74-77 (2001), incorporated herein by reference as if set forth in its entirety), this yields a seventeen-fold dilution from the injected concentration to the final intravitreal concentration of drug. The muscle cone is then entered and the optic nerve exposed. A longitudinal incision is made along the meningeal sheath to expose the optic nerve axons and to avoid disturbing the retinal blood supply. The axons of the optic nerve are then crushed with blunt forceps for 5 seconds 2 mm posterior to the globe under direct visualization. Complete interruption of the RGC axons is seen as a separation of the proximal and the distal optic nerve ends within the meningeal sheath. The skin is closed with absorbable suture and antibiotic ointment applied. The rats are given an intraperitoneal injection of buprenorphine (0.02 mg/kg) for analgesia and are returned to the cage. Rats with any kind of postoperative complication (e.g. cataract or retinal infarction) are excluded from analysis. Typically five to six animals are operated on at each sitting. To control for the effects of a test compound alone, some rats are injected with drug or with control without subsequent optic nerve crush. All animals are observed after recovering from anesthesia to ensure that they eat and drink normally.
Retinal Whole Mounts and BSL-I Staining: Seven to fourteen days after optic nerve crush and intravitreal injection (or intravitreal injection alone), the rats are euthanized with carbon dioxide. The eyes are rapidly enucleated, rinsed, punctured with a needle through the pupil and then fixed for 1 hour in 4% paraformaldehyde (PFA). The retinas are dissected, washed with PBS and then permeabilized in 0.2% Triton X-100 for 15 minutes. After another PBS wash, the retinas are stained with fluorescein-conjugated BSL-I (1:200) for two hours in order to label microglia, which can phagocytose DiI-containing apoptotic RGCs and thereby be confused with RGCs. See Shen et al., Neuron 23:285-295, (1999), incorporated herein by reference as if set forth in its entirety. The retinas are washed again and post-fixed with 4% PFA for 15 minutes. After a final wash, four cuts are made from the edge to the center of the retinas to flatten them. The flattened retinas are mounted with the RGCs facing up on glass slides in glycerol, and the coverslip is sealed with nail polish. The slides are stored in the dark at 4° C.
Results
RGC Density Determination: Retinal wholemounts are imaged with an Axiocarn HRc digital camera attached to a Zeiss Axiophot fluorescent microscope. Images are acquired using Axiovision 3.1 software. RGCs are identified by the presence of retrogradely transported cytoplasmic DiI. Fluorescein-conjugated BSL-I labeled cells appear green when viewed with fluorescein filters. The density of RGCs/mm 2 is determined by counting labeled DiI cells in three areas per retinal quadrant at three different eccentricities of the retinal radius for a total of twelve regions per retina. Cells positive for both DiI and BSL-I, as determined by bright yellow labeling when DiI (red) and BSL-I (green) images are merged, are subtracted from the total DiI count. An observer, masked to treatment or to the presence of optic nerve crush, performs the cell counts. A greater RGC density, reflecting reduced RGC death, is observed in animals administered PB1 or PB2 when compared to controls. Means are compared using a Student's unpaired t-test.
Example 3
Preventing RGC Death Associated with Ocular Hypertension In Vivo
Experimental Procedures
Unilateral experimental glaucoma is induced in the rat using the Quigley protocol for laser ablation of the trabecular meshwork and of the circumferential episcleral vessels. It causes steady RGC loss over a few weeks. See Levkovitch-Verbin et al., Invest. Ophthalmol. Vis. Sci. 43:402-410 (2002), incorporated herein by reference as if set forth in its entirety. The animals are anesthetized as in Example 2. A diode laser at 532 nm (0.2-0.4 watts and 0.3-0.7 second duration, depending on degree of pigmentation) is used to administer laser treatment at the trabecular meshwork and at the episcleral veins draining the perilimbal vessel plexus of vessel. In case a milder IOP rise is required, animals can be treated only at the trabecular meshwork. The laser treatment is repeated at 1 week if the IOP difference between the treated eye and the untreated eye is less than 6 mm Hg. Following laser treatment, sterile drug (i.e. PB1 or PB2) or control (BSS) is administered.
IOP is measured by putting a drop of 0.5% proparacaine in the eye, gently cradling the rat and touching the anesthetized eye with a Tonopen tonometer tip for a fraction of a second, usually for 3±2 times, more if the standard deviation is high. Tame Long-Evans rats typically do not require systemic anesthesia for this measurement procedure. Depending on the experiment, the IOP is initially measured daily and then weekly.
Results
After one to twelve weeks animals are sacrificed and RGC counts are performed as described in Example 2. RGC cell death is attenuated in animals administered PB1 or PB2 when compared to controls.
The invention has been described in connection with what are presently considered to be the most practical and the most preferred embodiments. However, the present invention has been presented by way of illustration and is not intended to be limited to the disclosed embodiments. Accordingly, those skilled in the art will realize that the invention is intended to encompass all modifications and alternative arrangements within the spirit and the scope of the invention as set forth in the appended claims.
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Methods and compositions involving a class of boron-protected phenylphosphine agents having increased cell permeability and having improved chemical stability for treating or for preventing neuronal cell death-related diseases or conditions in a human or a non-human animal.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of U.S. Provisional Patent Application No. 62/126,042 filed Feb. 27, 2015, which is hereby incorporated in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to food packaging and transport and, more particularly, to a method and apparatus for assembling and packaging cupcake bouquets for transport.
[0004] 2. Description of the Related Art
[0005] Baked goods, such as cupcakes, are widely served at a variety of festivities and occasions. Presentation is particularly important, and hosts seek to impress their guests with unique designs and patterns of cupcakes. One such unique presentation involves arranging cupcakes as a bouquet, creating a cupcake bouquet with a vase. However, it is a challenge to position cupcakes in the bouquet without either compromising the presentation or the integrity of the arrangement, leading to possible breakage. Additionally, it is a challenge to package the cupcake bouquet for easy display and removal by the customer without damaging the bouquet. Furthermore, it is another challenge to transport the cupcake bouquet package while avoiding damage to the bouquet and the cupcakes due to vehicle movement, vehicle breaking, and the like.
[0006] Therefore, there is a need in the art for a method and apparatus for assembling and packaging cupcake bouquets for transport.
SUMMARY
[0007] A cupcake holder in the form of a bouquet, and techniques for making and packaging the cupcake bouquet are described herein. The cupcakes are arranged over a hemispherical base, and are supported vertically and horizontally over the hemispherical base. The cupcake bouquet is enclosed in a box, and the movement of the cupcake bouquet within the box is restricted.
[0008] These and other features and advantages of the present disclosure may be appreciated from a review of the following detailed description of the present disclosure, along with the accompanying figures in which like reference numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a front view of a cupcake bouquet being assembled, according to one or more embodiments of the present invention;
[0010] FIG. 2 is a front view of the cupcake bouquet of FIG. 1 being assembled further, according to one or more embodiments;
[0011] FIG. 3 is a partial cut away view of the cupcake mount shown in FIG. 2 , according to one or more embodiments of the present invention;
[0012] FIG. 4 is a frontal view of a cupcake bouquet of FIG. 1 illustrating an alternate embodiment for mounting cupcakes of the present invention;
[0013] FIG. 5 is a frontal view of an assembled cupcake bouquet, according to one or more embodiments of the present invention;
[0014] FIG. 6 is a perspective view of a cupcake bouquet of FIG. 1 enclosed in a packaging box prior to being assembled, according to one or more embodiments of the present invention;
[0015] FIG. 7 is a perspective view of the assembled cupcake bouquet of FIG. 5 secured in the packaging box of FIG. 6 , according to one or more embodiments of the present invention;
[0016] FIG. 8 is a perspective view of an assembled cupcake bouquet fixed to a base plate, according to one or more embodiments of the present invention; and
[0017] FIG. 9 is a perspective view of the completed cupcake bouquet of FIG. 7 with complete packaging, according to one or more embodiments of the present invention.
[0018] While the method and apparatus for assembling and packaging cupcake bouquets for transport is described herein by way of example for cupcakes, those skilled in the art will recognize that the method and apparatus for assembling and packaging cupcake bouquets for transport is not limited to the embodiments or drawings described. It should be understood, that the drawings and detailed description thereto are not intended to limit embodiments to the particular form disclosed. Any headings used herein are for organizational purposes only and are not meant to limit the scope of the description or the claims. As used herein, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including, but not limited to.
DETAILED DESCRIPTION
[0019] Embodiments of the present invention generally relate to a method and apparatus for assembling and transporting cupcake bouquets for transport. The cupcakes are arranged in the form of a flower bouquet, having a vase forming the base of the bouquet, and a cupcake mount attached to the vase, for securing the cupcakes in the form of a bouquet. The mount includes support pins or a supporting disc to support the cupcakes arranged removably over the mount, such that the cupcakes stay stably positioned over the mount and the cupcakes may be removed as desired by a consumer of the cupcake bouquet without impacting other cupcakes in the arrangement. Skewers are inserted into the foam from the top of the foam to secure the cupcake. The cupcake bouquet is secured in a packaging box via two or more crossed skewers that are approximately the same length and width of the box. The vase of the cupcake bouquet is secured to the base of the box, and support pins passing through the mount restrict the movement of the cupcake bouquet in the box during transport. In some embodiments, the vase of the cupcake bouquet is affixed to a base plate, which restricts the movement of the cupcake bouquet in the box during transport.
[0020] Various embodiments of a method and apparatus for assembly and packaging of cupcake bouquets are described. In the following detailed description, numerous specific details are set forth to provide a thorough understanding of claimed subject matter. However, it will be understood by those skilled in the art that claimed subject matter may be practiced without these specific details. In other instances, methods, apparatuses or systems that would be known by one of ordinary skill have not been described in detail so as not to obscure claimed subject matter.
[0021] FIG. 1 is a frontal view of a cupcake bouquet 100 being assembled, according to one or more embodiments. The bouquet 100 includes a vase 102 , a mount 104 attached to the vase 102 using an adhesive 106 . The vase 102 forms the base of the bouquet 100 , and according to some embodiments, the vase 102 includes a glass vase, a plastic vase, a metal vase, among others. The mount 104 is generally a portion of a sphere, such as a hemisphere, to support cupcakes in a bouquet formation. The mount 104 may be made using a firm material capable of supporting the weight of the cupcakes, and to accommodate pins and skewers used for supporting cupcakes. According to some embodiments, the mount 104 is made using polystyrene foam, e.g., closed-cell extruded foam such as STYROFOAM, in a hemispherical shape. The adhesive 106 is any adhesive suitable for attaching the mount 104 to the vase 102 . According to some embodiments, the adhesive 106 is a thermoplastic adhesive such as hot melt adhesive applicable using a hot glue gun, an epoxy adhesive, and several other suitable adhesives as known in the art. In some embodiments, the mount 104 may partially overlap a top portion of the vase 102 to further ensure that the mount 104 is limited in movement. For example, the mount 104 may be shaped to have a portion fit snugly within an opening of the vase 102 , for example the mouth (not shown) of the vase 102 .
[0022] FIG. 2 is another frontal view of a cupcake bouquet 100 of FIG. 1 being assembled further, according to one or more embodiments. The bouquet 100 includes support pins 112 to provide support for cupcakes. The support pins 112 include for example, greenery pins (also called greening pins), U-shaped pins, and the like, and are inserted into the mount 104 . A portion of the support pins 112 projects outwards from the surface of the mount 104 to provide vertical support for cupcakes. Once inserted, the support pins 112 are not easily dislodged from the mount 104 . The portion of support pins 112 projecting from the mount 104 serve as a base to provide vertical support for a cupcake.
[0023] According to some embodiments, the bouquet 100 also includes a decorative colored sheet 108 covering the mount 104 , and a ribbon 110 for skirting the lower edge of the mount 104 . The colored sheet 108 may be made from paper, or plastics, such as cellophane, and the like and serve to mask the mount 104 with an aesthetically suitable color for the bouquet 100 appearance. Similarly, the ribbon 110 is an aesthetically suitable color and material, and may be crafted with different patterns, for example, patterns resembling plants and greens, or other desirable patterns. In one embodiment, the ribbon 110 is made from kale. In embodiments including the colored sheet 108 and/or the ribbon 110 , the support pins 112 additionally serve to hold the colored sheet 108 and the ribbon 110 in place. A decorative thread 109 to accommodate a tag 111 for displaying text 113 , such as, for addressing the recipient of the bouquet 100 may also be included.
[0024] FIG. 3 is a partial cut away view of a mount 104 shown in FIG. 2 illustrating the mounting of cupcakes 114 1 , 114 2 , and so on, collectively referred to as cupcakes 114 , according to one or more embodiments. Portions of support pins 112 project outwards from the mount 104 , and according to some embodiments, portions projecting from adjacent support pins 112 forms a base to hold the cupcakes 114 . The projection length of the support pins 112 is approximately equal to the portion of the cupcakes covered with cupcake baking cups 115 . Skewers 116 are inserted through the center of cupcakes 114 and into the mount 104 . The skewers 116 prevent a movement of the cupcakes 114 along the surface of the mount 104 . Although shown projecting outside the cupcakes 114 in FIG. 3 , the skewers 116 are inserted into the cupcakes 114 (or icing thereon) such that the skewers 114 are not visible. The skewers may be inserted into the cupcakes using any push tool, such as a cup bur used in the jewelry industry. In some embodiments, two or more skewers 116 are inserted into the cupcakes 114 and pushed closer to each other in configuration that ‘squeezes’ the baking material of the cupcakes 114 , thereby resulting in a tighter adherence of the cupcakes 114 to the mount 104 . The cupcakes 114 are mounted such that the cupcakes 114 project slightly upwards from the horizontal plane parallel to the base of vase 102 . For example, an axis 117 of the cupcake 114 2 is at a small angle 119 with the horizontal axis H. This slight upward projection of the cupcake 114 2 prevents an automatic movement of the cupcake 114 2 away from the mount 104 , for example, due to gravity.
[0025] The combination of the support pins 112 , the skewers 116 and a slight upward tilt of the cupcakes 114 provide a stable support arrangement to hold the cupcakes onto the mount 104 , so the cupcakes 114 are not easily dislodged from their position unless intentionally removed, for example, by a consumer of the cupcakes. The support arrangement described above maintains the cupcakes in position during transportation, without incurring any damage to the cupcakes. FIGS. 2 and 3 illustrate the use of support pins 112 to form a base to support the cupcakes 114 , and FIG. 4 illustrates an alternative embodiment to form a base to support the cupcakes 114 , as further described.
[0026] FIG. 4 is another frontal view of a cupcake bouquet 100 of FIG. 1 illustrating an alternate embodiment for mounting cupcakes. Instead of using support pins 112 to support a first level of cupcakes, the embodiment illustrated in FIG. 4 uses a supporting disc 130 . The supporting disc 130 is attached to the vase 102 with an adhesive 107 , and the mount 104 is attached to the supporting disc 130 using the adhesive 109 . The supporting disc 130 is made from material used for making carton boxes, for example, which is easily available due to the availability of carton boxes for packaging the bouquet 100 . According to some embodiments, the supporting disc 130 is made from other materials, including but not limited to, paper, glass, plastics, metal or a combination thereof. The adhesives 107 and 109 may be similar to or different from the adhesive 106 described above, and include suitable adhesives generally known in the art. The cupcakes 114 are secured to the mount 104 by use of skewers 116 , in a manner similar to that described with respect to the embodiment of FIG. 3 . The supporting disc 130 provides the vertical support provided by the support pins 112 in the embodiment of FIG. 3 . The supporting disc 130 provides vertical support to a first level of cupcakes, while other levels of cupcakes are supported by the first level of cupcakes in combination with further use of support pins and skewers, according to some embodiments.
[0027] FIG. 5 is a front view of an assembled cupcake bouquet 100 , according to one or more embodiments. According to some embodiments, about 16 support pins 112 are installed to support eight cupcakes 114 in a first level 119 1 of cupcakes 114 arranged around the mount 104 . A second level 119 2 of cupcakes 114 , for example, four cupcakes 114 can be mounted over the first level 119 1 . According to some embodiments, the cupcakes 114 of the first level 119 1 provide vertical support to the cupcakes 114 of the second level 119 2 , without requiring support pins 112 to support the cupcakes 114 of the second level 119 2 , however, the skewers 116 are provided for each cupcake. The second level 119 2 supports a third level 119 3 of one or more cupcakes 114 in a similar manner. According to some embodiments however, support pins 112 are provided for each cupcake 114 . While FIG. 5 illustrates the assembled cupcake bouquet 100 made by completing the embodiment illustrated in FIG. 3 , an assembled cupcake bouquet can be made similarly by completing the embodiment illustrated in FIG. 4 .
[0028] According to some embodiments, decorative elements 118 are included in the vase 102 . Such decorative elements 118 may be included in the vase 102 before attaching the mount 104 to the vase 102 as shown in FIG. 1 , or before attaching the supporting disc 130 to the vase 102 . The decorative elements 118 serve to increase the aesthetic of the bouquet 100 .
[0029] FIG. 6 is a perspective view of a cupcake bouquet 100 of FIG. 1 enclosed in a packaging box prior to being assembled, according to one or more embodiments. While the bouquet 100 may be packaged after assembly, that is, the bouquet 100 of FIG. 5 may be packaged, as show in FIG. 6 , securing the vase 102 within packaging material such as a carton box 120 before assembling the bouquet 100 protects the vase 102 from damage during the assembling process, for example, as illustrated in FIGS. 1-5 . The box 120 is generally made from paperboard, corrugated paper or corrugated fiberboard, however, other suitable materials may also be used without deviating from the scope and spirit of the present invention. FIG. 6 illustrates the box 120 partially, and a portion of the base 121 of the box 120 , and a portion of the wraparound portion 125 of the box are shown. The wraparound portion 125 includes cuts 122 and folds 124 to wrap around the box material around the neck of the vase 102 . The wrapped around box material is attached together by staples 126 , enclosing the vase 102 .
[0030] The vase 102 of the bouquet 100 is affixed to the base 121 using an adhesive 123 , which is a suitable adhesive similar to or different from the adhesive 106 . Affixing the vase 102 to the base 121 of the box 120 assists in preventing movement of the bouquet 100 within the box 120 , avoiding damage to the cupcakes mounted on the bouquet 100 during transport.
[0031] FIG. 7 is a perspective view of the assembled cupcake bouquet 100 of FIG. 5 installed in the packaging box 120 of FIG. 6 , according to one or more embodiments. The bouquet 100 further includes two box pins 128 to assist in preventing movement of the bouquet 100 within the box 120 . The box pins 128 are made of plastic, or any other suitable material that is lightweight yet rigid to sustain the movement of the bouquet 100 while being transported. The two box pins 128 are skewered through the mount 104 of the bouquet 100 , such that each of the box pins touches or nearly touches opposing walls of the box 120 . For example, one box pin 128 1 skewered through the mount 104 of the bouquet 100 has a length approximately equal to the distance between sidewalls 125 of the box 120 . The other box pin 128 2 has a length equal to the distance between a back wall 127 and a front wall 127 of the box 120 . When a lid (shown in FIG. 9 ) is mounted over the box 120 , movement of the box pins 128 will be constrained by the sidewalls 125 and the back wall 127 and a wall of the lid interfacing with the front wall 127 , thereby preventing the motion of the bouquet 100 within the box 120 , for example, when the bouquet 100 packaged in the box 120 is transported.
[0032] As illustrated by FIGS. 6 and 7 , attaching the vase 102 to the base 121 of the box, and the use of box pins 128 prevent the movement of an assembled bouquet 100 within the box. FIG. 8 illustrates an alternate technique to prevent the movement of an assembled bouquet 100 within the box, as further described.
[0033] FIG. 8 is a perspective view of an assembled cupcake bouquet 100 fixed to a base plate 132 , according to one or more embodiments. The vase 102 of the bouquet 100 is affixed to the base plate 132 by an adhesive 134 , similar to or different from the adhesive 106 , as generally known in the art. The base plate 132 has dimensions approximately equal to a base of a box in which the bouquet 100 is packaged, for example the base 121 of the box 120 . Due to the same size of the base plate 132 and the base 121 of the box 120 , the movement of the base plate 132 , and therefore the movement of the bouquet 100 attached thereon, is constrained. Such an arrangement therefore prevents the movement of the bouquet within the box 120 , and avoids damage to the bouquet 100 , for example, during transportation. According to alternative embodiments, the vase 102 is filled with heave materials such as pebbles to provide stability to the bouquet 100 to stay upright by balancing the top-heavy bouquet 100 due to the weight of the cupcakes 114 .
[0034] FIG. 9 is a perspective view of the completed cupcake bouquet 100 of FIG. 7 with complete packaging, according to one or more embodiments. The box 120 with the bouquet 100 installed therein is enclosed by a lid 136 . The lid 136 is made from a material similar to the material of the box 120 , and may include a label 136 for advertisement and/or addressing purposes. Additionally, the box 120 has two notched front corners which allow the lid 136 to easily pass over the box 120 , saving time and hassle.
[0035] Cupcake bouquets are assembled using the techniques illustrated with respect to FIGS. 2 and 3 , or alternatively FIG. 4 , such that the cupcakes are stably mounted on the bouquet. Thereafter, the assembled bouquets are packaged, for example, installed in carton boxes using the techniques illustrated with respect to FIGS. 6 and 7 , or alternatively FIG. 8 , such that the movement of the bouquets in the boxes is restricted. Various techniques described herein therefore provide a cupcake bouquet or cupcake holder having a stable mounting mechanism for the cupcakes, and a stable packaging arrangement, which prevent any damage to the cupcakes or the cupcake bouquet during transportation and handling.
[0036] Various elements are described above in association with their respective functions. These elements are considered means for performing their respective functions as described herein. While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof.
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The present invention relates to a cupcake holder for secure transport. In one embodiment, the cupcake holder comprises a vase, a mount for mounting a plurality of cupcakes, attached to the vase, a plurality of support pins attached to the mount, projections of pairs of the support pins of configured to support a cupcake; and at least one skewer corresponding to each of the plurality of cupcakes, inserted through each of the cupcake into the mount.
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This is a continuation of application Ser. No. 756,861, filed Jan. 4, 1977, now abandoned.
BACKGROUND OF THE INVENTION
The gypsum by-products derived from the production of phosphoric acid by the wet method and having the formula CaSO 4 .2H 2 O still constitute little used products which pose serious ecological problems. The production of phosphogypsum in phosphoric acid plants employing the wet method (action of sulfuric acid on phosphate rock) is increasing by hundreds of tons daily, and it is no longer possible for ecological reasons to continue dumping it into the sea or into rivers as has hitherto been the case. Moreover, storage of this product in dumps, as is currently practiced by numerous firms, also poses problems which are insurmountable in the long term.
Much research has been directed to the study of phosphogypsums in an effort to process from them raw materials having an intrinsic value.
Most of this research has been directed to the preparation, by more or less extensive dessication, of different types of plasters such as the semi-hydrates or more recently the hemi-hydrates, CaSO 4 .1/2H 2 O, of the α hard-plaster variety or the β flowable plaster of Paris variety and the anhydrous rehydratable CaSO 4 varieties such as hydraulic plasters.
On the other hand, there has been much less research into the anhydrous forms of CaSO 4 which are non-rehydratable after calcination, as these products were considered as having virtually no industrial importance.
SUMMARY OF THE INVENTION
There has now been developed a particularly important and novel type of anhydrous CaSO 4 which can be used to produce binders for the preparation of products having a high mechanical resistance and intended for use in place of conventional cements for all applications where the prepared coatings or surfacings are not in permanent contact with water or moisture.
The anhydrite bonding agent according to the invention comprises an anhydrite binder consisting of particulate anhydrous CaSO 4 having an insoluble CaSO 4 content of at least 93%, an average particle size diameter of 5 to 30μ with 15% by weight or more of the particles having a diameter smaller than 10μ and 20% by weight or more of the particles having a diameter larger than 20μ, and a pore volume of less than 0.29 cc/g in case of pores having a radius less than about 6.6μ. The invention also comprises the method of making such binders as hereinafter described.
DETAILED DESCRIPTION
The anhydrites of the present invention are prepared directly from phosphogypsums produced in the manufacture of phosphoric acid by the wet method. Such phosphogypsums are produced by the action of sulfuric acid on the fluoropatitic phosphofluoric minerals and no pretreatment is necessary as in the case of the processes currently employed for preparing plaster-type gypsum derivatives.
The starting products which are derived from the manufacture of phosphoric acid by the wet method are in the form of crystals collected in the breaker head (term of the art with respect to apparatus used in the wet process). The granulometry of the crystals is such that their size is between 2 and 350μ and the average diameter, i.e., the diameter which is such that 50% by weight of the product is on each side of this value, is on the order of 30μ. This phosphogypsum generally has a fairly constant diameter as it is filtered continuously during the manufacture of phosphoric acid. Its composition varies slightly according to the phosphates employed, but this does not affect its preparation and features of use in accordance with the present invention.
Research on the present invention has been based essentially on the use of a phosphogypsym having the following chemical composition after being dried at 80° C. at a constant weight:
______________________________________CaSO.sub.4 . 2H.sub.2 O 95-96%Fluorine 0.9-1.1%SiO.sub.2 0.7-0.9%Fe.sub.2 O.sub.3 0.15-0.30%Al.sub.2 O.sub.3 0.20-0.40%P.sub.2 O.sub.5 (water-soluble) 0.09-0.11%P.sub.2 O.sub.5 (insoluble) 0.4-0.6&______________________________________
The conversion of phosphogypsum into an anhydrite binder of the instant invention can be effected from phosphogypsum which is either obtained directly from the phsophoric acid preparation plant or from a stored product and comprises the following essential steps:
(a) calcination at a temperature of 450° C. to 1,200° C. and preferably 800° C. to 1,100° C. with the calcination being continued until the calcined granulated product has a pore volume of less than 0.25 cc/g in the case of pores having a radius smaller than 6.6μ and a granulometry which corresponds at least to the granulometry of the starting phosphogypsum; the product obtained at this stage is partially sintered and is friable, but is totally inactive, i.e., it is not rehydratable, and
(b) the second step consisting of a fine grinding operation which is regulated so as to obtain a product having a granulometry comprising at least 15% by weight of fine particles having a diameter smaller than 10μ and at least 20% by weight of particles having a diameter larger than 20μ, with an average particle diameter of 5 to 30μ.
The product thereby obtained which comprises at least 93% insoluble CaSO 4 and has a pore volume of less than 0.29 cc/g in the case of pores having a smaller radius than 6.6μ is easy to handle. It can thus be packed or delivered in bulk to the user. It has also returned to the hydratable state and can be used to prepare good quality anhydrite binders. These can be used in place of conventional cements for all applications where the coatings or coverings prepared are not in direct contact with water or moisture. The particular advantages of the products are their good fluidification properties and their low mixing water requirement.
Calcination of the phosphogypsum can take place in all types of furnaces such as rotating furnaces, tunnel furnaces, electric furnaces, blast furnaces, but the use of conventional rotating furnaces has proved especially advantageous. The length of the calcining process varies with the temperatures. When a rotating furnace is used at temperatures of 800° C. to 1,100° C. residence times of 1 to 2 hours are sufficient to obtain a calcined phosphogypsum having the requisite properties. As an example, the capacity of a fuel-heated rotating furnace which is 30 meters in length and 3 meters in diameter and equipped with a refractory lining is approximately 10 tons per hour.
The calcined phosphogypsum can be ground after storage in a single operation or preferably in a double operation. In the latter case, the calcined product is first crushed in a jaw type or cylinder grinder. It is then supplied to a ball mill or Forplex pin grinder and ground to the desired granulometry. The fineness of the grinding operation and simultaneous presence of fine grains and larger grains is essential to regulate the setting rate of a rapid setting cement product requiring very little mixing water.
The use of a ball mill is especially advantageous as it enables the activators required in the preparation of anhydrite bonding agents from the anhydrite binder to be introduced directly into the ball mill during the grinding operation.
To provide the anhydrite with suitable properties for the preparation of mortar, it is necessary to add small quantities of products known as activators to the anhydrites. The purpose of the activators is to increase the rehydration rate of the anhydrite while retaining the mixing water sufficiently long to prevent it from evaporating before sufficient hydration of the anhydrite. The activators can be added to the phosphogypsum before calcination, after calcination, or during grinding by adding them in the dry state or dissolved state or in suspension in the mixing water. The phrase "anhydrite bonding agent" is used herein to mean the mixture of activator and anhydrite of the present invention.
It is necessary to add 0.5 to 4% of the activators, based on the weight of the anhydrite. Examples of suitable activators include mineral agents such as sulfates, alkaline earth oxides and hydroxides, alkaline silicates, used either separately or in combination. The use of mixtures of potassium sulfate and slaked lime as activators has proved especially advantageous as the pastes produced with these elements when mixed with water possess both a rapid setting rate and good plasticity while eliminating the risk of releasing sulfurated hydrogen through hydrolysis of calcium sulfide during mixing.
The addition of fluidifying resins such as the alkaline salts of fulfonated styrene or substituted styrene polymers or copolymers, described in copending application Ser. No. 621,353, filed Oct. 10, 1975, and incorporated herein by reference, in amounts of 0.01 to 10% also enables the anhydrite according to the invention to be used for producing rapid setting self-smoothing coatings having only minimal sweating characteristics and good mechanical properties.
The anhydrite bonding agents prepared from the anhydrite produced by this invention are characterized upon use by certain advantageous properties.
At the normal mixing consistency, they possess a water content of less than 30% measured according to NF P15-402. This is an especially low water content. By comparison, flowable plasters have a normal mixing consistency of up to 80%. That of overburned plasters is approximately 40% and that of Portland cements, which is variable according to their composition, is currently 40%. The stoichiometric water absorption of anhydrite CaSO 4 to form CaSO 4 .2H 2 O is 26%.
The time taken for the bonding agent according to the invention to begin to set after activation with 1% K 2 SO 4 and 1% Ca(OH) 2 is from 20 minutes to 1 hour 30 minutes. It is in excess of 30 minutes in the case of Portland cements and 1 to 6 minutes in the case of plasters.
The anhydrite bonding agent according to the invention can be fluidified without a large amount of water. By adding 1% of the fluidifying resin described above, a paste is obtained which is capable of flowing at the rate of 30 kg/hxcm 2 through a circular orifice with a quantity of water which does not exceed by 3 points the water content at normal mixing consistency.
The products obtained possess good mechanical properties capable of satisfying the requirements of the building industry. For example, a bonding agent prepared from the subject anhydrite which is used without a fluidifying agent but with 1% K 2 SO 4 and 1% Ca(OH) 2 as activators produces the following results by comparison with anhydrite bonding agents according to German standard DIN 4208.
__________________________________________________________________________ Anhydrite bonding Anhydrite bonding agents as agents according defined by DIN 4208 to the invention AB 50 AB 125 AB 200 7 28 7 28 7 28 7 28 days days days days days days days days Min. Values Min. Values__________________________________________________________________________Tensile strengthaccording toNF P 15-451...kg/cm.sup.2... 40 80 15 35 30 50 40 80Compression strengthaccording to NF P15-451kg/cm.sup.2... 200 400 50 150 150 250 200 400Rockwell hardnessaccording toASTM E 18 method A -Scale R 70 85 -- -- -- -- -- --__________________________________________________________________________
The non-limitative examples provided below serve to illustrate the anhydrite and anhydrite bonding agents according to the invention as well as the mortars prepared from these bonding agents.
EXAMPLE 1
A phosphogypsum having the following average composition is taken from a dump:
______________________________________Water 13.5%CaSO.sub.4 . 2H.sub.2 O 83.0%F 0.85%SiO.sub.2 0.70%Fe.sub.2 O.sub.3 0.20%Al.sub.2 O.sub.3 0.25%P.sub.2 O.sub.5 (water-soluble) 0.09%P.sub.2 O.sub.5 (insoluble) 0.45%Various other elements such as Na - MgO <1%______________________________________
The product is in the form of a pulverulent material having the following granulometric characteristics:
Average diameter: 32 microns
20% by weight: larger than 60 microns
20% by weight: smaller than 12 microns
It is deposited on Inconel trays in layers 2 cm. deep. When these trays have been filled, they are inserted in an electric furnace which is initially at ambient temperature.
After a constant air flow rate has been established inside the furnace the heating operation is commenced. A substantially linear temperature rise enables the temperature to reach 885° C. after 12 hours. The product is kept at this temperature for 1/2 hour and then the heating operation is interrupted and the furnace opened. The temperature drops rapidly and reaches 350° C. 3 hours after termination of heating. The product is allowed to cool slowly until it can be recovered.
A pinkish-beige product is obtained. It is in the form of friable agglomerates which can be reduced to powder form simply by manual stirring.
When examined by X-ray diffraction, the solid will be found to consist exclusively of insoluble (CaSO 4 β) anhydrite.
Granulometric analysis produces the following results:
Average diameter: 38 microns
20% by weight: larger than 66 microns
20% by weight: smaller than 14 microns
The pH of an aqueous 10% suspension of this anhydrite is slightly basic.
The product is then subjected to the following tests for bonding agents:
1. Determination of the water content at normal consistency.
29.5% is determined according to NF P 15 402
2. Measurement of the setting rate with a Vicat needle.
Measured according to NF P 15 431
The anhydrite mixed with 29.5% of its weight with water in which 1% of its weight in K 2 SO 4 has been dissolved begins to set after 6 hours. Setting is terminated 10 hours after mixing.
3. Measurement of the mechanical resistances of pure paste.
Measured according to NF 15-451.
The results are the averages of five tests to determine the tensile strength and of ten tests to determine compression strength. The following values were obtained:
______________________________________ Values After 7 days 28 days______________________________________Tensile strength kg/cm.sup.2 65 70Compression strength kg/cm.sup.2 232 313______________________________________
4. Rockwell Hardness
Measured in accordance with ASTM E 18 (method A, scale R).
A 7 days: 71
A 28 days: 84
4. Fluidification Test
This test was carried out by the applicant to evaluate the anhydrite bonding agents when they are used, for example, to pour surfacings. In this case, it is especially advantageous to be able to prepare a paste having sufficient fluidity for it to flow through a pump and for it to be self-spreading and self-leveling. This considerably reduces the clean-up work required and lowers labor costs.
Fluidification of anhydrite mixed with water is obtained by adding thereto small quantities of specific resins of the types claimed in U.S. application Ser. No. 621,353. The test consists in measuring the flow rate of the paste flowing through a calibrated orifice disposed at the lower end of a 250 ml. pouring container filled with anhydrite and water. It also contains fluidifying resin at a ratio of 1% by weight of the calcium sulfate employed.
The fluidity is satisfactory when the flow rate reaches 30 kg/hxcm 2 .
It is obviously always possible to reach this value by merely adding sufficient water. However, if the amount of water is excessive the mechanical properties will be adversely affected. We have set the limits for the amount of water at 3 points above the normal consistency.
In the example described, the fluidity of the paste obtained by mixing an anhydrite with a maximum of 32.5% water and 1% resin is virtually 0. Although it possesses excellent bonding properties and is superior, for example, to the AB 125 variety of anhydrite bonding agents as defined by German Standard DIN 4208, the product as prepared above can be considered inadequate.
EXAMPLE 2
The phosphogypsum in Example 1 is removed from a dump by a machine which is used to supply a continuous proportioning device. After being transported on a conveyor belt, it is conveyed in transit by a hopper used upstream of a rotating furnace. The furnace is 30 meters in length and has a diameter of 3 meters. It consists of a metal sheating internally equipped with a refractory brick lining. It is heated by a fuel burner located on the axis of the furnace at the product discharge point and has a flow rate of 400 liters/fuel hour.
The phosphogypsum which enters at 10 tons per hour comes into contact with the combustion gases which are discharged at a temperature of approximately 450° C. As it passes through the furnace, it reaches a maximum temperature of approximately 900° C. and then cools down substantially in the last part of the furnace.
The sulfate is discharged at approximately 750° C. in the form of anhydrite approximately 1 hour after being introduced into the rotary furnace.
After cooling the anhydrite is coarsely ground and then sieved. The particles obtained have the following granulometric characteristics:
Average diameter: 60 microns
20% by weight: larger than 105 microns
20% by weight: less than 23 microns
This product has a water content at normal consistency of 22%. Mixed with 1% K 2 SO 4 it sets slowly:
commencement of setting: 7 hours
termination of setting: 10 hours
The mechanical resistances measured under normal conditions product the following results:
______________________________________ Values After 7 Days After 28 Days______________________________________Tensile strength kg/cm.sup.2 2.7 11.3Compression strength 5.7 25Rockwell hardness broken broken______________________________________
Fluidification of this anhydrite does not take place. When determining the proportions of the cake which subsequently sets, it is found that the quantity of gypsum is only 15.4%. This product which has no value as a bonding agent has a very low reactivity vis-a-vis, rehydration.
EXAMPLE 3
The anhydrite prepared as described in Example 2 by calcining phosphogypsum in a rotary furnace is supplied to a pin mill equipped with 0.1 millimeter grid.
The ground product is characterized by its Blaine surface which reaches 7.255 cm 2 /g and by its granulometry, of which the characteristic values of the particles are as follows:
Average diameter: 7 microns
20% by weight: larger than 16 microns
20% by weight: less than 2.7 microns
This anhydrite has a water content at normal consistency of 23.5%. When mixed with 1% K 2 SO 4 and 1% (Ca(OH) 2 it begins to set after 20 minutes and setting is terminated after 38 minutes.
The cake produced has excellent mechanical properties. Rockwell hardness is 96.6 after 7 days and, finally, 97.2 after 28 days.
Unfortunately, this product cannot be fluidified with the fluidifying resin descirbed in U.S. application Ser. No. 621,353. Neither can it be fluidified with any other product.
This limits the number of uses for this anhydrite.
EXAMPLE 4
The same anhydrite obtained by calcination in a rotary furnace is supplied to a ball mill. It remains in the mill for 47 hours. At the end of the 47 hours, a powder having the following characteristics is obtained:
Blaine surface: approximately 2500 cm 2 /g
Average diameter: 19 microns
20% by weight: larger than 51 microns
20% by weight: less than 7.4 microns
The water required at normal consistency is 23%. The setting of the product mixed with 1% K 2 SO 4 and 1% Ca(OH) 2 is measured with a Vicat needle. Setting begins 40 minutes after mixing and is terminated 20 minutes later.
The mechanical resistances of the products are as follows:
______________________________________Mechanical Properties of the Values Pure Paste After 7 Days After 28 Days______________________________________Tensile strength kg/cm.sup.2 61 84Compression strength kg/cm.sup.2 268 510Rockwell Hardness 91 94______________________________________
Moreover, when this anhydrite is mixed with 25% water in the presence of 1% fluidifying resins as described in U.S. application Serial No. 621,353, a paste is obtained whose fluidity is 34 kg/hxcm 2 .
With the same activators, K 2 SO 4 and Ca(OH) 2 , this paste sets 1 hour and 15 minutes to 1 hour and 45 minutes after mixing. The mechanical resistance values of the product are now the following:
______________________________________Mechanical Properties with Added Values Fluidifying Agent After 7 Days After 28 Days______________________________________Tensile strength kg/cm.sup.2 62 102Compression strength kg/cm.sup.2 277 578Rockwell Hardness 87 91______________________________________
This product is suitable for multiple bonding uses.
EXAMPLE 5
Phosphogysum of the type described in Example 1 is deposited on trays in a layer of approximately 2 cm. thickness. The trays are placed in a vertical electric furnace. The product is subjected to a thermal treatment of 2 hours duration. This treatment consists in rapidly raising the temperature to 721° C. followed by isothermic heating at this temperature for 38 minutes.
The anhydrite obtained is characterized by its porosity which is measured by mercury penetration. The pore volume of this product is 0.294 cc/g in the case of pores having a radius smaller than 6.6 microns. The product is then ground in a ball mill for 20 hours until it has the following particle granulometry:
average diameter: 18 microns
20% by weight: larger than 49 microns
20% by weight: smaller than 7.9 microns
Blaine surface: 6338 cm 2 /g
This product has a water content at normal consistency of 39%.
As the mechanical properties decline rapidly according to the proportion of water in the paste, the anhydrite calcined in the above manner at 721° C. has bonding agent properties which may be considered inadequate for certain uses.
EXAMPLE 6
The phosphogypsum is treated in the same apparatus as used in the preceding example so as to rapidly reach the temperature of 950° C. The product is kept at this temperature for 1/2 hour. The thermal treatment takes a total of 2 hours.
The calcined product has a pore volume of 0.07 cc/g in the case of pores having a radius smaller than 6.6 microns.
The product is placed in a ball mill and ground for 44 hours. Upon termination of this operation, the anhydrite has a Blaine surface of approximately 3000 cm 2 /g and its granulometry is characterized by the following:
an average diameter of: 18 microns
20% by weight: larger than 51 microns
20% by weight: smaller than 7.7 microns
This ground product also has a pore volume of pores with radii smaller than 6.6 microns of 0.18 cc/g.
This anhydrite only requires 20% water for mixing at normal consistency.
The setting process, in the presence of 1% K 2 SO 4 and 1% Ca(OH) 2 , begins 1 hour and 20 minutes after commencing mixing and is terminated after 2 hours and 10 minutes.
The cake thereby obtained has a Rockwell hardness after 7 days of 98. In the fluidification tests, a fluidity of 30 kg/hxcm 2 can be obtained with this anhydrite with 1% resin when it is mixed with only 22% water.
The fluidified anhydrite sets and reaches a hardness after 7 days of 95.2. Accordingly, this represents a cement product of excellent quality.
While the invention has been described in connection with the preferred embodiments, it is not intended to limit the invention to the particular forms set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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The present invention relates to an anhydrite binder and to the method of making the same from the gypsum by-product (phosphogypsum) resulting from the production of phosphoric acid by the wet method, said binder comprising particulate anhydrous CaSO 4 with an insoluble CaSO 4 content of at least 93%, an average particle size diameter of 5 to 30, with 15% by weight or more of the particles having a diameter smaller than 10μ and 20% by weight or more of the particles having a diameter larger than 20μ, and a pore volume of less than 0.29cc/g in the case of pores having a radius less than about 6.6μ.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to optical communication, and, more specifically, to optical channel monitors in dense wave-division multiplexing systems.
2. Description of the Related Art
Historically, the fibers in optical communications systems were illuminated with light consisting of one, or at most a handful, of wavelengths. With the widespread adoption of dense wave-division multiplexing (DWDM) technology, it is now common to light fibers with tens or even hundreds of different wavelengths simultaneously, each wavelength representing a different channel within the system. As the number of wavelengths and the general complexity of these systems have increased, correspondingly higher demands have been placed on the optical performance monitoring systems that are used to manage bandwidth, power, amplification, attenuation, and dynamic filtering within these systems. These optical performance monitoring systems and the system attributes they control are essential for robust operation of the network. They are also key elements of fault reporting, analysis, and management subsystems.
One of the primary functions of optical monitors in optical communications systems today is the detection of the channels that are present in the various optical links of these systems. The conventional approach to channel detection used by these optical monitors is based on certain assumptions about the optical spectrum of a DWDM signal. A typical DWDM signal spectrum consists of sharp peaks located at the centers of the channel wavelengths superimposed on a smooth background of additive spontaneous emission (ASE) noise. This is illustrated by FIG. 1 , which depicts power (dBm) versus wavelength (nm) for a DWDM signal composed of two channels 102 and 104 superimposed on an ASE noise background. Note that the peaks of the spectrum 102 and 104 correspond to the channels in the signal at typical International Telecommunications Union (ITU) standard 100-GHz grid channel-to-channel spacing in the vicinity of 1593 nm. Under these conditions, channels can be detected by finding the peaks in the spectrum. This approach works even in the presence of relatively strong ASE noise.
However, modern DWDM systems include additional components, notably optical add-drop multiplexers (OADMs), wavelength interleavers, and active optical switching and multiplexing components, which generally employ sharp wavelength filtering to accomplish their various functions. As DWDM signals pass through these components, the components' filtering functions are impressed on the smooth ASE noise background of the signals, resulting in sharp spectral features centered on and about the ITU channel locations. This is illustrated by FIG. 2 , which depicts power (dBm) versus wavelength (nm) for a DWDM signal that has passed through various filtering components. This signal includes three channels 202 , 204 , and 206 superimposed on an ASE noise background. Note that the peaks of the spectrum corresponding to channels 202 , 204 , and 206 are not significantly higher, in some cases, than the peaks of the filtered ASE noise. In particular, in FIG. 2 , some of the noise peaks 208 corresponding to the shorter wavelengths have more power than some of the channel peaks. Under these conditions, the peak-finding approach to channel detection is often inadequate. With increasing modulation rate and filter cascading, the width of the peak is not a clear indicator of the presence of a channel. Although it is still possible to distinguish the channel peaks from the interleaved ASE peaks given sufficient spectral resolution in the spectrometer within an optical monitor, such spectrometers are relatively expensive and have slower scan speeds than peak detection devices.
SUMMARY OF THE INVENTION
To address the above-discussed deficiencies of the prior art, one embodiment of this invention is a dense wave-division multiplexing (DWDM) channel detection system that includes an interferometer (e.g., Mach-Zehnder) coupled to a spectrum analyzer to differentiate interleaved additive spontaneous emission (ASE) noise from optical channels in a DWDM signal. The DWDM signal is assumed to include one or more channels, wherein the channels, if present, are centered at frequencies that are a fixed frequency offset from each other corresponding to a standardized channel grid (e.g., an ITU 100-GHz grid). The relative delay of the two paths within the interferometer is preferably chosen to be greater than the coherence time of the ASE noise but less than the coherence time of the channels. The relative delay is preferably further restricted such that the free spectral range (FSR) of the interferometer is an integer divisor of the channel-to-channel frequency spacing within the channel grid and consequently any channels present that conform to this grid experience a high degree of constructive interference.
In operation, the output of the interferometer is applied to an optical spectrum analyzer and a measurement is made of the power at each frequency of the grid. The phase delay of the interferometer may then be adjusted to maximize the destructive interference at each frequency aligned to the grid and a measurement may again be made of the power at each frequency of the grid. The difference between the constructive and destructive measurements is then calculated at each frequency on the grid and compared to a threshold to determine the presence or absence of channels in the DWDM signal.
In another implementation, two output port from a dual-output interferometer are used, one preset for maximum constructive interference and one preset for maximum destructive interference of frequencies aligned to the grid. Simultaneous measurements are made with both output ports of the power at each frequency of the grid and the difference at each frequency calculated and compared to a threshold, as before, to determine the presence or absence of channels.
In one embodiment, the invention is an optical channel detector, comprising (a) an interferometer connected to receive an input optical signal having one or more optical channel signals and generate one or more output optical signals, wherein each output optical signals corresponds to a sum of the input optical signal and a delayed version of the input optical signal; (b) at least one spectrum analyzer connected to receive at least one output optical signal from the interferometer and generate data signals corresponding to the power of the at least one output optical signal at a plurality of different grid frequencies; and (c) a control processor connected to receive the data signals from the at least one spectrum analyzer and generate a control signal to control the delay applied by the interferometer, wherein the control processor is adapted to control the delay applied by the interferometer at one or more different settings corresponding to different degrees of constructive/destructive interference of the one or more optical channel signals at the different grid frequencies; and the control processor is adapted to compare the data signals generated by the at least one spectrum analyzer for one or more different delay settings to determine whether an optical channel signal is present in the input optical signal at each grid frequency.
In another embodiment, the invention is a method for detecting optical channels. The method involves generating one or more output optical signals from an input optical signal, wherein each output optical signals corresponds to a sum of the input optical signal and a delayed version of the input optical signal. It also involves generating data signals corresponding to the power of the at least one output optical signal at a plurality of different grid frequencies. Additionally, it involves controlling the delay applied in generating the one or more output optical signals at one or more different settings corresponding to different degrees of constructive/destructive interference of the one or more optical channel signals at the different grid frequencies; and comparing the data signals generated for one or more different delay settings to determine whether an optical channel signal is present in the input optical signal at each grid frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which:
FIG. 1 depicts power (dBm) versus wavelength (nm) for a DWDM signal composed of two channels superimposed on an ASE noise background.
FIG. 2 depicts power (dBm) versus wavelength (nm) for a DWDM signal that has passed through various filtering components.
FIG. 3 is a block diagram of a dense wave-division multiplexing (DWDM) optical communications system according to one embodiment of this invention.
FIG. 4 is a block diagram depicting one implementation of the channel-detecting portion of each optical monitor of FIG. 3 .
FIG. 5 is a flowchart of the operation of the channel-detecting portion of each optical monitor of FIG. 3 for the implementation of FIG. 4 .
FIG. 6 is a block diagram depicting an alternative implementation of the channel-detecting portion of each optical monitor of FIG. 3 .
FIG. 7 is a block diagram depicting yet another alternative implementation of the channel-detecting portion of each optical monitor of FIG. 3 .
DETAILED DESCRIPTION
Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
DWDM System
FIG. 3 is a block diagram of a dense wave-division multiplexing (DWDM) optical communications system 302 according to one embodiment of this invention. System 302 includes start terminal 304 , end terminal 306 , intervening repeaters 308 , and optical add-drop multiplexers (OADMs) 310 interconnected by fiber optic links. System 302 also includes optical monitors (OMONs) 312 , each of which monitors the output of a repeater or OADM by tapping a small amount of power from its fiber optic output. Each OMON 312 also provides status and control to its associated repeater or OADM and to centralized management devices (not shown in FIG. 3 ) via simple network management protocol (SNMP) or an equivalent mechanism. Start terminal 304 and end terminal 306 typically include optical translation units (OTUs), multiplexers and demultiplexers with integral interleavers, and optical amplifiers (OAs). Each repeater typically includes OAs and one or more dispersion compensation modules (DCMs). Each OADM typically includes interleavers for multiplexing and demultiplexing of channels into and out of the fiber links and OAs and dispersion compensation modules (DCMs) for correcting optical dispersion introduced into the fiber paths. Each OMON includes circuitry for detecting the channels present in the optical fiber link it monitors and for adjusting the operational parameters of its associated repeater or OADM accordingly.
In the system illustrated by FIG. 3 , as a DWDM signal passes through the various filtering and interleaving devices (e.g., OADMs, multiplexers, and demultiplexers), the relatively smooth additive spontaneous emission (ASE) noise from the OAs is shaped into spikes at various frequencies, including those frequencies corresponding to standardized channel grids (e.g., the ITU 100-GHz grid). An exemplary signal spectrum, as discussed previously, is illustrated by FIG. 2 , where peaks corresponding to some of the actual channels 202 , 204 , and 206 are shown to be no higher than peaks ( 208 ) corresponding to some of the filtered ASE noise spikes. Because of this, those noise peaks that align to the standardized channel grid might be misinterpreted as representing active channels at the corresponding frequencies of the grid.
Channel Detector
FIG. 4 is a block diagram depicting one implementation of the channel-detecting portion of each OMON 312 of FIG. 3 . In particular, FIG. 4 shows interferometer 404 , spectrum analyzer 406 , and control processor 408 .
DWDM signal 402 is first input to optical interferometer 404 . Interferometer 404 may be of any suitable type including, for example, Mach-Zehnder or Michelson. A preferred embodiment utilizes a Mach-Zehnder interferometer. The interferometer splits the signal into two paths 412 and 414 , delays one path ( 412 ) with respect to the other path ( 414 ), recombines the two paths, and outputs the result to spectrum analyzer 406 .
Spectrum analyzer 406 may also be implemented in various ways. These implementations might involve spectral separating or filtering devices followed by multiple banks of power detectors, potentially all in the optical domain. FIG. 4 illustrates a preferred implementation. Here, within spectrum analyzer 406 , the output of interferometer 404 is split into separate spectral components via optical (e.g., fiber Bragg or bulk optics) grating 416 (alternatively, a prism could be used) and the result used to illuminate CCD array 418 . The array is read out under the control of control processor 408 yielding data ( 420 ) representing essentially the relative power vs. wavelength characteristics of the signal that was output from interferometer 404 . Control processor 408 controls the relative phase (i.e., delay) of interferometer 404 via control interface 410 . In operation, control processor 408 alternates the relative delay of interferometer 404 between two settings.
In the first setting, the relative delay of interferometer 404 is chosen such that each component of signal 402 with a frequency corresponding to a regular channel grid (e.g., the ITU standard 100-GHz grid) will substantially constructively interfere with itself. In the second setting, the relative delay of the interferometer is chosen so that each component of signal 402 with a frequency corresponding to a regular channel grid will substantially destructively interfere with itself. The signals output from interferometer 404 at the first setting are processed by spectrum analyzer 406 to obtain a first power estimate at each grid frequency. The signals output from interferometer 404 at the second setting are also processed by spectrum analyzer 406 to obtain a second power estimate at each grid frequency. A difference is then computed in control processor 408 at each grid frequency between the two different estimates, and each difference is thresholded to determine the presence or absence of channels at those frequencies. This procedure is captured by the flow diagram of FIG. 5 .
Single Output Interferometer Control Procedure
In step 502 of FIG. 5 , interferometer 404 of FIG. 4 is calibrated to determine the control voltage from control processor 408 to the interferometer via interface 410 that results in constructive interference at grid frequencies. This calibration might be done in the factory or in the initial configuration, or might possibly be integrated into the run-time operation of the system. If a run-time calibration is performed, it might be run at some externally configured interval and might make use of a priori knowledge of known channels within the system. In step 504 , a similar calibration is done to determine the correct control voltage that results in destructive interference at the grid frequencies. This may alternatively be derived given the prior voltage setting, knowledge of the interferometer characteristics, and the grid frequency spacing.
Once calibration is complete, the steady state operation of the channel detector of FIG. 4 commences in step 506 with the setting of interferometer 404 in step 508 to achieve constructive interference at the grid frequencies. In step 510 , control processor 408 scans CCD array 418 and adjusts the resulting data to produce estimates of the power content of the signal out of the interferometer at each grid frequency. In step 512 , these “constructive” estimates are stored.
In step 514 , the interferometer is set to achieve destructive interference at the grid frequencies. In step 516 , the control processor again scans the CCD array and adjusts the data to produce estimates of the power content of the signal out of the interferometer at each grid frequency. In step 518 , these “destructive” estimates are stored.
After power estimates at each grid frequency for both constructive and destructive settings of the interferometer are stored, the differences are calculated and thresholded by control processor 408 for channel detection. This process starts in step 520 where grid frequency counter F is initialized to zero. In step 522 , the counter is incremented to “one” to reference the constructive and destructive power estimates stored previously for the first grid frequency. Next, in step 524 , these stored values are retrieved and their difference is computed. In step 526 , this difference is compared to a threshold. If the difference is greater than the threshold, in step 528 , indication is provided by the control processor to the rest of the system that an active channel was found at that frequency. This can be done via a serial output from the control processor, an interrupt to an external microprocessor, a communication protocol (e.g., simple network management protocol (SNMP)), or other suitable means. In either case, in step 530 , the frequency counter is compared to a terminal grid frequency count to see if all the grid frequency values have been considered. If not, control returns to step 522 where the frequency counter is again incremented to process data for the next grid frequency. Steps 522 through 530 are repeated until all the grid frequency differences have been computed, thresholded, and active channel indications sent. After the last frequency has been considered, as determined in step 530 , control returns to step 506 where detection begins anew, potentially after some inter-detection delay.
Referring back to FIG. 4 and the related discussion, if the relative delay of the interferometer is set to 10 ps by control processor 408 , then the free spectral range (FSR) of the interferometer will be 100 GHz and the components of signal 402 that are aligned to a standard ITU 100-GHz grid will all experience constructive interference. Likewise, each component of signal 402 with a frequency corresponding to a regular channel grid of 200 GHz will also experience constructive interference, and more generally, each component of signal 402 with a frequency corresponding to a regular channel grid of N×100 GHz (where N is a positive integer) will also experience constructive interference.
Similarly, if the relative delay of the interferometer were set to 20 ps by control processor 408 , then the FSR of the interferometer would be 50 GHz and still the components of signal 402 that are aligned to a standard ITU 100-GHz grid will experience substantial constructive interference (as would those components that are aligned to a 50-GHz grid). More generally, if the relative delay of the interferometer is set to N×10 ps, each component of signal 402 that is aligned to the ITU standard 100-GHz grid will experience constructive interference (as will those components aligned to 100/N-GHz grids). This will result in relative peaks in the spectrum of the output of the interferometer corresponding to frequencies substantially aligned with the grid.
These peaks corresponding to constructive interference will occur when the components of signal 402 at the various frequencies are coherent (i.e., are phase continuous) relative to the relative delay of the interferometer (i.e., relative to the free spectral range of the interferometer). This is typically the case for active channels within optical communication systems since such channels rarely exhibit coherence times less than the symbol interval of the modulating carrier, and generally the coherence time for a CW laser (not data modulated) is much longer. Noise (e.g., additive spontaneous emission (ASE) noise), however, is generally uncorrelated and therefore exhibits a much shorter coherence time than active channels do. The result of this is that, as long as the relative delay of the interferometer is longer than the coherence time of the noise, the noise spectrum will be substantially unchanged by the interferometer, while components of input signal 402 corresponding to the channel grid will be emphasized.
Note that the second setting of the interferometer results in exactly the opposite effect. In other words, when the relative delay of interferometer 404 is changed to the second setting by control processor 408 , each component of signal 402 with a frequency that is aligned to the channel grid will substantially destructively interfere with itself, rather than substantially constructively interfering with itself.
By alternating the relative delay of the interferometer between (1) a first relative delay that yields constructive interference of coherent, grid-aligned components of signal 402 and (2) a second relative delay that yields destructive interference of coherent, grid-aligned components of signal 402 , control processor 408 is able to create (using interferometer 404 and spectrum analyzer 406 ) two signals whose difference, taken at each grid frequency has a spectrum that exhibits (i) peaks corresponding to the active channels that are substantially aligned with the channel grid and (ii) nulls where the input signal 402 has substantial, though, non-coherent (i.e., noise-related) power at grid-aligned wavelengths. By comparing these peaks with a predetermined or AGC-controlled or normalized threshold, control processor 408 is able to compute, with a high degree of certainty, the grid frequencies that contain active channels.
Dual-Output Interferometer Version
FIG. 6 depicts an alternative implementation of the channel-detecting portion of each OMON 312 of FIG. 3 . This device is similar to the device of FIG. 4 , except that, instead of using a single-output interferometer to drive a single spectrum analyzer and alternating between 0- and 180-degree phase shifts to achieve constructive and destructive interference at the channel grid-aligned frequencies, the device in FIG. 6 utilizes dual-output interferometer 604 and feeds each output to a different spectrum analyzer. Interferometer 604 is either calibrated in advance or controlled dynamically by control processor 614 via control interface 618 . This calibration or control of the relative delay of the interferometer is such that coherent, grid-aligned components of signal 602 constructively interfere at upper output 606 of the interferometer, in a manner similar to the operation of the single output of interferometer 404 of FIG. 4 . Additionally, the design of interferometer 604 is such that, at the same control setting, coherent, grid-aligned components of signal 602 destructively interfere at lower output 608 . The outputs of both upper ( 610 ) and lower ( 612 ) spectrum analyzers are processed by control processor 614 to produce the difference of the power detected at each frequency ( 616 ). As before, the differences at the noise frequencies will be relatively small, while the differences at frequencies corresponding to active channels will be relatively large. Note that this design, which is based on a dual-output interferometer, eliminates the need to alternate the interferometer between constructive and destructive phases, but at the cost of duplicating the spectrum analyzer hardware.
As stated before, many different implementations for both interferometer and spectrum analyzer are possible. FIG. 6 depicts Mach-Zehnder type dual-output interferometer 604 followed by two grid/CCD-array type spectrum analyzers 610 and 612 , though other implementations are possible, as would be understood to one skilled in the art. For example, instead of duplicating the spectrum analyzers, a 2×1 optical switch could be fashioned between the dual-output Mach-Zehnder and a single spectrum analyzer, as depicted in FIG. 7 .
Alternatively, each output of a dual-output Mach-Zehnder device could feed a different grid. These two grids could be controlled to alternately illuminate a single CCD-array in ping-pong fashion. The data read from the array after illumination by output of the first grid (e.g., data corresponding to constructive interference at grid-aligned frequencies) could be subtracted from the data read from the array after it has been illuminated by the output of the second grid (e.g., data corresponding to destructive interference at grid-aligned frequencies) to form the difference signal that is thresholded at each grid frequency to determine the active channels in the fiber link.
While this invention has been described with reference to illustrative embodiments, this description should not be construed in a limiting sense. Various modifications of the described embodiments, as well as other embodiments of the invention, which are apparent to persons skilled in the art to which the invention pertains are deemed to lie within the principle and scope of the invention as expressed in the following claims.
One or more elements of the present invention may be implemented as circuit-based processes, including possible implementation on a single integrated circuit. As would be apparent to one skilled in the art, various functions of circuit elements may also be implemented as processing steps in a software program. Such software may be employed in, for example, a digital signal processor, micro-controller, or general-purpose computer.
Although the steps in the following method claims, if any, are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those steps, those steps are not necessarily intended to be limited to being implemented in that particular sequence.
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A channel detection system includes an interferometer coupled to a spectrum analyzer to differentiate additive spontaneous emission (ASE) noise from optical channels in a dense wave-division multiplex (DWDM) signal. It is assumed that channels, if present, are centered at frequencies corresponding to a standardized channel grid. The relative delay of the interferometer is chosen to be greater than the coherence time of the ASE noise but less than the coherence time of the channels with the interferometer's free spectral range set to an integer divisor of the channel-to-channel frequency spacing of the grid such that active channels experience a high degree of interference. The phase delay of the interferometer is then adjusted to maximize the interference at each grid-aligned frequency. The spectrum-analyzed outputs are compared (e.g., subtracted from one another and then thresholded) to determine the channels present in the DWDM signal.
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TECHNICAL FIELD
[0001] The present disclosure relates generally to recovery boilers and more specifically to an adjustable fuel nozzle system for recovery boilers.
BACKGROUND
[0002] Recovery boilers are used in various processes, such as manufacturing paper. Some of the organic products used in the process are flammable. Instead of discarding this waste material, it may be burned as a fuel for the boiler. The inorganic chemicals are collected at the bottom of the furnace and are discharged through dedicated openings in the lower furnace into a dissolving tank.
[0003] FIG. 1 shows a prior art recovery boiler system 3 . Initially a fuel, such as natural gas, is released from gas jets 9 of a burner 7 and ignited. They create combustion in combustion chamber 11 .
[0004] After the boiler system 3 heats up enough, then fuel is sprayed through fuel nozzles 13 into combustion chamber 11 . This fuel may be the organic waste product such as that referred to as “black liquor” created in the paper manufacturing process. Therefore, throughout this document, it is to be understood that fuels nozzles may also be referred to as “liquor guns”.
[0005] The heated flue gasses rise and heat pipes 5 filled with water. Any smelt from burning other materials will form in the bottom of boiler system 3 and run into a dissolving tank 17 .
[0006] The droplet size of the fuel sprayed from nozzles 13 , the spray pattern, the location where the fuel is introduced, the temperature of the combustion chamber 11 when the fuel was introduced and other factors have an effect on the amount of combustion produced, the subsequent temperature at different locations in the combustion chamber 11 , the stability of the combustion and the emissions produced. Therefore, the droplet size and spray distribution of the fuel is very important. Many of these factors are determined by the nozzle design.
[0007] The prior art discloses simple fuel nozzles such as the type described in U.S. Pat. No. 4,462,319 issued Jan. 31, 1984 to Larsen. This descried the use of fuel nozzles for recover boilers and relies on the use spray holes to define droplet size. Larsen does not address the positioning of fuel nozzles to regulate the combustion to meet some of the needs listed above.
[0008] Currently, there is a need for a fuel nozzle system that allows a user to adjust the location where fuel is sprayed and the distribution of fuel droplets sprayed to increase efficiency and reduce the amount of unwanted pollutant gases created, such as NOx.
SUMMARY
[0009] The present invention may be embodied as an adjustable fuel nozzle system
[0010] for providing fuel to a combustion chamber [ 111 ] of recovery boiler [ 103 ]. It includes an upper fuel nozzle assembly [ 1100 ], a lower fuel nozzle assembly [ 1300 ], and an adjustment section [ 1500 ].
[0011] The upper and lower fuel nozzle assemblies [ 1100 , 1300 ] each include an inlet line [ 1110 ] for receiving said fuel, an extension [ 1130 ] having a central conduit for directing said fuel from the inlet line [ 1110 ] through the extension [ 1130 ] having a first and second end, the first end being fluidically connected to the inlet line [ 1110 ], a nozzle outlet [ 1143 ] fluidically connected to the second end of the extension [ 1130 ] allowing said fuel to exit the extension [ 1130 ] as a jet of fuel.
[0012] The adjustment section [ 1500 ] is adapted to hold both the upper and lower fuel nozzle assemblies [ 1100 , 1300 ] in a desired orientation relative to each other, and to permit adjustment of the orientation of both the upper and lower fuel nozzle assemblies [ 1100 , 1300 ] keeping the same desired relative orientation between the nozzle assemblies [ 1100 , 1300 ].
[0013] The proper relative positioning of the fuel nozzle assemblies [ 1100 , 1300 ] creates a more efficient spray pattern. By adjusting the spray pattern and adjusting the location where the fuel is sprayed may causes the recovery boiler [ 103 ] to become more stabile and create less pollutants.
OBJECTS OF THE INVENTION
[0014] It is an object of the present invention to reduce pollutant gasses, such as NOx emissions from chemical recover furnaces.
[0015] It is another object of the present invention to increase recover boiler firing and stability.
[0016] It is another object of the present invention to provide a system for more accurately creating and directing a fuel spray pattern.
[0017] It is another object of the present invention to provide a group of fuel nozzles that can be properly aimed together keeping their relative orientation.
[0018] It is another object of the present invention to provide a group of fuel nozzles that can be properly aimed together to impinge upon a desired target location.
[0019] It is another object of the present invention to provide a group of fuel nozzles in which the relative aim of at least one nozzle may be adjusted relative to the other nozzles to impinge upon a desired target location.
[0020] Other objects and advantages of the invention will become apparent from the drawings and specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Referring now to the drawings, wherein like items are numbered alike in the various Figures:
[0022] FIG. 1 is a perspective view of a prior art recovery boiler system;
[0023] FIG. 2 is an elevational view of one embodiment of an adjustable fuel nozzle system according to the present invention;
[0024] FIG. 3 is an enlarged front elevational view of the adjustment section of the adjustable fuel nozzle system shown in FIG. 2 ;
[0025] FIG. 4 is an enlarged side elevational view of the adjustment section of the adjustable fuel nozzle system according to the embodiment of the present invention shown in FIGS. 2 and 3 ; and
[0026] FIG. 5 is a top plan view of the adjustment section of the adjustable fuel nozzle system of the present invention shown in FIGS. 3 and 4 .
[0027] FIG. 6 is a top plan view of a portion of the upper fuel nozzle assembly.
DETAILED DESCRIPTION
[0028] As stated in the “Background” above, it is important to be able to adjust the spray pattern of the fuel nozzles. It is also important to position the spray nozzles to cause the boiler run within defined temperatures. The prior art does not address these problems; however, the present invention does.
[0029] FIG. 2 is an elevational view of one embodiment of an adjustable fuel nozzle system according to the present invention. The adjustable fuel nozzle system 1000 has an upper fuel nozzle assembly 1100 and a lower fuel nozzle assembly 1300 . Even though two are described here, the invention covers the use of multiple fuel nozzle assemblies.
[0030] Each of the fuel nozzle assemblies 1100 , 1300 includes an inlet line 1110 , 1310 for receiving fuel. The fuel is typically an organic manufacturing byproduct, such as ‘black liquor’ from a paper manufacturing process.
[0031] Extension 1130 , 1330 are connected to inlet lines 1110 , 1310 and pass the fuel to nozzles 1141 , 1341 , respectively.
[0032] The fuel is sprayed out of nozzle opening 1143 , 1343 into a combustion chamber 111 of boiler system 103 for combustion. If fuel is sprayed into the center of a hot flame, a larger amount of gasses such as NOx are created. However, if the fuel is only sprayed at the perimeter of the combustion chamber 111 , then it may liquefy and run into the smelt, wasting the fuel and causing additional problems in the smelt.
[0033] Therefore, it is best to be able to adjust the location as to where the fuel is being sprayed to control the combustion process.
[0034] In other uses, there is an optimum temperature to run the boiler system. Therefore, by altering the location of the fuel nozzles, one may control the boiler system keeping it within the proper range.
[0035] It is advantageous to break liquid fuel into small droplets. This causes more surface area and smoother, more complete combustion. One way to break liquid fuel into droplets is to use a spray head with small nozzle holes as described in U.S. Pat. No. 4,462,319 Larsen above. The smaller the hole, the smaller the droplet sizes created. This works well for pure fuel but blocks if solid particles are present in the fuel.
[0036] The present invention uses a nozzle with a nozzle opening, but causes the fuel jet exiting the nozzle opening to impinge upon a splash plate. This splash plate functions to break the liquid into small droplets, but is not as prone to blockage.
[0037] The present invention employs a plurality of fuel nozzles each having its own splash plate. The idea being that several smaller fuel nozzles would more efficiently spray the fuel into the combustion chamber and provide more uniform coverage.
[0038] Further, if the fuel nozzles are adjustable, the spray from one nozzle may be directed to supplement the spray pattern of another fuel nozzle, filling in areas that did not receive spray from the first nozzle. Once this adjustment of one nozzle relative to the second nozzle has been completed, it is desirable to keep them in the same relative position, but only to move them as a group, keeping the same relative orientation between them. The present invention employs such a relative adjustment and a group adjustment.
[0039] A relative hinge 1520 is used to adjust one fuel nozzle assembly 1100 relative to another fuel nozzle assembly 1300 , and then secure them to keep these in the same orientation relative to each other.
[0040] A group rotation hinge 1540 and an anchor hinge 1720 cause both fuel nozzle assemblies 1100 , 1300 to be moved together around a group rotation pivot 1541 and an anchor pipe 1710 , respectively. This may be done while preserving the relative orientation between the fuel nozzle assemblies 1100 , 1300 .
[0041] FIG. 3 is an enlarged front elevational view of the adjustment section of the adjustable fuel nozzle system shown in FIG. 2 . FIG. 4 is an enlarged side elevational view of the adjustment section 1500 of the adjustable fuel nozzle system 1000 according to the embodiment of the present invention shown in FIGS. 2 and 3 . FIG. 5 is a top plan view of the adjustment section of the adjustable fuel nozzle system of the present invention shown in FIGS. 3 and 4 .
[0042] The present invention will be described below in connection with FIGS. 3 , 4 and 5 .
[0043] In this embodiment, an upper clamp 1510 clamps around and secures the upper extension 1130 , shown here in phantom.
[0044] A lower clamp 1530 surrounds and clamps lower extension 1330 , also shown in phantom.
[0045] Upper clamp 1510 and lower clamp 1530 both are attached to a relative hinge 1520 that pivots about relative hinge pivot 1521 in the direction of the arrow marked “B”. This allows upper extension to pivot about relative hinge pivot 1521 altering the relative orientation between upper extension 1130 and lower extension 1330 . Adjustment bolts 1523 are screwed in to the proper depth to hold the desired orientation. An additional nut may be screwed down on these to lock them at their position.
[0046] The difference in orientation adjusts the area sprayed by nozzle outlet 1143 relative to that sprayed by nozzle outlet 1343 to ‘fill in’ missed areas, or intensify spray in a desired area.
[0047] Going into greater detail, it can be seen that upper clamp 1510 has a clamp top 1511 and a clamp base 1513 that surround upper extension 1130 . A thumbscrew 1515 pulls clamp top 1511 to clamp base 1513 securing upper extension 1130 between them.
[0048] Similarly, lower clamp 1510 has a clamp top 1531 and a clamp base 1533 that surround lower extension 1330 . Thumbscrews 1535 pulls clamp top 1531 to clamp base 1533 securing upper extension 1130 between them.
[0049] An anchor pipe 1710 is fixed into a stationery structure and is used to hold the upper and lower fuel nozzle assemblies 1100 , 1300 and the adjustment section 1500 .
[0050] Here two U-bolts 1723 attach anchor pipe to an anchor plate 1721 . Anchor plate 1721 is attached to a group rotation hinge 1540 . Group rotation hinge 1540 is also attached to clamp base 1531 of the lower clamp 1530 .
[0051] The U-bolts 1723 may be loosened to pivot the entire assembly (the anchor plate 1721 , the group rotation hinge 1540 , the lower clamp 1530 , the relative hinge 1520 the upper clamp 1510 , the lower fuel nozzle assembly 1300 and the upper fuel nozzle assembly 1100 ) around anchor pipe 1710 about its center 1715 in the direction of the arrows marked “A”. The U-bolts 1723 may then be tightened to keep them at that position. In effect, this is acting as a hinge or pivot.
[0052] The group rotation hinge 1541 allows the entire assembly above the anchor plate 1721 to pivot in the direction of the arrows marked “C”. The axis of rotation of “C” is approximately perpendicular to the axis of rotation of “A”.
[0053] Rotating according to the directions marked “A” or “C” would keep the same relative orientation between extensions 1130 and 1330 , and their respective nozzle outlets 1143 and 1343 , while moving both to aim at a different location.
[0054] This adjustability results in a system that more accurately adjusts spray patterns, keeps the same spray pattern as the aim of several nozzles are simultaneously adjusted to more accurately maintain the combustion of the boiler system.
[0055] FIG. 6 is a top plan view of a portion of the upper fuel nozzle assembly. Here nozzle 1141 and splash plate 1145 of the end of upper nozzle assembly 1100 are shown. The stream of fuel exiting the nozzle 1141 impact upon the splash plate 1145 and is sprayed as fuel droplets in the directions indicated by the arrows marked “D”. This embodiment of the splash plate 1145 is a planar, oval shape. It is attached directly within the stream of fuel flow and is wider than the nozzle 1141 and nozzle opening ( 1143 of FIG. 2 ). Its width is selected such that any fuel leaving nozzle 1141 at a slight angle will still impact the splash plate 1145 . This is to insure that all fuel is broken into droplets, since fuel that is not broken into droplets causes incomplete combustion, increased pollutants and a loss of efficiency.
[0056] The nozzle design of the present invention results in more consistent temperatures, greater combustion stability and reduced creation of pollutants, such as NOx emissions.
[0057] Although the invention has been described and illustrated with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. Accordingly, other embodiments are within the scope of the following claims.
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An adjustable fuel nozzle assembly [ 1000 ] for spraying fuel into a recovery boiler [ 13 ] includes at least two fuel nozzle assemblies [ 1100, 1300 ]. An adjustment section [ 1500 ] adapted to adjust the relative orientation between the nozzle assemblies [ 1100, 1300 ] and hold them at the desired orientation relative to each other to create a desired spray pattern. The adjustment section [ 1500 ] also adapted to simultaneously aim several fuel nozzles at a target location, retaining their relative orientation between the nozzle assemblies [ 1100, 1300 ]. This allows the nozzle assemblies [ 1100, 1300 ] to spray fuel with a desired spray pattern to a desired location to properly control combustion of the recovery boiler [ 13 ], thereby increasing stability of combustion minimizing the creation of pollutants such as NOx gases.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/092,149, filed on Jul 9, 1998.
FIELD OF THE INVENTION
The invention generally relates to the improvement of avian health. More particularly, the invention relates to a product comprising the combination of a bird repellent and a substrate, and more specifically litter, which, when applied within an avian house keeps avians from pecking the substrate, resulting in the production of healthier birds.
BACKGROUND OF THE INVENTION
Poultry raised commercially by intensive farming methods uses high-density growth conditions that can mitigate disease through the vector of the poultry house and, more particularly, the litter. The poultry house floor is basically a substrate for the poultry to stand on and provides a natural target for pecking. In addition, birds peck the litter as they would naturally peck the ground in search of food and grit for their gizzard. Grit is used in a bird's gizzard as a means to grind food. As birds ingest products deposited throughout the poultry house, and particularly in the litter, certain pathogenic organisms such as bacteria, viruses and parasites are introduced into the bird's system. As an example, the common disease coccidiosis is transmitted from bird to bird through feces that is mingled with litter and then ingested by the birds. It is also known in the industry that ingestion of litter by commercially raised poultry is a common source of several other diseases caused by pathogens such as Salmonella, Clostridia and other endoparasites, viruses and bacteria.
Presently, treatment for such diseases includes the addition of anticoccidials and any other medications to feed and/or water for the treatment and/or prevention of such specific pathogen based diseases. Other common medications for such diseases include antibiotics such as, for example, ionophores, which include Salinomycin and Monensin.
SUMMARY OF THE INVENTION
The present invention is a product and method for the multifunctional treatment of substrates within avian houses that improves avian performance. More specifically, the invention comprises the use of a bird repellent applied to any of a variety of substrates, and most preferably litter, located within avian houses. Such bird repellent-coated avian house substrates are effective in the following aspects:
One aspect of the invention is the reduction and prevention of litter and other substrate ingestion by avians in an avian house such that the disease exposure in those avians is significantly lowered.
Another aspect of the invention is that due to a reduction in litter and other substrate ingestion, the avians in the avian house have overall improved health.
An additional aspect of the invention is that due to the reduction in litter and other substrate ingestion, there is a resulting improvement in weight adjusted feed efficiency of avians.
The final aspect of the invention is that in the specific case of litter coated with a polycychic quinone compound, there is a resulting inhibition of sulfide generation by the litter, which, as a result, improves the odor conditions and lowers sulfide odors which may occur in a poultry house.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
The term “litter” means any material or covering used to provide a bed (syn. bedding material, bedding) for animals. (some examples of litter include wood shavings, rice hulls, and straw among others).
The term “avian” means any warm-blooded egg laying, feathered vertebrate provided with wings (syn. Bird).
The term “poultry” means any domestic fowl reared for the table, or their eggs or feathers including broilers, fryers, cocks and hens, capons, turkeys, ducks, geese and any others.
The term “avian house” means any building used to house or shelter poultry for any reason (syn. hen house, chicken coop, coop, hen coop, grow out barn, breeder house).
The term “weight adjusted feed efficiency” is based upon a feed efficiency corrected to a standard weight called the “weight adjusted feed efficiency” (WAFE). Feed efficiency can be adjusted to a standard weight of 2.00 kg. For every 31.78 grams difference in weight, the feed efficiency can be adjusted by 0.01. For example:
a) If the actual weight is higher than the standard weight then the feed efficiency is adjusted downward. If the actual weight is lower than the standard weight then the feed efficiency is adjusted upward. For example:
b) Assume a treatment group has an average weight of 2.032kg with a 2.0 feed efficiency.
c) Based upon an efficiency factor of 31.78 grams of weight equaling 0.01kg of feed efficiency then the WAFE would equal 1.99 for a standard with of 200kg.
The term “improved avian health” means any improvement in mortality (livability), and/or morbidity and/or condemnations.
The term “condemnation” means avian whole bodies, body parts or avian products (further processed meat, eggs etceteras) found unacceptable for human consumption by the governing meat and poultry inspection service.
The term “improved avian performance” means any improvement in an economic parameter used to determine improved revenues from the sale or barter of avian products for retail sale. For example, live body weight, carcass weight, salable meat yield, salable eggs, feed efficiency, average daily gain, eggs per hen housed, viable chicks, chicks per hen housed etceteras.
The term “bird repellent” means a compound or preparation that makes a bird select alternate behavior patterns in order to avoid contact, ingestion, odor or the presence of the compound.
The term “polycyclic quinone” or “PCQ” means bicyclic, tricyclic and tetracyclic condensed ring quinones and hydroquinones, as well as precursors thereof.
The term “active form of PCQ” means the formulation or finished state of the PCQ in which the molecule of PCQ is most effective.
The term “raw PCQ” means unprocessed active ingredient.
The term “non-toxic” means a substance judged by he U.S. Environmental Protection Agency as non-toxic by qualified analytical methods.
The term “spreader sticker” means any compound used as an adjuvant for improving the adherence of active ingredients to the surface of a leaf or other plant tissue.
The Invention
The present invention relates to the application of a bird repellant to various substrates within an avian house. It is the inventors'finding that the ability to repel avians from feeding on substrates within an avian house is an effective way to inhibit the uptake of material, such as disease bearing litter. The invention thus has the net result of affecting avian performance in the following manner: (i) improving weight gain and feed efficiency, resulting in an improved weight adjusted feed efficiency; (ii) lowering disease exposure to the avian, (iii) improving avian health; and (iv) in some cases, lowering sulfide odors within an avian house.
As described in greater detail below, the bird repellent can be any compound or substance which has bird repellency properties. The bird repellent can be added to any type of substrate within an avian house for purposes of this invention, a substrate can be any particle or surface found or located within the avian house. For example, it is contemplated that the bird repellent be applied to such substrates as the floor, walls or litter located within an avian house.
Bird Repellent
As mentioned above, any compound or substance which functions as a bird repellent can be used in the invention. The following paragraphs summarize various characteristics of bird repellent compounds which are preferred for use in this invention.
Initially, it is important to the effectiveness of the invention that the bird repellent, in whatever physical form it is applied, be persistent. More particularly, the active material of the applied bird repellent should preferably be able to resist erosion by wind and rain and other environmental forces to which the treated surface may be exposed. For example, it is preferred (1) that the active form of the bird repellent have a relatively low solubility in water so that it is not easily washed off the treated litter surfaces, and (2) that the bird repellent have a relatively high melting temperature so that it does not undergo excessive evaporation from the treated litter surfaces during exposure to high ambient temperatures. For these reasons, it is preferred that the active bird repellent material has a solubility in water under ambient temperature conditions of no more than about 0.001-1000 ppm and preferably in the range of 0.01-200 ppm. The melting temperature of the active bird repellent component should be at least about 150C. and preferably at least 200C.
Even when the active bird repellent material possesses the above-described preferred physical properties, and is maintained in the above-described environmental conditions, the material may still have poor persistence if it does not adhere well to the litter surface to which it is applied. This is a function of the different surface properties of the litter and the bird repellent material.
It is also preferred that the bird repellent be non-toxic to the specific avian with which it will be used. Although not required for the invention non-toxic bird repellent is preferred because although an avian may not peck the bird repellent-coated substrate, it will still stand on it or touch it in various other ways.
Coadjuvants
In an alternative embodiment, a coadjuvant can be used with any bird repellent to give the bird repellent certain properties which allow for more effective application of the bird repellent to the substrate. For instance, coadjuvant, as used herein, may refer to materials which have a bio-activity different than the bird repellents themselves. Such materials include pH adjustment, ammonia control agents, phosphate control agents, trigeminal bird repellents and mixtures thereof Both liquid and solid coadjuvants can be used in conjunction with the bird repellents, depending on the manner of application (See discussion below). Suitable coadjuvants for use with the invention, include Sodium bisulfate, 2-hydroxy acetophenone, limonene and other bird repelling terpenes, methyl anthranalate, alum, zeolytes, calcium sulfate, antibiotics, antiviral agents, inorganic and organic acids, among others.
Sticking Agents:
In an additional alternative embodiment, it is suggested that the bird repellent contain a “sticking agent”, i.e., a material which itself has good adhesion to the substrate and when mixed with the bird repellent causes the bird repellent to adhere to the substrate more firmly. Examples of preferred sticking agent include aqueous polymer lattices, which upon evaporation of the water therefrom, form a polymeric mass which is highly adhesive to the litter surface and holds particles of the active material firmly on the litter surface. Such latex sticking agents typically contain a small amount of surfactant dissolved in the aqueous phase. It is noted that any other sticking agent which causes or helps the bird repellent to adhere to the substrate can be used in the invention.
Additives
The inventors contemplate a further alternative embodiment wherein additives are combined with the bird repellent.
As used herein, the term “additives” refers to materials which augment the effectiveness of the bird repellents, but which do not by themselves have bio-activity. These include such materials as surfactants, wetting agents, defoaming agents, extenders, sticking agents, penetrants, plasticizers, activators, spreading agents, diluents, odorants and the like.
Polycyclic Quinone Composition
Although any bird repellent compound can be used in the invention, it is preferred that the bird repellant be a non-ionic polycyclic quinone (PCQ) and, more preferably, a PCQ selected from bi- to tetra-cyclic quinones, hydroquinones and mixtures thereof having (a) a light absorbency within the range of 200-400 nm, (b) solubility in water no higher than 1,000 ppm by weight, (c) a melting point no lower than 102C. and (d) LD 50 in female rats of at least 2,000 mg/kg.
It is the inventors discovery that the application to the litter repels away an avian by a mechanism of bird repellency as disclosed in U.S. patent application No. US97/05662 by Ballinger et al., which is incorporated herein in its entirety.
A wide variety of polycyclic quinones can be used in the invention. As used herein, the term “polycyclic quinone ” or “PCQ” refers to bicyclic, tricyclic and tetracyclic condensed ring quinones and hydroquinones, as well as precursors thereof. On the whole, the non-ionic polycyclic quinones and polycyclic hydroquinones (herein referred to collectively as PCQs) have very low solubility in water at ambient temperatures. For use in the invention, It is preferred that such PCQs have a water solubility no higher than about 1,000 ppm, by weight.
However, as noted above, certain precursors of such PCQs can also be used in the invention either combined with the relatively insoluble PCQs or by themselves. Such precursors include anionic salts of PCQs which are water soluble under alkaline anaerobic conditions. These materials, however, are not stable and are easily converted to the insoluble quinone form upon exposure to air. Thus, when anionic PCQs are applied to litter and exposed to air, they are quickly converted to the water-insoluble, more active quinone form.
Among the water-insoluble PCQs which can be used in the invention are anthraquinones (AQ), such as 1,2-dihydroxy anthraquinone, 1,4-dihydroxy anthraquinone, naphthoquinone, anthrone(9,10-dihydro-9-oxo-anthracene), 10-methylene-anthrone, phenanthrenequinone and the alkyl, alkoxy and amino derivatives of such quinones, 6,11-dioxo-1H-anthra[1,2-c]pyrazole, anthraquinone-1,2-naphthacridone, 7,12-dioxo-7,12-dihydroanthra[1,2-b]pyrazine, 1,2-benzanthraquinone, 2,7-dimethylanthraquinone, 2-methylanthraquinone, 3-methylanthraquinone, 2-aminoanthraquinone and 1-methoxyanthraquinone. Of the foregoing cyclic keytones, anthraquinone and 1,4-dihydroxyanthraquinone are preferred because they appear to be more effective. Naturally occurring AQs can be used as well as synthetic AQs.
Other PCQs which can be used include more soluble AQ compounds such as 1,8-dihydroxy-anthraquinone, 1-amino-anthraquinone, 1-chloro-anthraquinone, 2-chloro-anthraquinone, 2-chloro-3-carboxyl-anthraquinone and 1-hydroxy-anthraquinone. Various ionic derivatives of these materials can be prepared by catalytic reduction in aqueous alkali.
Also within the AQ family are a wide variety of anthrahydroquinone compounds which can be used in the method of the invention. As used herein, the term “anthrahydroquinone compound” refers to compounds comprising the basic tricyclic structure such as 9,10-dihydroanthrahydroquinone, 1,4-dihydroanthrahydroquinone, and 1,4,4a,9a-tetrahydroanthrahydroquinone. Anthrahydroquinone itself is 9,10-dihydroxyanthracene.
Both water-insoluble and water-soluble forms of anthrahydroquinone compounds can be used in the invention. The non-ionic compounds are largely insoluble in aqueous systems, while ionic derivatives, such as di-alkali metal salts, are largely soluble in water. The water soluble forms are stable only in high pH anaerobic fluids. Low pH fluids (pH less than about 9-10) will generally result in the formation of the insoluble molecular anthrahydroquinone. Aerobic solutions will incur oxidation of the anthrahydroquinones to anthraquinone. Thus, anthrahydroquinones will not exist for long periods of time in an aerated environment such as that which is experienced by spraying. For these reasons, anthrahydroquinone treatments are usually implemented with the soluble ionic form in a caustic solution. Sodium hydroxide solutions are preferred over the hydroxides of other alkali metals for economic reasons.
Regarding PCQs in general, the specific PCQ used should be preferably in a physical form small enough to be touched by the sensory organs of the avian and to affect the gut. If the particles are too large, the nerves may pick up the presence of the chemical poorly, if at all. Thus, for the PCQ to be most effective as a repellent, it is preferred that they be of a sufficiently small particle size in order to effectively be sensed by an avian.
In particular, it is preferred that the particles of PCQ be less than about 50 micrometers in diameter and more preferably, that the particles be less than 30 micrometers in diameter . Similarly, smooth continuous surfaces of PCQ cannot be adequately sensed, and, of course, if the PCQ is coated with anything which is non-repellent to the bird or to which the bird is taste insensitive, the PCQ is ineffective. It is preferred that the particles be of sufficient size or have a contour that contains areas that are small enough to be sensed.
When the PCQ is applied directly in particulate form, the size of the particles can be readily controlled. When such particles are applied as a single layer of particles, substantially all of the PCQ would be effective. However, if the particles are applied as a multiple of particle layers, essentially only the top layer would be effective. An important aspect of this analysis is that it is not important that the PCQ be applied as continuous covering.
As mentioned earlier, it is preferred that the bird repellent be non-toxic. PCQ compounds meet this criteria as they are essentially non-toxic, i.e., they have an LD 50 of at least 2,000 mg/kg in rats and preferably an LD 50 in rats of 5,000 mg/kg or higher. Because of this low toxicity, PCQs are not toxic to birds, animals and humans. Moreover, the toxicity level is sufficiently low that any active material that becomes leached into the soil will not be detrimental to the normal constituents of fertile soil layers. PCQ's with a degradation half-life of less than 60 days are preferred to insure that no bio-accumulation will occur.
Substrates
As described earlier, it is preferred that the bird repellent of choice be applied to a substrate within an avian house. For purposes of this invention, a substrate means any particle substance upon which a bird repellent can be deposited. Some examples of substrates include flooring, walls and litter disposed within or part of the interior of the house.
Use of such composition comprising a bird repellent and a substrate within an avian house is beneficial in at least four important respects: (1) avians raised thereon have improved health because they consume smaller amounts of the material and/or substrate; (2) the avians exhibit improved feed efficiency and weight gain because of their improved health; (3) the avians have lower mortality and morbidity rates arising out of the lower consumption of material and/or substrate; and (4) as a result of these benefits, higher densities of avians can be raised on whatever area of the substrate is available. Of particular importance is the fact that all of these benefits take place simultaneously merely by raising the avians on such a composition. No special grazing or other environmental conditions are required to obtain these advantages beyond use of the substrate of the invention as the grazing medium.
In a preferred embodiment, the substrate upon which the bird repellent is applied comprises avian litter. It is the inventors'finding that the use of a combination of litter and a bird repellent compound has the net effect of improving the agronomic conditions of avian production raised thereon. Litter comes in many forms, which include bedding materials of either natural or synthetic materials. Examples of such natural materials are grass, hay, straw, grain hulls, wood shavings and saw dust, shredded, macerated or pelletized paper derived from cardboard, Kraft paper or newsprint. Synthetic materials suitable for use as litter include synthetic foamed polymers and inorganic adsorbents such as silica. Upon use as poultry litter, these materials usually become admixed with varying amounts of manure, spilled food and feathers. As discussed hereinbelow, litter is often admixed with various adjuvant materials and additives either prior to or during use.
Other substrates include any flooring or wall materials used in an avian house. The bird repellent can be applied to the floor and/or walls of an avian house to keep the birds from pecking the same.
Methods of Application
The bird repellent compound can be applied to the substrate of interest in any way that allows the invention to work. It is preferred that the substrate of interest be coated and/or saturated with the bird repellent of choice, or precursors thereof, by spraying on the outer surface or, alternatively, by immersing the substrate in a liquid dispersion of the bird repellent or liquid dispersion of a precursor thereof A particularly preferred way of coating the substrate involves direct spraying in which the substrate is coated with the bird repellent or precursor thereof.
The bird repellent of choice can be applied to the substrate of choice in any quantity which is effective. In the particular case of a PCQ bird repellent, it is preferred that fine droplets of the PCQ dispersion formulated to 50% PCQ by weight are sprayed at a rate such that the upper layer of the substrate is treated at a rate between 0.001 gallons per thousand square feet and 10 gallons per thousand square feet and more preferably, between 0.066 gallons per thousand square feet and 0.33 gallons per thousand square feet.
The treating material can also be sprayed onto the substrate while it is fluidized in air. Both bird repellents and precursors thereof can be applied in this manner. Though the substrate can be coated by immersion in the treating solution, this method is not the most preferred because it involves intensive drying. So long as the coating is sufficient to provide an operable amount of the particulate coating, further coating thickness is not needed, for example, in the specific case of PCQ's, only small concentrations of PCQ or PCQ precursor need be applied to the substrate.
The advantageous properties of this invention can be observed by reference to the following examples that illustrate the invention.
EXAMPLES
Example 1
Evaluation Of the Efficacy Of AQ Applied to the Litter Used in Broiler Chicken Houses
A total of 3456 one-day-old straight run Ross x Hubbard HyY broiler chicks was used in the experiment. There were 6 treatments with 8 replicates per treatment and 72 birds per replicate. The individual pen was the experimental unit. The experimental treatments used follows:
1. Negative Control =No coccidiostat or growth promoting antibiotics and no litter treatment
2. Positive Control=BioCox® (full dose)+BMD®+3-Nitro and no litter treatment
3. BioCox® (full dose)+BMD®+3-Nitro+0.5× litter treatment*
4. BioCox® (full dose)+BMD®+3-Nitro+1.0× AQ litter treatment**
5. BioCox® (half dose)+BMD®+3-Nitro+0.5× AQ litter treatment
6. BioCox® (half dose)+BMD®+3-Nitro+1.0× AQ litter treatment
*0.5× Solution of AQ−⅛ Gallon/44,000sqft
**1.0× Solution of AQ−¼ Gallon/44,000sqfi
TABLE 1
42 Day Data
Treatment
Weight Gain Kg (42 days)
Feed Efficiency
Mortality %
1
2.134c
1.796d
6.338b
2
2.232ab
1.760c
4.754ab
3
2.224ab
1.761c
3.345a
4
2.249a
1.725a
4.577ab
5
2.200b
1.757bc
4.401ab
6
2.231ab
1.731ab
2.993a
*values with the same letters are not significantly different
Results and Conclusions
Results of this trial as set forth in Table 1 above. Table 1 shows that the forty-two day weight gain for the positive control was significantly improved over the negative control (p<0.05). Weight gain for treatments 3, 4, 5, and 6, were significantly improved over the negative control (p<0.05) but not different from the positive control (p<0.05) at 42 days.
Forty-two day feed conversion for the positive control was significantly improved (p<0.05) from the negative control. Treatments 3, 4, 5 and 6 indicated significant (p<0.05) improvement of feed efficiency over the negative control. Treatments 4 and 6 demonstrated a significant improvement (p<0.05) in feed efficiency over the positive control while treatment 5 demonstrated no improvement over the positive control.
Forty-two day mortality for treatments 3, and 6, indicated significant (p<0.05) improvement in mortality compared to the negative control. However, treatments 3, 4, 5 and 6, were not different from the positive control.
Based on the data obtained, AQ applied to the litter at the 1.0× dose resulted in an improvement in feed efficiency at both the full dose and half dose of coccidiostat in the feed.
Example 2
Evaluation Of the Efficacy of AQ Applied to the Litter Used in Broiler Chicken Houses
A total of 6912 one-day-old straight run Ross x Hubbard HyY broiler chicks was used in the experiment. There were 12 treatments with 8 replicates per treatment and 72 birds per replicate. The individual pen was the experimental unit. The experimental treatments used were as follows:
1. Negative Control—No coccidiostat or growth promoting antibiotics—No litter treatment
4. No litter treatment—BioCox (half dose)
3. 4× AQ litter treatment—No feed additives
4. 4× AQ litter treatment—BioCox (half dose)
5. 10.0× AQ litter treatment—No feed additives
6. 4.0× AQ litter treatment+BioCox (low dose)+BMD+3-Nitro
7. 4.0× AQ litter treatment BioCox (low dose)+BMD+3-Nitro
8. 10× AQ litter treatment−BioCox (half dose)
9. Positive Control BioCox (full dose)+BMD+3-Nitro
10. 4× AQ litter treatment−BioCox (full dose)+BMD+3-Nitro
11. 10× AQ litter treatment−BioCox (half dose)+BMD+3-Nitro
12. 10× AQ litter treatment−BioCox (full dose)+BMD+3-Nitro.
4× Solution of AQ−1 Gallon/44,000sqft×4.2 ml per 48sqft (one pen)
10× Solution of AQ−5 Gallons/44,000sqft=21 ml
TABLE 1
42 Day Data
Weight Gain Kg
Feed Efficiency
Treatment
(42 Days)
(42 Days)
Mortality
1
1.877f
1.945e
4.025ab
2
1.929de
1.936de
3.185a
3
1.908ef
1.909cd
6.992c
4
1.922de
1.937de
4.683abc
5
1.951d
1.876abc
6.583bc
6
2.050c
1.904c
4.464abc
7
2.096bc
1.884bc
5.531abc
8
1.972d
1.887bc
4.252abc
9
2.045c
1.901c
3.405ab
10
2.077c
1.895bc
5.311abc
11
2.113ab
1.855a
4.464abc
12
2.153a
1.857ab
3.397a
*values with the same letters are not significantly different
TABLE 2
Intestinal Lesion Scores
Treatment
14 Day Scores
21 Day Scores
1
2.0c
1.13d
2
2.0c
0.71abcd
3
1.54bc
1.33d
4
0.75a
0.25abc
5
1.33abc
0.75bcd
6
1.71bc
0.75bcd
7
0.96ab
0.88cd
8
1.0ab
0.42abc
9
1.38bc
0.21abc
10
0.67a
0.38ab
11
1.00ab
0.17abc
12
0.88a
0.65ab
*values with the same letter are not significantly different
TABLE 3
42 Day Data
Weight Adjusted
Treatment
Weight
Feed Efficiency
Feed Efficiency
1
1.877
1.945
1.963
2
1.929
1.936
1.946
3
1.908
1.909
1.922
4
1.922
1.937
1.948
5
1.951
1.876
1.883
6
2.05
1.904
1.897
7
2.096
1.884
1.870
8
1.972
1.887
1.891
9
2.045
1.901
1.895
10
2.077
1.895
1.884
11
2.113
1.855
1.839
12
2.153
1.857
1.835
*standard weight of 2.0 kg
31.78 grams of weight equals 0.01 less KG of feed
Results and Conclusions
Forty-two weight gain for the positive control was significantly improved over the negative control (p<0.05). Weight gain for treatment 3 was not different from the negative control. Treatment 5 was significantly improved over the negative control but was significantly less than the positive control (p<0.05) at forty two days of age. Treatments 2, 4, and 8 demonstrated significantly improved weight gain over the negative control but were significantly less than the positive control (p<0.05). The 42 day weight gains for treatments 6, 7, and 11 were significantly improved (p<0.05) over the negative control. Treatments 6 and 7 were not different from the positive control but treatment 11 was significantly improved over the positive control (p<0.05). Treatments 10 and 12 were significantly improved over the negative control (p<0.05) but only treatment 12 was significantly improved over the positive control for weight gain (p<0.05) while treatment 10 was not different from the positive control (p<0.05). In this dose titration study it can be concluded that the addition of AQ to the litter tends to improve weight gain numerically. When the 10× AQ dose is used to treat the litter and combined with typically used poultry diets, the weight gain is significantly improved (p<0.05) over the positive control.
Feed Conversion for the positive control was significantly improved (p<0.05) over the negative control. Treatments 3 and 5 indicated significant (p<0.05) improvement if feed efficiency over the negative control but no difference from the positive control. Treatments 2 and 4 were not different from the negative control while treatment 8 was significantly different (p<0.05) from the negative control but not different from the positive control for feed efficiency. Treatments 6 and 7 were significantly improved (p<0.05) over the negative control and not different form the positive control for feed efficiency. Treatment 11 was significantly improved (p<0.05) over both the positive and negative controls for feed efficiency. Treatments 10 and 12 demonstrated a significant (p<0.05) improvement in feed efficiency over the negative control. Treatment 10 was not different for the positive control while treatment 12 demonstrated a significant (p<0.05) improvement over the positive control. In this dose titration study it can be concluded that when the 10× AQ dose is used to treat the litter and combined with typically used poultry diets, the feed efficiency is significantly improved (p<0.05) over the positive control. When the 10× AQ dose is used to treat the litter and the diet contained no coccidiostat or antibiotic feed additive there was a significant difference between this treatment and the negative control (p<0.05) and no difference from the positive control.
The 14 day intestinal lesion scores indicated no statistical difference between the positive and negative control (p<0.05) indicating that the challenge in the pens was not severe enough to produce lesions in the unmedicated birds. Treatment 4 indicated a significant improvement (p<0.05) in lesion score when compared to the positive and negative controls. Treatment 8 while not statistically significant (p<0.05) from the positive and negative controls, was biologically significant from the negative control. This means that the lesion score difference was greater than 1 unit (scoring range of 0-4). Treatments 7 and 11 demonstrated significant improvement (p<0.05) over the negative control but was the same as the positive control. Treatment 6 was not different for the positive or negative control (p<0.05). Treatments 10 and 12 were significantly different from the positive and negative control (p<0.05). Based on the 14 day data, it can be concluded that when either the 10× or 4× AQ dose is used to treat the litter and combined with typically used poultry diets, the intestinal coccidia score is improved significantly (p<0.05) over the positive and negative control.
When feed efficiency is adjusted for weight, the adjusted feed efficiency demonstrates improvement over the negative control for every treatment (TABLE 3 ). Statistics can not be run on adjusted feed efficiency.
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A product and method for reducing and preventing the ingestion of substrates by avians wherein the substrates are disposed within an avian house. The product is a bird repellent in combination with a substrate disposed within an avian house. As a result of the reduced ingestion of substrates such as litter, healthier avians are achieved.
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FIELD OF THE INVENTION
The invention relates to absorbent articles for use with undergarments or other clothing, such as panty hose, swimsuits, or leotards. In particular, the absorbent articles of the present invention are drapeable.
BACKGROUND OF THE INVENTION
Disposable absorbent articles, such as pantiliners, sanitary napkins, interlabial devices, adult incontinence devices and diapers are well known in the art. These articles typically have a fluid permeable body-facing side and fluid impermeable garment facing side. Additionally, such articles may include an absorbent layer for retaining fluids therebetween.
Anatomical adaptation of an absorbent article may increase comfort to the wearer. That is, movement by the wearer may cause the absorbent article to conform to the geometry of the space between the wearer's thighs. In contrast, if the absorbent article is stiff to begin with, the wearer may experience discomfort and be conscious of the absorbent article. Additionally, if such an article bunches, there is a tendency to maintain its resulting distorted shape, thereby providing inadequate protection.
Various methods have been used to improve the flexibility of absorbent articles. For example, reducing the amount of absorbent material, using less stiff resilient materials and using thinner materials have been disclosed as possible solutions to the improving the flexibility of absorbent articles. See, for example, PCT Application No. WO 98/09593 to Gilman, which discloses a thin absorbent article that has a thickness of less than five millimeters and a crush recovery value of at least about fifteen mm.
EP 1077052 (Lariviere et al.) discloses using preferential bending zones extending along the longitudinal axis of an absorbent article together with a pair of longitudinal adhesive zones that register with the preferential bending zones to improve flexibility.
Another method that has been disclosed to improve flexibility is increasing the elasticity of the article. See, for example, U.S. Pat. No. 4,773,904 (Nakanishi et al.) and PCT Application No. WO 96/10978 (Palumbo et al.). In EP 0705583 and EP 0705586 (both to Querqui), the purported flexible absorbent article is disclosed as being elastically stretchable while having a water vapor permeable backsheet and a specific adhesive configuration.
Adding regions of corrugation have been disclosed as yet another method to increase flexibility or conformability of absorbent articles. EP 1088536 (Carvalho) discloses using longitudinal corrugations to provide lateral extensibility. Additionally, U.S. Pat. No. 5,607,415 (Datta et al.) purports to disclose an absorbent article having a basin-like moisture barrier with corrugations to provide an extendable region.
NZ 236101 (Hujber et al.) discloses a pants liner having a creped portion that attaches directly onto the crotch area of the wearer's pants. Parts of the liner are capable of being draped down the tubular leg portion of the pants, without any bunching or folding occurring in the creped portion of the liner.
However, the above absorbent articles are not fully flexible and do not adapt to the body as an undergarment alone does, thereby sacrificing comfort, protection and discretion. Thus, there is a need for a drapeable absorbent article that is fully flexible and adapts to the body as an undergarment alone does without sacrificing comfort, protection, and discretion. Applicants have surprisingly discovered such an absorbent article, which is described herein.
SUMMARY OF THE INVENTION
The present invention is directed to an absorbent article having a silhouette including a first end, a second end, wherein the second end being in opposite relation to the first end, and a first longitudinally extending edge opposed to a second longitudinally extending edge, the first and second longitudinally extending edges connecting the first end and the second end; and a layered portion having a body-facing layer and a garment-facing layer, wherein the absorbent article is drapeable.
In an alternate embodiment, the absorbent article also includes an absorbent layer and a transfer layer.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the terms “drapeable” and “drapability” are used interchangeably and mean having a flexural resistance of about 35 g. or less as tested by the Modified Circular Bend Test, ASTM 4032-82 as set forth in the Example section below. It has been found that, for example, cotton underwear (e.g., Hanes Cotton underwear) has a flexural resistance of less than 35 g. Drapeable articles of the present invention have also been found to have a flexural resistance of about 30 or less, about 20 or less, and about 17 or less.
As used herein, all ranges used herein expressly include at least all numbers that fall between the endpoints of ranges.
Absorbent articles of this invention have three portions: an anterior portion, a central portion, and a posterior portion and at least a body-facing layer and a garment facing layer. Any sample of the present invention taken from any portion of the entire article that includes all of the layers of the finished product is drapeable.
In one embodiment of the present invention, the absorbent article has a body facing layer and a garment facing layer. In another embodiment, the absorbent article additionally includes an absorbent layer therebetween. Other embodiments may include additional layers such as, a transfer or distribution layer, multiple layer absorbent layers and unitized versions of two or more layers.
The silhouette of absorbent articles of this invention includes those designed to fit garments having conventionally-shaped crotches, e.g., briefs and bikinis. Additionally, absorbent articles of the present invention may also be designed to fit garments having abbreviated crotches including thong, string underwear, G-string, Rio cut, Brazilian cut, etc.
The absorbent article of the present invention includes a liquid permeable layer also referred to as a body facing layer. The exterior of the body facing layer forms the body-facing surface of the absorbent article. The body facing layer may be a single layer or be made from multiple layers. The body facing layer may be formed from any fluid pervious material or combinations of materials that are comfortable against the skin and permits fluid to penetrate. For instance, the body facing layer may be a fibrous non-woven fabric made of fibers or filaments of polymers, such as polyethylene, polypropylene, polyester, or cellulose, and combinations thereof. Alternatively, the body facing layer may be formed from an apertured polymeric film. The thickness of the body facing layer may vary from about 0.001 inch (0.025 mm) to about 0.200 inch (5.000 mm), depending on the material chosen. The weight of the body facing layer material is between about 5 to about 150 gsm.
For example, any material with cloth-like features may be used for the body facing layer. Such material includes nonwoven, such as spunlace, woven, and knitted materials. In particular, spunlace material may be made from about 0 to about 100% rayon and from about 0 to about 100% polyester. The spunlace material may also be made from about 10 to about 65% rayon and from about 35 to about 90% polyester may be used. Optionally, the material used for the body-facing layer may include binders, such as thermoplastic binder fibers and latex binders.
In one embodiment, the body facing layer is a single sheet of material having a width sufficient to form the body-facing surface of the absorbent article. In another embodiment, the body facing layer has at least two layers.
The body facing layer, whether a single layer or multiple layers, may have absorbent capabilities, i.e., retains fluid. If a separate absorbent layer is used, the body facing layer may be longer and wider than the absorbent core or be of similar size as the absorbent core.
The garment facing layer of the present invention may be pliant and is typically referred to as a backsheet or barrier layer. The exterior of the garment facing layer forms the garment-facing surface of the absorbent article and, typically, is impermeable to fluids. In one embodiment, the garment facing layer may be any thin, flexible, fluid impermeable material, such as a polymeric film, e.g., polyethylene, polypropylene, or cellophane, or a normally fluid pervious material that has been treated to be impervious, such as impregnated fluid repellent paper or non-woven material, including non-woven fabric material, or a flexible foam, such as polyurethane or cross-linked polyethylene.
Additionally, the garment facing layer may be breathable, i.e., permits vapor to transpire. Known materials for this purpose include nonwoven materials and microporous films in which microporosity is created by, inter alia, stretching an oriented film. Single or multiple layers of permeable films, fabrics, melt-blown materials, and combinations thereof that provide a tortuous path, and/or whose surface characteristics provide a liquid surface repellent to the penetration of liquids may also be used to provide a breathable backsheet.
The thickness of the backsheet when formed from a polymeric film typically is about 0.001 inch (0.025 mm) to about 0.002 inch (0.051 mm).
One embodiment of the present invention includes an absorbent layer, which may be a single layer or, alternately, be made of multiple layers. Absorbent materials used in the absorbent layer may include, but are not limited to, absorbent fibers, such as cellulose fibers, including, but not limited to wood pulp, regenerated cellulose fibers, and cotton fibers, rayon fibers and the like; superabsorbent fibers or particles; other naturally occurring absorbent materials, such as peat moss; and other synthetic absorbent materials, such as foams and the like. The absorbent layer may also include one or more of the following: thermoplastic binder fibers, latex binder, perfumes, or odor-controlling compounds or compositions. The absorbent layer may be compressed or uncompressed, embossed, or calendered. Additionally, the absorbent core may be made from any known absorbent bicomponent fibers, including those made, for example, from polyester, polyethylene, polypropylene and any combinations thereof.
The absorbent material may be woven, nonwoven, or knitted and made by any process. For example the absorbent material may be wet laid, carded, or air laid.
Absorbent articles of this invention may or may not include wings, flaps or tabs for securing the absorbent article to an undergarment.
Wings, also called, among other things, flaps or tabs, and their use in sanitary protection articles is described in U.S. Pat. No. 4,687,478 to Van Tilburg; U.S. Pat. No. 4,589,876 also to Van Tilburg, U.S. Pat. No. 4,900,320 to McCoy, and U.S. Pat. No. 4,608,047 to Mattingly. The disclosures of these patents are incorporated herein by reference in their entirety. As disclosed in the above documents, wings are generally speaking flexible and configured to be folded over the edges of the underwear so that the wings are disposed between the edges of the underwear.
The shape of the wings may also be varied as desired. The wings may be rounded, rectangular, curvilinear, etc. The wings may be regular or irregular, symmetric or asymmetric in shape.
The overall dimensions of the absorbent article of the present invention may be as follows: a length of about 5 inches (127 mm) to 8 inches (203 mm) and a thickness of about 0.02 inch (0.5 mm) to 0.2 inch (5 mm).
Optionally, the absorbent article of the present invention may include a transfer or distribution layer. If included in the absorbent article, the transfer layer may be made of any known material that will take up fluid and then distribute and release it to an adjacent absorbent layer for storage. Transfer layers have a relatively open structure that allows for movement of fluid within the layer. Suitable materials for such transfer layers include fibrous webs, resilient foams, and the like.
The mass of materials making up the transfer layer may be absorbent, although the materials themselves are not absorbent. Thus, transfer layers that are made of hydrophobic, nonabsorbent fibers may be able to accept large volumes of fluid into interfiber void spaces while the fibers themselves do not absorb any significant quantities of fluid. Likewise, open-celled foam structures that are made from nonabsorbent materials may also absorb fluid into the cells of the foam. The walls of the cells, however, do not absorb any fluid. The cumulative spaces within the transfer layer, i.e., the interfiber void spaces in the fibrous transfer layer or the open cells in the foam transfer layer, function much like a container to hold fluid.
Typically, transfer layer fibrous webs are made of resilient, nonabsorbent materials to provide void volume and to allow for free movement of fluid through the structure. Transfer layers that are made from webs of mostly absorbent fibers absorb the fluid as it enters the structure and do not distribute it throughout the rest of the structure as efficiently as webs containing non-absorbent materials.
Adhesive is typically used to attach the layers into a single absorbent article. For example, in one embodiment, the body facing layer is attached to the barrier with adhesive HL 1491 available from H.B Fuller and Company (St. Paul, Minn.). The adhesive may be applied in any method.
Secure attachment of absorbent article of the claimed invention to the garment contributes to maintaining the feeling of the user that the absorbent article and the garment are one in the same, i.e., permits the absorbent article to move with the underwear.
The absorbent article of the present invention may be applied to the crotch by placing the garment-facing surface against the inside surface of the crotch of the garment. Various methods of attaching absorbent articles may be used. For example, chemical means, e.g., adhesive, and mechanical attachment means, e.g., clips, laces, ties, and interlocking devices, e.g., snaps, buttons, VELCRO (Velcro USA, Inc., Manchester, N.H.), zipper, and the like are examples of the various options available to the artisan.
Adhesive may include pressure sensitive adhesive that is applied as strips, swirls, or waves, and the like. As used herein, the term pressure-sensitive adhesive refers to any releasable adhesive or releasable tenacious means. Suitable adhesive compositions, include, for example, water-based pressure-sensitive adhesives such as acrylate adhesives. Alternatively, the adhesive composition may include adhesives based on the following: emulsion or solvent-borne adhesives of natural or synthetic polyisoprene, styrene-butadiene, or polyacrylate, vinyl acetate copolymer or combinations thereof; hot melt adhesives based on suitable block copoylmers—suitable block copolymers for use in the invention include linear or radial copolymer structures having the formula (A-B)x wherein block A is a polyvinylarene block, block B is a poly(monoalkenyl) block, x denotes the number of polymeric arms, and wherein x is an integer greater than or equal to one. Suitable block A polyvinylarenes include, but are not limited to Polystyrene, Polyalpha-methylstyrene, Polyvinyltoluene, and combinations thereof. Suitable Block B poly(monoalkenyl) blocks include, but are not limited to conjugated diene elastomers such as for example polybutadiene or polyisoprene or hydrogenated elastomers such as ethylene butylene or ethylene propylene or polyisobutylene, or combinations thereof. Commercial examples of these types of block copolymers include Kraton™ elastomers from Shell Chemical Company, Vector™ elastomers from Dexco, Solprene™ from Enichem Elastomers and Stereon™ from Firestone Tire & Rubber Co.; hot melt adhesive based on olefin polymers and copolymers where in the olefin polymer is a terpolymer of ethylene and a co-monomers, such as vinyl acetate, acrylic acid, methacrylic acid, ethyl acrylate, methyl acrylate, n-butyl acrylate vinyl silane or maleic anhydride. Commercial examples of these types of polymers include Ateva (polymers from AT plastics), Nucrel (polymers from DuPont), Escor (from Exxon Chemical).
Where adhesive is used, a release strip may be applied to protect the adhesive on the absorbent article prior to attaching the absorbent article to the crotch. The release strip can be formed from any suitable sheet-like material adheres with sufficient tenacity to the adhesive to remain in place prior to use but which can be readily removed when the absorbent article is to be used. Optionally, a coating may be applied to release strip to improve the ease of removability of the release strip from the adhesive. Any coating capable of achieving this result may be used, e.g., silicone.
Any or all of the cover, absorbent layer, transfer layer, backsheet layer, and adhesive layers may be colored. Such coloring includes, but is not limited to, white, black, red, yellow, blue, orange, green, violet, and mixtures thereof. Color may be imparted according the present invention through dying, pigmentation, and printing. Colorants used according the present invention include dyes and inorganic and organic pigments. The dyes include, but are not limited to, anthraquinone dyes (Solvent Red 111, Disperse Violet 1, Solvent Blue 56, and Solvent Green 3), Xanthene dyes (Solvent Green 4, Acid Red 52, Basic Red 1, and Solvent Orange 63), azine dyes (Jet black), and the like.
Inorganic pigments include, but are not limited to, titanium dioxide (white), carbon black (black), iron oxides (red, yellow, and brown), chromium oxide (green), ferric ammonium ferrocyanide (blue), and the like.
Organic pigments include, but are not limited to diarylide yellow AAOA (Pigment Yellow 12), diarylide yellow AAOT (Pigment Yellow 14), phthalocyanine blue (Pigment Blue 15), lithol red (Pigment Red 49:1), Red Lake C (Pigment Red), and the like.
The absorbent article may include other known materials, layers, and additives, such as, foam, net-like material, perfumes, medicaments or pharmaceutical agents, moisturizers, odor control agents, and the like. The absorbent article can optionally be embossed with decorative designs.
The absorbent article may be packaged as unwrapped absorbent articles within a carton, box or bag. The consumer withdraws the ready-to-use article as needed. The absorbent article may also be individually packaged (each absorbent article encased within an overwrap).
Also contemplated herein include asymmetrical and symmetrical absorbent articles having parallel longitudinal edges, dog bone- or peanut-shaped, and the like.
From the foregoing description, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications. Embodiments set forth by way of illustration are not intended as limitations on the variations possible in practicing the present invention.
EXAMPLE
Samples of commercially available pantiliners were compared to samples of the present invention and samples from the crotch portion of an undergarment.
Peak bending stiffness is determined by a test that is modeled after the ASTM D 4032-82 CIRCULAR BEND PROCEDURE, the procedure being considerably modified and performed as follows. The CIRCULAR BEND PROCEDURE is a simultaneous multi-directional deformation of a material in which one face of a specimen becomes concave and the other face becomes convex. The CIRCULAR BEND PROCEDURE gives a force value related to flexural resistance, simultaneously averaging stiffness in all directions.
The apparatus necessary for the CIRCULAR BEND PROCEDURE is a modified Circular Bend Stiffness Tester, having the following parts:
1. A smooth-polished steel plate platform, which is 102.0 mm by 102.0 by 6.35 mm having an 18.75 mm diameter orifice. The lap edge of the orifice should be at a 45 degree angle to/a depth of 4.75 mm;
2. A plunger having an overall length of 72.2 mm, a diameter of 6.25 mm, a ball nose having a radius of 2.97 mm and a needle-point extending 0.88 mm therefrom having a 0.33 mm base diameter and a point having a radius of less than 0.5 mm, the plunger being mounted concentric with the orifice and having equal clearance on all sides. Note that the needle-point is merely to prevent lateral movement of the test specimen during testing. Therefore, if the needle-point significantly adversely affects the test specimen (for example, punctures an inflatable structure), than the needle-point should not be used. The bottom of the plunger should be set well above the top of the orifice plate. From this position, the downward stroke of the ball nose is to the exact bottom of the plate orifice;
3. A force-measurement gauge and more specifically an Instron inverted compression load cell. The load cell has a load range of from about 0.0 to about 2000.0 g;
4. An actuator and more specifically the Instron Model No. 1122 having an inverted compression load cell. The Instron 1122 is made by the Instron Engineering Corporation, Canton, Mass.
In order to perform the procedure for this test, as explained below, five representative samples for each article are necessary. From each of the five samples to be tested, some number “Y” of 37.5 mm by 37.5 mm test specimens are cut. For undergarments, the crotch portion was made from at least one layer. For absorbent articles, test specimens were cut from anterior portion, the central portion, and the posterior portion. This test is directed to the overall drapeability of the article and not merely the peripheral portions thereof and, therefore, the drapeability of the present invention is more concerned with the drapeability of the entire article than any specific portion thereof.
The test specimens should not be folded or bent by the test person, and the handling of specimens must be kept to a minimum and to the edges to avoid affecting flexural-resistance properties.
The procedure for the CIRCULAR BEND PROCEDURE is as follows. The specimens are conditioned by leaving them in a room that is 21° C., +/−0.1° C. and 50%, +/−2.0%, relative humidity for a period of two hours. The plunger speed is set at 50.0 cm per minute per full stroke length. A specimen is centered on the orifice platform below the plunger such that the body facing layer of the specimen is facing the plunger and the barrier layer of the specimen is facing the platform. The indicator zero is checked and adjusted, if necessary. The plunger is actuated. Touching the specimen during the testing should be avoided. The maximum force reading to the nearest gram is recorded. The above steps are repeated until all of the specimens have been tested.
CALCULATIONS
The peak bending stiffness for each specimen is the maximum force reading for that specimen. Remember that “Y” number of sets of five samples were cut. The values received for each specimen were averaged. The flexural resistance for an article is the average peak bending stiffnesses for all “Y” specimens taken from each sample of that article.
TABLE 1
Average Peak
Percent Standard
Sample Number
Load (grams)
Deviation
Commercially Available
2.17
8.91
Underwear Sample 1
Commercially Available
2.83
12.37
Underwear Sample 2
Commercially Available
4.78
30.57
Underwear Sample 3
Inventive Sample 1
17.07
10.8
Inventive Sample 2
17.56
8.00
Inventive Sample 3
27.58
18.5
Comparative Sample 1
46.21
12.8
Comparative Sample 2
49.56
7.9
Comparative Sample 3
127.02
14.1
Comparative Sample 4
150.87
9.1
Comparative Sample 5
173.26
8.2
Comparative Sample 6
256.58
7.9
Comparative Sample 7
286.72
9.1
Commercially Available Underwear Sample 1 Hanes Her Way 100% Nylon with 100% Cotton Crotch (Grey) This article had two crotch layers, one was nylon and body-facing layer was cotton, which were not bonded together. Only the body-facing layer was tested.
Commercially Available Underwear Sample 2 Hanes Her Way 100% Nylon (black) ribbed crotch. This article had one crotch layer.
Commercially Available Underwear Sample 3 Fruit of the Loom 100% cotton jersey (cream colored). This article had two crotch layers, both were cotton. Only layer was tested.
Inventive Sample 1 having a 75 gsm spunlace body facing layer made from 75% polyester and 25% rayon (3P075V25P75 from Spuntech Industries Ltd., Upper Tiberias, Israel) and a 30 gsm microporous polyethylene backsheet (01030A1-1-1-1-2, FullSafe, Manila, Philippines).
Inventive Sample 2 having a 75 gsm spunlace body facing layer made from 75% polyester and 25% rayon (LBN040, from PGI, Benson, N.C.) and a 30 gsm microporous polyethylene backsheet (01030A1-1-1-1-2, FullSafe, Manila, Philippines).
Inventive Sample 3 having a 55 gsm spunlace body facing layer made from 35% polyester and 65% rayon (LIDRO 356355-Jacob Holm Industries S.A.S, Soultz, France), and a three-layer absorbent core made from three layers (first layer: 10 gsm 100% PET/PE, second layer: 15 gsm 66% PET/PE/34% rayon and third layer: 15 gsm 66 PET/PE/34% rayon) (JS40-1, Kang Na Hsiuing Enterprise Company, Ltd., Taipei, Taiwan), and a 30 gsm microporous polyethylene backsheet (01030A-1-1-1-1-2, FullSafe, Manila, Philippines).
Comparative Samples 1-7 were samples of pantiliners commercially available.
Sample number
Commercial Product Name (date code)
Comparative Sample 1
Sofy Regular Pantiliner
Comparative Sample 2
Sofy Breathable (00120702123)
Comparative Sample 3
Kotex Lightdays (LF101002C)
Comparative Sample 4
Carefree Ultrathins
Comparative Sample 5
Carefree Body Shape (1996M02341)
Comparative Sample 6
Carefree (Europe) (1057A)
Comparative Sample 7
Procter & Gamble Alldays Freshweave
(0344CA11762040B)
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An absorbent article having a silhouette including a first end, a second end, wherein the second end being in opposite relation to the first end, and a first longitudinally extending edge opposed to a second longitudinally extending edge, the first and second longitudinally extending edges connecting the first end and the second end; and a layered portion having a body-facing layer and a garment-facing layer, wherein the absorbent article is drapeable.
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(This application claims the benefit of U.S. Provisional Application No. 60/159,583 filed on Oct. 18, 1999.)
FIELD OF THE INVENTION
The invention is related to the field of converting a standard manually controlled valve into an electronically controlled automatic valve. One application of the automatic valve is to protect real property against water damage that can occur when a water conduit breaks. Thus the invention is also related to the field of protecting property against water damage. Although not limited to, the invention is particularly useful towards minimizing the damage that can occur if a water supply pipe or other water supply component freezes or breaks, or an appliance, such as a washing machine, dishwasher, ice maker, boiler, and water heater breaks. The invention is also related to the field of protecting real property against damage or excess water usage when outdoor spigots (valves) are left on or hoses break. Among other advantages, when used this way, the invention will serve to conserve water.
BACKGROUND OF THE INVENTION
Replacing a manually controlled valve with an electronically controlled automatic valve requires installing the valve on to an existing water supply conduit. In most cases, this requires a plumber or other person skilled at making such an installation. The cost to install an electronically controlled valve may exceed the cost of the valve. A method to easily and inexpensively convert a manually controlled valve into an automatic valve would provide a valuable solution to many applications.
Real property damage occurs when water supply pipes and other components break. A break can be caused by a variety reasons including freezing. Hoses that supply washing machines, dishwashers, and other appliances are particularly susceptible to breakage. The appliances can also break causing water to leak or gush. Water heaters wear out over time and are prone to leak or break suddenly.
A water supply break can cause substantial damage to property, especially if the property is not occupied during the time the break occurs. A device that can be added inexpensively and easily to shut off the water supply to a property or to an appliance located at the property and can be controlled to shut of the water under a variety of conditions would serve to minimize the damage to a property.
Another problem faced by property owners is the control of outdoor water supplies. Unauthorized people can turn on outdoor spigots allowing water to run for indefinite periods of time. Hoses can also break allowing large amounts of water to be wasted. A device that can control outdoor water sources from within the property and can be controlled automatically will serve to protect against such losses and provide a convenient means to control water used for outdoor activities.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a method and apparatus to convert a manually controlled valve into an automatically controlled valve that is responsive to an electronic controller.
The invention can be used to easily and inexpensively convert a variety of standard off the shelf valves such as ball valves, gate valves and valves that use washers into electronically controlled automatic valves. The automatic valve can be turned on or off locally or remotely. The automatic valve can be controlled to turn on or off based upon a variety of conditions using sensors.
It is also an object of the invention to control a valve assembly comprising two or more valves such as the valve assembly used to supply hot and cold water to an appliance, for example a washing machine.
It is also an object of the invention to provide a method and apparatus that will minimize the damage caused if a pipe or other water supply component breaks.
It is also the object of the invention to provide a method and apparatus that will control an outdoor water supply to prevent unauthorized use or minimize the water wasted when an outdoor hose breaks.
This and other objects are achieved according to the invention by a valve control device that is easily mounted to an existing manually controlled valve. The valve control device includes a motor, a means to increase torque and decrease revolutions per minute of the motor, a means to transfer torque from the motor or any torque/rpm conversion device to a valve without physically relocating the valve, and a means to secure the valve control device to the controlled valve. The valve control device turns the valve on or off based upon a variety of external conditions. The valve control device can be used in a variety of applications including but not limited to 1. Controlling the main water supply valve of a building so that water is shut off when the building is unoccupied and does not require water, 2. Controlling the water supply line that supplies water to an outdoor water supply, and 3. Controlling the hot and cold water valves that supply water to an appliance.
In the first case, the valve control device is fastened to the main water supply valve of a building. The valve control device turns the water supply off when no occupancy is sensed in the building for a predetermined period of time. Alternatively, the valve control device turns the water on for a predetermined period of time whenever occupancy is sensed. Occupancy sensing can be accomplished using a variety of methods including but not limited to acoustic sensing, infrared sensing, and visual sensing.
In the second case, the valve control device is fastened to the valve located inside a building that controls water to an outside water supply. The valve control device turns the water-on for a predetermined period of time based upon the users needs.
In the third case, the valve control device is fastened to one or more valves that supply water to an appliance. The valve control device turns the water on only when the water is needed to operate the appliance.
The above and other objectives are also achieved according to the invention by a method of controlling a valve that controls liquid flow.
In one embodiment, the method comprises the steps of
1. Sensing whether a building is occupied, and
2. Turning the valve off after a predetermined period of time after occupancy is no longer sensed or alternatively turning the valve on for a predetermined period of time after occupancy is sensed.
In a second embodiment, the method comprises the steps of:
1. Sensing through a human user interface that the user wants to turn on the valve, and
2. Turning on the valve for a period of time selected by the user or as required to serve a purpose such a watering a lawn.
In a third embodiment, the method comprises the steps of:
1. Sensing through a human interface or electronic interface that the appliance is on and requires water,
2. Turning on the valves that supply water to the appliance, and
3. Turning off the valves when the appliance no longer requires water either through a human interface, through a timer mechanism, or through sensing that the appliance no longer requires water.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing of a solenoid-controlled valve as used in prior art
FIG. 2 is a drawing of a motor driven valve as used in prior art
FIG. 3 is a drawing of certain elements of the invention including the motor controller, the motor, a gear drive, the motor mount, and a means to transfer torque from the motor using drive studs.
FIG. 4 shows the invention connected to a standard pre-mounted washer valve.
FIG. 5 shows the invention mounted to a standard gate valve. The gate is shown open.
FIG. 6 shows the invention mounted to a gate or washer valve using a cylindrical coupling device.
FIG. 7 shows the invention mounted to a gate or washer valve using a gear drive approach.
FIG. 8 shows the invention mounted to a ball valve. FIG. 8 also shows a detail of the drive connecting system.
FIG. 9 shows the invention mounted to a ball valve using a cylindrical coupling approach.
FIG. 10 shows the invention mounted to a ball valve using a gear drive approach.
FIG. 11 shows the invention mounted to a valve using a worm gear drive approach.
FIG. 12 is a block diagram of the motor controller including user interfaces.
FIG. 13 is a block diagram of the invention to show various elements that can interface to the motor controller to control the motor to turn the main valve that supplies water to a building on and off.
FIG. 14 is a block diagram of the invention to show various elements that can interface to the motor controller to control the motor to turn a valve that controls water flow to an outdoor water supply on and off.
FIG. 15 illustrates a multiple valve assembly with a single controlling lever such as that used to control hot and cold water to an appliance.
FIG. 16 shows the invention mounted to a multiple valve assembly.
FIG. 17 shows an alternative means to mount the invention to a multiple valve assembly.
DETAILED DESCRIPTION
Figure one and two show the current state of the art for electronically controlled valves. Figure one illustrates a solenoid actuated valve. Moving plunger 150 controls liquid flow from the inlet 110 to the outlet 130 . Current passing through wires 120 actuates solenoid coil 140 . Solenoid coil 140 moves plunger 150 such that plunger 150 either blocks the flow of water or does not block the flow of water. The valve can be constructed so that liquid flows when current passes through wires 120 or does not flow when current passes through wires 120 .
Figure two illustrates a motor controlled valve. This assembly includes a motor 260 , a motor drive gear 240 , connected to a valve gate drive gear 230 , a valve monitoring switch 220 , a gate 210 , and power wires 250 . The motor 260 gears 230 and 240 , and monitoring switch 220 can be constructed so that liquid flows when current passes through the power wires 250 or does not flow when current passes through the power wires 250 .
Valves of the type in Figures one and two are available in many forms from a variety of manufactures. They cannot be used to convert an existing manually controlled valve into an electronic valve. To make such a conversion, the electronically controlled valve must be attached to the pipes servicing the valve. Attaching such a valve usually requires a plumbing expense that exceeds the cost of the valve. A preferred approach would be to have a valve control system that easily mounts to an installed valve. A secondary benefit of separating the motor drive from the valve is to provide a system that converts standard commercial high volume inexpensive valves into electronically controlled valves.
The invention described provides such a system.
Figure three, one preferred embodiment of the invention, shows a motor, drive, and control assembly that can be mounted to a variety of valve types. Figure three includes motor 304 , drive 303 , drive connector 312 , drive couplers 307 and 311 , controller 306 , mounting bracket 301 , mounting studs 302 , 309 , motor mount 310 , motor control wires 305 , and power wires 308 . Motor 304 is connected to drive connector 312 through drive 303 . Drive 303 serves to reduce the speed and increase the torque of motor 304 . Drive 303 can be eliminated if the motor is designed to produce relatively high torque at low speeds. Drive connector 312 transfers rotary motion from drive 303 to the controlled valve using drive couplers 307 and 311 . Mounting bracket 301 is mounted behind the controlled valve and connected to motor mount 310 using mounting studs 302 and 309 . Drive connector 312 and drive couplers 307 and 311 transfer rotary motion to a standard valve handle. To prevent damaging the valve under fault conditions, drive couplers 307 and 311 can be designed to break at a stress level that is lower than a level that will break the valve. Thus the entire system can be easily assembled to a valve that is mounted to the pipes servicing the valve without the need to disturb the plumbing. Controller 306 provides power and control to motor 304 through wires 305 . Motor controller 306 receives power from power wires 308 . Motor controller 306 controls the rotational direction of motor 304 . Motor controller 306 controls motor 304 based upon one or more of the following:
user programming
current demanded by motor 304
the volt time product or current time product required to drive motor 304 to turn on or off the controlled valve
any other means to turn on and off the controlled valve
Figure four shows the assembly described above mounted to a standard washer type valve 405 . In this embodiment, the length of the drive couplers 401 and 402 compensate for the up and down movement of the valve stem 403 and valve handle 404 .
Figure five shows the assembly mounted to a standard gate valve 505 . This motor drive assembly is similar to the one shown in Figure four. However, the valve stem 503 and valve handle 504 do not move up and down for this valve type.
Figure six shows an alternative embodiment. The torque produced by motor 601 is transferred through drive 602 to valve 605 through a coupling device 603 . The coupling device 603 directly couples drive 602 to valve 605 . Coupler 603 of Figure six replaces the function of drive connector 406 and drive couplers 401 and 402 , of Figure four. To prevent damaging the valve under fault conditions, coupler 603 can be designed to break at a torque that is lower than a torque that will break the valve.
Figure seven shows another approach in which the motor drive transfers torque to valve 707 (hidden) through gears 704 and 706 . Motor mount 708 is mounted to the water pipes using mounts 703 and 705 .
Figure eight shows the assembly mounted to a ball valve. The drive connector 811 and drive couplers 807 and 808 differ from the prior embodiments illustrated in Figures four and five to accommodate the operation of the ball valve 809 . Figure eight, a preferred embodiment of the invention, includes motor 813 , drive 803 , drive connector 811 , drive couplers 807 and 808 , controller 801 , mounting bracket 810 , mounting studs 806 and 812 , motor mount 805 , motor control wires 802 , and power wires 816 . Motor 813 is connected to drive connector 811 through drive 803 . Drive 803 serves to reduce the speed and increase the torque of motor 813 . This can be done using gear reduction or other known techniques. Drive 803 is not necessary if the motor is designed to produce high torque at low revolutions per minute. Drive connector 811 transfers rotary motion from drive 803 to the controlled valve 809 using the drive couplers 807 and 808 . Mounting bracket 810 is mounted behind the controlled valve 809 and connected to motor mount 805 using mounting studs 806 and 812 . Drive connector 811 and drive couplers 807 and 808 transfer rotary motion to a standard valve handle of the type normally found on a ball valve. To prevent damaging the valve under fault conditions, drive couplers 807 and 808 can be designed to break at a torque that is lower than a torque that will break the valve. Thus the entire system can be easily assembled to a ball valve that is mounted to the pipes servicing the valve without the need to disturb the plumbing. Controller 801 provides power and control to motor 813 through wires 802 . Motor controller 801 receives power from power wires 816 . Motor controller 801 controls the rotational direction of motor 813 .
Figure eight also shows a detail of the method used to couple drive connector 811 to ball valve handle 814 . The ball valve handle 814 is secured to the valve stem 815 using standard techniques. Drive connector 811 mounts up against ball valve handle 814 . Drive connector 811 moves gate valve handle 814 in a rotary direction using drive couplers 807 and 808 . Drive couplers 807 and 808 are mounted on opposite sides of ball valve handle 814 such that drive coupler 807 pushes against ball valve handle 814 to move it in a clockwise direction and drive coupler 808 pushes against gate valve handle 814 to move it in a counter-clockwise direction. To prevent damaging the valve under fault conditions, drive couplers 807 and 808 can be designed to break at a stress level that is lower than a level that will break the valve.
Figure nine shows an alternative embodiment for the ball valve. The torque produced by motor 903 is transferred through drive 904 to valve 902 through a coupling device 901 . The coupling device 901 directly couples drive 904 to valve 902 . Coupler 901 of figure nine replaces the function of drive connector 811 and drive couplers 807 and 808 , of figure eight. To prevent damaging the valve under fault conditions, coupler 901 can be designed to break at a torque that is lower than a torque that will break the valve.
Figure ten shows another approach in which the motor drive transfers torque to a gate valve 1006 (hidden) through gears 1004 and 1005 . Motor mount 1008 is mounted to the water pipes using mounts 1002 and 1003 .
Figure eleven illustrates an embodiment for the washer, ball, or gate valves using a worm drive configuration. For this configuration, worm drive gear 1104 is mechanically coupled to gear 1103 to turn valve 1104 (hidden) on and off. Motor 1101 drives worm gear 1104 . Mounting bracket 1102 secures motor 1101 to the pipe.
Figure twelve is a block diagram representation of one possible embodiment of the motor control. For this embodiment, motor control 1201 consists of timer circuit 1203 , current sense circuit 1205 , voltage sense circuit 1211 , motor current control switch 1206 , logic driver 1204 , position sensor 1213 and user interface 1210 . Motor control 1201 provides voltage to motor 1208 through wires 1207 and 1212 . Motor 1208 can be of the type such that the motor turns in one direction (clockwise for purposes of this discussion) when wire 1207 is positive with respect to wire 1212 and the opposing direction (counter-clockwise) when wire 1212 is more positive than 1207 . In this example the clockwise direction turns the valve on and the counter-clockwise direction turns the valve off.
Motor control 1201 directs current flow based upon one or more of the following:
The current flowing through motor 1208
The last direction of rotation of the motor
The time required to turn on or off the controlled valve
The volt time product to turn the valve on or off
The current time product to turn the valve on or off
The position of position sensor 1213
User interface 1210
Figure thirteen shows one potential application of the invention. In this embodiment, the motor controlled valve 1301 (hidden) is the main shut off to a building. Motor control 1306 includes an occupancy sensor 1307 . Motor control 1306 turns valve 1301 on when building occupancy is sensed and off when building occupancy is not sensed. A delay can be added so that valve 1301 (hidden) is turned off after a pre-selected period after no occupancy is sensed in the building. Alternatively, a delay can be added that keeps the valve on for a pre-selected time after occupancy is sensed in the building. The motor drive can also contain circuitry that turns the valve on for short periods of time at specific intervals. This feature is useful under certain circumstances where equipment in the residence such as boilers, ice-cube makers, humidifiers, etc must be refurbished with water. The motor drive circuit can also include an override function to turn on the valve as required to operate other types of appliances such as lawn sprinklers. The valve would shut of concurrently with the equipment to minimize any damage done if a break had occurred in the water distribution system. The motor controller can also respond to a moisture detector 1308 , or other sensing mechanism 1309 . The motor controller can be set to turn on the valve using wires 1304 during periods when water is needed such as when a sprinkler system or outdoor spigot is turned on.
Figure fourteen illustrates a second application of the invention. In this embodiment, the motor controlled valve 1401 (hidden) is used to turn on and off water supply to an outdoor water spigot. Motor control 1406 turns valve 1401 on based upon a user interface. The user interface can be as simple as a switch 1402 or a more complicated timer 1403 or water supply measuring device 1404 .
Figure fifteen shows a multiple valve assembly, in this case two valves, in which both valves are controlled by a single user interface, in this case a lever 1570 . Pipe 1540 provides liquid to valve 1520 and pipe 1530 provides liquid to valve 1510 . Coupler 1580 connects valve 1510 to valve 1520 . Valve control lever 1570 is connected to coupler 1580 to turn valve 1510 and valve 1520 on and off. One implementation of this type of valve assembly is to turn the hot and cold water to a washing machine for cloths on and off. For this case hoses 1550 and 1560 connect the hot and cold water to the washing machine. However, this arrangement could be used to supply liquid to any machine or appliance.
Figure sixteen shows one method to couple a motor to the multiple valve assembly shown in figure fifteen. Motor 1620 is mounted to motor bracket 1610 . Motor bracket 11610 is either an integral part of valve brace 1640 or is mounted to valve brace 1640 using any suitable fastening system. Valve brace 1640 is a box like structure that has a top and four sides. One of the sides is cut to accommodate hoses 1550 and 1560 . The top has a slot that allows valve control lever 1570 to pass through and move freely. Valve brace 1640 is placed over the valve assembly such that hoses 1550 and 1560 pass through one of the sides and lever 1570 passes through the top. The valve brace braces the motor bracket to the valve assembly.
Lever 1630 is fastened to the motor shaft on one end and to coupler 1640 on the second end. One method to fasten lever 1630 to coupler 1640 is to use a pin such that the angle between lever 1630 and coupler 1640 can change as the motor rotates. The second end of coupler 1640 is fastened to valve control lever 1570 such that coupler 1640 transfers the rotary torque from lever 1630 to valve control lever 1570 in such a way as to turn the multiple valve assembly on and off.
Figure seventeen shows a second means to control valves 1520 and 1510 using the current invention. Motor 1720 is mounted to motor mount 1750 . Motor mount 1750 is either an integral part of valve brace 1640 or is mounted to valve brace 1640 using any suitable mounting method. Motor 1720 is mounted to motor mount 1750 such that its shaft runs parallel and above the front of valve brace 1640 . Lever 1730 is connected to motor 1720 's shaft at one end so that it rotates with the shaft. The second end of lever 1730 is connected to one end of connecting rod 1740 using a pin or similar connecting device. The second end of connecting rod 1740 is fastened to valve control lever 1570 such that connecting rod 1740 transfers the rotary torque from lever 1730 to valve control lever 1570 in such a way as to turn the multiple valve assembly on and off.
The invention is not limited in any way to the applications discussed. The invention can be used to automatically control the flow of liquid or gas in any application. In particular, the methods described earlier to control an individual valve including sensing current, voltage, occupancy, position, and instructions from a user interface apply to the control of a multiple valve assembly.
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A device and method to implement the device, to automatically adjust a single valve or a plurality of valves including turning the valve(s) on and off. The device includes a motor drive assembly, a mounting method, and a control method. Each component is discrete. The three components can be combined easily. The motor drive and control components can be mounted and connected to a valve that is currently connected to pipes. Thus one application of this invention is to provide a method to convert a manual valve to an automatic valve.
The control method can operate as a means to turn the valve on and off using a manually operated switch or can be automatically controlled in response to an external stimulus.
The invention has many applications including protecting real property from loss due to water damage, and against vandalism in cases where valves can be controlled by unauthorized people.
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This application is a continuation of prior U.S. patent application Ser. No. 13/532,843 filed on Jun. 26, 2012, which is a continuation of prior U.S. patent application Ser. No. 12/825,030 filed Jun. 28, 2010, which is a continuation of U.S. patent application Ser. No. 11/737,392 filed Apr. 19, 2007, now U.S. Pat. No. 7,795,130, which is a continuation of Ser. No. 11/305,987, filed Dec. 19, 2005, now U.S. Pat. No. 7,224,074, which is a divisional of prior patent application Ser. No. 10/698,184, filed Oct. 31, 2003, now U.S. Pat. No. 7,005,369, which claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 60/496,881, filed Aug. 21, 2003, and U.S. Provisional Application Ser. No. 60/507,539, filed Sep. 30, 2003, all of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
The present invention relates generally to the formation of semiconductor devices and in particular a formation of active circuits under a bond pad.
BACKGROUND
Integrated circuits comprise two or more electronic devices formed in and/or on a substrate of semi-conductive material. Typically, the integrated circuits include two or more metal layers that are used in forming select devices and interconnects between said devices. The metal layers also provide electrical paths to input and output connections of the integrated circuit. Connections to the inputs and outputs of the integrated circuit are made through bond pads. Bond pads are formed on a top metal layer of the integrated circuit. A bonding process (i.e. the bonding of a ball bond wire to the bond pad) can damage any active circuitry formed under the metal layer upon which the bonding pad is formed. Therefore, present circuit layout rules either do not allow any circuitry to be formed under the bonding pad or only allow limited structures that have to be carefully tested.
Damage under bonding pads can be caused by many reasons but mainly it is due to the stresses which have occurred during bond wire attachment process and the subsequent stresses after packaging. For example, temperature excursions after packaging exert both lateral and vertical forces on the overall structure. The metal layers of integrated circuit are typically made of soft aluminum that are separated from each other by harder oxide layers. The soft aluminum tends to give under the forces while the harder oxide layers do not. This eventually leads to cracks in the oxide layers. Once an oxide layer cracks, moisture can enter causing corrosion of the aluminum layers and eventually failure of the circuit function. Therefore, the bonding process typically requires the real estate below the bond pad serve only as a buffer against damage that occurs during the bonding process. However, as chip designers try and reduce the size of chips it would be desired to able to use the real estate under the bonding pad for active circuits or interconnects.
For the reasons stated above and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an improved integrated circuit that effectively allows for use of the real estate under bonding pads for active circuits and interconnects.
SUMMARY
The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention.
In one embodiment, a semiconductor structure is provided. The structure comprises a top metal layer, a bond pad formed on the top metal layer, a conductor formed below the top metal layer, and an insulation layer separating the conductor from the top metal layer. The top metal layer includes a sub-layer of relatively stiff material compared to the remaining portion of the top metal layer. The sub-layer of relatively stiff material is configured to distribute stresses over the insulation layer to reduce cracking in the insulation layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more easily understood and further advantages and uses thereof more readily apparent, when considered in view of the description of the preferred embodiments and the following figures in which:
FIG. 1 is a partial cross-sectional view of an integrated circuit of one embodiment of the present invention;
FIG. 2 is a top view of a portion of a metal layer with gaps of one embodiment of the present invention; and
FIGS. 3A through 3G are partial cross-sectional side views of one method of forming an integrated circuit in one embodiment of the present invention.
In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout Figures and text.
DETAILED DESCRIPTION
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the inventions 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 logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof.
In the following description, the term substrate is used to refer generally to any structure on which integrated circuits are formed, and also to such structures during various stages of integrated circuit fabrication. This term includes doped and undoped semiconductors, epitaxial layers of a semiconductor on a supporting semiconductor or insulating material, combinations of such layers, as well as other such structures that are known in the art. Terms of relative position as used in this application are defined based on a plane parallel to the conventional plane or working surface of a wafer or substrate, regardless of the orientation of the wafer or substrate. The term “horizontal plane” or “lateral plane” as used in this application is defined as a plane parallel to the conventional plane or working surface of a wafer or substrate, regardless of the orientation of the wafer or substrate. The term “vertical” refers to a direction perpendicular to the horizontal. Terms, such as “on”, “side” (as in “sidewall”), “higher”, “lower”, “over,” “top” and “under” are defined with respect to the conventional plane or working surface being on the top surface of the wafer or substrate, regardless of the orientation of the wafer or substrate.
Embodiments of the present invention provide a method and structure of an integrate circuit that allows the use of real estate under bonding pads for active devices and interconnects. Moreover, embodiments of the present invention provide a structure that can use all the metal layers below the bond pad for functional interconnections of the device. In addition, embodiments of the present invention also provide a structure that allows submicron interconnects lines with a TiN top layer and relatively wide lines capable of carrying high currents to exist simultaneously under a bond pad.
FIG. 1 illustrates a partial cross-section view of an integrated circuit 100 of one embodiment of the present invention. In this embodiment, the part of the integrated circuit 100 shown includes a N-channel MOS power device 102 , a N-DMOS device 104 and a NPN bipolar device 106 . As FIG. 1 also illustrates three conductive layers, which in this embodiment includes a first metal layer M 1 108 , a second metal layer M 2 110 and a third metal layer M 3 112 . The metal layers 108 , 110 , and 112 can be made of conductive material such as aluminum, copper and the like. Moreover, in another embodiment, at least one of the metal layers 108 , 110 and 112 is made by a sub-micron process that forms many sub-layers of alternating conductive layers. The third metal layer M 3 112 can be referred to as the top metal layer 112 . As illustrated, a bond pad 130 is formed on a surface of the third metal layer M 3 112 by patterning a passivation layer 132 . A ball bond wire 114 (bond wire 114 ) can be coupled to the bonding pad 130 to provide an input or output to the integrated circuit 100 . Although, this embodiment, only illustrates three metal layers 108 , 110 and 112 , other embodiments have more or less metal layers. For example, in an embodiment with more than three metal layers, additional metal layers are formed between metal layers 108 and 110 . Each interconnect metal layer 108 , 110 and 112 is formed by conventional methods known in the art such as depositing and patterning.
As illustrated in FIG. 1 , vias 116 selectively couple the interconnect metal layers 110 and 108 to form electrical connections between devices 102 , 104 and 106 of the integrated circuit 100 . Further shown are vias 118 that provide electrical connections to elements of the devices 102 , 104 and 106 and the first metal layer 108 .
In one embodiment, the sub-micron process is used to form metal layer M 2 110 and metal layer M 3 112 . The sub-micron process uses many sub-layers to form a metal layer. In one embodiment, the sub-layers are alternating layers of Ti, TiN and Al alloys. Further in one embodiment, the top layer of the sub-layers of metal layer 110 (i.e. the sub-layer facing metal 112 ) is a TiN layer 120 . The TiN layer 120 is used in this location because of its low reflective properties that aid in the pattering of metal layer 110 . However, the presence of sub-layer 120 tends to increase the probability that cracks will form in an oxide layer separating the metal layer 110 from metal layer 112 . In particular, because the TiN layer tends to be hard it doesn't yield when stress is applied. As a result, lateral stresses on the separating oxide tend to form cracks in the separating oxide layer. Further in another embodiment, a layer of TiW forms sub-layer 120 .
Embodiments, of the present invention reduce the probability of the cracks forming in the separating oxide layer 122 . In one embodiment, the separating oxide layer 122 (i.e. the oxide layer that separates metal layer 110 from metal layer 112 ) is formed to be relatively thick. In one embodiment, the separating oxide layer 122 is formed to be at least 1.5 um thick. The use of a separating oxide layer 122 that is relatively thick reduces the probabilities of crack forming in the oxide layer 122 . In further another embodiment, the separating oxide layer is generally a dielectric or insulating layer.
Moreover in one embodiment, the third metal layer M 3 112 includes a relatively hard sub layer 126 of very stiff and hard material. The hard sub-layer 126 is formed adjacent the separating oxide layer 122 and opposite a side of the third metal layer M 3 forming the bond pad 114 . The hard sub layer 126 is very stiff and hard compared to aluminum. The hard sub layer distributes lateral and vertical stresses over a larger area of the oxide 122 thereby reducing the propensity of cracking in the oxide 122 . In one embodiment, the material used for the hard sub-layer 126 is TiN. This is due to the compatibility of TiN with conventional sub-micron deposition and etch techniques. In yet another embodiment, the hard sub-layer 126 is a layer of nitride. In one embodiment, the hard sub-layer 126 is approximately 80 nm in thickness. In further other embodiments, materials such as TiW are used for the hard sub-layer 126 .
In further another embodiment, the second metal layer M 2 110 is formed to have gaps 124 in selected areas. Very wide (lateral widths) of the second metal layer 110 tend to weaken the structure thus creating a higher chance that cracks will occur in the separating oxide layer 122 . In this embodiment, the gaps 124 tend to strengthen the structure by providing pillars of harder oxide. The impact of the gaps 124 on the function of the integrated circuit is minimized by the proper layout. That is, the density of the gaps may be minimized so that a layout design is not constrained significantly. In one embodiment, the gaps 124 take no more than 10% of the total area of the second metal layer M 2 110 under the bond pads. In another embodiment, the gaps are oriented such that the impact on current flow through the second metal layer M 2 110 is minimized. An example of gaps 124 formed to minimize the impact on the current flow in the second metal layer M 2 is illustrated in FIG. 2 . FIG. 2 , also illustrates the third metal layer 112 .
FIGS. 3A through 3G illustrates the forming of relevant aspects of one embodiment of the present invention. FIG. 3A illustrates a partial cross-sectional side view of the start of the formation of an integrated circuit 300 on a substrate 301 . The partial cross-sectional side view illustrates that integrated circuit 300 in this embodiment includes a N-Channel MOS 302 , a N-DMOS 304 and a NPN device 306 . It will be understood in the art that other types of devices can be formed in the integrated circuit 300 and that the present invention is not limited to only integrated circuits with N-Channel MOS, a N-DMOS and NPN devices. Since the formation of the devices 302 , 304 and 306 are not a critical part of the present invention, FIG. 3A illustrates that they are already formed. These devices 302 , 304 and 306 are formed by techniques known in the art such as deposition, etching masking and implantation. A first insulating layer 308 is formed overlaying devices 302 , 304 and 306 . In one embodiment, the insulating layer 308 is a layer of first oxide layer 308 . Vias 310 are formed by techniques known in the art such as masking and etching. The vias 310 are then filled with conductive material to form contacts with the first metal layer 312 and elements of the devices 302 , 304 and 306 . The first metal layer 312 is formed by first depositing a metal layer and then patterning the first metal layer 312 to form select interconnects. A second insulating layer 314 is then formed overlaying the first metal layer M 1 312 and exposed areas of the first oxide layer 308 . In one embodiment, the second insulting layer 314 is a second oxide layer 314 . Vias are formed in the second layer of oxide 314 by masking a surface of the second layer of oxide and etching the vias 316 down to select portions of the patterned first metal layer 312 . The vias 316 are then filled with conductive material.
Referring to FIG. 3B , a second metal layer M 2 318 is deposited on a surface of the second oxide layer. In one embodiment, the second metal layer 318 is formed by a sub-micron process comprising a plurality of alternating layers of different metals. In one embodiment, the alternating layers of metal are Ti, TiN and Al alloys. A top sub layer 320 of the second metal layer M 2 318 is made of TiN which aids in the pattering of the second metal layer M 2 318 . The top sub layer 320 is illustrated in FIG. 3C . As illustrated in FIG. 3C , in this embodiment, the second metal layer 318 is then patterned to form gaps 322 . The gaps 322 strengthen the structure by providing pillars of hard oxide. A third insulating layer 324 is then formed overlaying the second metal layer M 2 . This is illustrated in FIG. 3D . In one embodiment, the third insulating layer 324 is a third oxide layer 324 . The third oxide layer 324 also fills in the gaps 322 . In one embodiment, the third oxide layer 324 (separating oxide layer 324 ) is formed to be relatively thick. Moreover, in one embodiment the thickness of the separating oxide layer 324 is at least 1.5 um.
A layer of relatively stiff and hard metal layer 326 is then formed on the surface of the separating oxide layer 324 . This is illustrated in FIG. 3E . This hard layer 326 distributes both lateral and vertical stress is over a larger area of the separating oxide layer 324 . Some embodiments of the hard layer 326 are formed by a layer of nitride such as TiN or SiN. In yet another embodiment the hard layer 326 is formed by a layer of TiW. Moreover, in one embodiment, the hard layer 326 is formed to be approximately 80 nm in thickness. Referring to FIG. 3F the third metal layer M 3 328 is formed overlaying hard layer 326 . In one embodiment, the hard layer 326 is a sub layer formed during the formation of the third metal layer M 3 328 by conventional sub-micron deposition and etch techniques. In still another embodiment (not shown), the hard layer 326 is a sub layer of the third metal layer M 3 328 formed near the separating oxide layer 324 . A bond pad 330 is then formed on an upper surface of the third metal layer M 3 328 by patterning a deposited passivation layer 332 . This is illustrated in FIG. 3G . Further as illustrated in FIG. 3G , a ball bond wire 334 is then coupled to the bond pad 330 . Although, not shown in the Figures, vias are formed in the relatively thick oxide 324 so that the top metal layer 328 can also be used to interconnect devices. Moreover, it will be understood in the art that a single integrated circuit may have multiple bond pads and the present invention is not limited to a single bond pad.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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A semiconductor structure comprises a top metal layer, a bond pad formed on the top metal layer, a conductor formed below the top metal layer, and an insulation layer separating the conductor from the top metal layer. The top metal layer includes a sub-layer of relatively stiff material compared to the remaining portion of the top metal layer. The sub-layer of relatively stiff material is configured to distribute stresses over the insulation layer to reduce cracking in the insulation layer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/829,600, filed May 31, 2013.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0003] Not Applicable
FIELD
[0004] This invention relates generally to a holding device for securing objects, such as towels, rags and other items, which could benefit from enhanced securing and organization. More specifically, the preferred embodiment of the invention incorporates a plurality of diaphragms, each having a plurality of deflectable tabs allowing for displacement of an object through the diaphragms.
BACKGROUND
[0005] In many fields of use, the lack of an elegant solution to store cleaning rags, cleaning implements and other flexible objects represents a frequent cause of frustration and inefficient work-practice.
[0006] Some devices known in the prior art attempt to solve this problem by utilizing a single diaphragm mechanism with a plurality of deflectable tabs that allow a portion of a flexible object to be inserted between the deflectable tabs. Such an object may also partially insert through the diaphragm. The resiliency of the tabs provides a retaining force that works to secure the object. By pulling axially on the object, said object may be withdrawn from the tabs. However, in such devices, the process of withdrawing such an object from the tabs leads to damage and excessive wear on objects interacting with such devices. When more fragile objects are stored by use of such devices, damage and excessive wear often includes tearing and other un-repairable damage.
[0007] A broad need exists to store and then easily remove from storage Non-Structural Flexible objects, such as plastic bags, towels and rags. As used herein, “Non-Structural Flexible” refers to the properties of an object, which can hold infinite forms with no external strain-inducing load applied to said object. This category of object comprises objects such as plastic bags, towels and rags. Workers in a variety of industries often carry Non-Structural Flexible objects. For example, window washers often carry a towel, while mechanics often carry rags. Other non-workers also often have a need to easily store or hold up Non-Structural Flexible objects on a routine basis.
[0008] Devices known in the prior art often utilize a single diaphragm mechanism to accomplish this task. Considerations relevant to diaphragm materials utilized dictate that the properties of materials used have characteristics to ensure that such materials remain resilient enough to retain an object while permitting enough deflection of diaphragm tabs without plastic deformation to enable release of said object without damage to either said object or said diaphragm tabs. Objects used in conjunction of such a holder vary in thickness and as such it may be desirable that such a device allow for holding objects having differing thicknesses. However, at least partially because of considerations relevant to the properties of materials used, many devices known in the prior art are limited in the size and thickness of the items such devices may retain.
[0009] The use of Non-Structural Flexible objects in conjunction with some existing single diaphragm holding devices known in the prior art poses a number of undesirable problems. Prior art devices typically require the user to partially insert a finger through the diaphragm to insert the object into the device for proper retention. Thus, the user's finger may become entrapped in the object holder. Given the stiff nature of the deflectable tabs, pulling said finger out creates a further constriction until the tabs deflect outward from the device. This results in painful and potentially injurious consequences to a user of such prior art devices.
[0010] Furthermore, the single diaphragm approach utilized by devices known in the prior art exhibits problems with Non-Structural Flexible object removal. A variety of Non-Structural Flexible objects, such as paper towels and napkins, have a high degree of fragility. As such, said variety of Non-Structural objects has a particular proclivity to tearing. The force required to deflect diaphragm material in prior art devices utilizing a single diaphragm approach may cause damage a Non-Structural Flexible object inserted within during extraction of said object. Such damage may comprise tearing, stretching, or excessive wear on a Non-Structural Flexible object.
[0011] In other applications known in the prior art, holding devices may be utilized in conjunction with the use of Structural Flexible objects to constrain them in an intended configuration comprising a user's belt, desktop, constrained to a wall or mounted to vehicle. As used herein, “Structural Flexible objects” refers to objects which maintain their intended manufactured form when fully supported with no external strain-inducing load but exhibit elastic deformation under strain inducing loads when operating within the range of intended use of the object. This category of object comprises objects such as writing implements, paint brushes, skis and fishing poles. A variety of problems associated with prior art devices designed to hold Non-Structural Flexible objects also similarly apply to prior art devices designed to hold Structural Flexible objects. In particular, generally speaking, prior art devices do not easily enable a user to store multiple Structural Flexible or Non-Structural objects within the same compartment. In other words, prior art devices generally require subdivided compartments to store multiple items, each subdivided compartment having its own single diaphragm. It follows, therefore, that such prior art devices necessarily suffer inefficiencies with regard to use of space and ease of use.
[0012] The above applications and other known prior art devices also exhibit problems associated with of the size and thickness of the object they can effectively retain. These limitations occur at least partially due to properties associated with diaphragm material used. Devices known in the prior art utilize diaphragms manufactured from plastic (e.g., polyethylene), which typically exhibits at least a minimum shore D Durometer hardness of 55. As a result, the diaphragm may accept only a limited range of effective diameter objects without plastic deformation caused to the tabs.
SUMMARY
[0013] In a flexible object holder employing the use of a plurality of diaphragms embodying principles of the invention, the device avoids the size and weight limitations associated with other known devices. A key feature of a holding device embodying principles of the invention is that it incorporates a plurality of diaphragms with tabs allowing for ease of acceptance and release of Non-Structural Flexible objects.
[0014] The use of multiple diaphragms in a device embodying principles of the invention allows for doubling, tripling etc. the number of tabs that engage flexible objects, such as a towel. In this regard, even though the retaining force or resiliency of an individual tab of the softer diaphragm material is less than the retaining force of other known prior art devices exhibiting a singular diaphragm, the increased number of tabs engaging an object allows the holding device to securely retain objects of varying effective diameter, weights and flexibility. The use of multiple diaphragms also allows for the storage of multiple objects within the same compartment in an embodiment of the invention. Such a configuration enables a more efficient usage of space associated with the design of the preferred embodiment of the invention. Further, the ability to store multiple Structural Flexible objects, as in the preferred embodiment of the invention, within the same compartment allows for a greater ease of use. A device embodying principles of the invention solves a variety of problems by the use of a plurality of diaphragms. The plurality of diaphragms allows for the use of softer diaphragm material. This softer diaphragm material permits greater tab displacement. The greater tab displacement allows a device embodying principles of the invention to accommodate objects with larger effective diameter. The greater tab displacement also permits the distal ends of the tabs to meet or nearly meet each other in order to engage objects with smaller effective diameter.
[0015] Moreover, a device embodying principles of the invention allows for the holding of fragile items without tearing or causing damage to fragile objects held by the device. Unlike holding devices known in the prior art, which incorporate a singular diaphragm and incorporate a harder diaphragm material, the preferred embodiment of the present invention utilizes multiple diaphragms constructed of softer material. The multiple diaphragms multiply the strength of a holding device embodying principles of the invention. By incorporating softer material in each diaphragm, however, the device embodying principles of the invention enables the storage of more fragile flexible items, while minimizing the risk of tearing or wear on the flexible objects held up by the said device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a prior art holding device.
[0017] FIG. 2 shows a prior art holding device.
[0018] FIG. 3 shows a perspective view of an embodiment of the presented holding device.
[0019] FIG. 4 shows a perspective view of an embodiment of the holding device of FIG. 3 holding a Flexible Non-Structural object.
[0020] FIG. 5 shows an exploded view of an embodiment of the presented holding device.
[0021] FIG. 6 shows further views of an embodiment of the holding device.
[0022] FIG. 7A shows an angular view of an embodiment incorporating principles of the invention holding a plurality of Flexible Structural objects, in this example, brushes.
[0023] FIG. 7B shows an angular sectional view of an embodiment incorporating principles of the invention holding a plurality of Flexible Structural objects, in this example, brushes.
[0024] FIG. 8 shows an view of an alternative embodiment incorporating principles of the invention designed to be attached to a wall holding a plurality of Flexible Structural objects, in this example, skis.
[0025] FIG. 9A shows an view of an alternative embodiment incorporating principles of the invention holding a singular Flexible Structural object, in this example, a screwdriver.
[0026] FIG. 9B shows a sectional view of an embodiment incorporating principles of the invention holding a singular Flexible Structural object, in this example, a screwdriver.
DETAILED DESCRIPTION
[0027] The preferred embodiment of the invention incorporates multiple diaphragms designed to hold a Non-Structural Flexible object 170 or Structural Flexible object 310 , 320 , 330 or a plurality of Non-Structural Flexible or Structural Flexible objects. It will be appreciated that a device incorporating embodiments of the invention may retain towels, paper towels, fabrics, plastics, or a variety of other Non-Structural Flexible objects. It will also be appreciated that a device incorporating embodiments of the invention may retain toothbrushes 310 , skis 320 , screwdrivers 330 , ink pens, paint brushes, or a variety of other Structural Flexible objects.
[0028] Reference will now be made to the accompanying drawings, which at least assist in illustrating various pertinent features of the presented inventions. The following description is presented for purposes of illustration and description and is not intended to limit the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described herein are further intended to explain the best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions.
[0029] FIGS. 3 , 4 and 5 illustrate one embodiment of an object holding device 100 in accordance with certain aspects of the presented invention. As shown, the device 100 includes a recessed housing 110 that supports at least a first and second membranes or diaphragms 150 over its open end. The diaphragms 150 A, 150 B each includes a plurality of slits 152 A, 152 B that extend there through. Furthermore the individual diaphragms as presented may embody a contiguous membrane or a plurality of individual geometrically shaped tabs to comprise a full diaphragm.
[0030] These slits define first and second sets pluralities of deflectable tabs 154 A, 154 B. As shown, each of the slits 152 intersect at a center of its respective diaphragm 150 . However, this is not a requirement. Referring to FIG. 5 , it is noted that illustrated holding device 100 utilizes first and second diaphragms 150 A, 150 B. However, it will be appreciated that other embodiments of the presented holding device 100 may utilize additional diaphragms. That is, other embodiments may utilize three, four, five or more diaphragms.
[0031] In use, in a device embodying principles of the invention, a user may displace a Non-Structural Flexible object such as a towel or rag 170 through the diaphragms 150 A, 150 B. See FIG. 4 . A user may do so by pressing a finger through the diaphragms 150 A, 150 B, a user may press the object between their finger and the diaphragms past the first and second sets of deflectable tabs 154 A, 154 B and into the interior 114 of the housing 110 . It will be appreciated that the design of the device 100 allows a user to grasp the housing and insert a Non-Structural Flexible object 170 through the diaphragm using a single hand.
[0032] As the Non-Structural Flexible object 170 passes through a diaphragm in a device embodying principles of the invention, the tabs 154 A, 154 B flex such that they are pushed inward into the recessed surface 114 of the housing 110 . Distal portions of at least a portion of the tabs engage the flexible object and work to maintain the Non-Structural Flexible object 170 within the device. That is, the resiliency of the tabs 154 A and 154 B when used in conjunction as in the preferred embodiment of the invention provide a retaining force that securely holds the Non-Structural Flexible object 170 within the holding device 100 . However, when a user pulls an object outward, the tabs will release the Non-Structural Flexible object 170 . In a preferred embodiment of the invention, a user would need to apply only a minimal pulling force to the object to cause said tabs to release said Non-Structural Flexible object 170 .
[0033] Furthermore, a user may displace a plurality of Structural Flexible objects such as skis 320 through the diaphragms 150 A, 150 B. See FIG. 8 . Alternatively and similarly, a user may displace a singular Structural Flexible object such as a screwdriver 330 through the diaphragms 150 A, 150 B. See FIGS. 9A and 9B . That is, by grasping the object 330 by one end and pressing the opposite end through diaphragms 150 A, 150 B, a user may press the object past the first and second sets of deflectable tabs 154 A, 154 B and into the interior 114 of the housing 110 . It will be appreciated that in the preferred embodiment of the invention the varying designs of the device 100 allow a user to insert the Structural Flexible object 310 , 320 , 330 through the diaphragm using a single hand.
[0034] As the Structural Flexible object 310 , 320 , 330 passes through the diaphragm, the tabs 154 A, 154 B flex such that they are pushed inward into the recessed surface 114 of the housing 110 . Distal portions of at least a portion of the tabs engage the flexible object and work to maintain the object within the device. That is, the resiliency of the tabs 154 A, 154 B provides a retaining force that securely holds the Structural Flexible object 310 , 320 , 330 within the holding device 100 . However, by applying a sufficient pulling force, the tabs will release the flexible object 310 , 320 , 330 .
[0035] It has been recognized that utilization of multiple diaphragms allows for providing adequate retention force for maintaining an object within the holding device while allowing the use of softer materials to form the diaphragms. In this regard, softer diaphragms allow the device to hold objects with very small effective diameters as well as objects exhibiting larger effective diameters.
[0036] The present inventor has discovered that devices known in the prior art are limited with regard to the size and thickness of objects that such devices can retain. These limitations occur at least partially due to properties associated with materials utilized in the construction of the diaphragm. Examples of limitations associated with prior art devices include the following. To hold objects with small effective diameter, the tabs 20 of such a diaphragm 10 may need to meet nearly in the center of the diaphragm. See FIG. 1 . The close spacing of the distal ends of such tabs 20 limits the thickness of objects that may be displaced through the diaphragm. Use of a softer diaphragm material permits displacement of a thicker object through such a diaphragm but results in a reduced retention force applied by each tab. As used herein, “effective diameter” refers to the measurement across the widest portion of the object as inserted into the device, whereas in the preferred embodiment of the invention a Structural Flexible object 310 , 320 , 330 , maintains a consistent effective diameter and that of a Non-Structural Flexible object 170 will depend upon the configuration and portion of the object which is inserted into the device.
[0037] The preferred embodiment of the invention addresses problems associated with size and thickness constraints associated with prior art devices. That is, rather than utilizing a stiffer plastic diaphragm, the diaphragms in a device incorporating embodiments of the invention are typically comprised of an elastomeric material that is considerably more pliable than most plastics. In this regard, it has been found by the inventor that materials having a Shore A Durometer hardness of less than 90 provide a suitable diaphragm for the device 100 .
[0038] Accordingly, use of lower Durometer materials, such as Shore A Durometer 90 and lower in a single diaphragm configuration can result in failure to retain Non-Structural Flexible objects 170 or Structural Flexible objects 310 , 320 , 330 within the holding device. Therefore, to hold thicker Non-Structural Flexible objects 170 or Structural Flexible objects 310 , 320 , 330 , holding devices typically utilize tabs 20 that are spaced from the center of the diaphragm 10 . See FIG. 2 . That is, the center of the diaphragm may include an aperture 12 and the tabs 20 extend around the periphery of this central aperture 12 . As will be appreciated, if a holder incorporates a central aperture, it cannot hold Non-Structural Flexible objects 170 or Structural Flexible objects 310 , 320 , 330 exhibiting a smaller effective diameter without design changes.
[0039] More specifically, materials having a Shore A durometer hardness of less than 90, more preferably less than 80 and yet more preferably less than about 70 provide diaphragms that allow deflection that is adequate to permit insertion of thick Non-Structural Flexible objects 1 while also permitting the engagement of thin Non-Structural Flexible objects. In one particular embodiment, the device utilizes neoprene rubber diaphragms having a thickness of approximately 1/16 of an inch. In contrast, most plastics (e.g., polyethylene, polypropylene etc.) have a Durometer hardness considerably in excess of the claimed range. That is, many plastics are too hard to be measured utilizing the Shore A Durometer scale. For instance, most plastics have a minimum Shore D Durometer hardness of 55, which equates to a hardness that is greater than the maximum measure of Shore A Durometer hardness.
[0040] The use of the multiple diaphragms allows for providing sufficient retention force to maintain a thicker and/or heavier Non-Structural Flexible object within the device. That is, even though each tab of the softer diaphragm material has a reduced resiliency, the increased number of tabs provided by the multiple diaphragms results in a holding device having sufficient retention force for thicker towels and other Non-Structural Flexible objects. Further, the use of a softer diaphragm material reduces the potential of painful or injurious results to a user's finger that is inserted into the device. That is, prior art devices having hard plastic tabs can result in a situation where a user pushes their finger through the stiffer tabs, which pinch the finger upon removal. Utilization of the more easily deflectable tabs prevents such inconvenience for the user. That is, the pliability of the tab material permits removal of a user's finger without risk of injurious or painful use.
[0041] As shown in FIG. 5 , the first and second diaphragms 150 A, 150 B are disposed adjacent to one another (e.g., stacked) and each have a periphery that engages a rim surface 112 of the housing 100 . In this regard, the diaphragms 150 A, 150 B each extend over the open end of the housing 110 . Stated otherwise, the diaphragms extend over the recessed inside surface 114 of the housing 110 such that they may deflect inward upon a Non-Structural Flexible object being displaced through the center portions of the diaphragms.
[0042] The peripheries of the diaphragms 150 A, 150 B are compressed against the rim 112 of the housing 110 by a retaining ring 130 . As shown, the retaining ring 130 is an annular element having a central aperture 132 that is disposed over the central portion of the diaphragms when the device is assembled. See FIG. 3 . The retaining ring 130 has an inner lip 134 that is smaller than the inside diameter/cross-dimension of the rim 112 of the housing 110 . Accordingly, when the retaining ring 130 is disposed onto the housing 110 the peripheries membranes 150 A, 150 B are compressed between the inner lip 134 and the rim 112 of the housing and thereby secured in place. A sidewall portion of the retaining ring 130 connects to an outside surface of the housing 110 . The retaining ring may be connected to the housing via a friction fit, adhesives or other fasteners.
[0043] In the present embodiment, the housing 100 is formed of generally circular cup having a closed bottom end. However, it will be appreciated that differently configured housings may be utilized. For instance, the housing may comprise any frame that allows for supporting the peripheries of multiple diaphragms such that tabs of the diaphragms may be deflected. Further, the housing need not be circular or annular nor does it need to exhibit a contiguous perimeter. In this regard, will be appreciated that various different geometric shapes, open and closed may be utilized. What is important is that the housing provide a frame that has an open aperture over which multiple diaphragms may be disposed.
[0044] As shown in the preferred embodiment, the diaphragms 150 A and 150 B are disposed adjacent (e.g., stacked) to each other. However, it will be appreciated that said diaphragms are not required to be stacked and may exhibit spacing between diaphragms. It will be further appreciated that in a configuration exhibiting a plurality of diaphragms in excess of two, the diaphragms need not exhibit equidistant spacing.
[0045] As shown in the preferred embodiment, the tabs 154 are formed such of their distal ends each meet at the center of their respective diaphragms 150 . However, it will be appreciated that other embodiments may be otherwise configured. For instance, each diaphragm may include a central aperture around which each of the slits radially extend from to define multiple tabs. However, it may be desirable that the distal tips of the tabs meet such that small Non-Structural Flexible objects may be held by the device.
[0046] In an embodiment of the invention, the embodiment further includes a clip 180 that allows the housing 110 to be connected to, for example, a user's belt. However, it will be appreciated that the housing 110 may also be secured to a supporting structure (e.g., wall) utilizing fasteners such as screws that extends through a bottom surface of the housing 110 .
[0047] This problem also extends to the use of Flexible Structural objects. For instance, a single diaphragm prior holder intended to hold a pen of diameter 0.5″ exhibiting a design of tabs 20 spaced from the center of the diaphragm creating an aperture 12 of size 0.3″ is not able to securely retain an artist's paintbrush with diameter 0.125″
[0048] Further embodiments of the invention may exhibit a geometrically shaped housing with open top and bottom ends allowing for insertion and retention of elongated objects such as skis 320 (See FIG. 8 ) or broomsticks. The preferred embodiment employs the use of a plurality of diaphragms allowing for the elongated objects to be inserted roughly half the length of the object and may be used for vertical storage of elongated objects. Furthermore, other embodiments may exhibit an open perimeter 400 allowing for lateral insertion and engagement of the diaphragms and object multiples of the embodiment may be used in conjunction to allow for secure lateral object retention mounted to mobile or static structures.
[0049] The foregoing description has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventions and/or aspects of the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described herein-above are further intended to explain best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
[0050] In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.
[0051] Moreover in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. The terms “coupled” and “linked” as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed. Also, the sequence of steps in a flow diagram or elements in the claims, even when preceded by a letter does not imply or require that sequence.
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An object holding device featuring multiple tabbed diaphragms in embodiments of the invention solves the lack of a previously existing elegant solution to store cleaning rags, cleaning implements and other flexible objects. The preferred embodiment of the present invention features a housing containing multiple tabbed diaphragms, which in the aggregate, when used as intended by the inventor, apply enough force to an object to hold an object within the tabbed diaphragms. Said embodiment also enables its user to easily remove objects from the plurality of tabbed diaphragms without causing damage to either the object or the tabbed diaphragms.
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FIELD OF THE INVENTION
This invention relates to a process for the production of α-hydroxy acids using an enzyme catalyst having nitrilase activity. More specifically, the invention pertains to production of glycolic acid from glycolonitrile using a catalyst having Acidovorax facilis 72W nitrilase activity.
BACKGROUND OF THE INVENTION
Glycolic acid (HOCH 2 COOH; CAS Registry Number is 79-14-1) is the simplest member of the α-hydroxy acid family of carboxylic acids. Its unique properties make it ideal for a broad spectrum of consumer and industrial applications, including use in water well rehabilitation, the leather industry, the oil and gas industry, the laundry and textile industry, and as a component in personal care products like skin creams. Glycolic acid also is a principle ingredient for cleaners in a variety of industries (dairy and food processing equipment cleaners, household and institutional cleaners, industrial cleaners [for transportation equipment, masonry, printed circuit boards, stainless steel boiler and process equipment, cooling tower/heat exchangers], and metals processing [for metal pickling, copper brightening, etching, electroplating, electropolishing]). New technology to commercially produce glycolic acid would be eagerly received by industry.
Various methods for preparing α-hydroxy acids are known, using the corresponding α-hydroxy nitrile as the starting material and a microorganism as the catalyst. Examples of α-hydroxy acids produced include: glycolic acid, lactic acid, 2-hydroxyisobutyric acid, 2-hydroxy-2-hydroxyphenyl propionic acid, mandelic acid, 2-hydroxy-3,3-dimethyl-4-butyrolactone, and 4-methylthiobutyric acid. These products are synthesized using microorganisms, such as those belonging to the genera Nocardia, Bacillus, Brevibacterium, Aureobacterium, Pseudomonas, Caseobacter, Alcaligenes, Acinetobacter, Enterobacter, Arthrobacter, Escherichia, Micrococcus, Streptomyces, Flavobacterium, Aeromonas, Mycoplana, Cellulomonas, Erwinia, Candida, Bacteridium, Aspergillus, Penicillium, Cochliobolus, Fusarium, Rhodopseudomonas, Rhodococcus, Corynebacterium, Microbacterium, Obsumbacterium and Gordona. (JP-A-4-99495, JP-A-4-99496 and JP-A-4-218385 corresponding to U.S. Pat. No. 5,223,416; JP-A-4-99497 corresponding to U.S. Pat. No. 5,234,826; JP-A-5-95795 corresponding to U.S. Pat. No. 5,296,373; JP-A-5-21987; JP-A-5-192189 corresponding to U.S. Pat. No. 5,326,702; JP-A-6-237789 corresponding to EP-A-0610048; JP-A-6-284899 corresponding to EP-A-0610049; JP-A-7-213296 corresponding to U.S. Pat. No. 5,508,181.)
However, most known methods for preparing α-hydroxy acids from the corresponding α-hydroxy nitrites as mentioned above do not produce and accumulate a product at a sufficiently high concentration to meet commercial needs. This is frequently a result of enzyme inactivation early in the reaction period. U.S. Pat. No. 5,756,306 teaches that “When an α-hydroxy nitrile is enzymatically hydrolyzed or hydrated using nitrilase or nitrile hydratase to produce an α-hydroxy acid or α-hydroxy amide, a problem occurs in that the enzyme is inactivated within a short period of time. It is therefore difficult to obtain the α-hydroxy acid or α-hydroxy amide in high concentration and high yield.” (col. 1, lines 49-54). Maintaining the aldehyde concentration (formed by the disassociation of α-hydroxy nitrile to aldehyde and hydrogen cyanide) and/or the α-hydroxy nitrile concentration in the reaction mixture within a specified range is one method to avoid this problem.
U.S. Pat. No. 5,508,181 addresses further difficulties relating to rapid enzyme inactivation. Specifically, U.S. Pat. No. 5,508,181 mentions that α-hydroxy nitrile compounds partially disassociate into the corresponding aldehydes, according to the disassociation equilibrium. These aldehydes inactivate the enzyme within a short period of time by binding to the protein, thus making it difficult to obtain α-hydroxy acid or α-hydroxy amide in a high concentration with high productivity from α-hydroxy nitrites (col. 2, lines 16-29). As a solution to prevent enzyme inactivation due to accumulation of aldehydes, phosphate or hypophosphite ions were added to the reaction mixture. U.S. Pat. No. 5,326,702 is similar to U.S. Pat. No. 5,508,181, except sulfite, disulfite, or dithionite ions are used to sequester aldehyde and prevent enzyme inactivation. However, the concentration of α-hydroxy acid produced and accumulated even by using such additives as described above is not great.
And finally, U.S. Pat. No. 6,037,155 also teaches that low accumulation of α-hydroxy acid products is related to enzyme inactivation within a short time due to the disassociated-aldehyde accumulation. These inventors suggest that enzymatic activity is inhibited in the presence of hydrogen cyanide ( Agricultural Biological Chemistry , Vol. 46, page 1165 (1982)) generated in the partial disassociation of α-hydroxy nitrile in water together with the corresponding aldehyde or ketone ( Chemical Reviews , Vol. 42, page 189 (1948)). The inventors solved the problem of aldehyde-induced enzyme inactivation by using microorganisms whose enzyme activity could be improved by adding a cyanide substance to the reaction mixture. The addition of a cyanide substance limited the disassociation of α-hydroxy nitrile to aldehyde and hydrogen cyanide.
With specific respect to the production of glycolic acid, glycolonitrile is known to reversibly disassociate to hydrogen cyanide and formaldehyde, either of which can inactivate enzyme activity. U.S. Pat. No. 3,940,316 describes a process for preparing an organic acid from the corresponding nitrile using a bacteria with “nitrilasic” activity, and lists glycolonitrile as a substrate. In particular, this patent describes the use of Bacillus, Bacteridium, Micrococcus, and Brevibacterium for this purpose. Though described as having nitrilasic activity, Brevibacterium R312 is the only strain used in all of the U.S. Pat. No. 3,940,316 examples. Brevibacterium R312 is known to have nitrile hydratase and amidase activities, but no nitrilase activity (Toumeix et al., Antonie van Leeuwenhoek, 1986, 52:173-182).
A method for preparing lactic acid, glycolic acid, and 2-hydroxyisobutyric acid by using a microorganism belonging to Corynebacterium spp. is disclosed in Japanese Patent Laid-open No. Sho 61-56086. JP 09028390 discloses a method for manufacturing high-purity glycolic acid from glycolonitrile by the action of Rhodococcus or Gordona hydrolase. Selectivity for glycolic acid is reported as almost 100%, without formation of glycolic acid amide. U.S. Pat. No. 6,037,155 also provides examples of methods for producing α-hydroxy acids from α-hydroxy nitrites, including glycolic acid. This disclosure acknowledges that not all microbial catalysts can produce high concentrations of glycolic acid due to the aforementioned problems and instructs that screening studies must be conducted in order to find industrially advantageous microorganisms. U.S. Pat. No. 6,037,155 specifically identifies microorganisms belonging to Variovorax spp. and Arthrobacter spp., which are resistant to the suppressing effect of α-hydroxy nitrile or α-hydroxy acid, have durable activity, and can produce the desired product at high concentration.
Acidovorax facilis 72W (ATCC 55746) is characterized by aliphatic nitrilase (EC 3.5.5.7) activity, as well as a combination of nitrile hydratase (EC 4.2.1.84) and amidase (EC 3.5.1.4) activities. U.S. Pat. No. 5,858,736 describes the use of the nitrilase activity of this microbe as a catalyst for the hydrolysis of aliphatic α,ω-dinitriles to the corresponding ω-cyanocarboxylic acids and ammonia in an aqueous reaction mixture. The nitrilase was found to be highly regioselective, where hydrolysis of an α-alkyl-α,ω-dinitrile produced only the ω-cyanocarboxylic acid resulting from hydrolysis of the ω-nitrile group. U.S. Pat. No. 5,814,508 discloses heating a suspension of Acidovorax facilis 72W (ATCC 55746) in a suitable buffer at 35-70° C. for a short period of time to deactivate the undesirable nitrile hydratase and amidase activities of the whole-cell catalyst, without producing a significant decrease in the desired nitrilase activity.
As illustrated above, developing an industrial process using a nitrilase catalyst to efficiently manufacture α-hydroxy acids has proved difficult. When concentration of a product is low, it is well known to those skilled in the art that the process tends to be complex, particularly for separating product from unreacted starting material, or for isolating a small amount of the desired product from a large volume of product mixture. The problem to be solved remains the lack of a facile enzymatic catalyst to convert α-hydroxy nitriles to the corresponding acid in a process characterized by high yield, high concentration and high selectivity, and with the added advantages of low temperature requirements and low waste production.
SUMMARY OF THE INVENTION
The invention provides a process for preparing glycolic acid from glycolonitrile with high specificity at 100% conversion. The invention has the steps of (a) contacting glycolonitrile in a suitable aqueous reaction mixture with an enzyme catalyst characterized by a nitrilase activity derived from Acidovorax facilis 72W (ATCC 55746); and (b) isolating the glycolic acid produced in (a).
Further embodiments of the invention use an enzyme catalyst having nitrilase activity in the form of whole microbial cells, permeabilized microbial cells, one or more cell components of a microbial cell extract, and partially purified enzyme(s), or purified enzyme(s). Microorganisms characterized by a nitrilase activity and useful in the process are Acidovorax facilis 72 W (ATCC 55746) and its mutants, Acidovorax facilis 72-PF-15 (ATCC 55747), and Acidovorax facilis 72-PF-17 (ATCC 55745). Additionally, transformed microbial cells containing A. facilis nitrilase activity are included in this invention. Escherichia coli SS1001 (ATCC PTA-1177) and Escherichia coli SW91 (ATCC PTA-1175) are examples of such a transformed microbial cell catalyst.
A further embodiment of the invention uses whole microbial cells characterized by (1) nitrilase activity and (2) nitrile hydratase and amidase activities, as the enzyme catalyst for converting glycolonitrile to glycolic acid. A preferred whole cell is the A. facilis 72W strain. In this embodiment, before use as an enzyme catalyst, the A. facilis 72W whole microbial cells are heated to a temperature of about 35° C. to 70° C. for between 10 and 120 minutes, whereby the nitrile hydratase and amidase activities are destroyed and the nitrilase activity is preserved. This treatment avoids the formation of an unwanted byproduct, glycolamide. Where the mutants and transformed whole microbial cells lack the nitrile hydratase and amidase activities, no heat-treatment step is needed. Escherichia coli SS1001 (ATCC PTA-1177) and Escherichia coli SW91 (ATCC PTA-1175) are examples of a transformed microbial cell catalyst that lacks nitrile hydratase and amidase activities.
In any form and optionally, the enzyme catalyst may be immobilized in or on a soluble or insoluble support.
BRIEF DESCRIPTION OF THE BIOLOGICAL DEPOSITS
Applicants have made the following biological deposits under the terms of the Budapest Treaty on the International Recognition of the Deposit of Microorganisms for the purposes of Patent Procedure:
Depositor Identification
Int’l. Depository
Reference
Designation
Date of Deposit
Acidovorax facilis 72-PF-17
ATCC 55745
8 March 1996
Acidovorax facilis 72W
ATCC 55746
8 March 1996
Acidovorax facilis 72-PF-15
ATCC 55747
8 March 1996
Escherichia coli SS1001
ATCC PTA-1177
11 January 2000
Escherichia coli SW91
ATCC PTA-1175
11 January 2000
As used herein, “ATCC” refers to the American Type Culture Collection International Depository Authority located at ATCC, 10801 University Blvd., Manassas, Va. 20110-2209, USA. The “International Depository Designation” is the accession number to the culture on deposit with ATCC.
The listed deposits will be maintained in the indicated international depository for at least thirty (30) years and will be made available to the public upon the grant of a patent disclosing it. The availability of a deposit does not constitute a license to practice the subject invention in derogation of patent rights granted by government action.
DETAILED DESCRIPTION OF THE INVENTION
Applicants have solved the stated problem by providing a process to prepare glycolic acid from the corresponding glycolonitrile in high yields and at high concentration using the nitrilase activity of Acidovorax facilis 72W. A nitrilase enzyme directly converts an aliphatic nitrile to the corresponding carboxylic acid, without forming the corresponding amide as intermediate (Equation 1).
The glycolic acid produced by the present invention has useful applications in a variety of industries.
Definitions
In this disclosure, a number of terms and abbreviations are used. The following definitions apply unless specifically stated otherwise.
“Enzyme catalyst” or “whole microbial cell catalyst” refers to a catalyst that is characterized by a nitrilase activity. The enzyme catalyst may be in the form of a whole microbial cell, permeabilized microbial cell(s), one or more cell components of a microbial cell extract, partially purified enzyme(s), or purified enzyme(s).
The terms “ Acidovorax facilis ” and “A. facilis” are used interchangeably.
The terms “ Escherichia coli ” and “ E. coli ” are used interchangeably.
The term “glycolonitrile” is synonymous with hydroxyacetonitrile, 2-hydroxyacetonitrile, hydroxymethylnitrile, and all other synonyms of CAS Registry Number 107-16-4.
The term “glycolic acid” is synonymous with hydroxyacetic acid, hydroxyethanoic acid, and all other synonyms of CAS Registry Number 79-14-1.
The term “suitable aqueous reaction mixture” refers to the materials and water in which the glycolonitrile and enzyme catalyst come into contact. Tables describing components of the suitable aqueous reaction mixture are provided herein and those skilled in the art appreciate the range of component variations suitable for this process.
The abbreviations in the specification correspond to units of measure, techniques, properties, or compounds as follows: “sec” means second(s), “min” means minute(s), “h” means hour(s), “d” means day(s), “mL” means milliliters, “L” means liters, “mM” means millimolar, “M” means molar, “mmol” means millimole(s), and “wt” means weight. “HPLC” means high performance liquid chromatography, “ca” means approximately, “O.D.” means optical density at the designated wavelength, “IU” means International Units.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Methods and Materials
Growth of Acidovorax facilis strain 72W (ATCC 55746)
One frozen seed lot vial of Acidovorax facilis strain 72W (ATCC 55746) was thawed and the 1 mL contents placed in 500 mL of sterile Inoculum Medium (components listed below in Tables 1 and 2). The inoculum was grown at 30° C. with shaking at 250 rpm in a 2 L flask for 24-30 h.
TABLE 1
Inoculum Medium
Final
Component
Concentration
potassium phosphate, monobasic
1.5
g/L
ammonium sulfate
1.5
g/L
magnesium sulfate, heptahydrate
0.4
g/L
Amberex 695 (Universal Foods)
1
g/L
potassium phosphate, dibasic
3.4
g/L
Trisodium citrate, dihydrate
1
g/L
Trace metal solution (below)
1
mL/L
glycerol (sterilized separately)
8
g/L
TABLE 2
Trace Metal Solution
Stock
Component
Concentration
hydrochloric acid
10
mL/L
calcium chloride, dihydrate
11.4
g/L
manganese sulfate, monohydrate
1.23
g/L
copper sulfate, pentahydrate
0.63
g/L
cobalt chloride, hexahydrate
0.16
g/L
boric acid
0.91
g/L
zinc sulfate, heptahydrate
1.77
g/L
sodium molybdate, dihydrate
0.05
g/L
vanadyl sulfate, dihydrate
0.08
g/L
nickel nitrate, hexahydrate
0.04
g/L
sodium selenite
0.04
g/L
ferrous sulfate, heptahydrate
6.0
g/L
The inoculum from the shake flask was transferred aseptically to a presterilized Braun Biostat C fermenter containing Fermenter Medium (components listed below in Table 3). Growth occurred under the following conditions: 32° C., pH 6.8-7.0, dissolved oxygen at 25% of saturation. At inoculation, the fermenter contained 8.5 L of Fermenter Medium plus 218 g of Nutrient Feed solution, giving a starting concentration of approximately 7 g/L glycerol. The Nutrient Feed solution includes the following components that were sterilized separately and combined after cooling: potassium phosphate, monobasic, 19.6 g in 0.25 L deionized water; magnesium sulfate, heptahydrate, 3.3 g, plus sulfuric acid, 4 mL, in 0.15 L deionized water; Trace Metal solution (components listed above in Table 2), 67 mL, plus 400 g glycerol in 0.80 liters deionized water. At 18 h post inoculation, feeding of Nutrient Feed solution began. Initially, the Nutrient Feed solution was added at a rate of 0.4 g feed/min (0.15 g glycerol/min). The culture OD 550 was approximately 8-9. At 26 h, the feed rate was increased to 0.9 g feed/min (0.3 g glycerol/min). The OD 550 was approximately 16-18. A final increase in feed rate to 1.8 g feed/min (0.6 g glycerol/min) was made at 34 h. This rate continued to the end of the run (about 42 h). The final OD 550 was approximately 65-75.
TABLE 3
Fermenter Medium
Stock
Component
Concentration
potassium phosphate, monobasic
0.39
g/L
Difco yeast extract
5.0
g/L
potassium phosphate, dibasic
0.39
g/L
Cells, as wet cell paste, were recovered by centrifugation and stored frozen until use. Dry cell weight of wet cell paste, obtained by lyophilization, was typically 24% of wet cell weight. For use as a biocatalyst, A. facilis 72W (ATCC 55746) cells were first optionally heated to 50° C. for 1 h in 0.35 M phosphate buffer (pH 7.0) to inactivate nitrile hydratase activity.
Use of Nitrilase Activity of Acidovorax facilis 72W for Glycolic Acid Production
A. facilis 72W whole cells contain a nitrile hydratase and an amidase in addition to the nitrilase. The nitrile hydratase produces glycolamide, an unwanted byproduct leading to yield loss (Example 2). To avoid this byproduct, the A. facilis 72W whole cell catalyst can be heat-treated to remove the nitrile hydratase/amidase activities to produce a microbial catalyst which gives high selectivity to glycolic acid with no glycolamide production at concentrations up to 1.0 M glycolic acid (Example 1). Enzymatic activity is sustained in a stable state for a prolonged period of time.
Whole microbial cells can be used as catalyst without any pretreatment such as permeabilization. Alternatively, the whole cells may be permeabilized by methods familiar to those skilled in the art (e.g., treatment with toluene, detergents, or freeze thawing) to improve the rate of diffusion of materials into and out of the cells.
The enzyme catalyst can be immobilized in a polymer matrix (e.g., alginate, carrageenan, polyvinyl alcohol, or polyacrylamide gel (PAG)) or on a soluble or insoluble support (e.g., celite) to facilitate recovery and reuse of the catalyst. Methods for the immobilization of cells in a polymer matrix or on a soluble or insoluble support have been widely reported and are well known to those skilled in the art. The nitrilase enzyme can also be isolated from the whole cells and used directly as catalyst, or the nitrilase can be immobilized in a polymer matrix or on a soluble or insoluble support. These methods have also been widely reported and are well known to those skilled in the art (Methods in Biotechnology, Vol. 1: Immobilization of Enzymes and Cells; Gordon F. Bickerstaff, Editor; Humana Press, Totowa, N.J., USA; 1997).
The concentration of enzyme catalyst in the reaction mixture depends on the specific catalytic activity of the enzyme catalyst and is chosen to obtain the desired rate of reaction. The wet cell weight of the whole microbial cell catalyst in hydrolysis reactions typically ranges from 0.001 g to 0.100 g of wet cells per mL of total reaction volume, preferably from 0.002 g to 0.050 g of wet cells per mL. The specific activity of the whole microbial cell catalyst (IU/gram wet cell wt.) is determined by measuring the rate of conversion of a 0.10 M solution glycolonitrile to glycolic acid at 25° C., using a known weight of whole microbial cell catalyst. An IU of enzyme activity is defined as the amount of enzyme activity required to convert one micromole of substrate to product per minute.
The temperature of the hydrolysis reaction is chosen to optimize both the reaction rate and the stability of the enzyme catalyst activity. The temperature of the reaction may range from just above the freezing point of the suspension (ca. 0° C.) to 70° C., with a preferred range of reaction temperature of from 5° C. to 35° C. The whole microbial cell catalyst suspension may be prepared by suspending the cells in distilled water, or in an aqueous reaction mixture containing a buffer (e.g., sodium or potassium phosphate), where the initial pH of the reaction is between 5.0 and 10.0, and preferably between 6.0 and 8.0. As the reaction proceeds, the pH of the reaction mixture may change due to the formation of an ammonium salt of the α-hydroxy acid from the corresponding nitrile functionality of the α-hydroxy nitrile. The reaction can be run to complete conversion of α-hydroxy nitrile with no pH control, or a suitable acid or base can be added over the course of the reaction to maintain the desired pH.
The glycolic acid thus obtained may be isolated by treating the reaction mixture, from which insoluble matter including the cells has been removed, by procedures well known to those of ordinary skill. Such procedures include but are not limited to concentration, ion exchange, electrodialysis, extraction, and crystallization. The product may be isolated as the ammonium salt, or after acidification, as glycolic acid.
Two mutants of the Acidovorax facilis 72W (ATCC 55746) strain have been prepared (U.S. Pat. No. 5,858,736) that produce only very low levels of the undesirable nitrile hydratase activity responsible for non-regioselective nitrile hydrolysis of aliphatic dinitriles. These mutant strains, Acidovorax facils 72-PF-15 (ATCC 55747) and Acidovorax facilis 72-PF-17 (ATCC 55745), do not require heat-treatment of the cells before use as an enzyme catalyst to hydrolyze an aliphatic cyanocarboxylic acid ester to the corresponding dicarboxylic acid monoester.
EXAMPLES
The present invention is further defined in the following Examples. It should be understood that these Examples, while indicating preferred embodiments of the invention, are given by way of illustration only. From the above discussion and these Examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usage and conditions.
In the following examples, the conversion of glycolonitrile to the reaction products glycolic acid and glycolamide was determined by HPLC using a Bio-Rad HPX-87H organic acid analysis column (30 cm×7.8 mm dia.) with precolumn at 50° C. and 0.010 N H 2 SO 4 as eluent, and a refractive index detector.
Example 1
Conversion of Glycolonitrile to Glycolic Acid Using Nitrilase Activity of Acidovorax facilis 72W
A suspension of 0.62 g (wet cell paste) Acidovorax facilis 72W cells (ATCC 55746) in 9.38 mL of 0.100 M potassium phosphate buffer (pH 7.0) was placed into a 15-mL polypropylene centrifuge tube, and the cell suspension heated at 50° C. for 1 h (to completely inactivate undesired nitrile hydratase and amidase activities), then cooled to 25° C. in a water bath. The suspension was centrifuged and the supernatant decanted: the cell pellet was resuspended in 9.48 mL of 0.020 M potassium phosphate buffer (pH 6.0), mixed at 25° C. for 15 min, and the suspension then centrifuged. The supernatant was decanted. The resulting cell pellet was resuspended in 9.38 mL of 0.020 M potassium phosphate buffer (pH 6.0). To the tube was then added 0.106 mL of a 55 wt % solution of glycolonitrile in water (0.10 M final concentration of glycolonitrile in the suspension), and the resulting suspension mixed on a rotating platform at 25° C. Samples for analysis (0.200 mL) were first adjusted to pH 2.5 with 6 N HCl to stop the reaction, centrifuged, and the supernatant filtered using a 0.2 micron filter. The resulting filtrate was analyzed by HPLC for glycolonitrile, glycolic acid, and glycolamide. After 2 h, the glycolonitrile had been completely converted to glycolic acid and no glycolamide was produced.
An additional 0.312 mL of a 55 wt % solution of glycolonitrile in water (0.30 M additional concentration of glycolonitrile added to the reaction mixture, 0.40 M total) was added to the reaction mixture after complete conversion of the initial concentration of glycolonitrile, and the reaction continued. After 14 h, the additional glycolonitrile was almost completely converted to glycolic acid, and an additional 0.624 mL of a 55 wt % solution of glycolonitrile in water (0.60 M additional concentration of glycolonitrile, 1.0 M total) was added to the reaction mixture. After 40 h, complete conversion of 1.0 M glycolonitrile to glycolic acid was observed, with no production of glycolamide.
Example 2 (Comparative)
Conversion of Glycolonitrile to Glycolic Acid and Glycolamide by Acidovorax facilis 72W Cells having both Nitrilase and Nitrile Hydratase/Amidase Activities
The reaction described in Example 1 was repeated, except that the suspension of A. facilis 72W cells in phosphate buffer was not heated at 50° C. for 1 h to inactivate the nitrile hydratase and amidase activities of the cells prior to use in the reaction. A suspension of 0.52 g (wet cell paste) A. facilis 72W cells (ATCC 55746) in 9.48 mL of 0.020 M potassium phosphate buffer (pH 6.0) containing 0.106 mL of a 55 wt % solution of glycolonitrile in water (0.10 M final concentration of glycolonitrile in the suspension) was mixed at 25° C. After 2 h, the conversion of glycolonitrile was complete, and the yields of glycolic acid and glycolamide were approximately 61% and 39%, respectively.
An additional 0.312 mL of a 55 wt % solution of glycolonitrile in water (0.30 M additional concentration of glycolonitrile added to the reaction mixture, 0.40 M total) was added to the reaction mixture after 2 h of reaction. After 4 h, a significant amount of the additional glycolonitrile remained, and the ratio of concentrations of glycolic acid and glycolamide was ca. 3.4:1. An additional 0.624 mL of a 55 wt % solution of glycolonitrile in water (0.60 M additional concentration of glycolonitrile, 1.0 M total) was added to the reaction mixture. After 22 h, ca. 40% glycolonitrile remained, and the ratio of concentrations of glycolic acid and glycolamide was ca. 9:1.
Example 3
Conversion of Glycolonitrile to Glycolic Acid Using Acidovorax facilis Mutants 72-PF-15 (ATCC 55747) or 72-PF-17 (ATCC 55745)
The reaction described in Example 1 is repeated except that the mutant strains A. facilis 72-PF-15 or 72-PF-17 are used instead of A. facilis 72W. A suspension of 0.50 g (wet cell paste) A. facilis 72-PF-15 or 72-PF-17 in 8.44 mL of 0.020 M potassium phosphate buffer (pH 6.0) is placed into a 15-mL polypropylene centrifuge tube. To the tube is then added 1.06 mL of a 55 wt % solution of glycolonitrile in water (1.0 M final concentration of glycolonitrile in the suspension), and the resulting suspension mixed on a rotating platform at 25° C. Samples of the suspension for analysis (0.200 mL) are first adjusted to pH 2.5 with 6 N HCl to stop the reaction, centrifuged, and the supernatant filtered using a 0.2 micron filter. After sufficient time, complete conversion of glycolonitrile to glycolic acid is obtained with no production of byproduct glycolamide.
Example 4
Conversion of Glycolonitrile to Glycolic Acid Using E. coli Transformants SS1001 (ATCC PTA-1177) or SW91 (ATCC PTA-1175)
The reaction described in Example 1 is repeated except that the E. coli transformant SS1001 or SW91 is used instead of A. facilis 72W. A suspension of 0.50 g (wet cell paste) E. coli SS1001 or SW91 in 8.44 mL of 0.020 M potassium phosphate buffer (pH 6.0) is placed into a 15-mL polypropylene centrifuge tube. To the tube is then added 1.06 mL of a 55 wt % solution of glycolonitrile in water (1.0 M final concentration of glycolonitrile in the suspension), and the resulting suspension mixed on a rotating platform at 25° C. Samples of the suspension for analysis (0.200 mL) are first adjusted to pH 2.5 with 6 N HCl to stop the reaction, centrifuged, and the supernatant filtered using a 0.2 micron filter. After sufficient time, complete conversion of glycolonitrile to glycolic acid is obtained with no production of byproduct glycolamide.
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The present invention relates to a method for producing α-hydroxy acids using an enzyme catalyst having nitrilase activity. More specifically, the invention pertains to use of Acidovorax facilis 72W (ATCC 55746) nitrilase to hydrolyze glycolonitrile to glycolic acid. Glycolonitrile is reacted in an aqueous mixture with a catalyst having Acidovorax facilis 72W nitrilase activity to give glycolic acid selectively, and at high concentration and high yield.
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BACKGROUND OF THE INVENTION
The present invention relates to a water soluble polyester suitable for use as a wire enamel or other type of protective coating. In recent years EPA and OSHA have become more insistent and stringent in their regulations concerning solvents and chemicals relative to their photochemical reactivity, toxicity and related health hazards. This has acted as an impetus toward the development of newer polymers that are capable of being solubilized in water that meet these new Federal and State regulations.
Another object is to prepare a non-trimellitic anhydride polyester with improved cut-through and heat shock properties as a wire enamel with a Class F or higher thermal rating.
A preview of prior art in this area is in order to better develop significant differences and features of the present invention over other polymer systems.
To better illustrate significant differences of the present invention over prior art one must consider the type of triol and diol, the critical ratio of these two materials, and the required excess hydroxyl content or the OH/COOH ratio. First of all, the present invention differs from the Laganis Patents U.S. Pat. No. 3,974,115 and U.S. Pat. No. 4,016,330 on at least five counts. One is that the polyester intermediate of the invention does not contain a tribasic carboxylic acid or more highly functional polycarboxylic aromatic acid to act as a solubilizing site to render it water soluble. Secondly, these polyesters are reacted to a relatively low acid number on the solids of 5-20 vs. an acid number ranging from 50 to 100 on a solids basis for the two cited patents. Thirdly, the range of excess hydroxyl groups is much higher for these new polyesters and ranges from 80 to 200% vs. 20 to 35% for the cited patents. Fourthly, the ratio of diol to triol is critical and no mention is made of this in the cited patents. Fifthly, and lastly, the new wire coating does not employ hydroxymethylated diacetone acrylamide as a crosslinking agent as in the cited patents.
Relative to Meyer-Zalewski patent U.S. Pat. No. 3,342,780, the present invention differs in at least three instances. Firstly, it differs in the OH/COOH ratio wherein the current invention has a minimum ratio starting from 1.8/1 up to a maximum of 3/1 compared to that of the cited patent of 1/1 up to a maximum of 1.6/1. Examples later on will demonstrate that a clear aqueous solution having less than 30% cosolvent cannot be obtained with less than 80% excess OH content. Secondly, there is the critical ratio of diol to triol to achieve water solubility. Thirdly, there cannot be used Tyzor TPT (tetra isopropyl titanate) as it is unstable in water, and there must be used a water soluble titanate such as the triethanol chelate of titanium or the ammonium lactate chelate of titanium to get a suitable wire coating.
There are many differences that distinguish the invention from the Chang patent U.S. Pat. No. 3,959,201, as to the polyester composition and the final blend. In Chang there are only two compositions shown in examples 77 and 102 that use an aromatic dicarboxylic acid, such as isophthalic acid, and none with terephthalic acid. Both of these examples chemically and molar-ratiowise are exactly identical, are linear in nature, and do not have a triol or any other polyhydric alcohol. Also these materials are blended with aminoplasts to cure, whereas the present compositions are not and have a much higher order of thermal stability and usage than that cited in this reference.
In Holzrichter U.S. Pat. No. 3,957,709, great emphasis is placed on the ester intermediate having a hydroxyl functionality of about 3, whereas in the present invention it ranges from 2.0 to 2.2. Further, the present polyesters have a molecular weight range of 800-1300 or 50 to 100% higher than those of Holzrichter and consequently, the polyesters of Holzrichter without a modifying alcohol do need the presence of a cosolvent as their water solubility and dilutibility are limited without it. From a thermal rating and wire properties in general it is absolutely essential to have a triol present. If one calculates the carbon to oxygen ratio (C/O) of THEIC which is 9/6 pr 4.5/3, then it falls outside the scope of this patent on the low end. It may also be noted that the hydantoin glycol, 1,3-hydroxyethyl-5,5 dimethyl hydantoin has a C/O of 9/4 or 6.75/3 and it is at the upper end of Holzrichter's range of about 7/3 which the patent says adversely affects the water solubility of the ester intermediate. This has not been found to be the case with the present polymers. Lastly, and also important, Holzrichter states in claims 1, 6, 7, 8 and 9 the need for an aminoplast and epoxy resin as curatives. Neither is present in the products of the invention as both would be detrimental on long-term thermal aging. The titanate is the only curing agent present in the present aqueous system and in the solvent system there is employed a phenolic and isocyanate intermediate, besides a titanate, as crosslinkers.
Preston U.S. Pat. No. 3,835,121 cites polyesters containing hydantoin radicals and isocyanurate radicals in the polymeric backbone, but no mention is made of the required excess hydroxyl content or its aqueous solubility characteristics in any of its claims. Furthermore, no mention is made of a monohydric alcohol, such as a glycol ether, which is an essential reactant in one alternative in the present invention. The extreme importance of the role that excess hydroxyl content plays in achieving aqueous solubility will be elaborated upon more fully below. Reviewing the six examples of Preston the excess hydroxyl content ranges from a low of approximately 17 to a high of approximately 63%. This is far below the minimum of 80% in the present case where THEIC only is present or where the hydantoin glycol is present alone with a triol other than THEIC. In both instances with a composition of this type a certain amount amount of cosolvent, namely, in the 10-30% range, is required. With the monohydric alcohol modified composition no cosolvent is necessary. Furthermore, a different titanate is needed, namely, Tyzor TE or other water soluble titanate for the present invention whereas the Preston titanate is not water soluble or stable in the presence of water. In general, the present solvent system is totally different from Preston's, and thus requires significant formulation changes to achieve a desirable and reasonably economical wire enamel system.
The present polyester composition differs from Hosokawa U.S. Pat. No. 4,011,185, in that it contains no aromatic tetracarboxylic acid or anhydride as required in Hosokawa's claims 1, 4 and 10. Furthermore, in the present invention reaction is carried out to an acid number range of 2-20 vs. 70 to 140 and 70 to 100 as cited in claims 14 and 15 of Hosokawa. The needed wire properties would not be obtained at these high acid numbers because of too many oligomers being present at the higher acid values or less reacted polymers. The organic amines used in this patent are not used solely as solubilizing agents, but react with the free carboxyl groups in the polymer to form amides which further distinguishes the present invention from it as applicant employs only tertiary amines as solubilizing agents and as cosolvents since they are amine alcohols. The product of this patent is thus a polyester-amide and not a straight polyester.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel insulating coating that is completely soluble in water alone or a mixture of water and cosolvent.
Another object is to provide improved aqueous polyester coatings for electrical conductors.
A further object is to provide wire enamels which exhibit good electrical and mechanical properties coupled with good thermal capabilities.
An additional object of the present invention is to prepare new water soluble polyesters.
The other objects and advantages of the present invention will become apparent from the following description.
During the development of the polyester intermediates that were readily soluble in water, it became evident that two important factors were operative. One was that the type of polyol was a key to greatly improved solubility in water. The other parameter was the excess hydroxyl content, and its critical range. As to the solubility of these polyesters they were either soluble in water alone or in a water cosolvent content of 70/30 by weight at the most.
To get the best values in terms of cut-throughs, heat shocks and other mechanical and electrical properties, along with a high thermal rating of Class F or higher, efforts were focused on a terephthalate-based polyester which contained various diols, triols and other adjuvants.
There are two types of polyesters within the invention:
1. A polyester that is completely soluble in water only may be obtained by reacting (1) an aromatic dicarboxylic acid or derivative thereof with (2) THEIC or an aliphatic polyhydric alcohol having at least three hydroxyl groups (3) a primary diol and (4) a monohydric alcohol; and,
2. A polyester that is completely soluble in a water/polar solvent or cosolvent in a weight ratio of 95/5 to 70/30, respectively and is obtained by reacting (1) an aromatic dicarboxylic acid or a derivative thereof with (2) THEIC or an aliphatic polyhydric alcohol having at least three hydroxyl groups and (3) a primary diol.
The term "aqueous" as referred here is meant to define a clear, stable aqueous solution with little or no opalescence thereto, and not to an emulsion, suspension or aqueous dispersion. In the formulation of these polyesters familiar terms such as equivalents, moles, and excess hydroxyl content calculated from the total hydroxyl equivalents divided by the total carboxyl equivalents, or more simply by the expression of OH/COOH ratio, are referred to frequently.
The critical ratio of triol to diol on a molar basis shall be referred to frequently in pointing out its importance in achieving aqueous solubility concommitant with good wire properties. The critical molar ratio of diol/triol may range from 75/25 to 40/60, respectively. With respect to the critical content of the monohydric alcohol necessary to achieve complete aqueous solubility without any cosolvent present it may range from 2 to 25 equivalent percent of the total diol equivalents present.
The polyester intermediates of this invention may be characterized as reaction products of aromatic dicarboxylic acids and hydroxyl-bearing compounds having one or more hydroxyl groups per mole of reactants. Furthermore, the water solubility and further dilutibility with water will vary somewhat with the particular constituents so that small amounts of cosolvent may be necessary to achieve a clear, aqueous solution. The polyesters are polymeric in nature, and having molecular weights ranging in value from 800 to 1300. This provides a favorably high solids wire enamel ranging from 45 to 75% solids along with a low acid number to minimize water sensitivity of the baked film on wire. The acid number of the polyesters of the invention is usually quite low, e.g., 2-20, usually 5-20 when using THEIC.
The polyesters are condensation products produced by esterifying aromatic dicarboxylic acids with polyols at a OH/COOH ratio of 1.8/1 to 3/1. The polyol may be a trihydric alcohol, such as tris(2-hydroxyethyl)isocyanurate (hereinafter referred to as THEIC), and used in combination with a primary diol, such as ethylene glycol or 1,3-dihydroxyethyl, 5,5-dimethyl hydantoin (hereinafter referred to as DHEDMH).
In another form of the invention a polyol in combination with a diol and a monohydric alcohol is used to achieve complete solubility in water alone with the resultant polyester. The monohydric alcohol, such as glycol ether, was substituted for ethylene glycol on an equivalent basis and at a range of 2 to 25 equivalent percent the polyester would stay clear as an aqueous solution with 20% or less of cosolvent. At the 10 and 20 eq. % of monohydric alcohol no cosolvent was required and the best wire properties were obtained.
The principal reactants in the preparation of one class of polyesters are:
aromatic dicarboxylic acids
diols
triols or higher polyols
monohydric alcohols
For the other class of polyesters it employs the same reactants as above, except for the absence of monohydric alcohols. As the dicarboxylic acid, one or more aromatic dicarboxylic acids (including anhydrides of such acids) or a combination of aromatic with a cycloaliphatic acid (or anhydride thereof) may be employed. Also, the dimethyl or diethyl esters or chlorides thereof may also be used.
Carboxylic Acids and Derivatives
a. Aromatic-terephthalic acid, isophthalic acid, phthalic anhydride, phthalic acid, benzophenone-4,4'-dicarboxylic acid, naphthalene-1,4-dicarboxylic acid, naphthalene-1,5-dicarboxylic acid, 4,4'-dicarboxydiphenyl sulfide, 4,4'-dicarboxydiphenyl sulfone, 3,3'-dicarboxydiphenyl sulfone, 4,4'-dicarboxydiphenyl ether, 4,4'-dicarboxdiphenyl methane, 4,4'-dicarboxydiphenyl ketone, 4,4'-dicarboxydiphenyl propane and the corresponding di lower alkyl esters and acid chlorides.
b. Cycloaliphatic-tetrahydrophthalic anhydride, hexa hydrophthalic anhydride, 1,4-cyclohexane dicarboxylic acid, 3,6-endo-methylene-4-tetrahydrophthalic anhydride as well as the corresponding free acids. The cycloaliphatic dicarboxylic acid (or anhydride, acid chloride or di lower alkyl ester) can be present in an amount of 0 to 50%, e.g., 1 to 50% of the total equivalents of acid component, the balance being the aromatic dicarboxylic acid or derivative.
One or more dihydric alcohols may be used in combination with triols or higher polyhydric alcohols and with or without monohydric alcohols of the glycol ether type, benzyl alcohol type, or tertiary amino alcohols.
Diols -- ethylene glycol, propylene glycol, 1,3-butylene glycol, neopentyl glycol, 1,3-di(hydroxyethyl)-5,5-dimethyl hydantoin, 1,5-pentanediol, 1,6-hexanediol, 1,4-cyclohexanedimethanol, 1,4-cyclohexanediol, diethylene glycol, dipropylene glycol, Union Carbide's "Ester Diol 204", Dow's 565, dipropylene glycol, 4,4'-di(hydroxymethyl)diphenyl methane.
Triols -- trishydroxyethyl isocyanurate (THEIC), glycerine, trimethylolethane, trimethylolpropane, 1,2,5-hexanetriol, polyether triol (avg. mol. wt. 268 ethoxylated glycerine), etc.
Higher polyols -- mono-, di- and tri-pentaerythritol, Monsanto's RJ-100 (styrene-allyl alcohol copolymer with avg. mol. wt. 1600), etc.
Monohydric alcohols -- glycol ethers, such as methoxy diethanol, ethoxy diethanol, butoxy diethanol, methoxy ethanol, ethoxy ethanol, butoxy ethanol, phenoxy ethanol, phenoxy propanol, phenoxy propoxy propanol, phenoxy diethanol, phenoxy tetraethanol, etc. Other alcohols are benzyl alcohol, hydrogenated abietic acid or abietyl alcohol. Tertiary amino mono alcohols, such as N,N-dimethylamino ethanol, N,N'-phenyl ethyl ethanolamine, N,N'-diethyl amino ethanol, N,N'-dibutyl amino ethanol, etc.
The preferred reactants are terephthalic acid (or dimethyl terephthalate, THEIC and ethylene glycol). If a monohydric alcohol is present it is preferably a lower alkoxyethanol, a lower alkoxyethoxyethanol, phenoxyethanol or phenoxyethoxyethanol.
As the dicarboxylic acid reactant there can be employed one or more free aromatic dicarboxylic acid, the anhydrides of such acids, e.g., phthalic anhydride, the lower alkyl esters of such acids, e.g., dimethyl terephthalate, diethyl terephthalate, dibutyl terephthalate and dimethyl isophthalate or the acid chloride, e.g., terephthaloyl chloride. As used in the claims when there is recited the reaction product of an "acid" is used this is intended to cover the free acid, the anhydride (if it exists), the lower alkyl ester and the acid chloride. If the term "acid" in the claims is limited to the free acid then the word "free" will precede "acid". In the specification, however, the term "acid" means the "free acid" unless another meaning is clear from the context.
In the preparation of the polyester, the proportions of the alcohols to the acids have been calculated on equivalents of hydroxyl (OH) and carboxyl (COOH) groups. The proportions of each type of reactive groups are critical. The proportions may be expressed in a ratio, such as OH/COOH, or as a percentage of excess OH groups over the total of COOH groups. The OH/COOH ratio may range from 1.8/1 to 3/1 or an excess % OH from 80 to 200. The preferred excess hydroxyl content may range from 80 to 150%.
The preferred triol is THEIC, a nitrogen and carbonyl containing polyol, and when used alone or as the predominant one in admixture with other triols, the critical molar ratio of diol/triol may range from 75/25 to 40/60, respectively.
It has also been discovered that another nitrogen and carbonyl-containing hydantoin diol, such as 1,3-hydroxyethyl-5,5-dimethyl hydantoin yields clear, aqueous solutions at cosolvent levels of 30% or less when combined with glycerine as a polyol. Hitherto clear aqueous solutions had been obtained only when THEIC was present as a polyol in combination with ethylene glycol or other diols. Now, unexpectedly, hydantoin glycol alone or in combination with other diols may be used with polyols other than THEIC to get equally good solubility. Obviously, combinations of hydantoin glycol and THEIC may be utilized as well to get the desired aqueous solubility. Again the molar diol/triol ratio may range from 75/25 to 40/60, respectively.
The use of water soluble titanates is critical when blended with the polyesters of the invention to make wire enamels not only to obtain good mechanical and electrical properties as a wire coating, but also to get low dissipation factors.
The polyester wire enamel is modified by the incorporation of 1-10% of organic titanate, such as titanate chelates or salts, on the total solids of the enamel. The addition of an adjuvant of this type enhances the thermoplastic flow properties of the enamel and provides lower dissipation factors. Typical examples of suitable titanates include the triethanolamine chelate of titanium, known as Tyzor TE (Du Pont Trademark), and the ammonium lactate salt of titanium, known as Tyzor LA (Du Pont Trademark). These titanates and any others that are hydrolytically stable, e.g., titanium acetyl acetate, may be used as crosslinking agents. The amount of titanate used may be 1-10% of the total enamel solids, and preferably 2-6%.
To solubilize these inherently water-insoluble resinous prepolymers in water various amines may be employed that react with the free carboxyl groups available to form the salts that are soluble in water. These amines may be of the alkyl, alkanolamine, or morpholine types. In general, the tertiary amines work best from the standpoint of fast cure, and confer the least moisture sensitivity in the resultant baked film.
Thus, there can be used trialkyl amines, N-alkyldiethanolamine, N,N-dialkyl alkanolamines, N-alkyl morpholine, N-hydroxyalkyl morpholine, etc. The alkyl group is usually lower alkyl, e.g., of 1 to 4 carbon atoms.
Typical examples of tertiary amines are: triethyl amine, trimethyl amine, tributyl amine, triethanolamine
N,n-dimethyl ethanolamine (a preferred tertiary amine)
N,n-diethyl ethanolamine
N,n-diisopropyl ethanolamine
N,n-dibutyl ethanolamine
triisopropanolamine
N,n-dibutyl isopropanolamine
N-methyl diethanolamine (a preferred tertiary amine)
N-ethyl diethanolamine, N-propyl diethanolamine
N-methyl morpholine
N-ethyl morpholine
N-(2-hydroxyethyl)morpholine
2-amino-2-methyl 1-propanol
2-dimethylamino-2-methyl 1-propanol
A sufficient quantity of amine is employed to raise the pH of the aqueous solution to a range of 7-9 and preferably 7.5-8.5.
The incorporation of a polar solvent, as a minor component of a water/cosolvent blend, enhances the solubility of those polyesters which may not be soluble in water alone. Furthermore, the polar solvent enhances the flow during cure of the enamel and ultimately the smoothness and concentricity of the resultant baked film.
Typical polar solvents that may be incorporated are principally water-miscible. They include:
N-methyl pyrrolidone
butyrolactone
dimethyl sulfoxide
diacetone alcohol
dioxane
glycol ethers, e.g., methoxyethanol, ethoxyethanol, butoxyethanol, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether and the other alkoxyalkanols and alkoxyalkoxyethanols mentioned above as monohydric alcohols
alcohols, e.g., ethyl alcohol, isopropyl alcohol, methyl alcohol, glycols such as ethylene glycol, diethylene glycol, triethylene glycol, trimethylene glycol, propylene glycol, dipropylene glycol
ketones, e.g., acetone, methyl ethyl ketone glycol ether acetates, e.g., methoxyethyl acetate, ethoxyethylacetate, butoxyethyl acetate
glycol diethers, e.g., diethylene glycol dimethyl ether, diethylene glycol diethyl ether
The amount of cosolvent incorporated along with water may range from 0-30% of the total blend, e.g. 5 to 30%, and preferably 10-25%.
The polyester consists of or consists essentially of the stated dibasic acid, trihydric alcohol, dihydric alcohol plus or minus the monohydric alcohol. The wire enamel also consists essentially of the polyester dissolved in the solvent. There can be added conventional phenol-formaldehyde resins and polyurethanes, if desired.
The wire enamels can be applied to copper, silver and other metal conductors.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Examples 1-18 disclose the method for making the polyester component of the composition.
EXAMPLE 1
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 395 6.37 12.74(B) THEIC 1438 5.51 16.53(C) Terephthalic Acid 1328 8.00 16.00OH/COOH = 1.83/1______________________________________
Materials A, B and C were charged into a 5 liter, three-neck flask equipped with agitator, thermometers for flask and distilling head, 3-bubblecap Snyder fractionating column and water-cooled condenser.
Heat was applied and the batch temperature was gradually increased to 400°-420° F in approximately 4 hours. More importantly the distilling head temperature was controlled at 200°-212° F to keep glycol losses down to 2% or less. The batch was maintained at the top temperature range of 400°-420° F until the melt was clear hot and the total distillate collected at this point was 250 mls. It was then checked for viscosity and acid number, and the following results were obtained:
Viscosity: Q 1/2 measured at 30% solids in cresylic acid No. 43
Acid No: 9 on solids
The base was discharged into a metal container and allowed to solidify.
b. Preparation of Aqueous Wire Enamel
The hard resin was broken into large pieces, and an aqueous enamel was prepared with it as follows:
______________________________________ Wt. Grams Letter______________________________________Polyester of Example 1 1200 AN-Methyl Pyrrolidone (NMP) 120 BDimethyl Ethanolamine (DMEA) 120 CDistilled Water 560 DNMP 20 ETriethanolamine Chelate of Titanium(80% in isopropanol)* 75 F______________________________________ *hereinafter referred to as Tyzor TE (Du Pont)
Materials A and B were charged into a 3-liter, 3-neck round bottom flask, and heated to 290°-300° F until the polymer was fluid and dissolved. The contents were then cooled to 250° F, and material "C" was added carefully. Materials "D" and "E" were added, and allowed to mix until a homogeneous solution resulted. The solution was allowed to cool to 110° F and material "F" was added, and stirred in thoroughly. The liquid properties of the aqueous enamel were:
Viscosity: X 3/4
pH: 7-8
% solids: 60.1
% Cosolvent: 20
EXAMPLE 2
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 576 9.29 18.58(B) THEIC 1148 4.40 13.20(C) Terephthalic Acid 1328 8.00 16.00OH/COOH = 2/1______________________________________
The same equipment and procedure as outlined in Example 1(a) were employed in preparing this polymer. It was controlled to a final viscosity of J-L measured at 30% solids in cresylic acid, and then discharged into a pan to solidify.
b. Preparation of Aqueous Wire Enamel
Using the same equipment and procedure as described in Example 1(b) an aqueous enamel was prepared by blending 500 grams of base polymer 2(a) with 50 grams NMP, 50 grams DMEA, 200 grams distilled water, and 18.8 grams Tyzor TE. Its liquid properties were:
Viscosity: V
% solids: 62.9
pH: 7-8
% cosolvent: 20
EXAMPLE 3
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 474 7.645 15.29(B) THEIC 1726 6.613 19.84(C) Terephthalic Acid 1394 8.400 16.80OH/COOH = 2.09/1______________________________________
The same equipment and procedure as outlined in Example 1(a) were employed in preparing this polymer. It was reacted to a final viscosity of O-P measured at 30% solids in cresylic acid, and discharged into a pan to solidify.
b. Preparation of Aqueous Wire Enamel
Using the same equipment and procedure as described in Example 1(b) an aqueous enamel was compounded by blending 1390 grams of base polymer 3(a) with 139 grams NMP, 139 grams DMEA and 556 grams distilled water with the following liquid characteristics:
Viscosity: W
pH: 7-8
% solids: 62.5
% Cosolvent: 20
EXAMPLE 4
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 474 7.645 15.29(B) THEIC 1726 6.613 19.84(C) Terephthalic Acid 1195 7.200 14.40OH/COOH = 2.40/1______________________________________
The same equipment and procedure as outlined in Example 1(a) were employed in preparing this polymer. It was reacted to a final viscosity of M 1/2 measured at 30% solids in cresylic acid and then dropped into a pan to harden.
b. Preparation of Aqueoue Wire Enamel
Using the same equipment and procedure as described in Example 1(b) an aqueous enamel was prepared by blending 700 grams of base polymer 4(a) with 60 grams NMP, 70 grams DMEA, 240 grams distilled water, and 43.75 grams Tyzor TE with liquid properties as follows:
Viscosity: T
% solids: 66
pH: 7-8
% cosolvent: 20
EXAMPLE 5
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 434 7.000 14.00(B) THEIC 1131 4.333 13.00(C) Terephthalic Acid 996 6.000 12.00OH/COOH = 2.25______________________________________
The same equipment and procedure as outlined in Example 1(a) were employed in preparing this polymer. It was reacted until the melt was clear and 196 mls of distillate had been collected. The molten resin was dropped into a pan and allowed to harden.
b. Preparation of Aqueous Wire Enamel
Using the same equipment and procedure as described in Example 1(b) an aqueous enamel was prepared by compounding 500 grams of base polymer 5(a) with 50 grams each of NMP and DMEA, 200 grams distilled water and 18.75 grams Tyzor TE having the following solution properties:
Viscosity: O
% solids: 6.29
pH: 7-8
% cosolvent: 20
To demonstrate the effect of a monofunctional reactant, such as a glycol ether, in completely eliminating the need of any cosolvent to effect good aqueous solubility, the following Examples 6-8 are offered as evidence.
EXAMPLE 6
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 305 4.914 9.828(B) THEIC 1233 4.725 14.175(C) Terephthalic Acid 966 6.000 12.000(D) Methyl Ether of Di-ethylene Glycol 131 1.092 1.092OH/COOH = 2.09/1______________________________________
The same equipment and procedure as outlined in Example 1(a) were employed in preparing this polymer. It was reacted until the melt was clear and 206 mls of distillate had been collected.
b. Preparation of Aqueous Wire Enamel
Using the same equipment and procedure as described in Example 1(b) an aqueous wire enamel was prepared by compounding 500 grams of base polymer 6(a) with 50 grams DMEA, 200 grams distilled water and 18.75 grams Tyzor TE. This is the first example of an aqueous enamel that is clear and not requiring any cosolvent. It had a viscosity of V, a solids content of 67%, and a pH of 7-8.
EXAMPLE 7
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 271 4.368 8.732(B) THEIC 1233 4.725 14.175(C) Terephthalic Acid 966 6.000 12.000(D) Methyl Ether of Di-ethylene Glycol 262 2.184 2.184OH/COOH = 2.09/1______________________________________
The same equipment and procedure as described in Example 1(a) were employed in preparing this polymer. It was reacted until the melt was clear and 198 mls of distillate had been collected. The molten resin was dropped into a pan and allowed to harden.
b. Preparation of Aqueous Wire Enamel
Using the same equipment and procedure as described in Example 1(b) an aqueous enamel was prepared by blending 600 grams of base polymer 7(a) with 60 grams DMEA, 150 grams distilled water and 22.5 grams Tyzor TE with liquid properties as follows:
Viscosity: X 3/4
% solids: 74.2
pH: 7-8
% cosolvent: 0
EXAMPLE 8
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 305 4.914 9.828(B) THEIC 1233 4.725 14.175(C) Terephthalic Acid 996 6.000 12.000(D) Phenyl Ether ofEthylene Glycol 155 1.092 1.092OH/COOH = 2.09______________________________________
The same equipment and procedure as outlined in Example 1(a) were employed in preparing this polymer. It was reacted until the melt was clear, and the final acid number was 9.2 on the solids, a hydroxyl number of 312 and the distillate collected was 193 mls. The molten resin was dropped into a pan and allowed to harden.
b. Preparation of Aqueous Wire Enamel
Using the same equipment and procedure as described in Example 1(b) an aqueous enamel was prepared by blending 600 grams of base polymer 8(a) with 50 grams DMEA, 300 grams distilled water and 37 grams Tyzor TE with the following liquid properties:
Viscosity: X
% solids: 63.8
pH: 7-8
% cosolvent: 0
To demonstrate the effect of a certain critical excess hydroxyl content has on aqueous solubility the following polyesters vs. Example 9 and their comparison data are presented in Table 1.
EXAMPLE 9
a. Preparation of Polymer
______________________________________Reactants Wt. Grams Mols Equivalents______________________________________(A) Ethylene Glycol 395 6.37 12.74(B) THEIC 1438 5.51 16.53(C) Terephthalic Acid 1640 9.88 19.76OH/COOH = 1.48/1______________________________________
The same equipment and procedure as described in Example 1(a) were employed in preparing this polymer. It was reacted to a final viscosity of X 1/4 at 30% solids in cresylic acid, and the total distillate collected was 313 mls. The molten resin was dropped into a pan, and allowed to harden.
b. Preparation of Aqueous Wire Enamel
Using the same equipment and procedure as described in Example 1(b) 600 grams of base polymer 9(a) was blended with 70 grams NMP, 90 grams DMEA and 280 grams distilled water, but the solution was very cloudy. Another mix was prepared with the same material and amounts, save for the DMEA which was increased to 130 grams and the solution was again quite cloudy.
In Table 1 the relationship of average functionality (avg. f) and OH/COOH content or % excess OH to solubility is shown with the various polyester and aqueous wire enamel examples.
Table 1__________________________________________________________________________Polyester Example No. 9(a) 1(a) 2(a) 3(a) 4(a)OH/COOH Ratio 1.48 1.83 2.00 2.09 2.44% Excess OH 48.00 83.00 100.00 109.00 144.00Avg. f 2.253 2.277 2.203 2.292 2.308Aqueous Wire Enamel Example No. 9(b) 1(b) 2(b) 3(b) 4(b)Solution Appearance very very sl. clear clear clear cloudy hazeViscosity -- X 3/4 V U 1/2 T% Solids 57.3 60.1 62.9 63.2 66.0pH 7-8 7-8 7-8 7-8 7-8% Cosolvent 20.0 20.0 20.0 20.0 20.0__________________________________________________________________________
As the results indicate, at a OH/COOH ratio of 1.48 the aqueous wire enamel was very cloudy and at 1.83 there was a distinct improvement with only a very slight haze. All the higher OH/COOH ratios provided clear aqueous solutions -- indicating at 83% excess OH content and upward is needed to achieve clarity in a solvent blend composed of 80% water and 20% cosolvent.
The profound effect of a specific diol in an otherwise standard formulation on aqueous solubility is shown in Table 2. The polyesters were prepared with the same equipment and procedure as outlined in Example 1(a) and the aqueous wire enamels in the same manner as Example 1(b).
Table 2__________________________________________________________________________"Effect of Diols on Aqueous Solubility" Polyesters__________________________________________________________________________ Example 10(a) Example 11(a) Example 12(a) Example 13(a) grams grams grams mols grams mols grams molsTerephthalic Acid 1328 8 1328 8 830 5 830 5Glycerine (96%) 512 5.336 512 5.336 378 3.94 378 3.94Ethylene Glycol 496 8Neopentyl Glycol 832 8Hydantoin Glycol (DHEDMH) 855 4.55Hydroquinone Di- 900 4.55Hydroxyethyl Etheravg. f 2.25 2.25 2.292 2.292OH/COOH 2.0 2.0 2.09 2.09Process PhysicalsViscosity at 60%NV in MCA* G- J 3/4 -- --Acid Number 33.6 22 29.2 24.4 Example 10(b) Example 11(b) Example 12(b) Example 13(b) grams grams grams grams grams gramsPolyester 600 600 600 600 600 600DMEA 60 60 60 60 60 4.6NMP 280 -- 300 60 -- --Butoxyethanol -- 350 -- -- 60 360Water 200 200 200 200 200 15.4Tyzor TE -- -- -- 33.75 33.75 --Solution PropertiesAppearance cloudy cloudy cloudy clear clear cloudy-2 phasesViscosity -- -- -- X T --% Solids 52.6 49.6 51.7 65.7 65.7 61.2% Cosolvent 58.3 63.6 60.0 23.1 23.1 95.9__________________________________________________________________________ *Methyl Cellosolve Acetate
As the data indicates, only a hydantoin glycol-based polyester had reasonably good solubility in water having either NMP or butoxyethanol at a 23.1% level. All the other diols were cloudy at high cosolvent levels ranging from 58.3 to 95.9%. Thus, a polyester with hydantoin glycol and glycerine as a triol has solubility characteristics equal to Example 3(b) with ethylene glycol and THEIC.
Similarly, the type of triol employed in a specific polyester formulation greatly influences its aqueous solubility characteristics. Again, the polyesters and their respective aqueous wire enamels were prepared as outlined in Example 1(a) and Example 1(b). This information is summarized in Table 3.
Table 3__________________________________________________________________________"Effect of Polyols on Aqueous Solubility" Polyesters__________________________________________________________________________ Example 14(a) Example 15(a) Example 16(a) Example 17(a) Example 18(a) Ex.3(a) Control grams mols grams mols grams mols grams mols grams mols grams molsTerephthalicAcid 1328 8 1328 8 1328 8 1328 8 996 6 1394 8.4Ethylene Glycol 124 2 318 5.12 124 2 124 2 331 5.34 474 7.645Neopentyl Glycol 483 4.64 483 4.64 483 4.64 483 4.64Glycerine (96%) 598 6.24Mono-Pentaery-thritol 424 3.12Trimethylol-ethane 749 6.24Trimethylol-propane 836 6.24Niax PolyolLG 650 1190 4.44THEIC 1726 6.613Avg. f 2.299 2.299 2.299 2.299 2.281 2.292OH/COOH 2.0 2.0 2.0 2.0 2.0 2.09Process PhysicalsViscosity at O-P at 30% NV60% NV in in CA #43MCA H 1/2 M J I 1/4 -- (cresylic acid)Acid Number 11.8 32 33 36 58 -- Example 14(b) Example 15(b) Example 16(b) Example 17(b) Example 18(b) Ex.3(b) Control grams grams grams grams grams grams gramsPolyester 500 600 600 600 600 600 1390DMEA 65 60 60 60 60 60 139NMP -- 160 210 260 -- -- 139Butoxyethanol -- -- -- -- 260 160 --Methyl Ether ofDiethyleneGlycol 153 -- -- -- -- -- --Water 112 250 200 200 200 200 556Tyzor TE -- 33.75 33.75 -- 33.75 -- --Solution PropertiesAppearance v. cloudy clear clear cloudy clear cloudy clearViscosity -- W- U -- L 1/4 -- WSolids (%) 60.2 56.8 56.8 53.6 54.4 58.8 62.5Cosolvent (%) 57.7 39 51.2 56.5 56.5 44.4 20__________________________________________________________________________
The triols listed in Table 3, save for THEIC, in the polyester compositions shown required cosolvent contents of 39% or higher to get clear aqueous solutions in some cases; in others they were still cloudy at levels up to 57.7%. Example 3(b) with THEIC in its composition exhibits its superior aqueous solubility at a cosolvent level of 20%.
To illustrate the excellent properties of these aqueous wire enamels, a few of the many examples were selected and their solvent-based counterparts using the same base polymer were compared propertywise. For details, consult Table 4.
The effect of titanate was studied with aqueous wire enamels prepared with the polymer of Example 3(a) and 3(b). These enamels had the following compositions:
______________________________________ Example 3(b).sup.1 Example 3(b).sup.2 Example 3(b).sup.3______________________________________Example 3(b) 730 730 730Tyzor TE 14.3 28.5 42.8Viscosity V 1/2 U 1/2 U 1/4+% Tyzor TE 2.5 5 7.5______________________________________
As indicated in Table 5 at the 7.5% titanate level there was a slight decrease in cut-through temperature. The best values were obtained with the titanate content at 5%; otherwise the other wire properties were all quite comparable.
Table 4__________________________________________________________________________Water-Based Enamels vs. Solvent-Based Enamels Example 1(a) Ex.3(a) Example 4(a) Ex.5(a) Ex.6(a) Ex.7(a) Aqueous Solvent Aqueous Aqueous Solvent Aqueous Aqueous Aqueous Ex.1(b) Based Ex.3(b) Ex.4(b) Based Ex.5(b) Ex.6(b) Ex.7(b)__________________________________________________________________________Wire Propertieson AWG #18Copper WireBuild in mils,basecoat 2.0 2.3 2.0 2.0 2.3 2.0 2.3topcoat 0.9 0.7 1.0 0.9 0.7 1.0 0.7Type of Topcoat Nylon Nylon Nylon Nylon Nylon Amide- Nylon Amide- Imide ImideSpeed, ft/min 50 50 50 50 50 45 50 45Appear, basecoat 3 2-3 3 3 3 3 3 3topcoat 3 3 3 3 3 3 3 3Cut-ThruTemp., ° C 242 265 255 228 280 240 278Heat Shocks,20% prestretch1X 40 90 70 80 0 80 02X 90 100 90 100 10 100 203X 100 100 100 100 60 100 804X 100 100 100 100 80 100 901/2 hr at ° C 175 175 175 175 260 175 260Mandrel AfterSnap 1X 1X 1X 1X Failed Snap 1X 1XBurnout 5.84Abras., unilat. 1800 1800 2000 1400 1850 1916 1933 2000 1480 1950Elect.Str.,dry KVTower Temp.at 900° F__________________________________________________________________________
Table 5__________________________________________________________________________"Effect of Titanate Content on Wire PropertiesEnamel Number Example 3(b).sup.1 Example 3(b).sup.2 Example 3(b).sup.3__________________________________________________________________________Wire Properties, on AWG #18 Copper WireBuild in mils, basecoat 2.0 2.0 2.0 topcoat 1.0 1.0 1.0Type of Topcoat Nylon Nylon NylonSpeed, ft/min 50 50 50Appearance, basecoat 3 3 2-3 topcoat 3 3 3Cut-Through, Temp. ° C 255 255 241Heat Shocks, 20% Prestretch, 1X 0 70 0 80 50 2X 80 90 80 90 90 3X 100 100 100 100 100 4X 100 100 100 100 100 1/2 hr at ° C 175 175 200 175 200Mandrel After Snap 1X 1X 1XAbrasion, unilateral 1125 1800 2000 1691 1916 2000Burnout 5.96 5.84 5.36Electric Strength, dry, KV 12.2 13.1 11.1Tower Temp. at 900° F__________________________________________________________________________
The polyesters of the invention are thermosetting. Unless otherwise indicated, all parts and percentages are by weight.
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Water soluble polyesters are prepared by reacting an aromatic dicarboxylic acid, a diol and a triol (the molar ratio of diol to triol being 75:25 to 40:60) with or without a monohydric alcohol. The polyesters have a molecular weight of 800 to 1300, an OH/COOH ratio of 1.8:1 to 3:1. The polyesters are useful in making wire enamels.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a division of U.S. patent application Ser. No. 08/996,047, filed Dec. 22, 1997 U.S. Pat. No. 6,083,085, Jul. 4, 2000.
TECHNICAL FIELD
The present invention relates to mechanical and chemical-mechanical planarization of microelectronic substrates. More particularly, the present invention relates to conditioning polishing pads and other planarizing media used to planarize the surfaces of microelectronic substrates.
BACKGROUND OF THE INVENTION
Mechanical and chemical-mechanical planarization processes remove material from the surfaces of semiconductor wafers, field emission displays and many other microelectronic substrates to form a flat surface at a desired elevation. FIG. 1 schematically illustrates a planarizing machine 10 with a platen or base 20 , a carrier assembly 30 , a planarizing medium 40 , and a planarizing solution 44 on the planarizing medium 40 . The planarizing machine may also have an under-pad 25 attached to an upper surface 22 of the platen 20 for supporting the planarizing medium 40 . In many planarizing machines, a drive assembly 26 rotates (arrow A) and/or reciprocates (arrow B) the platen 20 to move the planarizing medium 40 during planarization.
The carrier assembly 30 controls and protects a substrate 12 during planarization. The carrier assembly 30 generally has a substrate holder 32 with a pad 34 that holds the substrate 12 via suction, and an actuator assembly 36 typically rotates and/or translates the substrate holder 32 (arrows C and D, respectively). However, the substrate holder 32 may be a weighted, free-floating disk (not shown) that slides over the planarizing medium 40 .
The planarizing medium 40 and the planarizing solution 44 may separately, or in combination, define a polishing environment that mechanically and/or chemically-mechanically removes material from the surface of the substrate 12 . The planarizing medium 40 may be a conventional polishing pad made from a relatively compressible, porous continuous phase matrix material (e.g., polyurethane), or it may be an abrasive polishing pad with abrasive particles fixedly bonded to a suspension medium. In a typical application, the planarizing solution 44 may be a chemical-mechanical planarization slurry with abrasive particles and chemicals for use with a conventional non-abrasive polishing pad, or the planarizing solution 44 may be a liquid without abrasive particles for use with an abrasive polishing pad.
To planarize the substrate 12 with the planarizing machine 10 , the carrier assembly 30 presses the substrate 12 against a planarizing surface 42 of the planarizing medium 40 in the presence of the planarizing solution 44 . The platen 20 and/or the substrate holder 32 then move relative to one another to translate the substrate 12 across the planarizing surface 42 . As a result, the abrasive particles and/or the chemicals in the polishing environment remove material from the surface of the substrate 12 .
Planarizing processes must consistently and accurately produce a uniformly planar surface on the substrate to enable precise fabrication of circuits and photo-patterns on the substrate. As the density of integrated circuits increases, the uniformity and planarity of the substrate surface is becoming increasingly important because it is difficult to form sub-micron features or photo-patterns to within a tolerance of approximately 0.1 μm when the substrate surface is not uniformly planar. Thus, planarizing processes must create a highly uniform, planar surface on the substrate.
In the competitive semiconductor and microelectronic device manufacturing industries, it is also desirable to maximize the yield of individual devices or dies on a substrate. Typical semiconductor manufacturing processes fabricate a plurality of dies (e.g., 50 - 250 ) on each substrate. To increase the number of dies that are fabricated on each substrate, many manufacturers are increasing the size of the substrates to provide more surface area for fabricating additional dies. Thus, to maximize the yield of operable dies on each substrate, planarizing processes should produce a uniformly planar surface across the entire substrate.
In conventional planarizing processes, the substrate surface may not be uniformly planar because the rate at which material is removed from the substrate surface (the “polishing rate”) typically varies from one region on the substrate to another. The polishing rate is a function of several factors, and many of the factors may change during planarization. For example, some of the factors that effect the polishing rate across the substrate surface are as follows: (1) the distribution of abrasive particles and chemicals between the substrate surface and the planarizing medium; and (2) the condition of the planarizing surface on the planarizing medium.
To reduce deviations in the uniformity of the substrate surface, several existing planarizing media are polishing pads with holes or grooves that transport a portion of the planarizing solution below the substrate surface during planarization. A Rodel IC-1000 polishing pad, for example, is a relatively soft, porous polyurethane pad with a number of large slurry wells approximately 0.05-0.10 inches in diameter that are spaced apart from one another across the planarizing surface by approximately 0.125-0.25 inches. During planarization, small volumes of slurry are expected to fill the large wells, and then hydrodynamic forces created by the motion of the substrate are expected to draw the slurry out of the wells in a manner that wets the substrate surface. U.S. Pat. No. 5,216,843 describes another polishing pad with a plurality of macro-grooves formed in concentric circles and a plurality of micro-grooves radially crossing the macro-grooves. In such grooved pads, it is expected that the grooves hold a portion of the planarizing solution below the substrate surface during planarization.
Although polishing pads with holes or grooves improve the uniformity of substrate surfaces, they may not produce adequately uniform surfaces on substrates after several planarizing and conditioning cycles. One factor affecting the uniformity of the substrate surface is the condition of the polishing pad. The planarizing surface of the polishing pad typically deteriorates after polishing a number of substrates because waste matter from the substrate, planarizing solution and/or the polishing pad accumulates on the planarizing surface. For example, when a doped silicon glass layer is planarized, a portion of the glass glazes over areas of the planarizing surface. The waste matter typically does not accumulate uniformly across the planarizing surface, and thus the waste matter alters local polishing rates across the pad. Polishing pads are accordingly “conditioned” by removing the waste matter from the pad to restore the polishing pad to a suitable condition for planarizing substrates.
Polishing pads are conventionally conditioned with devices that contact the waste matter with an abrasive element or a water jet to remove the waste matter from the pad. One conventional method for conditioning polishing pads is to abrade the planarizing surface with a diamond end-effector that abrades the waste matter accumulations and exposes portions of the planarizing surface on top of the polishing pad. Another conventional method is to spray the polishing pad with a jet of deionized water that separates the waste matter accumulations from the polishing pad.
Conditioning polishing pads with the existing methods, however, may produce deviations in the uniformity of the substrate surface because it is difficult to consistently condition a polishing pad so that it has the same planarizing characteristics from one conditioning cycle to the next. For example, diamond end-effectors and water jets are surface contact elements that may not remove waste matter embedded in depressions below the planarizing surface (e.g., holes, pores or grooves). Conventional conditioning systems accordingly may not return such polishing pads to a state in which they can hold an adequate amount of planarizing solution below the substrate surface. Another concern of conventional conditioning systems is that diamond end-effectors may produce a non-planar surface on a polishing pad because they remove material from exposed areas on the planarizing surface while removing waste matter from covered areas on the planarizing surface. As such, diamond end-effectors may produce low points in the planarizing surface that were exposed at an early stage of a conditioning cycle. Conventional conditioning systems, therefore, may not return polishing pads and other planarizing media to a condition in which they uniformly planarize substrate surfaces.
SUMMARY OF THE INVENTION
The present invention is a method and apparatus for conditioning planarizing media used in mechanical and/or chemical-mechanical planarization of microelectronic substrates. In one embodiment, a conditioning device has a support assembly with a support member and a conditioning head attached to the support member. The support member may be a pivoting arm or gantry that carries the conditioning head over the planarizing medium. The conditioning head may have a non-contact conditioning element that transmits a form of non-contact energy to waste matter on the planarizing medium. The non-contact conditioning element, for example, may be an emitter that transmits a selected non-contact energy capable of penetrating the planarizing medium and the waste matter. In operation, the selected form of non-contact energy may weaken or break bonds in the waste matter and/or bonds between the planarizing medium and the waste matter.
In one particular embodiment, the conditioning head may have a carrier plate attached to the support member, a retention skirt depending downwardly from a perimeter portion of the carrier plate, and a fluid supply line attached to the carrier plate. The carrier plate and the retention skirt define a cavity, and the fluid supply line may have an outlet in the cavity. In this embodiment, the non-contact conditioning element may be a mechanical-wave transmitter attached to the carrier plate and coupled to a signal generator. The mechanical-wave transmitter, for example, may be an ultrasonic transducer that generates ultra-sonic energy-waves at desired frequencies and amplitudes. In operation, a fluid supply pumps deionized water through the fluid supply line to fill the cavity with a transmission medium, and the mechanical-wave transmitter sends mechanical energy-waves through the transmission medium to the planarizing medium. Several embodiments of the present invention may be particularly useful for removing waste matter accumulations from polishing media with depressions (e.g., holes, pores or grooves) because the mechanical energy-waves may separate the waste matter in the depressions from the planarizing media.
Another embodiment of the present invention also has a contact conditioning element attached to the carrier plate in addition to the non-contact conditioning element. The contact conditioning element may be a diamond disk or a sprayer that engages the waste matter in conjunction with the energy-waves from the non-contact conditioning element. For example, a diamond end-effector may be mounted to the carrier plate in the cavity along with a plurality of mechanical-wave transmitters to abrade the planarizing medium as the mechanical-wave transmitters transmit energy-waves against the planarizing medium.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a planarization machine in accordance with the prior art.
FIG. 2 is a schematic side elevational view of a conditioning machine for conditioning planarizing media in accordance with an embodiment of the invention.
FIG. 3 is a partial schematic cross-sectional view of the conditioning machine of FIG. 2 taken along line 3 — 3 .
FIG. 4 is a partial schematic cross-sectional view illustrating an aspect of operating a conditioning machine in accordance with one embodiment of the invention.
FIG. 5 is an enlarged view of a portion of the planarizing medium of FIG. 4 illustrating a detailed aspect of operating a conditioning machine in accordance with an embodiment of the invention.
FIG. 6 is a partial schematic cross-sectional view of another conditioning machine in accordance with another embodiment of the invention.
FIG. 7 is a partial schematic cross-sectional view of still another conditioning machine in accordance with still another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is an apparatus and method for mechanical and/or chemical-mechanical planarization of substrates used in the manufacturing of microelectronic devices. Many specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 2-7 to provide a thorough understanding of such embodiments. One skilled in the art, however, will understand that the present invention may have additional embodiments or that the invention may be practiced without several of the details described in the following description.
FIG. 2 is a schematic side elevational view illustrating one embodiment of a conditioning machine 100 in accordance with the invention, and FIG. 3 is a partial schematic cross-sectional view of the conditioning machine 100 taken along line 3 — 3 . The conditioning machine 100 has a support assembly 120 carrying a conditioning head 130 to condition a planarizing surface 42 of a planarizing medium 40 . The support assembly 120 may have a support member or arm 122 with a first end 121 a (FIG. 2) attached to an actuator 124 (FIG. 2) and a second end 121 b (FIG. 2) carrying a bracket 126 . The actuator 124 moves the arm 122 vertically (arrow V) and pivots the arm 122 (arrow P) to position the conditioning head 130 relative to the planarizing medium 40 . The support assembly 120 may also have another actuator (not shown) coupled to the conditioning head 130 and the arm 122 instead of the bracket 126 . Accordingly, different support assemblies may be used for carrying the conditioning head 130 over the planarizing medium 40 .
The conditioning head 130 may have a carrier plate 132 coupled to the bracket 126 and one or more non-contact conditioning elements 150 attached to the carrier plate 132 . The non-contact elements 150 may be transmitters that direct a form of non-contact energy 152 against the planarizing medium 40 . For example, the non-contact energy may be an energy-beam or energy-waves 152 that act against waste matter accumulations (not shown) and the planarizing medium 40 . In one particular embodiment, the non-contact elements 150 are mechanical-wave transducers that emit longitudinal mechanical waves 152 at desired frequencies and amplitudes to weaken or break apart the waste matter on the planarizing medium. The mechanical-wave transducers may accordingly be coupled to a signal generator, such as a radio frequency generator 154 , to select the appropriate amplitude and frequency of the waves 152 . It will be appreciated that a person skilled in the art may empirically determine the suitable waveform for operating the mechanical-wave transducers to remove a particular type of waste matter from a particular polishing medium. Moreover, a plurality of different waveforms may be used to operate each mechanical-wave transducer during a single conditioning cycle so that the mechanical energy-waves 152 remove the waste matter without damaging the planarizing medium 40 or the conditioning machine 100 . Also, mechanical-wave energy at other than RF frequencies, such as at ultrasound frequencies, may be used.
When the non-contact elements 150 are mechanical-wave transducers, a fluid system may be coupled to the conditioning head 130 to maintain a volume of deionized water or another fluid as a transmission medium for the waves 152 . The fluid system may have a primary conduit 160 (FIG. 2) coupled to a fluid supply (not shown), a distributor 161 coupled to the primary conduit 160 , and a plurality of secondary conduits 162 a and 162 b (FIG. 3) coupled to the distributor 161 . The secondary conduits 162 a and 162 b may each pass through one of the non-contact conditioning elements 150 into a cavity 168 defined by a bottom surface 134 of the carrier plate 132 and a retention skirt 164 depending downwardly from a perimeter region of the carrier plate 132 . The retention skirt 164 may be a flexible material attached to the perimeter of the carrier plate 132 to maintain a transmission medium 166 in the cavity 168 as the arm 122 translates the conditioning head 130 over the planarizing medium 40 . For example, the retention skirt 164 may be a rubber ring around the carrier plate 132 or a plurality of bristles (not shown). Additionally, deionized water or another fluid may also continually flow through the secondary conduits 162 a and 162 b to maintain the transmission medium 166 in the cavity during conditioning.
FIG. 4 is a partial schematic cross-sectional view illustrating an aspect of operating the conditioning device 100 on a planarizing medium 40 with grooves 44 . Additionally, FIG. 5 is an enlarged view of a portion of FIG. 4 . In this example, a plurality of waste matter accumulations 47 cover portions of the planarizing surface 42 and occupy a plurality of the grooves 44 . The energy-waves 152 may possibly act against the waste matter accumulations 47 and the planarizing medium 40 to break apart the waste matter accumulations 47 or to separate at least a portion of the accumulations 47 from the planarizing medium 40 . In one possible application, the energy-waves 152 may alter the bonds within the waste matter and/or the bonds at the interface between the planarizing medium 40 and the waste matter accumulations 47 . As best shown in FIG. 5, for example, the energy-waves 52 may possibly cause gaps 49 to form between the waste matter accumulations 47 and the inclined surfaces 45 of the grooves 44 . The non-contact elements 150 may accordingly transmit the energy-waves 152 to the planarizing medium 40 until the waste matter accumulations 47 within the grooves 44 separate from the planarizing medium 40 . Thus, to condition the entire surface area of the planarizing surface 42 , the support assembly 120 (FIG. 4) may translate the conditioning head 130 (FIG. 4) across the planarizing medium 40 as the transducers 150 continually transmit the energy-waves 152 through the transmission medium 166 .
The conditioning machine 100 may be particularly applicable for removing waste matter from fixed-abrasive planarizing media and planarizing media with depressions. The non-contact conditioning elements 150 are expected to remove waste matter embedded into a planarizing medium because the energy-waves can act against portions of the waste matter below the planarizing surface. As such, the non-contact conditioning elements 150 are expected to remove waste matter accumulations from depressions in planarizing media that would not otherwise be removed by conventional surface contact conditioning devices. Compared to conventional conditioning devices, therefore, the conditioning machine 100 is expected to return planarizing media with depressions to a state in which the media are able to hold more slurry under the substrate surface during planarization.
The planarization machine 100 is also expected to remove material from planarizing media without over conditioning some regions of the planarizing surface. As discussed above, conventional conditioning devices with abrasive elements typically produce low points on the planarizing surface because the abrasive elements may remove pad material from exposed areas of the planarizing surface while still removing waste matter from other areas. Unlike conventional conditioning devices, the conditioning machine 100 separates waste matter from a planarizing medium with a non-contact conditioning element that does not alter the contour of the planarizing surface. As such, if the planarizing surface is substantially planar prior to conditioning, the conditioning machine 100 is not expected to alter the planarity of the planarizing surface after conditioning.
FIG. 6 is a partial schematic cross-sectional view of another conditioning machine 200 in accordance with another embodiment of the invention. The conditioning machine 200 of FIG. 6 has many similarities with the conditioning machine 100 described above in FIGS. 2-5, and thus like reference numbers refer to similar parts in these figures. The conditioning machine 200 has a conditioning head 130 with a carrier plate 132 , a plurality of non-contact conditioning elements 150 coupled to the carrier plate 132 , and a retention skirt 164 depending from a perimeter region of the carrier plate 132 . The conditioning head 130 also has a contact conditioning element 270 attached to the bottom surface 134 of the carrier plate 132 . In one embodiment, the contact element 270 is a stone or a diamond-embedded disk with an abrasive contact face 272 for engaging the planarizing surface 42 of the planarizing medium 40 . The cavity 168 for containing the transmission medium 166 is accordingly defined by the contact conditioning element 270 , the carrier plate 132 and the retention skirt 164 .
As described above with respect to the conditioning machine 100 , the non-contact conditioning elements 150 transmit energy-waves 152 to the planarizing medium 40 to weaken or separate waste matter (not shown) from the planarizing medium 40 . Additionally, the contact face 272 of the contact conditioning element 270 abrades the planarizing medium 40 to further remove waste matter from the planarizing surface 42 . The conditioning machine 200 , therefore, augments the non-contact removal of waste matter with a contact or abrasive force that further removes waste matter from the planarizing surface.
FIG. 7 is a schematic cross-sectional view of still another planarizing machine 300 in accordance with still another embodiment of the invention for conditioning the planarizing medium 40 . The planarizing machine 300 also has many similarities with the planarizing machines 100 and 200 , and thus like reference numbers refer to similar components in FIGS. 2 — 7 . In addition to the non-contact elements 150 , the conditioning machine 300 also has one or more contact conditioning elements 370 that may be spray nozzles coupled to a fluid supply (not shown) to direct contact streams 372 of fluid against the planarizing medium 40 . The spray nozzles 370 may be attached to the ends of the secondary conduits 162 a and 162 b , or the spray nozzles 370 may be attached to separate fluid lines outside of the retention skirt 164 (shown in phantom). In this embodiment, the contact streams 372 impinge the planarizing medium 40 as the non-contact conditioning elements 150 transmit the energy-waves 152 through the transmission medium 166 . The conditioning machine 300 may be particularly useful for removing waste matter from depressions in a planarizing medium because the energy-waves 152 may form gaps between the waste matter and the surface of the planarizing medium (shown in FIG. 5 ), and then the contact streams 372 may flush the waste matter from the depressions.
From the foregoing, it will be appreciated that specific embodiments of the invention have been described above for purposes of illustration, but that various modifications can be made without deviating from the spirit and scope of the invention. For example, the transmission medium 166 may be a chemical composition that also selectively dissolves the waste matter accumulations. Additionally, the non-contact conditioning element may produce another form of energy that penetrates the waste matter to weaken or otherwise remove the waste matter from the planarizing medium. The retention skirt 164 may also be a plurality of stiff, densely packed bristles that define another contact element to further remove waste matter accumulations from the polishing pad. Accordingly, the invention is not limited except as by the appended claims.
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A method and apparatus for mechanical and/or chemical-mechanical planarization of microelectronic substrates. In one embodiment, a conditioning device for removing waste matter from a microelectronic planarizing medium has a support assembly with a support member and a conditioning head attached to the support member. The support member may be a pivoting arm or gantry assembly that carries the condition head over the planarizing medium. The conditioning head may have a non-contact conditioning element that transmits a form of non-contact energy to waste matter on the planarizing medium. The non-contact conditioning element, for example, may be an emitter that transmits a selected waveform capable of penetrating the planarizing medium and the waste matter on the planarizing medium. In operation, the selected non-contact energy may impart energy to the waste matter that weakens or breaks bonds in the waste matter and/or bonds between the planarizing medium and the waste matter.
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FIELD OF THE INVENTION
[0001] The present invention is directed to a valve and a method to enhance production from gas wells, and particularly gas wells with low flow pressures and inconsistent production line pressure.
BACKGROUND
[0002] Gas wells, and in particular sour gas wells with varying quantities of H 2 S are produced throughout the Western Canada Sedimentary Basin. Even when reservoir pressures deplete, the remaining gas volumes left in the reservoir are usually significant. The challenge is to produce the remaining reserves with low flowing pressures and inconsistent production line pressures.
[0003] Sour gas wells are typically completed with a packer in place to isolate the sour production from the annular space between the well casing inside diameter and the outside diameter of the production tubing. The packer prevents sour gas from entering the annulus and corroding the casing string, which is the barrier between the wellbore and any adjacent ground water or aquifer. Additionally, the annulus above the packer is typically filled with inhibited brine solution to enhance corrosion protection and provide an additional barrier preventing migration of sour gas into the annulus.
[0004] All gas wells will produce a quantity of liquid during gas production. Liquid loading is a symptom of the well's inability to unload liquids that are naturally produced during the production life of the well and is the most common cause of production decline in a gas well. In addition to liquid loading, there are a number of other reasons why wells will not produce at the maximum level. If a number of wells are drilled into the same reservoir and the gas is depleted at a faster than normal rate, the competitive drainage of the reservoir will reduce production. In a compartmentalized reservoir, where reservoir size is limited because of lack of connectivity between the permeable parts of the formation, there may be production issues. Also, production may be limited because of formation damage caused to the near well bore while drilling the well or on subsequent work over with a service rig or natural near well bore damage may also be caused by liquid loading or natural scaling effects of the produced well effluent.
[0005] When a well is initially drilled, it is typically in a virgin part of the reservoir, and therefore reservoir pressures and volumes are usually quite high. The surface production lines that will transport the gas and liquids are operated at pressures that allow the well to flow to surface. The difference between the surface lines pressure and the flowing bottom hole pressure of the well will dictate how much the well can flow. Other factors also relate directly to this such as gas density, friction effect, liquid density and depth of the well. As the well ages and flowing bottom hole pressure depletes, the well will experience reduced flow capability.
[0006] It is well known that liquid loading affects gas production when gas velocity drops below the level necessary to carry liquid droplets upwards, known as the critical gas velocity. Critical gas velocity is a function of flowing pressure, fluid and gas density, droplet size, surface tension, temperature and pipe diameter.
[0007] One method of increasing gas velocity is to change tubular size or decrease surface pressure, and the effect on the wells ability to unload liquid can be dramatic when such solutions are applied. However, these solutions will only last as long as the bottom reservoir pressure can produce against the new conditions.
[0008] Unfortunately for most sour gas wells, the option to change tubulars or decrease surface pressures is often uneconomic, and the well is abandoned long before its usable reserves are depleted. The cost to change out tubulars is high (rig, safety equipment, pump trucks etc.) and there is a significant risk of potential damage to the formation, which may occur as the well has to be killed using a fluid having hydrostatic weight equal or greater than the shut in reservoir pressure. In many cases the depth of the well and the low reservoir pressure will not hold a full column of kill fluid and the fluid will fracture into the formation face, causing damage that cannot be repaired.
[0009] Surface pressure may be reduced by using a compressor to reduce the flowing wellhead pressure in the wellbore. The cost is directly related to the size of compressor required to have sufficient suction pressure that allows the well to unload liquid with the elevated velocity required to produce the gas to the gathering system lines. Most compressors for sour gas are required to have numerous safety shutdown systems and expensive coolers to reduce the heat of compressed gas and noise emission controls.
[0010] Artificial lift in these wells is difficult to implement. Most types of downhole mechanical or electrical pumps do not work well in a high gas environment due to gas locking and cavitation. The costs of the modifications or additional completion components required to adapt the pumping systems to efficient operation in high gas ratio environments can also be prohibitively expensive.
[0011] Therefore, there is a need in the art for an innovative and economical solution to produce gas from these aging reservoirs.
SUMMARY OF THE INVENTION
[0012] In one aspect, the invention comprises a down hole crossover valve as part of an operational system that uses reservoir energy and injected gas to produce gas. In one embodiment, the produced gas and injected gas may activate a plunger which reciprocates up and down the well bore, which acts as interface between the produced liquid and produced gas, thereby unloading all liquid to surface. The plunger may be cycled numerous times throughout the day and the frequency of cycling is only dependent on how much gas is available for each cycle.
[0013] Therefore, in one aspect, the invention comprises a method of producing a vertical, deviated or horizontal gas well having an annular space defined by a well casing and a concentrically disposed production tubing, said well having a lower producing zone open to the production tubing, wherein the annulus is isolated from the lower producing zone by a packer, comprising the steps of:
[0014] (a) opening a communication path through the tubing into the annulus, and if necessary, removing any liquid in the annulus;
[0015] (b) landing at least one crossover valve within the production tubing exposed to the annulus, wherein the crossover valve has a pilot section having a predetermined closing pressure, a power section and a crossover fluid passage; and
[0016] (c) injecting gas into the annulus to at least the closing pressure to activate the pilot section, thereby exposing the power section to the annulus, thereby opening the crossover fluid passage and allowing injected gas to enter the production tubing, wherein the injected gas lifts liquids in the production tubing to the surface.
[0017] In one embodiment, the at least one crossover valve is deployed on a continuous or jointed tubing string or by wireline, within the production tubing.
[0018] In another aspect, the invention may comprise a crossover valve assembly for insertion into production tubing, or integral with production tubing, comprising:
[0019] (a) an outer housing;
[0020] (b) an inner production tube;
[0021] (c) a pilot section responsive to external pressure above a pre-determined pressure to open an activation passage;
[0022] (d) a power section responsive to pressure in the activation passage to open an injection opening; and
[0023] (e) a crossover valve responsive to the external pressure to open a crossover port, allowing fluid communication from outside the outer housing to within the inner production tube.
[0024] In one embodiment, the invention comprises a crossover valve assembly comprising:
[0025] (a) a pilot section comprising an outer housing and an inner production tube disposed concentrically within the housing, defining an annular space therebetween, a pilot valve assembly within the annular space and comprising a valve seat and a pilot piston moveable between a closed position and an open position, a pilot chamber exposed through a pilot opening in the outer housing, and a spring for biasing the pilot piston towards the closed position;
[0026] (b) a power section comprising an outer housing and an inner production tube disposed concentrically within the housing, defining an annular space therebetween, a power valve assembly disposed within the annular space and comprising a valve seat, a valve mandrel and an activation piston, wherein the valve mandrel and the activation piston are moveable between a closed position and an open position, wherein the power section defines an activation chamber;
[0027] (c) an activation fluid passage between the pilot chamber and the activation chamber, which is closed when the pilot piston is in its closed position, and open when the pilot piston is in its open position, and wherein fluid pressure in the activation fluid passage moves the activation piston and valve mandrel to their open position;
[0028] (d) a crossover fluid passage through the power section outer housing and the power section inner production tube which is closed when the activation piston and the valve mandrel are in their closed position.
[0029] In one embodiment, the pilot piston is biased in the closed position by a pre-determined closing pressure created by means of a mechanical spring such as a coil spring, or a gas spring, or both a mechanical and gas spring, acting within the pilot section. The power section may comprise an equalization pathway between the activation chamber and open to outside the outer housing, which equalization pathway is more restrictive to gas flow than the activation passage. In one embodiment, the gas spring is connected to a gas supply line which can be activated to increase or reduce the pressure of the gas spring, thereby increasing or reducing the closing pressure.
[0030] In one embodiment, the crossover valve assembly comprises an electrical control module operatively connected to a remote controller, comprising a solenoid and pilot pressure regulator, which opens to expose the pilot section to external pressure, and closes to isolate the pilot section from external pressure.
[0031] In one embodiment, the crossover valve assembly further comprises an electrical control module operatively connected to a remote controller, comprising a pilot gas supply line and a pilot gas regulator, for remotely charging or discharging the gas spring.
[0032] In another aspect, the invention may comprise a system for producing a vertical, deviated or horizontal gas well having an annular space defined by a well casing and a concentrically disposed production tubing, said well having an annulus and a lower producing zone open to the production tubing, wherein the annulus is isolated from the lower producing zone by a packer, comprising:
[0033] (a) a communication path through the production tubing into the annulus;
[0034] (b) at least one crossover valve within the production tubing exposed to the annulus through the communication path;
[0035] (c) a surface gas injector and a gas supply for injecting gas into the annular space to open the crossover valve and enter the production tubing;
[0036] (d) a plunger for reciprocating within the production tubing; and
[0037] (e) a controller for controlling the gas injector, wherein the controller is responsive to a signal indicative of one or more of the following: the position of the plunger, pressure in the annulus, pressure, gas flow in the production tubing, tubing fluid level, or pressure differential between the tubing and the annulus
[0038] In one embodiment, the at least one crossover valve is deployed on a continuous or jointed tubing string, within the well casing. In one embodiment, the system may further comprise a plunger for reciprocating within the production tubing. The system may further comprise a controller for controlling the gas injector, wherein the controller is responsive to a signal indicative of one or more of the following: the position of the plunger, pressure in the annulus, pressure or gas flow in the production tubing, tubing fluid level, or pressure differential between the tubing and the annulus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] In the drawings, like elements are assigned like reference numerals. The drawings are not necessarily to scale, with the emphasis instead placed upon the principles of the present invention. Additionally, each of the embodiments depicted are but one of a number of possible arrangements utilizing the fundamental concepts of the present invention. The drawings are briefly described as follows:
[0040] FIG. 1 is a schematic representation of a wellbore with an annulus and lower producing zone, sectioned vertically along its length and depicting the crossover valve through-tubing completion.
[0041] FIG. 2 is a schematic representation of the crossover valve device sectioned along its length to reveal all of the working components.
[0042] FIG. 3 is a detailed view of area A shown in FIG. 2 , showing the power section valve assembly.
[0043] FIG. 4 is a detailed view of area B of FIG. 2 , showing the pilot section valve assembly.
[0044] FIG. 5 is a tranverse cross-sectional view along line C-C in FIG. 2 .
[0045] FIG. 6 is a cross sectional view of the crossover valve of FIG. 2 , shown with the pilot valve assembly in its open position.
[0046] FIG. 7 is a cross sectional of the power section of the crossover valve of FIG. 2 , shown with the power valve assembly in its open position.
[0047] FIG. 8 is a cross sectional of the power section of the crossover valve of FIG. 2 , shown with the RCV valve in its open position.
[0048] FIG. 9 is a schematic representation of one embodiment of a crossover valve assembly having an electrical control module.
[0049] FIG. 10 is a schematic representation of one embodiment of a crossover valve with direct solenoid actuation of the pilot section.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0050] When describing the present invention, all terms not defined herein have their common art-recognized meanings. To the extent that the following description is of a specific embodiment or a particular use of the invention, it is intended to be illustrative only, and not limiting of the claimed invention.
[0051] This invention relates to a controllable crossover valve and systems which incorporate the valve to enhance gas production by means of gas lift or gas re-circulation workflows. During gas lift/gas re-circulation workflows, the working fluid comprises injected gas which moves from outside the production tubing to within the production tubing.
[0052] In one embodiment, the apparatus of the present invention is designed to facilitate production of gas wells with low flow pressures and/or inconsistent production line pressure, and sour gas wells in particular. However, the term “fluid” is used herein as comprising both liquids and gases.
[0053] As shown in FIG. 1 , a producing gas well comprises a casing string ( 1 ) and a concentric production tubing string ( 2 ), defining an annular space between them. A packer ( 3 ) within the annulus provides a seal between the tubing outside diameter and the casing inside diameter, and isolates the upper annulus from the producing zone. The packer prevents cross-flow of produced liquids and gas above the packer and protects the casing from corrosion usually associated with H 2 S, as the casing is the only barrier between the wellbore and the surrounding natural formation.
[0054] Many sour gas well sites are equipped with high pressure, sweet fuel gas for instrumentation operation. This source gas may also be an excellent medium for annular circulation gas. Therefore, in one aspect, the invention comprises a method of producing natural gas from an isolated zone, such as a sour gas zone, by using injected sweet gas to lift liquids in the production tubing to the surface. In general terms, in another aspect, the apparatus of the present invention comprises a crossover valve device, which opens in response to pressure in the casing annulus, or as result of direct control, to permit fluid flow from the annulus into the tubing string.
[0055] The crossover valve assembly ( 10 ) comprises a number of inner tubular elements ( 11 ) assembled together to define an internal production flow path, and an outer housing ( 12 ). Various functional components described below are disposed in the annular space between the inner tubulars ( 11 ) and the outer housing ( 12 ). In one embodiment, the valve assembly comprises a pilot section ( 13 ) and a power section ( 14 ), connected by an intermediate pup joint ( 16 ) defining an annular fluid passage ( 17 ). In one embodiment, the valve assembly ( 10 ) is adapted to be run on wireline, or deployed on continuous or jointed tubing string. In one embodiment, the valve may be an integral component of a tubing string.
[0056] The pilot section comprises a concentric sliding pilot piston ( 18 ), a pilot valve seat ( 20 ) and an annulus pressure opening ( 22 ) in the outer housing ( 12 ). In its closed position, as shown in FIGS. 2 and 4 , the downhole end of the pilot piston ( 18 ) is seated against valve seat ( 20 ), closing off the pup joint fluid passage ( 17 ) from external pressure. The pilot piston ( 18 ) is appropriately sealed with seals which slide against the inner surface of the housing ( 12 ) and the outer surface of the inner tubing ( 11 ).
[0057] The pilot piston ( 18 ) is biased towards its closed position by a mechanical spring ( 26 ), or a gas spring ( 28 ), or a combination of a mechanical spring and a gas spring. As shown in FIG. 2 , a pilot pressure chamber ( 28 ) is filled with a gas, preferably an inert gas such as nitrogen, through a valve ( 24 ), and resists upward movement of the pilot piston ( 18 ). The external pressure in the casing annulus required to activate the pilot section ( 13 ) must overcome the closing pressure, which is the sum of the gas pressure in chamber ( 28 ) and the pressure exerted by the mechanical spring.
[0058] To activate the crossover valve assembly, gas (G) is injected into the casing annulus until the annular pressure is greater than the closing pressure. The injected gas bears on the pilot piston ( 18 ) through the external pressure opening ( 22 ), and the pilot piston ( 18 ) is urged upwards as injected gas fills the pilot chamber ( 23 ), until the external pressure equals the closing pressure exerted by the mechanical spring and the gas spring.
[0059] As the pilot piston ( 18 ) unseats, the injected gas in the pilot chamber ( 23 ) then travels through the pup joint fluid passage ( 17 ) and enters an activation chamber in the power section ( 14 ), bearing upon the power piston ( 30 ), which is also a sealed concentric sliding piston. In one embodiment, the power piston is biased in a closed position by a mechanical spring ( 31 ).
[0060] The power piston ( 30 ) pushes against a mandrel ( 32 ) having a valve face ( 34 ) which is seated against an injection gas inlet ( 36 ) through the outer housing. The injection gas inlet may be provided in a circumferential groove ( 38 ) around the outer housing which has an angled conical section. The valve face ( 34 ) has a matching conical section which sealingly engages the injection gas inlet ( 36 ) when closed.
[0061] As injected gas (G) in the casing annular space enters the power section ( 14 ) through gas inlet ( 36 ), it proceeds through the valve assembly between the power section inner tubular ( 11 A) and the outer housing ( 12 ) until it reaches the redundant check valve or RC valve ( 50 ). The injected gas has sufficient pressure to unseat the , and pass through crossover port ( 52 ) and enters the internal production flow path of the valve ( 10 ). The RC valve ( 50 ) is biased closed by a mechanical spring ( 51 ), the force of which may be overcome by the injected gas pressure. The RC valve ( 50 ) is shown seated (closed) in FIG. 6 and unseated (open) in FIG. 8 .
[0062] When the external annular pressure outside the valve assembly drops below the closing pressure of the pilot section, the pilot piston ( 18 ) will be urged towards its closed position until it seats against the valve seat ( 20 ), which initiates the crossover valve closure sequence. If the annular pressure continues to drop, the fluid in the pup joint fluid passage ( 17 ) and the activation chamber is allowed to slowly equalize to the lower external annular pressure through a restrictive bypass ( 42 ) which exists between the power section inner tubular ( 11 A) and the outer housing ( 12 ) around the power piston ( 30 ). Once the pressure in the activation chamber is lower that the biasing force exerted by the power section mechanical spring ( 31 ), the power piston ( 30 ) returns to its closed position. When the power piston returns to its closed position, the valve face ( 34 ) seats on and closes the injection gas inlet ( 36 ). The RCV valve ( 50 ) will then close and the crossover valve assembly ( 10 ) again isolates the annulus from the production tubing.
[0063] The restrictive bypass ( 42 ) is always open, but provides sufficient resistance to gas flow to allow gas pressure from the pilot section to open the power piston through the activation passage, while allowing equalization within a reasonably short period of time, in one embodiment, in the order of a few minutes.
[0064] Therefore, the valve assembly ( 10 ) will open an injection opening at annular pressures above the pilot section closing pressure, and will begin a closing sequence when the annular pressure drops below the closing pressure. In one embodiment, the closing pressure of the pilot section of the valve is adjusted by adjusting the strength of the mechanical spring and the gas spring, if both are used. The selected closing pressure may be determined by considering the well depth, annulus volume available and gas/liquid ratios. In one embodiment, the closing pressure of the pilot section will be set significantly higher than the minimum tubing pressure], thereby ensuring no sour gas in the production tubing can escape into the annulus through the valve assembly ( 10 ). For example, the closing pressure may be set at 500 kPa over the minimum tubing pressure. This will ensure the valve assembly is always closed, except when there is significant higher pressure in the annulus, which is particularly important in the absence of the inhibited annulus fluid to prevent sour gas migration into the annulus. In addition, the valve may be equipped with isolation mechanisms (or barriers) between the production tubing inside diameter where sour gas resides and the annulus which is required to remain sweet.
[0065] In one embodiment, the gas spring can be charged to a very high pressure during assembly of the valve assembly ( 10 ), before use in the field, and can then be adjusted to a desired pressure for the particular downhole conditions it will encounter before installation down hole. The mechanical spring provides a fixed closing pressure, while the gas spring may provide a variable customizable closing pressure.
[0066] In one embodiment, the gas spring may be connected with gas capillary lines, a regulator, and a controller. The gas spring may thus be charged with gas to increase the pilot closing pressure, or gas may be discharged to decrease the pilot closing pressure, after installation, as desired.
[0067] Therefore, in one embodiment, the crossover valve comprises three actuating components, the pilot section, the power section and the RC valve, which interact by gas pressure and not physical linkage. External pressure causes the pilot section to expose an activation chamber to the external pressure, thereby activating the power section, which opens an injection opening which then opens the RC valve.
[0068] In one embodiment of operation, and with reference to FIG. 1 , a bottom hole check valve ( 8 A) is placed into the bottom of production tubing string, which functions to prevent gas injected from surface entry into the formation when the well is completed, but does allow gas flow from the formation into the tubing string.
[0069] The crossover valve ( 10 ) assembly can be run using wire line techniques or coiled or jointed tubing techniques that are well known in the industry and need not be further described here. If an existing sliding sleeve is part of the production string, it may be opened. Alternatively, the tubing ( 2 ) may be perforated above the isolation packer ( 3 ). The valve ( 10 ) is landed above the isolation packer ( 3 ), level with an open sliding sleeve or with tubing perforations. The valve is located in between two thru-tubing pack-offs ( 4 , 5 ) which isolate the production tubing ( 2 ) above and below the valve ( 10 ). Any gas from the annulus can only enter the production tubing through the valve ( 10 ). Suitable anchor and packer configurations are described, for example, in co-owned U.S. Pat. No. 7,347,273 B2, the entire contents of which are incorporated herein by reference (where permitted).
[0070] Any inhibited fluid in the annulus may be removed using conventional means, such as by circulation of nitrogen gas.
[0071] Once the downhole equipment has been installed and any inhibited fluid has been removed, a sweet gas compressor ( 102 ) can compress low volume gas from the instrument supply line ( 104 ) and inject it down the casing tubing annulus. Once the annular pressure exceeds the closing pressure of the crossover valve ( 10 ), the injected sweet gas (G) will pass through the valve ( 10 ) into the production tubing, overcome the flowing bottom hole pressure, and cause the bottom check valve ( 8 A) to close. Thus, all the sweet annular gas (G) will move upwards in the production tubing. This will increase the gas velocity, preferably to above the critical rate, and drive any liquid column in the production tubing to the surface.
[0072] Once the liquid column is produced, the pressure in the annulus may be reduced, closing the valve ( 10 ), while still maintaining a positive pressure differential against the production tubing. With the liquid hydrostatic column removed from the well bore, the well can now produce to full potential through the bottom check valve ( 8 A). The production cycle is repeated when the injected gas pressure in the annulus has reached the required pressure to open the crossover valve ( 10 ) again.
[0073] A plunger assembly (not shown) may be introduced into the tubing string to allow the well to be operated at lower gas velocities, as is well known in the art. The plunger acts as an interface between the liquid column and the injected gas. Because the plunger is a dynamic seal with close tolerance between the plunger body and the tubing wall (as opposed to perfect seal), it still requires velocity to move the liquid up hole, however the cross sectional area of the plunger coupled with the gas velocity trying to pass the outside creates a differential pressure from below which drives the plunger and the liquid column to surface.
[0074] In an alternative embodiment, a crossover valve assembly ( 100 ) includes the components described above, and further comprises an electrical control module ( 110 ) or ECM, The ECM ( 110 ) is operative to modify operation of the crossover valve ( 100 ), either by controlling delivery of pilot gas to charge or discharge the pilot gas spring, or by otherwise modulating or overriding operation of the pilot section, or both.
[0075] As shown schematically in FIG. 9 , a pilot gas regulator ( 120 ) is connected by a capillary line ( 122 ) to a supply of pilot gas, which may be at the surface. A pilot controller (not shown) connects to the regulator ( 120 ) by a control line ( 124 ), and actuates the regulator ( 120 ) to open or close a valve ( 126 ) to charge or discharge the gas spring as required.
[0076] Another control line ( 130 ) connects a controller (not shown) to a solenoid ( 132 ), which actuates a pilot control valve ( 134 ). When open, the pilot control valve ( 134 ) exposes the pilot section of the crossover valve assembly ( 100 ) to injection gas pressure ( 102 ) in the casing annulus. If closed, the pilot section remains isolated from the casing annulus pressure, and therefore, the pilot section cannot actuate the power section to open the crossover valve. Thus, the controller can deactivate a crossover valve assembly ( 100 ) while still injecting as into the casing annulus above the closing pressure of the pilot section,
[0077] In an alternative embodiment, as shown schematically in FIG. 10 , the pilot section ( 202 ) of the crossover valve assembly ( 200 ) is directly regulated by a control signal received over a control line ( 204 ) which connects to a controller (not shown). A pressure transducer ( 208 ) senses injection gas pressure ( 206 ) in the casing annulus and may connect to the control line ( 204 ) via a controller ( 209 ) and a relay ( 210 ). Accordingly, at a pre-determined pressure in the casing annulus, as sensed by the pressure transducer, the controller will actuate the solenoid ( 212 ) to release the pilot section. The injected gas will then activate the pilot section as described above. In this case, the pilot section closing pressure is determined by the combined action of the pressure transducer, controller and solenoid, and not by any physical biasing means contained in the pilot section. A control signal may then close the pilot section after a desired length of time, or at a pre-determined pressure as determined by the pressure transducer.
[0078] In one embodiment, the system may comprise electronic monitoring and pressure recording to determine when the system operates, such as, for example, by using a PLC (Programmable Logic Controller) with various analog and digital inputs and outputs, which can read and record signals from external sensors such as pressure transducers or flow meters. These transducers constantly sample the well pressures and will signal the PLC control box to open casing valves to flow or shut in. The PLC may also have a proximity switch which detects the plunger arrival at surface and records times and flow rates. With these electronic instruments and control, the well can be left with no human intervention once the flow cycles are set into the controller. These set pressures and times can be adjusted to suit the changing well conditions.
[0079] Alternate means exist of completing this production workflow including, but not limited to a locking and sealing mandrel assembly (as is well known in the art) to engage and seal in an existing selective profile nipple integral to the production tubing string. This would replace the tubing packer ( 5 ) depicted in FIG. 1 . This completion is possible if a selective profile nipple exists and is easily accessible in the wellbore relative to the location of the communication ports through the production tubing wall. In another alternative, the tool string may be landed across an open sliding sleeve providing communication through the wall of the tubing from the annulus. All of the elements of the tool string may be designed to pass through the largest standard selective profile nipple size in order to easily facilitate landing said tool string across an existing sliding sleeve (equipped with profile nipple) or below an existing profile nipple in the event that complex wellbore geometry is encountered.
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A crossover valve assembly for insertion into production tubing, or integral with production tubing, includes an outer housing, an inner production tube, a pilot section responsive to external pressure to open an activation passage above a pre-determined pressure, a power section responsive to pressure in the activation passage to open an injection opening; and a crossover valve responsive to pressure in the injection opening to open a crossover port, allowing fluid communication from outside the outer housing to within the inner production tube. The crossover valve assembly may be used in a method of producing a vertical, deviated or horizontal gas well having an annular space defined by a well casing and a concentrically disposed production tubing, wherein an annulus exists above a packer isolating the annulus, includes the steps of (a) opening a communication path through the tubing into the annulus, and if necessary, removing any fluid in the annulus, (b) landing a crossover valve assembly within the production tubing above the packer and exposed to the annulus; and (c) injecting gas into the annular space to open the crossover valve and enter the production tubing, wherein the injected gas lifts liquids in the production tubing to the surface.
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FIELD OF THE INVENTION
The present invention relates generally to surfactants and cleaning compositions useful in cosmetic and personal care applications such as soaps shampoos, toiletries and the like. In particular, the present invention relates to the preparation of these compositions and an improved process that is both user and environmental friendly.
BACKGROUND OF THE INVENTION
Surfactants, or surface active agents, are useful in cleaning compositions as they reduce the intermolecular attraction of one compound or material from that of another. In other words, they reduce the surface tension that exists between dirt, oil or grease and the skin, hair, or some other inert material such as porcelain, fabric, hard surfaces and the like. In so doing, the dirt or grease is released from the surface of the second material which is consequently cleaned.
There are three basic types of surfactant and many different species of each. Detergents reduce the surface tension of water and specifically exert emulsifying action at oil-water interfaces and in this way function to remove soils. Emulsifiers are basically a type of detergent and hold two or more liquids in suspension. Wetting agents reduce the surface tension of water whereby it is able to more easily penetrate or spread over the surface of another material.
Surfactants can also be classified in terms of their charge. Anionic surfactants are negatively charged, cationic are positively charged, non-ionic possess no charge while amphoteric surfactants can be either positive or negatively charged depending on their environment and have the capacity of acting as either an acid or a base depending on the pH of the surrounding solution. Again, there are many different species of each group and each may function in a different manner. Imidazoline-derived amphoteric surfactants are generally characterized by their relative mildness, which makes them ideal for applications in personal care compositions such as baby shampoo formulations. Moreover, they tend to be stable and effective over a wide pH range, and this is a useful property for many alkaline and acid cleaners used in specialty cleaner applications.
U.S. Pat. No. 3,187,003 to McBride discloses a process for the preparation of zwitterions of 1-(2-amino-ethylimidazolines) that are useful as oil stabilizers, grease additives, fabric anti-static agents and the like. An imidazoline having an aminoethyl substituent is reacted with an α-β-unsaturated acid of from 12 to 22 carbon atoms.
U.S. Pat. No. 2,820,043 to Rafney et al. discloses a process for the preparation of imidazoline propionic acid derivatives which are amphoteric surfactants by nature and are useful as wetting agents, penetrating agents, emulsifying agents, dispersing and cleansing agents. They are allegedly useful over a wide range of pH and are prepared by reacting a 2-hydrocarbon substituted imidazoline with a lower alkyl acrylate in the presence of heat, thus forming the lower alkyl ester of 2-substituted imidazoline propionic acid which is then hydrolyzed.
U.S. Pat. No. 3,555,041 to Katz discloses a class of amphoteric imidazoline surfactants having effective surfactant properties over a wide range of pH values. These surfactants are produced by reacting long chain imidazoline compounds containing amino-, alkyl-, or hydroxyalkyl-substituted groups with acrylonitrile, methyl acrylate or beta-propiolactone. Preferably, methyl acrylate is used.
Finally, U.K. Patent No. 1,078,101 to Arndt teaches a class of amphoteric imidazolines known as 2-R-imidazoline-1-ethylene-2-oxy-propanoic acids prepared by the condensation reaction of aminoethyl ethanolamine and a fatty acid to yield an imidazoline intermediate which is then reacted with acrylic acid to yield the final product. The compounds are asserted to be useful as emulsifiers, detergents, wetting and surface active agents over a wide range of pH.
Imidazoline-based amphoteric surfactants can be divided into two groups: salt-containing and salt-free. Salt-containing imidazoline amphoteric surfactants having the general structure as shown in FIG. 1 are usually made from the condensation reaction of imidazoline and sodium monochloroacetate, while sodium chloride is produced as a by-product. ##STR1##
Salt-free amphoterics such as monoamphopropionate as shown in FIG. 2 have several advantages over the salt-containing counterparts in industrial applications. Salt-free amphoterics can be made by the Michael addition reaction between imidazoline with either methyl acrylate or acrylic acid under anhydrous conditions, followed by alkaline hydrolysis. Unfortunately, the reactions usually give complex mixtures as suggested by NMR, capillary electrophoresis and HPLC. Alternatively, the reactions can be carried out in aqueous media but the conversion is low. It would therefore be highly desirable to produce a salt-free amphoteric from imidazoline and acrylic acid with high amounts of mono-amphopropionate as shown in FIG. 2. ##STR2## Wherein R=C 11 -C 17 alkane
The use of acrylic acid as a reactant compound as opposed to methyl acrylate provides a number of benefits. Acrylic acid for example, has a higher flash point and is therefore safer and easier to work with. The compound also has a far less objectionable odor.
Of perhaps greater value in the process of the present invention, is that the production of salt-free amphoteric surfactants such as monoamphopropionate does not generate methanol as a by-product. Methanol is listed as a hazardous chemical by the Environmental Protection Agency (EPA). Most amphopropionate surfactants produced using methyl acrylate contain from 2.0% to over 5.0% methanol as a by-product. Storage of methyl acrylate requires expensive tanks as well as effective ventilation and absorbing equipment for removal of the vapor.
Another major problem with the production of salt-free amphopropionates using the processes known in the art is the relatively low yields of monoamphopropionates achievable. Reacting an imidazoline coco-condensate with methyl acrylate produces salt-free monoamphopropionate in yields of just 20%-25%. This is also a very impure product with up to seven (7) different compounds produced in the reaction mixture.
SUMMARY OF THE INVENTION
An improved process for the production of salt-free amphoteric surfactants in high yields comprises the condensation reaction of imadazoline with a mixture of acrylic acid and sodium acrylate in a molar ratio of about 1:3, respectively. The reaction is carried out in aqueous medium at elevated temperatures of from about 85° C. to 100° C.
DETAILED DESCRIPTION OF THE INVENTION
It is well known that imidazoline readily undergoes Michael addition reactions with methyl acrylate or acrylic acid under anhydrous conditions. Carbon-13 NMR analyses suggest that the reaction product after hydrolysis with sodium hydroxide contains many components rather than a single compound, the desired amphopropionate as shown in FIG. 2. One possible explanation as to why Michael addition reactions afford complex mixtures is outlined in Scheme 1. In the first step, Michael addition may take place on the sp 2 nitrogen to give intermediate 2a, which is stabilized by the formation of 2b through the resonance mechanism. ##STR3##
Hydrolysis of the adduct (2a) and (2b) by sodium hydroxide gives two monopropionates (3) and (4) upon cleavage of either one of the two C--N bonds. In the presence of excess alkylating reagents, (3) and (4) can be further converted to dipropionates (5) and (6), respectively. It was found that in the case of methyl acrylate, besides the nitrogen atoms in the imidazoline ring, the hydroxyl group underwent a Michael addition reaction as well. This is evidenced by the appearance of carbon-13 signals in the regions of 67 ppm. ##STR4##
It is possible for the alkylation to occur on the sp 3 nitrogen atom as well. However, the resulting intermediate (7) as shown in Scheme 2 is less stable than intermediate (2) which is stabilized by resonance structures. Consequently, the desired amphopropionate surfactant is just a minor component in the mixture. ##STR5##
Product obtained by running the reaction in aqueous media is expected to contain more of (8) since imidazoline is known to undergo hydrolysis by water to give amidoamine (9) together with small amount of 10, which will then react with an alkylating reagent on the amine nitrogen to give (8) and (11) respectively (see Scheme 3.) The conversion of imidazoline to the product is low and the finished product contains significant amount of unreacted amidoamine (9). ##STR6##
The present invention is a process to produce a salt-free amphoteric surfactant with a high content of mono-amphopropionate (8) from the readily available acrylic acid and coco-imidazoline. Clearly, a Michael addition reaction has to be utilized to produce amphopropionate (8) from acrylic acid and coco-imidazoline. However, treatment of imidazoline directly with acrylic acid would give a salt through a typical acid-base type reaction which can compete with the Michael addition reaction. One way to overcome this problem is through the use of sodium acrylate.
The Michael addition with amidoamine (9) would first give intermediate (12) as shown in Scheme 4, which then undergoes rearrangement to give (8) in relatively high yields. ##STR7##
The present invention then involves the preparation of a salt-free amphoproprionate surfactant in high yields of monoamphoproprionates with few impurities and other undesirable by-products. The process generally comprises reacting an imidazoline with a mixture of acrylic acid and sodium acrylate in an aqueous medium at elevated temperatures. The use of acrylic acid in place of methyl acrylate enables the reaction to be run without the production of methanol, an otherwise hazardous by-product. In the past, methanol was produced in amounts of up to 2.0% to 5.0% by weight of the total end product mixture.
By removing methanol as a by-product altogether, salt-free amphoteric surfactants can be produced which can be incorporated into personal care items and, in particular, cosmetic compositions where they afford superior cleaning efficacy with little to no irritation. These surfactants can also be formulated in hypoallergenic compositions which are growing in demand worldwide.
The Michael reaction occurs in an aqueous medium at elevated temperatures. The imidazoline and acrylic acid/sodium acrylate mixture are combined in a molar ratio of 1:1, i.e, equal parts imidazoline and acid/acrylate mixture. The mixture itself is comprised of acrylic acid and sodium acrylate in molar weight ratios of from about 1:6 to about 1:3. Preferably the two compounds are mixed in an amount of 25 parts acrylic acid to 75 parts sodium acrylate. The compounds are mixed together in water prior to the addition of the imidazoline. Imidazoline derivatives useful in the practice of the present invention are prepared from 2-(2-aminoethylamino)ethanol and fatty acids. Examples of fatty acids can include coconut oil fatty acids, caprylic, capric, lauric, myristic, polmitic and stearic acids.
When lauric imidazoline (Structure 1; R═C 11 H 23 ) was treated with sodium acrylate prepared from acrylic acid and sodium hydroxide in aqueous media at 70° C., the desired Michael addition reaction did not occur after 5 hr. Carbon-13 NMR showed that imidazoline was hydrolyzed to amidoamine after 1 hr. under the reaction conditions employed. The reaction mixture was then heated to 90° C. and the temperature was maintained for 20 hrs. A Carbon-13 NMR spectrum of the reaction product showed the desired Michael addition reaction had occurred and the amphopropionate surfactant (Structure 8) was formed in 37% yield based on imidazoline. The structure assignment for 8 was based on the comparison of its 13 C-NMR spectrum with that of the well-known amphoacetate as shown in FIG. 1.
The following examples are designed to better disclose the invention with more particularity in an effort to more specifically enable one to practice the process of the present invention. They are for illustrative purposes only however, and it is recognized that minor changes and alterations may be made thereto that are not contemplated herein. It is to be understood that to the extent that any such changes or alteration do not materially affect the final reaction product or results, they are to be considered as falling within the spirit and scope of the invention as defined by the claims that follow.
EXAMPLE I
To a four-neck round bottom flask equipped with a stirrer, thermometer and dropping funnel was added 268 g (1.0 mol) of coco-imidazoline, 400 g of water and a mixture of acrylic acid and sodium acrylate that was prepared in a separate vessel by adding 72 g (1.0 mol) of acrylic acid to 24 g of 50% NaOH (0.3 mol) in 200 g of water with stirring and cooling. The reaction mixture was heated to 90° C. and continued for 20 hr.
The product analyzed was 38.0% solid. Analysis by carbon-13 NMR indicated the reaction produced mono-amphopropionate (8) in a 40% yield based on the amount of coco-imidazoline and 20% of unreacted amidoamine (9).
EXAMPLE II
This example illustrates that the yield of mono-amphopropionate (8) can be improved by varying the ratio of acrylic acid to sodium acrylate.
The process of Example 1 was repeated using a mixture of acrylic acid and sodium acrylate prepared from 72 g (1.0 mole) of acrylic acid and 60 g of 50% sodium hydroxide (0.75 mol) in 200 g of water. The yield of mono-amphopropionate (8) was improved to 52% based on the amount of coco-imidazoline.
EXAMPLE III
This example demonstrates that using solely sodium acrylate above does not increase the yield of mono-amphopropionate (8).
The process of Example 1 was followed using sodium acrylate prepared from 72 g (1.0 mol) of acrylate acid and 80 g of 50% sodium hydroxide (1.0 mol) in 200 g of water. The yield of amphopropionate (8) was 37% based on the amount of coco-imidazoline.
EXAMPLE IV
This example describes the procedure wherein the imidazoline is first converted to the amidoamine by sodium hydroxide and then alkylated by a mixture of acrylic acid and sodium acrylate. It also shows that the yield of amphopropionate (8) can be further increased by using an excess amount of a mixture of acrylic acid and sodium acrylate.
To a four-neck round bottom flask equipped with a stirrer, thermometer and dropping funnel was added 268 g (1.0 mol) of coco-imidazoline, 4 g of 50% NaOH (0.05 mol) aqueous solution and 200 g of water. The resulting mixture was heated at 85° C. for 1 hr. with stirring. In a separate container, a mixture of acrylic acid and sodium acrylic was prepared by adding 90 g (1.25 mol) of acrylic acid to 71 g of 50% NaOH (0.89 mol) in 200 g of water with stirring and cooling. Two hundred grams of water was added to the reaction flask, followed by the mixture of acrylic acid and sodium acrylate. Heating was continued for another 16 hr and the reaction temperature was maintained at 85° C.
The product analyzed was 38.4% solids. Analysis by carbon-13 NMR indicated that an 80% yield of mono-amphopropionate (8), based on the amount of imidazoline was obtained together with less than 10% of unreacted amidoamine (9) and about 10% of unidentified components, probably dipropionates such as (5) and (6). The high content of monoamphopropionate (8) in the product compared to a commercial product such as Miranol C2M SF from Rhone-Poulenc, Inc., was also confirmed by capillary electrophoresis. Under these conditions, the reaction conversion with respect to amidoamine was shown to be 90%. About 25% of the acrylate mixture was left unconsumed at the end of reaction as determined by NMR as well as liquid chromatography. Although it is possible to get a higher reaction conversion by using a larger excess of acrylate mixture, it is certainly not desirable to have a large access of unreacted acrylate in the finished product. The finished product may contain up to 10% of dipropionates such as structures (5) and (6).
The unconsumed acrylate can be easily removed, as desired, by the treatment with an stoichiometric amount of sodium bisulfite at 85° C. for 1 hour. The possible acrylic acid reformation, via a reversed Michael addition reaction, does not occur at a noticeable rate over a three-month period. This is supported by the fact that the finished product contains less than 100 ppm acrylic acid after being treated with sodium bisulfite was found to contain still less than 100 ppm of acrylic acid after 3 months at room temperature. Preferably, the reaction is carried out in the presence of air, otherwise the finished product can become cloudy which is attributed to the polymerization of acrylic acid or sodium acrylate.
EXAMPLE V
The functional surfactant characteristics of the salt-free amphoterics of the present invention were compared to those of a commercially available amphoteric, Miranol C2M SF® (Rhone-Poulenc Inc., Monmouth Jct, N.J.) a sodium cocoamphopropionate. The surface active properties of the salt-free amphoacetate were compared both before and after the amphoacetate was treated with sodium bisulfite. The results are summarized in Table 1.
TABLE 1__________________________________________________________________________Surface Properties of MiranolSF and Salt-Free Amphopropionate CMC γ.sub.cmc Foams Height (mm) WettingSurfactant (mole/l) (dynes/cm) pC-20 (0--> 5 min) Time (sec)__________________________________________________________________________Miranol SF 1.0 × 10.sup.-4 31.5 5.1 142 --> 132 60Amphopropionate 4.0 × 10.sup.-5 28.9 5.6 153 --> 138 38before Na.sub.2 SO.sub.3Amphopropionate 1.0 × 10.sup.-5 27.5 5.5 148 --> 138 47after Na.sub.2 SO.sub.3__________________________________________________________________________
As shown in Table 2, compared to Miranol C2M SF, the salt-free amphopropionate either treated or untreated with sodium bisulfite is more efficient in reducing the surface tension and forming micelles. The new amphoteric surfactant also exhibits better foaming and wetting properties than Miranol C2M SF.
EXAMPLE VI
This example demonstrates an alternative procedure to that set forth in Example 1. Imidazoline was added to sodium acrylate so that a separate vessel for the preparation of acrylic acid/sodium acrylate mixture can be avoided.
To a four neck round bottom flask containing 75 g of 50% NaOH (0.94 mol) and 300 g of water was added 63.9 g (0.89 mol) of acrylic acid, followed by 268 g of coco-imidazoline. The resulting mixture was heated at 65° C. for 1 hr with stirring, and then 26.1 g (0.36 mol) of acrylic acid was added. The reaction temperature was allowed to increase to 90° C. and maintained at this temperature for 20 hr.
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A novel, salt-free monoamphopropionate amphoteric surfactant is prepared in yields of from 75% to 80%, from a reaction comprising an imidazoline and a mixture of acrylic acid and sodium acrylate in an aqueous medium. The acrylic acid/sodium acrylate mixture is comprised of the two components in a range of molar ratios of from about 1:6 to about 1:3, respectively, and by replacing methyl acrylate, the reaction does away with the production of methanol which is an unwanted, hazardous and toxic byproduct. The imidazoline reacts in amounts in excess of 90% resulting in the highly pure yields and any left over unreacted acrylic acid can be easily removed by treating it with sodium bisulfate.
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CROSS REFERENCE TO RELATED APPLICATION
This application involves additions and improvements to the invention described in an application of John F. Straitz, III for Flare Burner, filed Mar. 28, 1977, Ser. No. 781,849.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to ground flare stacks and more particularly to such stacks for the burning of waste combustible gases containing various hydrocarbons.
2. Description of the Prior Art
It has heretofore been proposed to burn waste combustible gases employing successive stages to accommodate varied quantities of gas to be burned.
Nahas, in U.S. Pat. No. 3,322,178, shows a flare apparatus for staged combustion in a pit below ground level, Venturi burners being disposed along the sides of the pit.
Hoy, et al., in U.S. Pat. No. 3,881,857 show a combustor with a chamber divided into a plurality of zones having increasing numbers of air tubes so that progressively increasing areas may be ignited.
Beck, in U.S. Pat. No. 2,625,992 shows in a flat burner arrangement multiple gas burners in groups with provisions for utilizing a plurality of groups sequentially as required.
Reed et al., in U.S. Pat. No. 3,749,546, show in a flat pit burner a plurality of flow lines connected to a plurality of burners for utilization in stages, determined by the pressure of the gas.
The foregoing all require a relatively large flat surface area with the combustion exposed to view from the surrounding land area.
Pillard et al., in U.S. Pat. No. 3,885,919, show a residual gas burner with a smoke evacuating conduit at the base and a plurality of superposed coaxial combustion chambers of increasing volume with gas supplied to a number of burners varying in the same manner as the outflow of gases.
The waste gas burners of the staged type heretofore available require excessive area, do not adequately conceal the combustion glare and noise and have other shortcomings.
SUMMARY OF THE INVENTION
In accordance with the invention a ground flare stack is provided having an interior combustion chamber with a plurality of lower quantity level of combustion stages, the interior chamber being surrounded by the lower part of the stack which converges upwardly to a location above the top of the chamber, with other combustion stages at the top of the chamber, the stack extending upwardly and a fluidic diode being provided in the upper part of the stack to prevent downflow in the stack and to minimize possible combustion pulsations. Air induced at the various combustion stages enters at the bottom of the stack which is shielded by an acoustical, glare and wind shielding fence. Provisions are made for introduction of water containing oil and other combustibles and for the introduction of snuffing steam.
It is the principal object of the invention to provide a ground flare stack which is effective in the disposal of waste combustible gases and waste liquids, which does not require excessive area for installation and which does not adversely effect the nearby area by transmission of odors, noise or glare.
It is a further object of the invention to provide a ground flare stack which can accommodate a wide range of flow rates with stages of increasing capacity for this purpose.
It is a further object of the invention to provide a ground flare stack which can be utilized for the burning of a large variety of hydrocarbon waste streams.
It is a further object of the invention to provide a ground flare stack for proper disposal of waste water through the use of the energy available in the waste gas and without any supplementary fuel and without adversely affecting the gaseous combustion process.
It is a further object of the invention to provide additional safety features including a snuffing and purging action.
Other objects and advantageous features of the invention will be apparent from the description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The nature and characteristic features of the invention will be more readily understood from the following description taken in connection with the accompanying drawings forming part hereof in which:
FIG. 1 is a vertical central sectional view of a ground flare stack in accordance with the invention;
FIG. 2 is a horizontal sectional view taken approximately on the line 2--2 of FIG. 1;
FIG. 3 is a horizontal sectional view, enlarged, taken approximately on the line 3--3 of FIG. 1 and showing multiple stages of burners;
FIG. 4 is a horizontal sectional view taken approximately on the line 4--4 of FIG. 1;
FIG. 5 is a vertical sectional view taken approximately on the line 5--5 of FIG. 4; and
FIG. 6 is a diagrammatic view of a control system for the burners of the successive stages.
It should, of course, be understood that the description and drawings herein are illustrative merely and that various modifications and changes can be made in the structure disclosed without departing from the spirit of the invention.
Like numerals refer to like parts throughout the several views.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings in which a preferred embodiment is shown a foundation 10 is provided from which circumferentially spaced inner posts 11 and circumferentially spaced outer posts 12 extend upwardly.
The foundation 10 is provided with a drain pipe 13 for discharge of rain water tending to collect above the foundation 10. The central portion of the foundation 10 and inwardly of the posts 12 is preferably covered with a layer of coarse gravel 14, preferably in concaved or dished form. The gravel is approximately 20 to 50 mm. in size and the minimum depth is preferably of the order of 150 mm. for noise absorption and reflection.
The posts 11 support, through a horizontal plate 15, an interior combustion chamber 16.
The combustion chamber 16 has a central circular cylindrical wall 17, a lower inclined outwardly extending wall 18 from which a horizontal wall 19 extends with a downwardly extending cylindrical wall 20 and an inwardly horizontally extending rim 21 with a central opening 22.
The central cylindrical wall 17 has an outwardly inclined wall 25 from which a circular cylindrical wall 26 extends upwardly with an upper converging wall 27 thereabove with a central opening 28.
The walls 17, 18, 19, 20, 21, 25, 26 and 27 are preferably of sheet metal and lined with a heat and sound insulating layer 30, preferably of a stable high temperature alumina silica ceramic fibrous material.
Within the space bounded by the walls 18, 19, 20 and the rim 21 a horizontal sound and heat baffle plate 32 is provided with its circumference inset from the wall 20 and its lining 30.
The baffle plate 32, as shown in detail in FIG. 5, has an inner perforated sheet 33 to permit the passage of sound, a central core 34 of ceramic fibrous material like the lining 30, and an outer metal plate 35.
The baffle plate 32, on the upper face thereof, has a plurality of pivoted streamlined vanes 36, carried on pivot pins 37 and adjusted in any desired manner to control the flow of air entering at the opening 22 and passing around the baffle plate 30 for delivery to the interior of the combustion chamber 16.
Within the combustion chamber 16 at the lower part of the wall 17 and its lining 30 first stage waste gas burners 40 are provided three being shown in FIGS. 2 and 3, with combustible waste gas supplied thereto by header 41. The burners 40 can be of any desired type but those shown in the U.S. Pat. No. 3,463,602 to Gordon M. Bitterlich are suitable. Pilots 43 are provided for igniting the combustible gas from the burners 40.
Preferably at the same level in the combustion chamber 16 as the first stage burners 40, a plurality of second stage waste gas burners 44 are provided, nine being shown in FIGS. 2 and 3 with combustible waste gas supplied thereto by headers 45.
The posts 12 support a plurality of vertical acoustical and wind shield baffle wall panels 50 of metal plates 51 with interior linings 52 of high temperature alumina silica ceramic fibrous material and exterior linings 53 of sound absorbent glass fibrous material.
Extending outwardly from the tops of the panels 50 a hood 55 is provided with a lining 56 of sound absorbent glass fibrous material.
Louvres 57 having spaced inclined slats 58 for entrance of air extend downwardly from the hood 55 to base panels 59 carried on the foundation 10 and which preferably have linings 60 of sound absorbent glass fibrous material. Inclined louvres 62, having spaced inclined slats 63, for entrance of air, connect the lower margins of the panels 50 with the horizontal plate 15.
The wall panels 50 have extending upwardly therefrom a frustoconical wall 65 with a lining 66 of ceramic fibrous material from which a cylindrical stack 67 extends upwardly. The stack 67, has a ceramic fibrous lining 68 and at the upper part thereof has a fluidic diode 70 as shown in U.S. Pat. No. 3,730,673 for preventing down flow in the stack 67.
Within the wall 65 and its lining 66 (see FIGS. 1 and 3) and at a frusto-conical location perpendicular to the wall 65 and extending to the upper end of the wall 27 of the inner combustion chamber 16, a plurality of third stage burners 75 are mounted in two concentric circles, eighteen burners 75 being shown. Pilots 76 are provided with each group of three burners 75 for ignition. The burners 75 are connected to a manifold 77 for supplying waste gas thereto.
A plurality of fourth stage burners 80, are provided, preferably in the same concentric circles as the burners 75, thirty six burners 80 being shown. The burners 80 are connected to a manifold 81 for the supply of waste gas thereto.
A waste water supply manifold 84 is provided, preferably through the wall 25 and its covering 30, for introduction of waste water into the interior combustion chamber 16 through atomizing nozzles 85 for vaporization and incineration, the waste water being accompanied by oil and solid combustibles for disposal.
A lower steam snuffing nozzle 86 with a steam supply pipe 87 connected thereto and a plurality of upper steam snuffing nozzles 88, three being shown with a steam supply pipe 89 connected thereto may also be employed. The snuffing is employed in the event of failures or emergency conditions occurring as herein pointed out.
Any desired system may be utilized to control the delivery of the waste gas to the respective stages of burners. As shown in FIG. 6, the main waste gas supply pipe 90 has a plurality of branch lines 91, 92, 93 and 94 respectively connected thereto. The branch line 91 is connected to the manifold 41 for the first stage burner nozzles 40, the branch line 92 is connected to the manifold 45 for the second stage burner nozzles 44, the branch line 93 is connected to the manifold 77 for the third stage burner nozzles 75 and the branch line 94 is connected to the manifold 81 for the fourth stage burner nozzles 80.
Each of the branch pipes 92, 93 and 94 is provided respectively with an air or solenoid operated valve V2, V3 and V4 normally held closed by an air or electric signal, the valves being respectively moved to open position at predetermined gas pressure levels, sensed by a pressure sensor PS in each branch pipe and as determined by the quantity of waste gas delivered for combustion. The valves V2, V3 and V4 are held in open positions for a predetermined time interval after a closing signal determined by decreasing flow at a flow sensor FS in each branch line. These valves are intended to fail safe, i.e. open in the event of failure of electric power of air failure.
The mode of operation will now be pointed out.
Assuming that there is waste gas in the supply pipe 90 and in the branch pipe 91, waste gas will be delivered from the supply pipe 90 through the branch pipe 91 to the manifold 41 and thence to burner nozzles 40 for ignition by the pilots 43.
Air for combustion will be induced by the inner combustion chamber 16 and by the stack 67. Air for combustion of waste gas from burner nozzles 40 enters through louvres 57, between the posts 12, between the supports 11 and through the opening 22 in the rim 21 and then moves upwardly around the baffle plate 32 with a flow as determined by the setting of the vanes 36. The combustion of the gas from the burner nozzles 40 will occur preferably with a short flame in the lower part of the combustion chamber 16 and preferably below the levels of the waste water nozzles 85. Air induced by the stack 67 passes through louvres 62 and upwardly outside the rim 15 and the walls 26 and 27 for contact with the gases rising from the combustion chamber 16.
If there is an increase in the available waste gas sufficient to require the utilization of the second stage burner nozzles 44 this will be effected by reason of the pressure switch PS in the branch line 92 and the gases from the burner nozzles 44 will be ignited by the burning gases from the burner nozzles 40.
If a further increase in available combustible waste gas occurs this will be effective through the pressure switch PS in the branch pipe 93 for delivery of gas through the manifold 77 and the burner nozzles 75 outside the combustion chamber 16. The pilots 76 are effective for igniting the combustible waste gases from the burner nozzles 75.
Similarly, if further increase in availability of the waste gas occurs, delivery will be effected in the manner previously indicated through branch pipe 94 to the manifold 81 and burner nozzles 80. Ignition will be effected from the flames of the adjoining burner nozzles 75 of the third stage. The air for the combustion of the gas discharged from the burner nozzles 75 and 80, induced by the discharge and by the stack 67, passes upwardly outside the combustion chamber 16 being drawn through louvres 63 and into contact with the burning gases for aiding in their combustion.
The gases from one or more stages pass upwardly through the stack 68 and past the fluidic diode 70 for discharge from the stack 67. The fluidic diode 70 reduces downflow in the stack.
It will be noted that the panels 57 and 59 provide a wind shield reducing the effect of external wind. The panels 59 reduce light transmission and by reason of their interior linings 60 will reduce the transmission of low frequency vibrations of combustion and higher frequency vibrations of air entrance to the exterior.
The acoustical linings 53 of the wall panels 50 and the acoustical lining 56 of the hood 55 further aid in reducing sound transmission to the exterior.
The location of the water injector nozzles 55 at the locations shown in the combustion chamber 16 permit introducing waste water and vaporizing the same by the ascending hot gases without interfering with combustion and without smoke formation.
In the event of an unexpected emergency in the ground flare such as flame failure of all the pilot burners due to liquid carry-over, blocking by foreign matter, reduced pilot pressure or other abnormal occurrences, it will be desired to shut off the supply of waste gas delivered through the pipe 90 and otherwise dispose of it such as by discharge through an elevated flare or vent stack (not shown).
At the same time it is desirable that the ground flare be purged with steam supplied through the central nozzle 86 into and through the combustion chamber 16 and also through the nozzles 88 to further purge the flare. The nozzles 86 and 88 inspirate air which aids in the purging. These nozzles are preferably of the same type as those of the burner heads 40, 44, 75 and 80. The discharge of steam will quench any flames which might have continued.
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A ground flare stack is described having a plurality of stages for combustion to accommodate various quantities of combustible waste gas, the stack having a dished base of gravel with a central combustion chamber with an enlarged opening at the bottom for entrance of air to support combustion, the central combustion chamber having an enlargement at its upper end with a converging discharge, a plurality of stages of combustion being provided within the chamber, the central combustion chamber being surrounded by a stack in spaced relation with a converging portion disposed around the combustion chamber enlargement and a cylindrical stack thereabove, with a diode to prevent downflow through the cylindrical stack, an acoustical and wind shielding fence being around the bottom of the stack permitting air to be supplied to the bottom of the stack and of the combustion chamber, additional stages of combustion being provided outwardly of the upper end of the central combustion chamber.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/498,598, file Dec. 14, 2004, which is a 371 national phase application of PCT Application Ser. No. PCT/US2002/39930, filed Dec. 12, 2002, which claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 60/341,180, filed Dec. 12, 2001. The disclosure of this application is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention is directed to the extraction and purification of lipids, and in particular, lipids containing long chain polyunsaturated fatty acids (LCPUFAs). In particular, processes are provided for obtaining high concentrations of desired LCPUFAs and low concentrations of undesired compounds such as trisaturated glycerides.
BACKGROUND OF THE INVENTION
In general, winterization is the name given to the process of removing sediment that appears in vegetable oils at low temperature. It originated from the early practice of allowing cottonseed oil to remain in outdoor storage during the cool winter months and filtering off the sediment-free oil. Dry fractional crystallization is a process wherein triglycerides with the highest melting temperature preferentially crystallize during cooling from a neat liquid (e.g., liquid lipid). After crystallization is complete, the solid phase is separated from the liquid phase by one of several types of physical processes. Alternatively, solvent crystallization is used to promote triglyceride crystal formation, because triglycerides at low temperature generally form more stable crystals with solvent than without solvent.
Docosahexaenoic acid (DHA)-rich lipid was extracted using conventional techniques and solvents (e.g., hexane) from Schizochytrium sp. biomass produced by fermentation, and the resulting extracted lipid was winterized by chilling it to −2 to 2° C. followed by centrifugation. The lipid was then refined, bleached and deodorized, and put into gelatin capsules for sale as nutritional supplements. A problem arose with this product in that a haze would form in the product over time.
In one process for recovering lipids from biomass, as illustrated in FIG. 1 , dried microalgae are suspended in commercial-grade n-hexane and wet milled. Hexane primarily extracts triglycerides, diglycerides, monoglycerides and esterified sterols, although other components of the total lipid fraction, such as phospholipids, free sterols and carotenoids, can also be extracted to a lesser degree. Centrifugation is employed to separate spent biomass from a lipid-rich miscella. The resultant mixture of lipid and solvent is referred to as miscella. The lipid content of the clarified miscella is adjusted to about 45 wt % using n-hexane. The miscella is winterized, in particular, the miscella is chilled to approximately −1° C., and held for 8 to 12 hours, to crystallize any saturated fats, or high melting point components. The miscella is then filtered to remove the crystallized stearine phase. Hexane is removed from the miscella, leaving behind the winterized lipid.
As illustrated in FIG. 2 , the winterized lipid is heated and treated with citric acid or phosphoric acid to hydrate any phosphatides present in the lipid. Sodium hydroxide is added to neutralize any free fatty acids present. The resulting gums (hydrated phosphatides) and soapstock (neutralized fatty acids) are removed using a centrifuge. The lipid is mixed with water and re-centrifuged to remove any residual gum/soapstock. This step can be carried out with the first centrifugation. The refined lipid is bleached with silica and bleaching clay following pre-treatment with citric acid, to remove peroxides, color compounds, and traces of soapstock, phospholipids and metals. Filter aid is added at the end of the cycle to facilitate removal of the spent bleaching compounds from the lipid via filtration.
An additional step can be performed, where the bleached lipid is chilled to from about 5° C. to about 15° C. and held for about 6 to about 8 hours to crystallize any remaining stearines or waxes, if it is apparent that a sediment layer will form upon standing. Filter aid can be used to facilitate removal of the crystals via filtration, if this step is performed.
A deodorizer, operated at elevated temperatures under high vacuum, is used to destroy peroxides, which if left intact could later decompose and initiate free radical reactions. This step also removes any remaining low molecular weight compounds that can cause off-odors and flavors. Contact times in the deodorizer are minimized to prevent the formation of trans-fatty acids. Safe and suitable food approved antioxidants are added. The stabilized lipid is packaged in a phenolic-lined metal container under a nitrogen atmosphere to prevent oxidation.
The haze that formed in the lipid-filled gelatin capsules was analyzed and found to be composed of crystals of triglycerides containing myristic (14:0) and palmitic (16:0) fatty acids, a trisaturated fatty acid glyceride. These crystals had a melting point of about 50-55° C. The trisaturated glycerides comprised 6-8% of the crude extracted lipid. The above-described winterization process lowered the concentration of these trisaturated glycerides to <1%; however, not low enough to completely eliminate haze formation in the lipid. Additionally, about 30% of the lipids, and a corresponding 30% of the DHA, is removed in this traditional hexane (55% hexane and 45% crude oil) winterization process. Another problem was that when the temperature was lowered to crystallize the remaining <1% of the trisaturated triglycerides, more of the desired LCPUFA, e.g., disaturated triglycerides containing one DHA molecule, would also crystallize out. This would cause significant losses of the target product, DHA. Losses could be an additional 8-10% of the lipids. So by trying to solve one problem, another was created. It would be desirable to have a process by which the LCPUFA level could be maintained at a desirably high level and the haze could be reduced or eliminated.
SUMMARY
The present invention includes a process for purifying a lipid composition having predominantly neutral lipid components wherein the composition contains at least one long chain polyunsaturated fatty acid (LCPUFA) and at least one other compound. The process includes contacting the lipid composition with a polar solvent and the solvent is selected such that the other compound is less soluble in the solvent than is the LCPUFA. For example, the polar solvent can be selected from acetone, isopropyl alcohol, methanol, ethanol, ethyl acetate and mixtures thereof. The process further includes maintaining the lipid composition at a temperature range effective to precipitate at least a portion of the other compound. For example, the temperature range can be from about −20° C. to about 50° C., from about −5° C. to about 20° C., from about −5° C. to about 5° C. or about 0° C. The process then includes removing at least a portion of the other compound from the lipid composition to form a lipid product. The process can be specifically for the reduction of the formation of haze in a lipid composition in which the compound being removed is a haze-forming compound.
In various embodiments, the lipid composition can include at least 50% or 85% neutral lipid, or at least 50% triglyceride. The concentration of LCPUFA, on a weight percentage basis, can be greater after the process than before, and the concentration of the other compound, on a weight percentage basis, can be less after the process than before. For example, the total concentration of any phosphorus-containing compounds present in the lipid, on a weight percentage basis, is less after the process than before. The process of the present invention can result in an acceptable product with less downstream processing required, such as with reduced degumming or no degumming required.
The LCPUFA can be arachidonic acid (ARA), omega-6 docosapentaenoic acid (DPA(n-6)), omega-3 docosapentaenoic acid (DPA(n-3)), eicosapentaenoic acid (EPA) and/or docosahexaenoic acid (DHA). The other compound can be trisaturated glycerides, phosphorus-containing materials, wax esters, saturated fatty acid containing sterol esters, sterols, squalene, and/or hydrocarbons. Alternatively, the other compound can be trisaturated glycerides, phosphatides and wax esters. Alternatively, the other compound can be trisaturated glycerides of lauric (C12:0), myristic (C14:0), palmitic (C16:0) and stearic (C18:0) fatty acids and/or mixtures thereof. In a particular embodiment, the lipid composition initially comprises at least one LCPUFA and at least one trisaturated glyceride. The LCPUFA can be obtained from a LCPUFA-containing biomaterial selected from LCPUFA-containing microbial biomass and oilseeds from plants that have been genetically modified to produce LCPUFA-containing lipid. Also, the LCPUFA can be obtained from plants that have been modified with LCPUFA-producing genes from microbes. In another embodiment, the LCPUFA can be obtained from a source selected from the group consisting of thraustochytrid biomass, dinoflagellate biomass, Mortierella biomass, and oilseeds from genetically modified plants containing genes from thraustochytrids, dinoflagellates or Mortierella . In a further embodiment, the LCPUFA is obtained from the group comprising Schizochytrium, Thraustochytrium or Crypthecodinium cohnii biomass or oilseeds from genetically modified plants containing genes from Schizochytrium or Thraustochytrium.
In various embodiments of the invention, the solvent:lipid composition ratio is from about 1:10 to about 20:1, from about 1:8 to about 10:1, from about 1:5 to about 5:1, from about 1:2 to about 2.5:1, or about 1:1. In other embodiments, the time of contact between the solvent and the lipid composition is from about 0.5 to about 12 hours, from about 2 to about 6 hours, or about 4 hours.
In another embodiment of the invention, lipid is extracted using the polar solvent at low temperatures such that triglyceride molecules containing the LCPUFA are selectively extracted and other compounds that are not soluble in the polar solvent are not extracted. In a further embodiment, the lipid composition is extracted from a biomass and cellular debris and precipitated other compounds are separated from a miscella comprising the LCPUFA and the polar solvent.
A further embodiment of the invention includes employing the polar solvent to recover lipid in an extraction process conducted at temperatures that solubilize substantially all triglyceride components; forming a miscella comprising a mixture of the lipid composition and the polar solvent; cooling the miscella to selectively precipitate the undesired compounds; and separating the precipitated other compounds from the miscella. In this embodiment, the lipid composition can be extracted from biomass and cellular debris and precipitated other compounds are separated from a miscella comprising the LCPUFA and the polar solvent.
Another embodiment of the invention includes employing the polar solvent to recover lipid from a biomass in an extraction process conducted at temperatures that solubilize substantially all triglyceride components, forming a miscella comprising a mixture of the lipid composition, the polar solvent and cellular debris. The process further includes separating the cellular debris from the miscella and cooling the miscella to selectively precipitate the undesired compounds. Finally, the precipitated other compounds are separated from the miscella.
A further embodiment of the invention includes employing a nonpolar solvent to recover lipid in an extraction process conducted at temperatures that solubilize substantially all triglyceride components, forming a miscella comprising a mixture of the lipid composition and the nonpolar solvent. The process further includes removing most of the nonpolar solvent from the miscella, adding a polar solvent to the miscella, and cooling the miscella to selectively precipitate the undesired compounds. Finally, the precipitated other compounds are separated from the miscella. A still further embodiment of the invention includes employing a nonpolar solvent to recover lipid in an extraction process conducted at temperatures that solubilize substantially all triglyceride components, forming a miscella comprising a mixture of the lipid composition and the nonpolar solvent and winterizing the miscella. Most of the nonpolar solvent is removed from the miscella, and a polar solvent is added to it. The miscella is cooled to selectively precipitate the undesired compounds which are separated from the miscella. When the nonpolar solvent is removed from the miscella, the residual nonpolar solvent after removal is from about 0 to about 4 weight percent or from about 1 to about 4 weight percent.
In the various embodiments of the invention using a nonpolar solvent, the nonpolar solvent can be hexane. In various embodiments of the invention employing a separating or removing step for the precipitated other compound, the step can be a liquid/solid separation technique, such as centrifugation, filtering or combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram of a prior extraction process.
FIG. 2 is a flow diagram of a prior refining, bleaching and deodorizing process.
FIG. 3 is a flow diagram of a DHA-rich lipid extraction process of the present invention using acetone in one step.
FIG. 4 is a flow diagram of a DHA-rich lipid extraction process of the present invention using acetone in two steps.
FIG. 5 is a flow diagram of a DHA-rich lipid hexane extraction process and acetone winterization process of the present invention.
DESCRIPTION OF THE INVENTION
In accordance with the present invention, processes are provided for preferentially reducing the level of undesired components in a lipid, while maintaining high levels of desired LCPUFAs. As used herein, LCPUFAs are fatty acids with 20 or more carbon atoms and two (preferably three) or more double bonds. The LCPUFAs can be in a variety of forms, such as phospholipids, free fatty acids and esters of fatty acids, including triglycerides of fatty acids. It will be appreciated that when referring to the desired LCPUFA, what is meant is the LCPUFA in the form that exists in the lipid, most typically a triglyceride, and to a lesser extent mono- and diglycerides. Preferably, the concentration of the desired LCPUFA, as measured on a weight percent basis, is higher in the resulting lipid product than it is in the starting lipid composition. The undesired components are preferably trisaturated glycerides, such as trisaturated glycerides of lauric (C12:0), myristic (C14:0), palmitic (C16:0) and stearic (C18:0) fatty acids and mixtures thereof. Examples of other undesired components, in addition to trisaturated glycerides, include phosphorus-containing compounds (e.g., phosphatides or phospholipids), wax esters, saturated fatty acid containing sterol esters, sterols, squalene, hydrocarbons and the like. Preferably, two or more of the undesired compounds are reduced in the resulting product as compared to the starting lipid, as measured on a weight percent basis. As used herein, amounts will generally be on a weight percent basis, unless indicated otherwise.
In a preferred embodiment of the present invention the resulting product is subject to less haze or cloudiness when compared to the starting lipid. As a result of the process of the present invention, subsequent processing steps such as refining, can be reduced or eliminated. For example, subsequent processing steps such as bleaching and/or deodorizing can help reduce or eliminate the refining (or degumming) step. An example of the refining, bleaching and deodorizing process is set forth in comparative Example 2. If the refining process is not eliminated, it can be reduced by reducing the amount of caustic employed. While not wishing to bound by any theory, it is believed that a primary cause of haze or cloudiness results from trisaturated triglycerides. It does not appear to be as important to reduce the mono- and di-substituted triglycerides.
As used herein the term “lipids” will refer generally to a variety of lipids, such as phospholipids; free fatty acids; esters of fatty acids, including triglycerides of fatty acids; sterols; pigments (e.g., carotenoids and oxycarotenoids) and other lipids, and lipid associated compounds such as phytosterols, ergothionine, lipoic acid and antioxidants including beta-carotene, tocotrienols, and tocopherol. Preferred lipids and lipid associated compounds include, but are not limited to, cholesterol, phytosterols, desmosterol, tocotrienols, tocopherols, ubiquinones, carotenoids and xanthophylls such as beta-carotene, lutein, lycopene, astaxanthin, zeaxanthin, canthaxanthin, and fatty acids such as conjugated linoleic acids, and omega-3 and omega-6 highly unsaturated fatty acids such as eicosapentaenoic acid, docosapentaenoic acid, and docosahexaenoic acid, arachidonic acid, stearidonic acid, dihomogammalinolenic acid and gamma-linolenic acid or mixtures thereof. For the sake of brevity, unless otherwise stated, the term “lipid” refers to lipid and/or lipid-associated compounds.
The undesirable components share the common characteristic of being relatively insoluble in cold acetone or in an analogous polar solvent. On the other hand, desired LCPUFAs, such as arachidonic acid (ARA), omega-6 docosapentaenoic acid (DPA(n-6)), omega-3 docosapentaenoic acid (DPA(n-3)), eicosapentaenoic acid (EPA) or docosahexaenoic acid (DHA), are soluble in cold acetone or in an analogous solvent. The key characteristic of the solvent, whether it is acetone or an analogous polar solvent, is that the desirable LCPUFAs are soluble in the solvent at the desired temperatures, and the undesirable compounds are not soluble in the solvent at the same temperatures. A useful guide is to select solvents that have dielectric constants close to those of acetone or ethyl acetate. Preferred solvents for use in connection with the present invention include acetone and analogous polar solvents such as isopropyl alcohol, methanol, ethanol, ethyl acetate or mixtures of these solvents. The solvents are all polar, and the LCPUFAs, with their double bonds and long carbon chains, are also polar and therefore soluble in the polar solvents. However, if the solvents are too polar, the LCPUFAs may not dissolve. The solvent is also preferably useful in food applications.
It was unexpectedly found that acetone can be used to selectively precipitate the trisaturated glycerides from the crude lipid. When an unwinterized lot of DHA-rich lipid from Schizochytrium sp. was treated with 5 volumes of acetone and chilled, essentially all of the trisaturated glycerides were removed by crystallization followed by centrifugation. This process removed little or none of the DHA-containing triglycerides. The resulting winterized lipid contained 41% DHA as compared to 37% by the standard winterization process.
There are ways to further utilize this discovery by combining acetone or analogous solvent extraction with “in-situ” winterization concepts to better improve the recovery efficiency of long chain polyunsaturated fatty acid containing triglycerides at the expense of trisaturated glycerides or from triglycerides containing two saturated fatty acids and one mono-unsaturated fatty acid. One advantage of the process of the present invention is that less of the desired LCPUFAs are lost. For example, in prior processes about 30% of the extracted lipid, which contained the desired LCPUFAs, was lost during winterization. In contrast, the embodiment of the process of the present invention (i.e., hexane extraction followed by acetone winterization) that is most directly comparable to the prior process results in the loss of only about 7% to about 10% of the starting extracted lipid as a result of the acetone winterization. As a result, in this embodiment of the present invention, about 40% or more reduction in yield loss is realized. This is a significant improvement over the prior process (hexane extraction and winterization plus full refining, bleaching and deodorizing (RBD)). The largest loss of both DHA and lipid is incurred in the winterization step of the prior process.
First, in a preferred process, lipid is extracted using acetone or analogous polar solvent (instead of hexane) at low temperatures such that triglyceride molecules containing LCPUFA are selectively extracted from Schizochytrium sp. biomass. A flow diagram of such a process is illustrated in FIG. 3 . Due to the selectivity of acetone at low temperature (trisaturated glycerides are not soluble in cold acetone, while LCPUFA-containing triglycerides are soluble in cold acetone), it is feasible to selectively remove the LCPUFA-containing triglyceride from biomass and thus eliminate the need for a separate winterization step. The solvent extraction can be conducted in any suitable manner. For example, the dry biomass can be subjected to mechanical (e.g., in a mill or homogenizer) or chemical (e.g., using an acid, enzyme or base) lysing in the presence of a cold solvent. The cellular debris and precipitated trisaturated glycerides are separated from the miscella in one step. Post processing steps, such as purification by refining, bleaching and deodorizing, can be performed, if desired.
A second option is to utilize acetone or analogous polar solvent to quantitatively recover lipid from biomass in a conventional extraction process (including any type of solvent grinding technique). This extraction is conducted at temperatures that solubilize all triglyceride components. Prior to removing cellular debris from the miscella (lipid containing triglycerides in solvent), the miscella is chilled to selectively remove the trisaturated glycerides. The chilled miscella is then centrifuged, filtered, or separated using other techniques to remove both the cellular debris and trisaturated glyceride component. This option combines the concept of extraction and winterization into one step.
A third option is to utilize acetone or analogous polar solvent to quantitatively recover lipid from biomass in a conventional extraction process (including any type of solvent grinding technique). This extraction is conducted at temperatures that solubilize all triglyceride components. The cellular debris from the miscella (lipid containing triglycerides in solvent) is removed using conventional separation techniques. The miscella is then chilled to crystallize the trisaturated glycerides, which are removed by centrifugation, filtration, or separation using other techniques. This option utilizes extraction and winterization in two stages; however, acetone or an analogous polar solvent is utilized to accomplish both tasks. A flow diagram illustrating such a process is shown in FIG. 4 .
A fourth option is to utilize a nonpolar solvent such as hexane (e.g., n-hexane, isohexane or a combination thereof) as an extraction solvent and utilize acetone as a winterization solvent. Preferably, at least 95%, more preferably at least 96%, more preferably at least 97%, more preferably at least 98% and more preferably at least 99% of the nonpolar solvent is removed prior to winterization. The winterization step can be employed at any stage prior to deodorization. A flow diagram illustrating such a process is shown in FIG. 5 .
A fifth option is to utilize conventional hexane extraction and hexane-based winterization to remove the majority of the trisaturated glyceride component and employ a “polishing” step prior to deodorization to remove the small amounts of trisaturated glycerides contributing to the haze formation in the lipid. The polishing step employs acetone and/or an analogous solvent. This option removes the problems caused by haze, but the lipid level is also reduced.
Preferably, the lipid composition initially comprises at least one LCPUFA and at least one trisaturated glyceride. Preferably, the other or undesired compound results in the formation of haze when present in the initial concentration in the initial lipid composition. Preferably, the LCPUFA-containing biomaterial for lipid extraction is selected from the group including: LCPUFA-containing microbial biomass or oilseeds from plants that have been genetically modified to produce LCPUFA containing lipids, particularly plants that have been modified with the LCPUFA-producing genes from microbes (algae, fungi, protists, or bacteria). More preferably, the LCPUFA-containing biomaterial for lipid extraction is selected from the group including thraustochytrid biomass, dinoflagellate biomass and/or Mortierella biomass, and/or oilseeds from genetically modified plants containing genes from thraustochytrids, dinoflagellate and/or Mortierella . More preferably, the LCPUFA-containing biomaterial for lipid extraction is selected from the group including Schizochytrium, Thraustochytrium and/or Crypthecodinium (preferably, Crypthecodinium cohnii ) biomass or oilseeds from genetically modified plants containing genes from Schizochytrium or Thraustochytrium and/or Crypthecodinium (preferably, Crypthecodinium cohnii ).
Preferably, the initial lipid composition is predominantly made up of neutral lipids. Preferably, the initial lipid composition comprises at least 50% neutral lipids, preferably, at least 60% neutral lipids, preferably, at least 75% neutral lipids, preferably at least 85% neutral lipids and preferably at least 90% neutral lipids. Preferably, the neutral lipid predominantly comprises triglyceride. Preferably, the initial lipid composition comprises at least 50% triglyceride, preferably, at least 60% triglyceride, preferably, at least 75% triglyceride and preferably at least 85% triglyceride. The foregoing percentages in this paragraph refer to weight percentages. Preferably, the concentration of the desired LCPUFA is greater in the resulting product than in the initial lipid composition.
Preferred polar solvent:lipid ratios, based on weight, for the extraction or winterization process are from about 1:10 to about 20:1; more preferably from about 1:8 to about 10:1, preferably from about 1:5 to about 5:1, and preferably from about 1:2 to about 2.5:1. Preferably the contact time between the polar solvent and lipid is from about 0.5 to about 12 hours, preferably from about 2 to about 6 hours, and preferably about 4 hours. Preferably, if a nonpolar lipid is used, the residual nonpolar lipid is from about 0 to about 4 weight percent, and preferably from about 1 to about 4 weight percent.
Preferably the temperature for the: (i) cold extraction process, (ii) extraction followed by chilling and filtration/centrifugation, (iii) extraction, filtration/centrifugation of cellular debris, followed by chilling and filtration/centrifugation; and (iv) chilling conditions for solvent winterization or polishing steps is from the solidification point of the lipid to the melting point of the undesirable component (e.g. trisaturated glycerides), more preferably from about −20° C. to about 50° C., more preferably from about −5° C. to about 20° C., more preferably from about −5° C. to about 5° C., more preferably about 0° C.
Other preferred attributes of the process include the selective recovery of only LCPUFA-containing triglycerides at the expense of trisaturated glycerides and other components that are relatively insoluble in cold acetone including phosphatides, wax esters, saturated fatty acid containing sterol esters, sterols, squalene, hydrocarbons and the like. By selectively recovering only the LCPUFA-containing triglyceride at the expense of these undesirable components allow the possibility of eliminating or reducing additional downstream purification steps (such as winterization, refining, and bleaching).
Example 1
Summary
A sample of DHA-rich lipid obtained from Schizochytrium (Sample 1, unwinterized lipid, a.k.a. “high melt”) and an isolated sediment from another DHA-rich lipid obtained from Schizochytrium (Sample 2) were analyzed to determine the nature of the solid phase (Sample 1) and the floc/sediment (Sample 2).
Unwinterized lipid Sample 1 produced at plant scale (a semi-solid at ambient temperature) was dissolved in 4 volumes of cold acetone and mixed. A solid white powder (approximately 7% by weight) was isolated by filtration through a glass fiber filter. The solid white powder had a melting temperature of 52.4-53.5° C., was shown to be triglycerides (based on a single spot by thin layer chromatography (TLC)), and contained predominantly myristic (26%) and palmitic acids (66%) when analyzed by GLC. This high melting triglyceride fraction contains saturated fatty acids with very little DHA/DPA. The isolated lipid fraction (91% by weight) was an orange-colored liquid at room temperature and contained 41.0% DHA and 16.0% DPA. DHA and DPA were enriched by approximately 8% compared to the starting fatty acid profile of Sample 1—this is a true “purification” of DHA and DPA.
Another DHA-rich reprocessed lipid from Schizochytrium contained an obvious floc-like material (haze) when stored for a period of days at ambient temperature. The floc was isolated by centrifugation. The floc/sediment (“Sample 2 sediment”) was dissolved in 10 volumes of cold acetone, mixed and filtered. Approximately 15% by weight of a solid white powder was isolated by filtration through a glass fiber filter. The solid white powder had a melting temperature of 50.1-51.4° C. and was shown to be triglycerides (based on single spot by TLC) containing predominantly myristic (29%) and palmitic acids (59%). This is a high melting triglyceride fraction containing saturated fatty acids with little DHA/DPA. The isolated lipid fraction (85% by weight) was a clear, orange-colored liquid at room temperature and contained 41.1% DHA and 16.3% DPA. The floc formation in reprocessed lipid from Schizochytrium is believed to result from a high melting triglyceride, containing myristic and palmitic fatty acids, which crystallizes from lipid upon standing.
Experimental
General—A sample of DHA-rich lipid from Sample 1 (250 g bottle) was pulled from frozen storage. This is a sample of unwinterized lipid. The sample was allowed to warm to ambient temperature and used as is.
Sediment (Sample 2) was isolated from DHA-rich lipid using a lab centrifuge. The DHA-rich lipid was a reprocessed lot of lipid that contained a visible floc when left to stand at ambient temperature. The floc was isolated by centrifuging the sample and decanting the liquid fraction from the sediment. The liquid fraction remained clear at ambient temperature; therefore the floc was believed to be present in the isolated sediment.
Acetone Winterization—Unwinterized lipid (Sample 1) and sediment isolated from reprocessed lipid (Sample 2) were fractionated using an acetone winterization procedure. The sediment and unwinterized sample were dissolved in excess cold acetone (ice/water bath temperature) and mixed to dissolve and suspend lipid components. The solution/suspension was immediately filtered through a glass fiber filter under vacuum. The filter paper and the contents remaining on the paper were washed with small amounts of cold acetone. The contents of the filter paper were air dried and weighed. The lipid/acetone fraction was concentrated under vacuum to afford neat lipid and weighed.
TLC—TLC was performed to determine lipid class composition using silica gel 60 plates. The developing solvent system consisted of a 90:10:1 mixture of petroleum ether: ethyl ether: acetic acid. The R f of the spots were compared to those listed in “Techniques in Lipidology” by Morris Kates.
Melting point determination—Melting points were determined using a lab constructed melting point apparatus.
Infrared spectrometry—Infrared spectra were obtained using a Perkin Elmer 283B Infrared Spectrometer. Liquid fractions were analyzed neat. Solid fractions from acetone winterization were analyzed in chloroform.
Fatty Acid Methyl Esters (FAMEs)—Aliquots of DHA-rich lipid Sample 1, Sample 2 (reprocessed) along with acetone winterization fractions were transesterified using anhydrous HCl in methanol following procedures for determining the free fatty acid profile, from C12 to C22:6. All FAME preparation and GLC work were completed. FAME's were identified and quantified using NuChek Prep analytical reference standard 502 using an internal standard (C19:0) to determine empirical response factors.
Gas-liquid chromatography—Gas-liquid chromatography of methyl esters was performed using a Hewlett-Packard Model 6890 Series II gas-liquid chromatograph equipped with a Hewlett-Packard autosampler, ChemStation software, a 30 m×0.32 mm SP-2380 capillary column (Supelco), and a flame-ionization detector. The oven temperature was held at 120° C. for 3 min, programmed to 190° C. at 5° C./min, held at 190° C. for 1 min, programmed to 260° C. at 20° C./min, and then held for 3 minutes at 260° C. The injector temperature was set at 295° C. and the detector temperature was set at 280° C. Helium was used as a carrier gas and a split injection technique was employed.
Results
DHA-Rich Lipid Sample 1
A sample of unwinterized DHA-rich lipid (250 g bottle) was pulled from frozen storage, Sample 1. This sample remained semi-solid at ambient temperature and can be technically referred to as a “fat”, not an “oil”. An aliquot (14.44 g) of the fat was transferred to an Erlenmeyer flask and 60 ml of cold acetone (ice/water bath) was added. The flask was swirled to dissolve/suspend the fat components and immediately filtered through a glass fiber filter under vacuum. A solid white fraction remained on the filter paper and was washed with a few milliliters of cold acetone and dried. The solid white fraction was isolated in a 6.3% yield (0.91 g starting from 14.44 g fat).
The lipid/acetone fraction resulting from filtration was concentrated by rotary evaporation to afford 13.13 g of an orange-colored liquid material (liquid at ambient temperature). This resulted in a 91% overall recovery; therefore approximately 2% of material was lost at bench scale.
The solid white fraction and the lipid fraction isolated after “acetone winterization” were analyzed by TLC to determine lipid composition. The solid white fraction was shown to be triglycerides based on TLC (one spot with an R f corresponding to a triglyceride was observed). Many spots were observed by TLC upon spotting and developing the lipid fraction. The R f of the spots was consistent with lipid components comprising squalene, steryl esters, triglycerides, and sterols (all tentative assignments). No further analysis of lipid class composition was performed.
The solid white fraction isolated after acetone winterization had a melting point range of 52.4-53.5° C.
The solid and liquid fraction isolated after acetone winterization were transesterified to methyl esters and the methyl esters were analyzed by gas-liquid chromatography. The complete profile of FAME's for both the solid and liquid fraction isolated by acetone winterization along with unwinterized DHA-rich fat (Sample 1) is shown in Table 1. As is evident, the solid fraction contained very little DHA (2.4%) and DPA (0.9%) with methyl myristate (26%) and methyl palmitate (66%) as the predominant fatty acids. The liquid fraction isolated after acetone winterization contained myristate (8.3%), palmitate (23.1%), DPA (16.0%), DHA (41.0%) along with other minor fatty acids. When this profile is compared to that of the starting unwinterized lipid, an enrichment of the DHA of approximately 8% is seen, consistent with the removal of the predominantly trisaturated glyceride component. This represents a purification step.
DHA-Rich Lipid Sediment (Sample 2)
The sediment that was produced from re-refined lipid was completely miscible in hexane and not miscible in methanol. When small quantities of acetone were added to the sediment, a white precipitate formed which separated from the liquid, yellow-colored lipid/acetone phase. Based on these dissolution tests, acetone fractionation was used to isolate the white powder.
An aliquot (1.11 g) of sediment was transferred to an Erlenmeyer flask and 10 ml of cold acetone (ice/water bath) was added. The flask was swirled to dissolve/suspend the fat components and immediately filtered through a glass fiber filter under vacuum. A solid white fraction remained on the filter paper and was washed with a few milliliters of cold acetone and dried. The solid white fraction was isolated in a 15% yield (0.17 g starting from 1.11 g sediment).
The lipid/acetone fraction resulting from filtration was concentrated by rotary evaporation to afford 0.94 g of an orange-colored liquid material (liquid at ambient temperature). This resulted in an 85% overall recovery.
The solid white fraction and the lipid fraction isolated after acetone fractionation were analyzed by TLC to determine lipid composition. The solid white fraction was shown to be triglycerides based on TLC (one spot with an R f corresponding to a triglyceride was observed). Many spots were observed by TLC upon spotting and developing the lipid fraction. The R f of the spots was consistent with lipid components comprising squalene, steryl esters, triglycerides, and sterols (all tentative assignments). No further analysis of lipid class composition was performed.
The solid white fraction isolated after acetone winterization had a melting point range of 50.1-51.4° C.
The solid and liquid fraction isolated after acetone winterization were transesterified to methyl esters and the methyl esters were analyzed by gas-liquid chromatography. The complete profile of FAME's for both the solid and liquid fraction isolated by acetone winterization along with Sample 2 sediment is shown in Table 1. As is evident, the solid fraction contains very little DHA (6.4%) and DPA (2.6%) with methyl myristate (29%) and methyl palmitate (59%) as the predominant fatty acids. The liquid fraction isolated after acetone winterization contains myristate (8.4%), palmitate (23.2%), DPA (16.3%), DHA (41.1%) along with other minor fatty acids.
TABLE 1
Fatty acid profile of unwinterized oil (Sample 1), Sample 2 sediment and fractions
isolated from Sample 1 and Sample 2 sediment by acetone fractionation
Isolated
Isolated
Isolated
Solid
Liquid
Isolated
Liquid
Fraction
Fraction Lot
Unwinterized
Solid
Fraction
Sample 2
Sample 2
21A
FA Name
Sample 1
Fraction
Sample 1
Sediment
Sediment
Sediment
14:0
9.6
25.9
8.3
12.2
27.0
8.4
16:0
25.9
66.0
23.1
30.5
58.8
23.2
16:1
0.3
<0.1
0.3
0.3
0.2
0.3
18:0
0.7
1.8
0.6
0.7
1.5
0.6
18:4 n3
0.4
<0.1
0.4
0.3
<0.1
0.4
20:3 n6
0.4
0.2
0.4
0.3
0.2
0.5
20:4 n7
2.8
<0.1
2.6
1.8
<0.1
2.4
20:4 n6
0.9
<0.1
1.0
0.8
0.1
1.0
20:4 n3
0.8
<0.1
0.9
0.8
<0.1
0.9
20:5 n3
2.2
<0.1
2.3
1.9
0.3
2.3
22:4 n9
0.2
<0.1
0.1
0.2
<0.1
0.2
22:5 n6
14.7
0.9
16.0
13.6
2.6
16.3
22:6 n3
37.7
2.4
41.0
34.2
6.4
41.1
Comparative Example
Table 2, set forth below, represents a comparative prior method as shown in Comparative FIG. 1 followed by Comparative FIG. 2 .
TABLE 2
Certificate of Analysis
( Schizochytrium Biomass)
Refined, Deodorized, Bleached (RDB) Winterized
Schizochytrium oil after antioxidants addition
Specification
Result
Method Reference
Peroxide Value,
Maximum 3.0
0.42
AOCS Cd 8-53
meq/kg
Free Fatty Acids, %
Maximum 0.25
0.06
AOCS Ca 5a-40
Moisture and
Maximum 0.05
0.03
AOCS Ca 2d-25
volatiles, %
Trace Metals, ppm
POS AS.SOP-103
Lead
Maximum 0.20
<0.20
Arsenic
Maximum 0.20
<0.20
Iron
Maximum 0.20
0.04
Copper
Maximum 0.05
<0.05
Mercury
Maximum 0.20
<0.20
DHA, % of FAME,
Minimum 32.0
43.5
POS AS.SOP-104
wt/wt
DHA, mg/g of oil
Minimum 300
397.3
POS AS.SOP-104
Residual Hexane,
Maximum 10
<1.0
AOCS Ca 3b-87
ppm
Specification
Value
Method Reference
Neutral oil, %
N/A
99.69
p-Anisidine Value
N/A
0.74
AOCS Cd 18-90
Colour, 1.0″ Lovibond
N/A
70.0Y
AutoTintometer
(PFX 990 AOCS)
7.1R
Colour
Colour, Gardner Scale,
N/A
12.3
(1 cm)
β- Carotene (PFX990),
N/A
276.41
ppm, (0.01 cm)
Note: not true β-
Carotene
Unsaponifiables, %
N/A
2.24
AOCS Ca 6b-53
Insoluble Impurities, %
N/A
0.01
AOCS Ca 3-46
AOM, hr
N/A
7.66
AOCS Cd 12-57
Rancimat (80° C.), Hr
N/A
22.7
Spin test, % solids by
N/A
~0.2*
volume, 20° C./24 hrs
after antiox addition
Spin test, % solids by
N/A
zero
Vol, before antiox
addition
Fatty Acid Composition
N/A
POS AS.SOP-104
(absolute), mg/g
C12
2.6
C14
69.4
C14:1
0.8
C15
3.1
C16
187.8
C16:1
4.4
C18
4.6
C18:1
7.2
C18:2
3.6
C18:3n6
2.3
C18:4
3.0
C20
1.2
C20:4n6
7.4
C20:4n3 AA
8.5
C20:5n3 EPA
18.2
C22
0.6
C22:5n6† DPA
151.6
C22:6n3 DHA
397.3
C24
1.8
C24:1
1.9
Others
35.1
Total, mg/g
912.4
DHA, % of FAME
43.5
Ascorbyl palmitate, ppm
224
Tocopherols, ppm
1,760
*ppte from Addition of Rosemary extract.
Table 3, set forth below, represents a process of the present invention, as set forth in FIG. 5 followed by the bleaching, deodorizing and refining of Comparative FIG. 2 .
TABLE 3
Acetone Winterized Schizo oil
RDB Schizo oil after antioxidants addition
(From Schizochytrium biomass)
Specification
Result
Method Reference
Peroxide Value,
Maximum 3.0
1.32
AOCS Cd 8-53
meq/kg
Free Fatty Acids, %
Maximum 0.25
0.06
AOCS Ca 5a-40
Moisture and
Maximum 0.05
0.03
AOCS Ca 2d-25
volatiles, %
Trace Metals, ppm
POS AS.SOP-103
Lead
Maximum 0.20
<0.20
Arsenic
Maximum 0.20
<0.20
Iron
Maximum 0.20
0.11
Copper
Maximum 0.05
<0.05
Mercury
Maximum 0.20
<0.20
DHA, % of FAME
Minimum 32.0
42.8
POS AS.SOP-104
DHA, mg/g of oil
Minimum 300
385.5
POS AS.SOP-104
Residual Hexane,
Maximum 10
<1.0
AOCS Ca 3b-87
ppm
Specification
Value
Method Reference
Neutral oil, %
N/A
99.69
p-Anisidine Value
N/A
1.08
AOCS Cd 18-90
Colour, 1.0″ Lovibond
N/A
70.0Y
AutoTintometer
(PFX 990 AOCS)
6.3R
Colour
Colour, Gardner Scale,
N/A
12.0
(1 cm)
β- Carotene (PFX990),
N/A
228.0
ppm, (0.01 cm)
Note: not true β-
Carotene
Unsaponifiables, %
N/A
2.11
AOCS Ca 6b-53
Insoluble Impurities, %
N/A
0.01
AOCS Ca 3-46
AOM, hr
N/A
7.00
AOCS Cd 12-57
Rancimat (80° C.), Hr
N/A
19.9
Spin test, % solids by
N/A
≈0.2
volume, 20° C./24 hrs
Fatty Acid Composition
N/A
POS AS.SOP-104
(absolute), mg/g
C12
3.9
C14
90.1
C14:1
0.8
C15
3.4
C16
193.9
C16:1
6.5
C18
4.8
C18:1
8.1
C18:2
3.6
C18:3n6
1.7
C18:4
2.6
C20
1.5
C20:4n6
4.9
C20:4n3 AA
7.7
C20:5n3 EPA
12.5
C22
0.8
C22:5n6† DPA
129.7
C22:6n3 DHA
385.5
C24
1.9
C24:1
1.6
Others
34.5
Total, mg/g
900.0
DHA, % of FAME
42.8
Ascorbyl palmitate, ppm
222
Tocopherols, ppm
1940
Example 3
A crude extract of Schizochytrium oil was subjected to a variety of winterization procedures in which a lipid composition was extracted from biomass with hexane. The hexane was removed to produce a crude extracted oil having a residual amount of hexane. The extracted oil was then extracted with acetone at a particular acetone/oil ratio and winterized at a particular temperature for a given amount of time. The % residual hexane, acetone/oil ratio, winterization temperature and winterization time were varied in different experiments. The processes were evaluated in terms of filtration time, oil recovery and haziness after two weeks. The details of the experiments and the results are shown below in Table 4.
TABLE 4
The levels of tested variables and observations of acetone-winterized Schizochytrium oil
Winter-
Winter-
Oil
Haziness
Experiment
Hexane
Acetone/
ization
ization
Filtration
Recovery
After 2
No.
%
Oil Ratio
Temp. (C.)
Time (H)
@ (sec)
(%)
weeks
1
1
1.5
5
3
67
87.8
Clear
2
2
1
0
2
165
86.4
PPT
3
2
1
0
4
195
87.7
Clear
4
2
1
10
2
178
88.1
PPT
5
2
1
10
4
154
89.8
PPT
6
2
2
0
2
85
84.1
PPT
7
2
2
0
4
75
86.2
Clear
8
2
2
10
2
67
88.9
PPT
9
2
2
10
4
82
86.7
PPT
10
3
0.5
5
3
264
84.3
PPT
11
3
1.5
−5
3
102
83.4
Clear
12
3
1.5
5
1
87
85.5
PPT
13
3
1.5
5
3
109
85.4
Clear
14
3
1.5
5
3
123
86.3
Clear
15
3
1.5
5
3
82
87.5
Clear
16
3
1.5
5
3
110
87.9
Clear
17
3
1.5
5
5
117
86.6
PPT
18
3
1.5
15
3
255
94.8
PPT
19
3
2.5
5
3
73
87.2
PPT
20
4
1
0
2
262
87.5
Clear
21
4
1
0
4
115
91.2
PPT
22
4
1
10
2
245
83.7
PPT
23
4
1
10
4
375
86.7
PPT
24
4
2
0
2
52
88.4
PPT
25
4
2
0
4
80
89.3
PPT
26
4
2
10
2
92
86.8
PPT
27
4
2
10
4
83
88.7
PPT
28
5
1.5
5
3
86
87.1
PPT
Control
150
90.9
PPT*
Control: Hexane winterization (45:55, Oil:Hexane) at −3 C. for 5 h
PPT—Precipitate observed after spin-test
*The hexane winterized sample showed PPT after filtration (the same day), an indication of incomplete crystallization. The recovery obtained in the lab would not be duplicated in the plant as the thorough drying of the cake may not be achievable with the enclosed filters.
Typical recovery in plant is around 70-75%.
TABLE 5
The oil recovery, filtration time and analytical data
of crude oil, hexane and acetone-winterized oils.
Plant-
Lab-
Acetone-
Acetone-
Hexane
Hexane-
winterized oil
winterized oil
Observations/
winterized
winterized
(Verification
(Verification
analysis
Crude oil
oil
oil
trail-1)
trail-2)
Oil recovery (%)
70%
90.9
86.9
85.3
Filtration @ (Sec)
—
150
158
114
Color (1″ cell)
Too dark
—
70Y
Too dark
Too dark
(1 cm cell)
70Y 11.2R
12.3R
70Y 12R
70Y 11.1R
Phosphorus (ppm)
474.3
—
474.0
271.6
144.3
Free fatty acids
0.53
—
0.49
0.52
0.43
PV (meq/kg)
0.00
—
1.82
3.32
4.27
Anisidine value
4.11
—
4.37
3.73
3.66
Fatty acid comp. (mg/g)
C12:0
2.3
—
2.1
2.2
2.1
C14:0
67.2
—
57.8
58.5
58.9
C14:1
0.7
—
0.7
0.8
0.8
C15:0
3.3
—
3.1
3.1
3.2
C16:0
204.9
—
185.2
187.0
188.1
C16:1
3.3
—
3.5
3.6
3.5
C18:0
5.1
—
4.5
4.5
4.7
C18:1
3.9
—
4.0
4.0
4.0
C18:2
2.6
—
2.7
2.7
2.7
C18:3n6
2.3
—
2.5
2.5
2.6
C18:4
3.3
—
3.5
3.6
3.6
C20:0
1.2
—
1.0
1.0
1.0
C20:4n6
9.4
—
9.7
10.2
10.3
C20:4n3
8.0
—
8.3
8.5
8.6
C20:5n3
23.6
—
24.9
25.4
25.6
C22:0
0.6
—
0.6
0.5
0.6
C22:5n6
142.9
—
149.6
152.7
154.0
C22:6n3
351.1
369.0*
369.0
378.6
382.2
C24:0
1.9
—
1.6
1.6
1.6
C24:1
4.0
—
4.1
4.3
4.2
Others
35.2
—
37.5
37.9
38.4
Recovery of DHA
73%
95.6%
93.8%
92.8%
*The estimation of DHA recovery of Pilot Plant hexane -winterized oil is based on the past data of Schizo oil process
TABLE 6
The fatty acid composition of acetone-winterized wax.
Observations/
Acetone-winterized wax
Acetone-winterized wax
Analysis
(Verification trail-1)
(Verification trail-2)
Wax recovery (%)
13.1
14.7
Fatty acid comp.
(mg/g)
C12:0
2.8
2.6
C14:0
112.4
103.2
C14:1
0.4
0.4
C15:0
3.8
0.6
C16:0
303.4
282.6
C16:1
2.1
2.1
C18:0
8.6
8.7
C18:1
3.3
3.6
C18:2
1.3
1.7
C18:3n6
1.1
1.0
C18:4
1.5
1.4
C20:0
2.2
2.0
C20:4n6
4.9
4.6
C20:4n3
4.1
4.0
C20:5n3
11.9
11.9
C22:0
1.3
1.2
C22:5n6
76.8
75.7
C22:6n3
175.2
170.5
C24:0
3.8
3.5
C24:1
2.1
2.0
Others
16.6
18.1
CONCLUSIONS
Based on an analysis of the Sample 2 sediment, it is believed the floc is triglycerides containing predominantly myristic and palmitic acids. This is based on TLC, IR, and resulting FAME analysis by GLC. The triglycerides comprising the floc had a high melting temperature (50.1-51.4° C.).
The high melting temperature of the isolated white powder, coupled with the triglyceride lipid class composition of this fraction, indicates that the winterization step employed during standard processing is not quantitatively removing “high melting” fractions from the lipid. Therefore, an additional “polishing” step is recommended to achieve clarity in the finished goods product.
To estimate the solid contribution of unwinterized lipid in Sample 1, an acetone winterization procedure was employed. A solid white fraction isolated from Sample 1 in 6-7% yield was shown to be triglycerides containing predominantly myristic and palmitic acids (>94% of the fatty acids in this triglyceride component were saturated fats). Palmitic and myristic acid are present in roughly a 2:1 ratio and, coupled with the narrow range in melting temperature, suggest a defined structure to this triglyceride. Very little DPA and DHA were present in the solid triglyceride fraction. The isolated liquid fraction following acetone winterization contained 41.0% DHA (expressed as a percentage of total fatty acid methyl esters) compared to 37.7% DHA in the starting unwinterized lipid. This is an approximate 8% enrichment of DHA, consistent with the removal of 7% trisaturated fatty acid glycerides.
Very little loss of DHA was shown in the bench scale acetone winterization process, indicating near quantitative recovery of DHA can be obtained during winterization.
Solid or solvent assisted winterization (acetone winterization demonstrated herein, however other solvent alternatives exist) offer the following possibilities and can be considered as processing options.
(1) A true removal of high melting, solid material can be accomplished. (2) The solid material is mainly trisaturated fatty acid glyceride (>94% saturated fatty acids) with very little DHA (2.4%). (3) As an example calculation, starting from 1,000 kg's of DHA in crude lipid, an approximate loss of 2 kg's of DHA would be encountered during acetone winterization (1,000×0.07×0.024). This is approximately a 0.2% recovery loss of DHA on an absolute weight basis. (4) A clear liquid remains following winterization, with enrichment of DHA compared to the starting unwinterized lipid fatty acid profile. (5) Solvent assisted winterization can be used to achieve DHA purification. (6) Because of the high melting temperature of the trisaturated fatty acid glyceride component (>50° C.), traditional low temperature chilling conditions may not be required.
This application incorporates by reference U.S. Provisional Patent Application No. 60/341,180, filed on Dec. 12, 2001.
While various embodiments of the present invention have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. It is to be expressly understood, however, that such modifications and adaptations are within the scope of the present invention, as set forth in the following claims.
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A process for purifying a lipid composition having predominantly neutral lipid components having at least one long chain polyunsaturated fatty acid is disclosed. The process employs contacting the lipid composition with a polar solvent, such as acetone, wherein the solvent is selected such that contaminants are less soluble in the solvent than is the long chain polyunsaturated fatty acid. The process is typically conducted at cooler temperatures, including about 0° C. Upon precipitation of the contaminants from the lipid composition, a separation is conducted to remove the precipitated material from the lipid composition. The long chain polyunsaturated fatty acids can include ARA, DPA, EPA, and/or DHA. The process of the present invention effectively winterizes lipid compositions, thereby reducing the tendency of such compositions to become hazy.
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FIELD OF THE INVENTION
The present invention is concerned with improvements in or relating to traction devices as employed in orthodontic procedures, such devices each comprising a connection member of appropriate length having two attachment members fastened to its respective ends by which it is attached to respective anchor members provided by other orthodontic devices.
REVIEW OF THE PRIOR ART
Traction devices of various types are used in orthodontic procedures to produce desired tooth and jaw movements, and for that purpose must be attached at their ends between two spaced orthodontic devices constituting respective anchor members and providing respective anchor points, such as between any two of a bracket or a buccal tube attached to a tooth, a hook or an arch wire. In one such traction device known hitherto the connection member is a spring provided at its two ends with eyelets, or their equivalent, which cooperate with respective hooks on respective orthodontic devices attached to the arch wire or to the teeth. Owing to the wide variety of spring lengths and tensions that may be required it is not easy to provide a series of springs of fixed length and tension characteristics, and systems have therefore been developed with which the orthodontist is supplied with a length of the spring material and a number of separate eyelet members from which springs of custom length can be fabricated in the operatory as required.
Another type of traction appliance that is employed connected in the mouth between two spaced anchor points is intended to correct mandibular malformations, such as extreme overjet. Such an appliance may employ either a traction or a compression spring as the connection member, which may be regarded as an "active" member, or may employ what may be regarded as a "non-active" member, such as a telescoping tube and rod, which serves only to limit the amount of intermaxillary movement without applying any spring force between the jaw members. Both active and non-active devices require that the ends be readily but securely attached to their respective anchoring devices. An example of an "active" device is the "Jasper Jumper" appliance sold by Allener Orthodontic Appliances of Sturtevant, Wis., which uses compression springs, while an example of a "non-active" device is the "Herbst" telescoping appliance sold for example by CorMar Inc. of Salisbury, Md.
It is often found with a particular patient that the procedure is not progressing as fast as expected, based on past experience, and frequently this clearly is due to the fact that the patient is disconnecting the traction device for appreciable periods of time, on the grounds of discomfort and/or appearance. The patient will usually deny that this has been done and it is therefore desirable with such a patient to be able to provide attachment members that are relatively easy for the orthodontist to attach and detach in the operatory, but are difficult if not impossible for the patient to detach and attach at home.
DEFINITION OF THE INVENTION
It is an object of the invention to provide new orthodontic traction devices which permit their economical manufacture, and also their ready custom fabrication as required in the operatory.
It is another object to provide such new devices with attachment members which permit their ready attachment and detachment by the orthodontist in the operatory but inhibit detachment by the patient.
In accordance with the present invention there is provided an orthodontic traction device comprising a length of connection material having grooves formed in at least its exterior cylindrical surface and two end attachment members attached respectively at its two ends:
each attachment member comprising a body having at one end thereof an attachment means for its attachment to an orthodontic anchor member, and having at another end thereof a collar portion having a cylindrical body recess formed therein, the recess being of radial dimension sufficient to snugly receive therein the respective end of the connection member with the collar portion embracing the connection member end;
the attachment member being attached to the connection member either by an interposed adhesive material which has entered into the portions of said helical grooves of the connection member end within the recess, or being attached by material of the body radially compressed inwards into the portions of said helical grooves of the connection member end within the recess;
the attachment being such as to prevent withdrawal of the connection member end from the body recess under tension applied to or by the device.
The connection member may be a piece of hollow helical coiled spring having helical grooves in both its interior and exterior cylindrical surfaces between the butting coils of the spring;
wherein the attachment member body has a cylindrical annular body recess formed between the collar portion and a cylindrical inner body boss portion; and
wherein the radially inward compression has forced body material into the portions of the helical grooves in both the interior and exterior cylindrical surfaces of the connection member.
Preferably an end of the boss portion protrudes from the body, and the protruding end has a tapered nose facilitating its insertion into the interior of the hollow spring material. The boss portion may be slightly larger in external diameter than the interior diameter of the hollow spring material, so that insertion of the boss portion into the interior of the spring material causes radially outward expansion thereof and increases the frictional engagement between them.
Alternatively, the connection member may be a piece of wire rope having exterior helical grooves formed between the butting strands thereof.
The attachment member body may have a tongue shaped extension in which the attachment means is formed.
A traction device of the invention may be used in combination with a hook member to which an attachment member thereof is to be attached;
wherein the attachment means comprises an eyelet hole in the tongue extension;
wherein the thickness of the tongue shaped extension is greater than the height dimension of the hook member mouth; and
wherein the width of the endmost portion of the tongue which borders the eyelet hole is less than the height dimension of the hook member mouth, so that the attachment member can only be mounted on and dismounted from the hook member with the attachment member in the attitude required to present the tongue shaped extension border to the height dimension of the hook member mouth.
Alternatively a traction device of the invention may be used in combination with another orthodontic device having a headed pin with a smaller diameter shaft as an anchor member;
wherein the attachment means comprises an eyelet hole having a portion of enlarged diameter adjacent to the collar portion through which the head of the headed pin can pass, the eyelet hole having a portion of smaller diameter further from the collar portion through which the head cannot pass but in which the smaller diameter shaft of the headed pin can move longitudinally.
The attachment means may comprise a hook formed in the tongue shaped extension, and may be used in combination with another orthodontic device having a headed pin with a smaller diameter shaft as an anchor member, wherein the hook opening comprises a shaft-receiving slot, and wherein dismounting of the hook from the headed pin is prevented by engagement of the attachment member body with the body of the other device unless the hook is in a predetermined angulation relative to the last mentioned body. The shaft receiving slot may be elongated in the longitudinal direction to permit corresponding longitudinal movement of the hook on the shaft of the headed pin.
A device in accordance with the invention may be used in combination with another orthodontic device having a headed pin with a smaller diameter shaft as an anchor member, wherein an eyelet hole provided in the attachment member is elongated in the longitudinal direction to permit corresponding longitudinal movement of the attachment member on the shaft of the headed pin.
In another device of the invention the attachment member body may be provided adjacent one end with a lingually extending protrusion and a mesially-distally extending arch wire receiving passage is provided in the protrusion; the arch wire receiving passage may taper inwardly from both its ends to be of smaller occlusal-gingival dimension intermediate its ends.
In a further device of the invention the attachment member body may be spherical and the attachment means thereof may comprise a hemispherical surface of the body, and wherein an associated anchor member has a mesial-distal extending passage through which the connector member passes and a distal-opening hemispherical cup into which the spherical body enters to limit the relative mesial-distal movement of the connector and anchor members, while permitting angulation of the connector member relative to the anchor member. When the connector member is a piece of wire rope the part of the connector member not required to pass through the mesical-distal passage may be coated with a plastic material.
DESCRIPTION OF THE DRAWINGS
Particular preferred embodiments of the invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings, wherein:
FIG. 1 is a buccal elevation showing a traction spring of the invention as used in an intermaxillary procedure connected between an archwire hook on an upper archwire and a buccal tube attached to a tooth in the lower jaw;
FIG. 2 is a longitudinal cross section through one end of a traction spring assembly employing a helical wire spring prior to the crimping attachment of an eyelet attachment member to one spring end;
FIG. 3 is a plan view corresponding to FIG. 2 to show the configuration of a tongue shaped extension of the attachment;
FIG. 4 is a longitudinal cross section corresponding to FIG. 2 and showing the assembly end subsequent to the crimping attachment of the eyelet attachment member to the spring end;
FIG. 5 is a simplified graph illustrating the stress/strain characteristic typical of nickel/titanium superelastic spring materials especially suitable for the manufacture of orthodontic traction springs of the invention;
FIG. 6 is a side elevation view of the archwire hook anchor member of FIG. 1 in combination with an eyelet attachment member that is another embodiment of the invention, the combination permitting ready attachment and detachment of the eyelet to the hook by the orthodontist but not by a patient;
FIG. 7 is a cross section similar to FIG. 4 of a buccal tube and an eyelet attachment member similar to that of FIG. 6, showing the manner of employment of the attachment member in combination with a cooperating hook member on the buccal tube;
FIG. 8 is a part elevation, part cross-section, of a hooked attachment member of the invention illustrating its use in combination with a headed pin anchor member on a buccal tube;
FIG. 9 is an end elevation of the hooked attachment member and buccal tube of FIG. 8;
FIGS. 10 and 11 are views similar to FIG. 8 to show the two different angularities of the hooked attachment member relative to the buccal tube required to remove the attachment member from a headed pin anchor member on the buccal tube;
FIG. 12 illustrates another form of hooked attachment member of the invention;
FIGS. 13 and 14 are side and top elevations respectively illustrating another form of eyelet attachment member of the invention;
FIGS. 15 and 16 are two different buccal elevations similar to FIG. 1 showing a traction member of the invention employing a wire rope as the connection member;
FIG. 17 is a part elevation, part cross-section, illustrating a method of attachment of a wire rope connection member to a hooked attachment member;
FIG. 18 is also a part elevation, part cross-section, illustrating another method of attachment of a wire rope connection member to an eyelet attachment member;
FIGS. 19 and 20 are respectively a side elevation with part cross sectioned and a top elevation of another form of attachment member of the invention to permit a traction device to be connected to an arch wire;
FIG. 21 is a buccal view of a another form of intermaxillary device of the invention comprising a buccal tube anchor member in combination with a wire rope connection member terminating in a spherical attachment member;
FIG. 22 is a view from the distal of the buccal tube alone of FIG. 21;
FIG. 23 is a side elevation of an attachment member with an elongated slot as shown in FIG. 16 and prior to mounting it on a T-headed pin anchor.
FIG. 24 is a side elevation of an another attachment member with an elongated slot prior to mounting it on a headed pin anchor, showing also a pair of jaws of a tool for mounting the attachment member on the post by crimping it;
FIG. 25 is a side elevation similar to FIG. 24 showing the attachment member after its mounting on the post by the crimping; and
FIG. 26 is a section on the line 26--26 in FIG. 24.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a typical use of a helical wire traction spring of the invention in an intermaxillary procedure between upper and lower jaws. An orthodontic bracket 10, for example as disclosed in my prior U.S. Pat. No. 4,492,573, the disclosure of which is incorporated herein by this reference, is attached to each of the four upper teeth 12 that are shown, and to two of the four lower teeth 12 that are shown. The four upper tooth brackets are connected by an upper arch wire 14 on which is mounted an arch wire gripping hook 16. The two lower tooth brackets and two different buccal tubes 18 and 20, which will be described below, are connected by a lower arch wire 22. A connection member consisting of a piece 24 of the helical wire spring is connected between the hook 16 and a headed pin 26 on the buccal tube 18 as respective end anchor members. It is a characteristic of such a helical spring wound from wire that it is hollow and has in its cylindrical exterior and interior surfaces respective helical grooves 28 formed between the butting turns.
The traction devices can be pre-formed and supplied to the orthodonist in different lengths, or each made to the length required in the operatory by the orthodontist, cuts a piece of the spring material from a longer length thereof and attaches the required attachment members to its ends; in this embodiment these attachment members comprise a hook member 29 and an eyelet member 30 attached to respective ends. Referring now to FIGS. 2-4, an eyelet attachment member of the invention consists of a body having one end 32 of cylindrical shape while the other end has the shape of a thinner flattened tongue with a rounded end, the tongue having a cylindrical eyelet hole 34 formed therein. The cylindrical shape end 32 is provided with a coaxial cylindrical annular recess 36, so as to have a cylindrical annular collar portion 38 and a coaxial cylindrical boss portion 40, the dimensions of the recess and these portions being such that the recess 36 will snugly but easily receive the hollow spring end, the end embracing the boss portion and in turn being embraced by the collar portion. The boss end has a tapered conical nose that protrudes beyond the collar and facilitates its entry into the centre of the spring. Preferably the boss is a little larger in diameter than the spring recess so that the spring is expanded as it is pushed on to the boss.
The spring material is inherently a hard metal and the metal from which the attachment member is formed is much more ductile, to the extent that it can readily be compressed by squeezing radially inward to plastically deform it into the inner and outer grooves of the helical coil without deforming the coil spring, so that thereafter the eyelet is held securely on the end of the spring under the relatively small tension loads that are applied to it. A suitable material for the attachment member is for example 17-4 PH or 316 dead soft stainless steel. Owing to the small size of the member the force required for such plastic deformation is correspondingly small and if performed by the orthodonist can readily be applied using a pair of hand-operated pliers, preferably with the opposed jaws formed with cooperating semi-cylindrical recesses.
A series of shape-memory nickel/titanium metal alloys, sometimes called "superelastic" alloys, have been developed for use in the fabrication of orthodontic springs having the stress/strain characteristic illustrated by FIG. 5. Thus, the tension required to stretch the spring increases progressively from zero elongation, as with springs of more usual metals, but very rapidly the characteristic becomes relatively very flat, so that the tension remains correspondingly constant irrespective of the degree of elongation, until the extension approaches the elastic limit of the material, which can be as much as 500%. It is therefore possible to provide springs having the required low tension characteristic over a wide range of movement, as is encountered in intermaxillary procedures, with the added advantage that because of the large extra elastic elongation that is possible it becomes unlikely that the spring can become over-stressed and weaken or fail. These spring materials are sold by Ortho Tony Inc., of Japan and springs fabricated from these materials are sold in North America by G.A.C. International Inc.
Typically the springs are fabricated from wire of 0.190 mm (0.0075 in) or 0.228 mm (0.009 in) diameter to have an inner coil diameter of 0.711 mm (0.028 in) or 0.812 mm (0.032 in). In a preferred embodiment where the coil uses the 0.228 mm wire and is of 0.812 mm inner diameter the overall length of the eyelet attachment member is 2.616 mm (0.103 in) and the outer diameter of the cylindrical end 28 is 1.625 mm (0.064 in). The annular recess 34 is 0.686 mm (0.027 in) deep, with an internal diameter (external for the boss portion 38) of 0.787 mm (0.031 in) and an external diameter (internal for the collar portion 36) of 1.213 mm (0.052 in), so that the spring end can easily be pushed therein and will remain in place by friction until it can be crimped in place. The thickness of the tongue 30 is 0.508 mm (0.020 in) while in this embodiment the eyelet hole 32 is relatively large, of 1.016 mm (0.040 in) diameter, so that it fits freely over the hooks and can easily be placed and removed, either by the orthodontist or by the patient.
The dimensions of the attachment members can of course vary somewhat from those of the preferred embodiment, but it is the constant endeavour in this field to make all components as small as possible because of their location in the mouth and the desire to avoid as much as possible any physical contact between the appliances, gums, mouth lining, etc. The dimensions are also dictated very considerably by the dimensions of the spring material with which it is to be used. For example, the outer diameter of the boss portion 38 could be increased to about 0.85 to 0.95 mm (0.034 to 0.038 in), which will somewhat increase the friction between the spring and the boss as the spring is inserted. The external diameter of the attachment body should then be increased correspondingly to about 1.65 to 1.70 mm (0.066 to 0.068 in).
As described above, it is often found that the patient for various reasons disconnects the traction spring, and FIGS. 6 and 7 illustrate hook and eyelet combinations that inhibit this, while permitting the orthodontist to readily connect and disconnect the traction spring in the operatory. The eyelet embodiment illustrated in FIG. 6 is used in combination with the hook 16 which is held against endwise movement by stops 42, while as illustrated in FIG. 7 it used in combination with a buccal tube 44 mounted on arch wire 22 and having eyelet-receiving anchor member hook 46 and elastomer-receiving hook 48. The hook mouth or entrance 50 between the hook end and its body has a dimension D that is smaller than the thickness of the eyelet tongue, but which is larger than the longitudinal dimension d of the rear endmost portion of the tongue bordering the eyelet hole 34. It is not possible therefore to unhook the eyelet tongue from the hook by a simple linear extension and small rotation of the spring end, as with the previously described embodiment, and instead it can only be removed by first rotating the attachment member through a ninety degree angle from the position shown in FIG. 6 in solid lines to that shown in broken lines, when the member is in the required attitude and the dimension d of the border portion is appropriately aligned with the larger hook mouth dimension D, so that the border portion is able to pass through it. This will usually require the use of a gripping tool to hold the eyelet, which the average patient is unlikely to have available, and also involves stretching and bending the spring 24 to an extent which the average patient is unlikely to attempt, thinking that it will weaken or break it. Owing to the special characteristic of such spring materials this extreme bending and stretching is well within their capabilities without damage.
The eyelet attachment member 30 may be used at both ends of the spring connector member 24 or, as shown in FIG. 1 and illustrated to a larger scale in FIGS. 8-11, a hooked attachment member 29 may be used instead, the hook cooperating with the headed pin 26 on the buccal tube 18 in a manner described below to also inhibit its removal by the patient. It will be seen from FIG. 9 that the hook embraces the small diameter post or shaft of the pin and is rotatable thereon. The occlusal-gingival dimension of the part of the buccal tube body through which the arch wire 22 passes is about the same as that of the head of the pin 26, and it will be seen from FIG. 8 that it is not possible to remove the hook from the pin shaft while it is in the operative attitude of FIGS. 1 and 8, since the distal and occlusal movements required are prevented by the consequential physical engagement of the cylindrical body 32 with the end of the buccal tube. Thus, the hooked member can only be removed if it is either rotated to the attitude shown in FIG. 10, when it can be moved occlusally (arrow 52) with the attachment member body passing occlusally along the mesial end of the buccal tube, or alternatively is rotated to the attitude shown in FIG. 11, when it can be moved distally (arrow 54) with its body passing distally along the occlusal surface of the buccal tube. Both of these angulations are sufficiently extreme for it to be unlikely that they would be attempted by a patient, and also sufficient usually to require the use of a gripping tool for easy installation and removal.
A hooked attachment member 56 which is another embodiment of the invention is shown in FIG. 12, the hook being provided with a pin-receiving slot 58 that is elongated longitudinally of the member to provide for a small amount of mesial-distal movement of the member on the pin. As with the hook of the embodiment of FIGS. 8-11, because the entrance 50 to the hook slot is immediately adjacent to the member cylindrical body 32, it cannot be removed while in the operative attitude of FIG. 1, but only if rotated to either of the relatively extreme attitudes of FIGS. 10 or 11. The purpose of a hook that permits this longitudinal movement between the hook and its anchoring pin is explained below in connection with FIG. 16.
FIGS. 13 and 14 show another form of eyeletted attachment member 60 that can be used with the headed post 26 of the buccal tube 18, or with a similar headed post if provided on any of the other orthodontic devices, such as on a bracket. The tongue is flattened and the eyelet hole in the tongue is elongated longitudinally of the member so as to comprise an enlarged part 62 immediately adjacent the cylindrical body 32 that is of large enough diameter to allow the post head to pass freely through it; the hole also comprises a smaller diameter portion 64 further from the body 32 that will not allow the head to pass but freely embraces and is rotatable on the pin. The tension of the spring connector member urges the member mesially and holds the smaller diameter portion 64 in engagement with the pin post, so that it cannot be removed from the pin. This attachment can be removed relatively readily by the patient and therefore preferably is used only when this is permissible.
FIGS. 15 and 16 illustrate the structure and operation of two respective traction devices of the invention in which the connection member 24 between the eyelet attachment member 30 and the hooked attachment member 29 is an "inactive" member, as contrasted with the "active" helical spring member 24. A particular preferred material for this member is wire rope in that this multi-strand is strong and flexible and also, as with the helical spring, has a plurality of helical external grooves 28 into which an adhesive material can enter, or into which the material of the body 32 is forced by crimping, so as to facilitate the retention of the connection member in the attachment members. A suitable material is for example the stainless steel wire rope of about 0.813 mm (0.032 in) diameter sold by Winifred Berg of East Rockway, N.Y. Since the wire rope is solid throughout its cross section the recess 36 is cylindrical and not annular.
FIG. 16 also illustrates another attachment member 66 for attaching one end of the inactive connection member to a headed pin, this member permitting a predetermined amount of mesial-distal movement of the anchor member on the pin post, as compared to the equivalent hook and post structure 26,29 of FIG. 15. Thus, the member 66 has a mesial-distal longitudinally extending slot 68 of occlusal-gingival dimension large enough for it to slide freely on the pin post, but not large enough to allow the pin head to pass through, the member being mounted on the pin in a manner described below, so as to permit the attachment member to be connected to the post. The device of FIG. 15 does not allow the patient to extend the mandible because the connection member is inextensible once it has become taut, while the device of FIG. 16 permits the possibility of some functional protrusion, for example during eating.
FIG. 17 illustrates another method of attaching one end of the solid cross-section wire rope connector member to a hook attachment member 29, namely by means of a layer 69 of fusible metal, such as brazing metal, or of a high-strength inert adhesive, such as an epoxy resin.
FIG. 18 illustrates another method of attaching one end of a wire rope connecting member 24 to an attachment member, the method being illustrated in connection with an eyeletted member 60. The cylindrical body portion 32 is hollow with a bore 70 that tapers with an inside diameter that reduces away from the tongue further end 60 and toward the connection member 24. The end of the rope within the bore 70 is splayed radially outwards to increase the size of the helical grooves after the rope has been fed endwise through the bore in the direction of the arrow 72, and the larger recesses thus formed are filled with a fusible metal or with a resin, so that the rope end is thereafter retained securely in the bore.
FIGS. 19 and 20 illustrate another attachment member 74 for attachment to one end of a traction device of the invention and for attachment in turn to an arch wire, the member illustrated being intended for use with a wire rope connecting member 24, but also being usable with a helical spring. The body of the device is elongated in the mesial-distal direction and its end further from the cylindrical body 32 is provided with a labially-protruding cylindrical boss 76 through which passes an arch wire passage 78 for reception of the arch wire. The two ends of this passage are tapered inwards toward each other to meet at two generally opposed labial-lingual extending rounded edges defining a passage of dimensions such that the arch wire slides freely with a limited transverse play. Thus, the device is free to slide distally along the arch wire 22 if the mandible is further protruded, as during function, the extent of the movement permitted along the arch wire being determined by its contact with the brackets or buccal tubes also on the wire, or with strategically placed stops such as the stops 42 of FIG. 6 mounted on the wire.
The geometry of the inwardly tapered slot allows approximately 30 degrees of occluso-gingival rotation and also sufficient bucco-lingual rotation. The cylindrical boss is placed in position between the devices that are to act as its stops and the arch wire threaded through; the resultant traction device does not interfere with the desired additional protrusion of the mandible over a considerable range in view of the fact there is always a relatively long span of arch wire between, for example, the buccal tubes on the first and second molars by which the attachment member is confined. Without this freedom to protrude the mandible the wire rope connector member would need to bow and flex during functional movements with increased possibility of fatigue failure.
FIGS. 21 and 22 illustrate another traction device of the invention comprising an attachment member of new form that cooperates with a new anchor member comprising part of a buccal tube 80 through which the arch wire 22 passes. A wire rope connector member 24 is employed and the attachment member on one end is a spherical ball 82 into which the connector member protrudes to be fastened therein, as by the method illustrated by FIG. 18, the far end of the bore being closed with the adhesive material and the outer surface of the ball being rendered smooth and spherical. The connector member passes freely through a bore 84 in a labially protruding body portion 86 of the buccal tube, the distal end 88 of the bore being hemi-spherical to form a cup that receives and mates with the adjacent hemi-spherical surface of the spherical ball 82, which can therefore swivel freely therein. The mesial end 90 of the bore is tapered outwardly mesially to permit the desired occluso-gingival and bucco-lingual rotations. The centre portion of the length of the wire rope connection member is provided with a smooth plastic coating 92, where it may contact the gums and mouth lining, the uncovered portion immediately adjacent the ball being of sufficient length to permit the required distal travel of the ball away from the surface 88 during functional movements of the mandible. With a wire rope 24 of 0.812 mm (0.032 in) diameter the ball 82 will be about 1.372 mm (0.054 in) diameter.
FIG. 23 illustrates one manner of mounting the attachment member 66 of FIG. 16 on a headed pin anchor member 26 provided with a head 94 that together with its shaft is of T-shape in one plane that is also a transverse cross-section. The width of the head at right angles to that plane is just sufficient for the head to pass through the slot 68 when the longer dimension of the head is aligned with the longer dimension of the slot, but the head is retained if there is even a small misalignment between these longitudinal dimensions. As with other embodiments therefore the member can only be mounted on the pin and removed therefrom when they are in two predetermined orientations, in this case two orientations at 180 degrees to one another, both of which will require an extensive amount of rotation of the member relative to the pin and consequent deformation of the connector member from its normal shape.
FIGS. 24-26 illustrate another manner of mounting the attachment member 66 of FIG. 16 on the headed pin anchor member 26 when the slot 68 is again too small for the head of the pin to pass through. As shown in FIGS. 24 and 26 the attachment member is produced with the slot enlarged transversely to be of approximately oval shape with its width at the minor axis just enough to permit the head of the pin to pass through it. Thereafter, with the pin in place the orthodontist applies the beak surfaces 96 of a pair of jaws 98 to the opposite sides of the device and squeezes to crimp the member and move the two sides toward one another until the jaw stop surfaces 100 meet, when the sides of the slot will be parallel and able to retain the headed pin therein while also permitting the pin to slide freely along the length of the slot. Removal of the device will entail its destruction by cutting through one side of the member and bending the separated parts until the head passes through the resultant gap.
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New orthodontic traction devices that can be pre-assembled or custom assembled in the operatory using connector members consisting of cut lengths of metal spring material or wire rope material uses attachment members each of which has a recess into which the respective end of the spring or rope material is inserted. The attachment member is crimped radially inward to plastically deform the metal into the helical grooves in the connector member external surfaces and thus retain the end; alternatively the end can be secured by brazing or cementing. If spring material is used the attachment member has a central boss which protrudes into the spring. An eyelet attachment member is non-removable from an anchor hook, except by the orthodontist, by making the tongue with the eyelet hole too thick to pass through the hook mouth, while the tongue end-most border portion can pass through, so that the eyelet must be rotated to a required attitude before it can be placed on or removed from the hook. A hooked attachment member used with an enlarged-head anchor pin is non-removable by arranging that the attachment member body fouls the anchor body unless they are in required relative attitudes. Other forms of eyelet hole and hook and a ball and socket attachment system are also disclosed.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent application U.S. Ser. No. 60/373,393, filed Apr. 18, 2002, the entire content of which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made in part with Government support under SBIR Grant No. R43-HL68375-01 awarded by the PHS. The Government may have certain rights in the invention.
FIELD OF THE INVENTION
The present invention generally relates to a method for forming hollow fibers.
DESCRIPTION OF THE RELATED ART
Artificial gas exchange to and from biological fluids is widely performed in the clinical settings as well as in the laboratory for research purposes. In the clinical setting the use of blood oxygenators during extracorporeal life support (ECLS), is commonly used to replace or aid in the function of the lungs during heart surgery, or long-term cardiorespiratory support. Gas exchange is accomplished by creating a diffusion potential across a gas permeable membrane that drives a transfer of gas from a high partial pressure on one side, to a low partial pressure on the other side of the membrane, as provided by Fick's law of diffusion: m . g = K A t ( p g 1 - p g 2 )
where {dot over (m)} g is the rate of gas mass transfer across the membrane, K is a factor that is proportional to the solubility of the gas in the membrane and to the membrane diffusion coefficient, A is the membrane surface area, t is the membrane thickness and p g is the gas partial pressure on either side of the membrane. This equation suggests that for a given partial pressure difference across a membrane, more gas transfer is accomplished by increasing the membrane surface area, and by decreasing the membrane thickness.
Blood oxygenating devices that make use of gas transfer across a membrane come in a variety of styles. One design makes use of microporous membrane hollow fibers (MMHF). Microporous membrane hollow fibers are very small hollow tubes, with a typical outer diameter between 250 and 380 microns (μm) and a typical wall thickness of about 50 microns (μm). Multiple microporous membrane hollow fibers are typically wound into a fiber bundle, using a desired weaving pattern among the fibers. A typical fiber bundle constructed of microporous membrane hollow fibers is shown at 10 in FIG. 1 . The individual fibers 12 forming the bundle 10 are illustrated with a greatly exaggerated diameter and wall thickness.
Blood oxygenating devices utilizing microporous membrane hollow fibers have become common for use during short-term cardiorespiratory support for procedures, such as routine bypass operations. In such a device, the ends 14 and 16 of the bundle 10 are each firmly potted into a potting material, which interconnects and seals to the ends of the fibers 12 . A portion of the potting material is then sliced off so as to expose the hollow lumens 18 of each of the fibers 12 . The potting material serves to interconnect and seal the outer surfaces of each of the fibers so that they are manifolded together at both ends. The potted bundle is then positioned in the oxygenator housing such that gas may be introduced into the lumens 18 while blood is passed over the outer surfaces of the fibers. Then, as oxygen flows inside the hollow fibers and blood flows over the outside of the fibers, the blood picks up oxygen and releases carbon dioxide across the microporous membrane, by diffusion.
In the fiber bundle, the walls of each fiber act as gas exchange membrane. Therefore, it is possible to compress a large membrane surface area into a relatively compact volume. In addition, as the blood flows outside the fibers, an increased convective mixing is achieved since the fibers downstream are within the wake or “eddies” of those upstream. In this description, “membrane hollow fibers” refers to hollow fibers where the walls of the hollow fibers act as membranes, and are typically thin to facilitate the transfer of mass and energy across the walls.
Microporous membrane hollow fibers are notorious for suffering from fowling and plasma leakage when they are used for extended periods of time: The blood plasma eventually leaks through the pores, thus compromising gas exchange, or rendering it completely ineffective.
Manufacturers of microporous membrane hollow fibers are incessantly seeking solutions to the plasma leakage problem, such as developing smaller pore size membranes that presumably have lower incidence of plasma leakage. Yet, no reports have been published showing improvement. Mitsubishi Rayon (Tokyo, Japan) introduced a multi-layered composite hollow fiber membrane (MHF) that contains a polyurethane interlayer sandwiched between two microporous polyethylene supporting layers. However, polyurethane has poor gas transfer properties, and fowling can still occur on the microporous side exposed to blood. There have been a number of other attempts to add dense coatings over microporous hollow fibers, yet none are available commercially. Notwithstanding the commercial availability of coated microporous membrane hollow fibers, the gas transfer through microporous membranes coated with silicone is reduced compared to the microporous membrane alone; gas must diffuse through the solid membrane in addition to the microporous membrane. Therefore, the tradeoff is reduced gas transfer.
Yet another potential problem associated with microporous membrane hollow fibers oxygenators is that if the gas side pressure becomes higher than the blood side, air can be readily transmitted through the micropores into the blood. Gas embolization may have fatal consequences if the gas bubbles are pumped into the patient. This can occur if the ports designed to vent the gas to atmosphere become occluded or if water condensation accumulates inside the lumen of the fibers, thus plugging the exhaust of oxygen. Consequently, gas side pressure must always be below the blood pressure to prevent gas embolization.
Because of the plasma leakage problem with microporous membrane hollow fibers oxygenators, spiral coil silicone membrane lungs (Medtronic Perfusion Systems, Brooklyn Park, Minn.), also known as Kolobow oxygenators, are used in long term applications because they do not have a propensity for plasma leakage. However, these solid membrane oxygenators require almost twice the surface area to achieve the same gas exchange as microporous hollow fibers. This is not because the membranes are not microporous, but because of the lack of convective mixing achievable over relatively “flat” membranes, compared to the mixing achievable over a bundle of thousands of hollow fibers. It should be noted that the oxygenated blood boundary layer, and not the membrane itself presents the major obstacle to oxygen diffusion to the blood.
A possible solution to the leakage problem with microporous membrane hollow fibers is to instead form hollow fibers out of a material that is not microporous, such as silicone. Gas diffusion can still occur across a silicone membrane, without the risk of gas embolization and plasma leakage. However, manufacture of blood oxygenators using silicone hollow fibers has not been commercially realistic.
Small silicone fibers can be extruded by polymer extruders in sizes comparable to the microporous polypropylene fibers. However, with the prior art there are two major barriers to the development of practical gas exchange devices. First, extrusion of solid silicone fibers is much more difficult and slower than extruding microporous polypropylene hollow fibers. Polypropylene is a thermoplastic polymer, whereas silicone is a cross-linked thermoset polymer. This means that polypropylene can be heated up, melted, and drawn-down to small diameters by pulling the extrudate as it comes out of the die, similar to making micropipettes with molten glass tubes. This allows for a significant reduction of fiber diameter from a manageable size die. Moreover, the polymer can be cooled quickly by water quenching once the fiber has been appropriately sized. Additional proprietary stretching processes are applied to render the fiber microporous.
Silicone, on the other hand, starts out as clay-like material that is extruded cold through the die (still as a clay) and then is heated to cure or cross-link the polymer, with much more limited drawdown compared to thermoplastics. Moreover, the clay like material has very little strength and is not as forgiving as molten plastic. As a result, the extrudate must be cross-linked or vulcanized quickly in order to control the tiny fiber. Thus, silicone extrusion is significantly slower than that of polypropylene to allow for polymer cure and subsequent handling such as winding in spools and fiber bundles. Further complicating the extrusion of tiny silicone fibers is the significant static buildup as the fiber cures through the oven. The static electricity makes it difficult to handle and wind the silicone fibers, especially if multiple fibers are extruded simultaneously.
The difficulty and the time-consuming process necessary to produce tiny silicone fibers are reflected in the product pricing. The price in 2002 for extruding one meter of silicone fiber (350 μm OD, 250 μm ID) was 33 cents, or $333 per kilometer (Specialty Manufacturing, Midland, Mich.). This compares to the microporous polypropylene hollow fiber price of $16 per kilometer (Celgard X30 240, Hoechst Celanese, Charlotte, N.C.). Thus the cost of the silicone fibers alone required for a device with 2.5 m 2 of diffusion surface area could cost as much as $750.
Secondly, manufacturing oxygenators with silicone fibers is also significantly more difficult than with microporous membrane hollow fibers because silicone is elastic and flimsy. The winding of the fiber bundle becomes much more challenging and thus significantly slower. Moreover, potting the fiber bundle is not easy since the elastic silicone fibers tend to deform as the fiber bundle is subjected to large forces during centrifuging. Manufacturing of silicone fiber oxygenators is not impossible, but very difficult and therefore prohibitively expensive.
In view of the forgoing limitations and shortcomings of the prior art, as well as other disadvantages not specifically mentioned above, it should be apparent that there exists a need in the art for an improved gas permeable hollow fiber.
BRIEF SUMMARY OF THE INVENTION
The present invention overcomes many of the shortcomings of the prior art by providing a method for producing a membrane hollow fiber which is not susceptible to plasma leakage and gas embolization. According to the present invention, a thin-walled microtube is formed by providing a continuous elongated member having an outer surface. The elongated member is at least partially formed of a water soluble material. A coating material is then provided, with the coating material being a silicone compound. The silicone structure is curable so as to form a substantially non-porous silicone. The outer surface of the elongated member is coated with the coating material so as to form a substantially uniform and continuous layer on the outer surface of the elongated member. The layer of coating material is then cured, and the elongated member is dissolved and purged from the layer of coating material. This leaves a micro tube formed of silicone. According to a further aspect of the present invention, the microtube formed according to the present invention may be assembled into a bundle and potted into a potting material at its ends prior to dissolving and purging the elongated member contained therein. After the fiber bundle is formed and potted, the elongated members in each of the microtubes may be dissolved and purged.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an enlarged perspective view of a prior art microporous membrane hollow fiber bundle with the fibers oriented in a parallel fashion;
FIG. 2 a is a perspective view of a portion of a first fiber to be coated according to the present invention;
FIG. 2 b is a perspective view of the fiber of FIG. 2 a with a coating formed thereon;
FIG. 2 c is a perspective view of a portion of a microtube formed after the first fiber of FIG. 2 a is dissolved and purged from the coating of FIG. 2 b;
FIG. 3 a is a perspective view of a portion of a gas exchange device formed by potting the ends of coated fibers;
FIG. 3 b is a perspective of a portion of the gas exchange device of FIG. 3 a , with the first fibers dissolved and purged so as to leave a plurality of microtubes;
FIG. 4 is a cross-sectional view of one embodiment of a coating die for coating an elongated fiber according to the present invention;
FIG. 5 is a cross-sectional view of a second embodiment of a coating die for use with the present invention; and
FIG. 6 is a cross-sectional view of a third embodiment of a coating die for use with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 2 a - 2 c a method of constructing a silicone membrane hollow fiber embodying the principles of the present invention will be discussed.
It should be noted that alternate processes could be used to construct hollow fibers in different materials with different mass transfer properties, heat transfer properties, and any property desired in the membrane material, without departing from the principles of the present invention.
The first step in constructing a silicone membrane hollow fiber or microtube 30 involves the formation a first fiber or member first material, preferably a water-soluble polymer such as polyvinyl-alcohol (PVA). PVA is a non-toxic and environmentally safe polymer that is easily extruded much like polypropylene, and can be engineered to dissolve in water at any desired temperature. Other materials may also be used. It is preferred that they be water-soluble, such that they dissolved or partially dissolve when exposed to water. Preferably, hot water or steam is used for dissolving the materials. The materials may only partially dissolve, with parts of the material remaining solid or in a gel form. For purposes of the present invention, “water soluble” is defined as material that is sufficiently transformable from its solid state that it can be used in accordance with the present invention. In some embodiments, the material may have reinforcing fibers or non-soluble portions to adjust the physical characteristics of the first member 32 . Referring to FIG. 2 a , the PVA fiber 32 is preferably extruded hollow having an outside diameter of about 25 to 400 μm (microns). The hollow fiber or member 32 preferably has a wall thickness between 5 and 100 microns. Alternatively, the member 32 may be solid. It may also have cross-sections other than cicular. For example, it may have an oval or square cross-section. As shown, it is preferred that the member 32 be a continuous elongated member when the outer surface is not interrupted by any side branches or portions extending therefrom. In the embodiment wherein the outer surface is generally cylindrical, it may be said that the fiber has a central axis and all portions of the outer surface are equally distant from the central axis. The PVA fiber 32 can be manufactured by any well-known method including, but not limited to molding and extrusion.
Next, as illustrated in FIG. 2 b , the PVA fiber 32 is uniformly coated with a thin layer of about 5 to 100 μm of a second material, in this case silicone elastomer compound, to form a coated fiber 32 ′ having a coating 21 over the surface on the underlying fiber 32 . Once the PVA fiber is coated with silicone, depending on the silicone compound, the coated fiber 32 ′ may be heated to cure the silicone coating 21 over the PVA fiber 32 . Other coating materials may require different processing to render them as desired in the final membrane. In each case, the processing necessary to convert the silicone coating to a silicone compound is referred to as curing, herein. After curing, the cured silicone layer preferably has a thickness of between 5 and 100 microns, with 5 to 50 microns being more preferred. In one preferred embodiment, the coating material is a two-part platinum, heat cure silicone resin with an uncured viscosity below 60,000 Cp, with a cured durometer (shore A) greater than 15, preferably greater than 80. More than one coating material may be applied over fiber 32 to achieve a composite or multi-layered membrane, with or without curing in between coats. Also, multiple coatings of the same material may be applied, with or without curing in between coats. Preferably, the silicone used to form the microtubes is of the type known to those of skill in the art as a solid membrane. That is, it is substantially nonporous and nonmicroporous.
Once the coating 21 has cured, the water-soluble PVA fiber 32 is removed by exposing the PVA to water or steam thus dissolving or melting the PVA, which can then be purged leaving behind the desired silicone hollow fiber 30 as shown in FIG. 2 c . In one preferred embodiment, hot water is passed through the hollow first member 32 causing it to dissolve and be purged from the microtube 30 . In embodiments where the inner fiber or member is solid, the member or fiber may be dissolved by exposing the assembly to steam and/or hot water. For example, steam may be used to additionally soften and/or dissolve the inner member, with water subsequently being used to further the dissolve and to flush the member out of the silicone tube.
Because pure silicone hollow fibers 30 are flimsy and difficult to handle, even after fully cured, it is preferred to leave the PVA fiber support within the silicone coating as in 32 ′ until after the gas exchange device has been manufactured. The cured coated fiber 32 ′ can be handled and wound into bundles using the same techniques that are used with current polypropylene microporous hollow fibers since the PVA is semi rigid much like the polypropylene. The microtubes, with the inner fiber or member as a support, are preferably potted using a potting centrifuge and a silicone resin as a potting material.
Referring to FIGS. 3 a - 3 b , it is simple to dissolve and remove the PVA fiber 32 once the coated fibers 32 ′ are firmly potted with potting material 35 (such as within a gas exchange device). This can be accomplished by flowing water within the lumen 20 of the PVA fibers 32 thus dissolving the PVA fibers 32 from the inside out. Note that when the fibers are potted, access to the PVA fibers' lumen 20 is obtained through the potted ends 36 and 37 where all fibers are manifolded. Thus, warm or hot water can be infused through one potted end 36 and purged through the other 37 . As shown in FIG. 3 b , once the PVA fibers 32 are dissolved and purged, the remaining silicone membrane hollow fibers 30 will remain-potted such that gas can flow though the lumens 33 of the hollow fibers 30 , and blood can flow on the outside of the hollow fibers 30 , or vice versa.
The first material fiber 32 can be configured as a hollow fiber (as in the example above) or as a solid fiber with any cross-section desired. Note that the shape of the first material fiber will dictate the shape of the inner lumen of the resulting hollow fiber. The first material in the above description was PVA but can be any material that can be subsequently removed or altered chemically, thermally, electrically, or mechanically; or that can be rendered porous by any method to allow fluid flow (or vacuum) through the lumen of the resulting hollow fiber.
The second material or coating material 21 can be any material that can be processed in such a way that will allow for depositing a layer of the second material over the first material fiber 32 . The coating can be achieved by any suitable process such as, but not limited to extrusion and dipping. The second material may be selected such that the mass and heat transfer properties are suitable for the application where the resulting hollow fibers are used. For example, for a heat transfer application the coating material used may have a high heat-conducting coefficient. As one example, fluoropolymers may be used.
One method of continuously coating the first material fiber 32 with a coating 21 of the second material is illustrated in FIG. 4 . Referring to FIG. 4, the fiber 32 is coated using a coating die 40 (also called a centering crosshead die) of the kind commonly used for coating electric wire. The fiber 32 is threaded through the fiber guide 42 of the coating die 40 , and the second material is injected into the die as designated by arrow 43 and flows toward the coating head 44 as designated by arrow 43 ′ and coats the fiber 32 at 45 . The coated fiber 32 ′ is then pulled as designated by arrow 46 using commonly known extrusion takeoff equipment. The coated fiber may be heated, cooled, or processed as necessary at 47 between the coating die 40 and takeoff equipment to harden, cure, or render the coating material as needed.
Another method of continuously coating the first material fiber 32 with the second material coating 21 is illustrated in FIG. 5 . Referring to FIG. 5, the first material fiber 32 is coated using a tubing die 50 similar to the kind commonly used for extruding tubing. A fiber of the first material 32 is threaded through the needle 52 , and the coating material is injected into the tubing die 50 as designated by arrow 54 and flows toward the needle as designated by arrows 54 ′ where it is extruded as tubing at 56 , and then drawn-down onto, and coating the moving fiber 32 at 58 . Coated fiber 32 ′ is pulled as designated by arrow 60 using commonly known takeoff equipment. The coated fiber may be heated, cooled, or processed as necessary between the tubing die and takeoff equipment at 62 to harden, cure, or render the coating material as needed. Note that this method allows for draw down of the coating material as tubing before contacting fiber 32 , thus allowing for a tubing die with a larger cross section compared to the cross section of the resulting fiber 30 . Also, note that the fiber 32 need not fit tightly through the needle 52 to allow venting to the lumen of the extruded tubing, and to allow for small variations in fiber diameter 32 .
Both methods presented above allow for additional stretching and draw down of the coated fiber 32 ′ after it has been coated but before the coating material has hardened, cured or rendered as needed
Yet, another method of continuously coating the first material fiber 32 with a second material coating 21 is illustrated in FIG. 6 . This approach is well adapted to coating fiber 32 with low consistency liquid coating materials and is preferred for some embodiments of the present invention. Referring to FIG. 6, the first material fiber 32 is coated using a coating die 70 . A fiber of the first material 32 is threaded through the die inlet orifice 72 and the die nozzle hole 74 , and the coating material is continuously metered and injected into the die 70 as designated by arrow 76 . As the fiber 32 is pulled through the die 70 in the direction indicated by arrow 78 , the coating material 75 flows toward the nozzle 19 as indicated by arrows 80 as a result of viscous drag produced by the fiber 32 moving within the die 70 .
The die 70 may be vented to atmosphere through orifice 72 thus minimizing the pressure on coating material 75 , resulting in a substantially viscous driven flow (Couette flow) of coating material 75 through nozzle 74 . Note that the rate of injection of coating material must equal the rate that coating material is applied to the fiber 32 at nozzle 74 .
The coated fiber 32 ′ is then pulled as designated by arrow 82 using commonly known extrusion takeoff equipment. The coated fiber may be heated, cooled, or processed as necessary at 84 between the coating die 17 and takeoff equipment to harden, cure, or render the coating material as needed.
The annular Couette flow pattern in nozzle 74 allows for sizing the nozzle hole larger than the final coating outer diameter of fiber 32 ′. In one preferred embodiment, the coating die 70 is vented to atmosphere with a die hole diameter estimated using an analytical solution to the Navier Stokes equations of Newtonian flow driven by viscous forces through the annular space between the die hole and the moving fiber. In one exemplary embodiment, a coating thickness of 25 microns is formed on a first fiber or member with an outside diameter of 250 microns, and the die hole has a diameter of approximately 354 microns.
Note that positive gas pressure or vacuum may also be applied to the die 70 through orifice 72 to achieve a combination of Couette and Poiseuille flow at nozzle 74 thus allowing for different hole sizes at nozzle 74 that produce the same coating outside diameter of coated fiber 32 ′. Also note that coating material 75 may be dispersed or dissolved in an appropriate solvent, such that subsequent processing at 84 evaporates or flashes-off the solvent resulting in a coating of reduced outside diameter on coated fiber 32 relative to undissolved coating material. This is a useful feature when very thin coatings are desired.
The fiber 32 ′ may be stretched or drawn down prior to curing if desired to achieve smaller diameter coated fibers. Also, the multiple coatings may be applied sequentially before or after curing the previous coating.
While the above description constitutes the preferred embodiment of the present invention, it will be appreciated that the invention is susceptible to modification, variation, and change without departing from the principles of the present invention.
While the description above constitutes one embodiment of the present invention in the context of mass transfer across mass permeable membrane hollow fibers, it will be appreciated that the method of the present invention will find utility in numerous applications, including but not limited to energy transfer across membrane hollow fibers as well as any other context where hollow fibers are utilized.
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A thin walled microtube is formed by providing a continuous elongated member having an outer surface. The member is at least partially formed of a water soluble material. A coating material is provided. The coating material may be a silicone compound that is curable such that the coating material cures into a substantial non-porous silicone. The outer surface of the elongated member is coated with a coating material so as to form a substantially uniform and continuous layer of coating material on the outer surface. The layer of coating material is cured so as to form a substantial uniform and continuous layer of substantially non-porous silicone on the outer surface. The elongated member is at least partially dissolved using water and purged from the silicone layer, such that an elongated tube of substantially non-porous silicone is formed.
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FIELD OF THE INVENTION
The present invention relates to a method of removing a binder material from a preform in pre-sintering preparation of ceramics before sintering the shaped preform. Particularly it relates to a method of removing efficiently binder material from the preform body in the preparation step before sintering the shaped preform comprising refractory (heat resistant) particulate material and binder material.
The term "preform" herein is used to describe a shaped bod formed from particulate raw material such as ceramic raw material, for example, metal powder, metal oxide powder, refractory particulate material, such as nitrides, carbides, and the mixture thereof, by an appropriate forming techniques such as moulding, compressing, injection and extruding in a pre-sintering preparation for the production of ceramic material in the desired shape. The preform can be said to be the shaped "green" ceramic material and must be fired in a kiln or a furnace in the neighbourhood of any temperature which would ensure to develop sintering the grains of the desired ceramic material.
The preform must be formed by containing small amount of binder material(s) other than the particulate raw material, because the use of only raw powder can not form into a certain shape of the body and the addition of binder material(s) to the raw powder can impart some formability of the powder, that can be considered to be by imparting smoothness among the material particles and some rigidity to the formed body.
DESCRIPTION OF THE PRIOR ART
In the production of ceramics from refractory particulate materials, the particulate raw material must be formed into a preform of a given shape, for example, injection moulding or extrusion or press into the shaped preform, then the so prepared preform must be sintered to produce ceramics of the given shape. In those pre-sintering preparation procedures, generally, binder material(s) in an amount of order of 5 to 30 weight % is added to particulate raw materials so as to impart plasticity to the particulate materials and further to impart strength to the shaped preform.
When the preform is fired as it is, the binder contained in the preform will rapidly vaporize to somehow expand the preform and/or deform same. As a result, all fired products would be substandard. Therefore, binder materials must be removed (defat), before sintering a preform. There have been practiced various processes for the removal of the binder materials; for example, the process comprising increasing the temperature very slowly under the atmospheric pressure, the process comprising putting the preform in an atmosphere of reduced pressure with increasing the temperature very slowly, and the process comprising contacting with an inert gas passing by the preform together with increasing the temperature very slowly.
However, when the removal (defat) of the binder materials is carried out in short period of time, the preform is affected by expansion or gasification of the binder materials to generate deformation such as fracture, swelling, and bending. Therefore, an extremely long period of time (several days) is necessary in the conventional slow removal of the binder. This is significant particularly to the preform containing the binder in a greater amount, and further to the thick preform. Therefore, there are found many problems particularly in much long period for defat, less treatment quantity and higher energy cost.
SUMMARY OF THE INVENTION
The inventors have been investigating on research of efficient removal of binder materials from the formed preform to be used for the production of ceramics and at last developed a process of effectively removing the binder materials from the preform in a relatively short period and further found that the binder that has been removed can be re utilized or recycled by the inventive process.
It is an object of the present invention to provide a method capable of efficiently removing the binder materials from the preform in the pre sintering preparation for the production of ceramics of the given shape.
It is another object of the invention to provide a process of removing the binder material from the preform in a relatively shorter period of time in the pre sintering preparation.
It is a further object of the invention to provide a system of recycling the binder materials in the forming of the preform and the removal of the binder materials from the preform for the pre-sintering preparation procedure of the production for refractory ceramic material.
The foregoing and other objects of the present invention can be attained by the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of one embodiment of system for carrying out the present invention.
FIG. 2 shows a graph indicating the distribution of the residual binder material, and a view of the preform in partial section to indicate the measuring position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In accordance with the present invention, the novel process for removing binder materials from the preform to be used for the production of shaped ceramics is illustrated and applied to the method of the production of ceramics in the given shape and ceramics product produced thereby.
After intensive research of efficient process of making ceramic material from particulate raw material, the inventors developed the efficient removal of binder materials from the preform in the pre-sintering preparation for the production of ceramic material in the desired shape. The efficient process which the inventors have developed for removing binder material(s) from the preform in a pre-sintering preparation for the production of ceramics in a given shape comprises exposing the preform comprising refractory particulate material(s) and binder material(s) in a given shape, to fluid in the supercritical state thereby to dissolve binder materials in the supercritical fluid; discharging the fluid from a vessel under supercritical condition; and recovering binder materials from the fluid by reducing the pressure to the fluid or elevating the temperature of the fluid thereby to recycle the binder materials and fluid for further use thereof.
The basic concept of "supercritical fluid extraction" is described for example in `P. F. M. Paul, et al; "The Principles of Gas Extraction" M&B Monograph CE/5, Mills and Boon, London, 1971` and at `N. Gangoli, et al. Ind. Eng. Chem. Prod. Res. Dev., 16, (3) 208 (1977)`.
The supercritical fluid extraction utilizes the solvent power of the fluid under the supercritical condition, in the other words, the supercritical fluid extraction is a separation method utilizing the elevation of the vapor pressure of the substance in the presence of the supercritical fluid as well as the difference of chemical affinities.
The ability of the supercritical fluid to function as a solvent is greatly dependent on its density increase. The density of the fluid under the supercritical condition is much higher than that of the gaseous fluid under ambient temperature and atmospheric pressure and is competitive to that under the liquidized state. Such increase of the density will elevate the affinity with the solute so as to accelerate the solvent power of the fluid so that it functions as a separator so effectively.
When the pressure is extremely high, the solubility in the supercritical fluid of the substance to be extracted will highly increase with the increase to the temperature of the supercritical fluid. This effect is caused because the increase of the vapor pressure of the substance to be extracted is more significant than the decrease of the density of the supercritical fluid by the increase of the temperature. On the contrary, when the pressure is not so high, the solubility will decrease with the increase of the temperature. In this case, the density of the supercritical fluid is significantly decreasing, whereas the vapor pressure of the substance to be extracted is slightly increasing.
The substance being extracted is solute in the supercritical fluid under the supercritical condition. Such substance can be easily separated from the fluid, and easily recovered. The separation can be easily carried out by reducing the pressure at the constant temperature, or elevating the temperature at the constant pressure.
In accordance with the present invention, the fluid should have the critical temperature near the operation temperature, but the critical temperature may be lower than the operation temperature. Generally, because the extraction is carried out under the room temperature, the fluid should have the critical point above 0° C., and be gaseous at 0° C.
The binder materials should have two functions; one is to impart binding strength to the preform when the particulate material is compressed with binder materials into the preform, and the other is to impart the lubricity or lubricating action when the preform is being formed by injection moulding or extrusion or press.
The binder materials used commonly may be organic materials such as higher alcohols, higher fatty acid, higher hydrocarbons, polymer or resin.
The refractory particulate material used in the present invention may include metal powder, metal oxide powder, ceramic materials, such as nitrides, carbides, boronitrides, carbonitrides, and the mixture thereof.
The binder materials may include solid materials under ambient temperature, such as higher alcohols (for example octadecanol), fatty acids (for example stearic acid), wax, polyethylene and the like.
The fluid used in the present invention, whih can be kept in a supercritical state, may be a gas under ambient temperature and ambient pressure, the critical temperature of which is higher than 0° C. The fluid may be selected from the group consisting of CO 2 , and FREON® (chlorofluorocarbons) gas and the mixture thereof.
In reference to the drawings, the present invention will be further illustrated in the following description.
The inventive process comprises two major steps of (1) exposing a preform to the fluid in a supercritical state thereby to remove the binder materials from the preform, and (2) isolating binder materials from the fluid so as to recover binder material for further recycling.
The preform is put in the binder extracting vessel 1, and then the fluid (for example, CO 2 , and FREON® (chlorofluorocarbons),) compressed at the pressure higher than the critical pressure by a compressor, 3 is fed in the vessel 1. A temperature control means 2 maintains the temperature in the vessel 1 higher than the critical temperature. The preform is exposed to the fluid kept under the supercritical state in the vessel 1 (the supercritical fluid) so as to dissolve the binder materials from the preform into the supercritical fluid.
The supercritical fluid in which binder materials are dissolved is transferred through a pressure reducing apparatus 4 to a separator 5 having a temperature control means 6 where the density of the fluid will be reduced so as to loose a dissolving power and to isolate the binder materials from the fluid in a separator 5. The binder materials are continuously recovered from the line 8, and the recovered binder materials can be reutilized for forming a preform.
On the other hand, the fluid isolated in the vessel 5 is fed into the compressor 3 to enable recycling. The supplementary feed is provided through a line 7.
In accordance with the present invention, the fluid kept in the supercritical state exhibits an extracting power by increase of density of the fluid enabling to dissolve and remove the binder material. In this process, the binder material will not expand the preform body nor evaporate in the preform, which materials are dissolved into the supercritical fluid, resulting in substantially neither deformation nor defects in the preform.
In accordance with the present invention, the fluid for extraction of binder materials is present under the condition above the critical pressure and above the critical temperature, because it becomes so densified to dissolve the binder materials and remove them from the preform which is exposed to the fluid, when it is under the supercritical state.
However, the fluid should be at the temperature lower than the decomposition temperature of the binder, because it cannot be recovered nor recycled when it is at above the decomposition temperature. Further, the operation temperature should be lower than the composition temperature of the binder materials.
Since the supercritical fluid has a higher diffusion coefficient but a lower viscosity, it can penetrate quickly into the inside of the preform, and dissolve the binder materials into the fluid for extracting the materials.
In the conventional process for removal of the binder materials by burning the materials, the binder materials are gasified, and therefore, the phase change of solid to gas occurs to produce some expansion in the preform, that can easily generate some deformation or defects in the preform. On the other hand, any phase change or volumetric change will not be generated where the binder materials can be extracted and removed by the supercritical fluid from the preform without any defects found in the preform.
In accordance with the present invention, the binder materials are substantially uniformly removed along the entire surfaces from the entire body of the preform as shown in FIG. 2. The graph in FIG. 2 demonstrates that the uniform substantial extraction of the binder materials eliminates deformation in the preform.
The inventors have confirmed that in accordance with the present invention, CO 2 , and Freon-12 can extract the following groups of binder materials;
1. higher alcohol (such as octadecanol);
2. organic fatty acid (such as stearic acid);
3. wax (such as paraffin).
Therefore, the binder materials comprising as a major component the above mentioned binder materials can be surely removed by the claimed process. However, it is to be noted that the claimed process can be applied to the other binder materials. The inventors found that polymeric materials (resin) are difficult to extract, but the polymeric binder materials can be as a minor component contained in the shaped preform to the extent that they do not affect to the sintering step. In view of convenience of handling the preform in the subsequent steps, it is better to retain some of the binder materials in the preform, rather than completely removing of the binder materials.
In accordance with the present invention, the exposure of the preform to the supercritical fluid to remove binder materials can reduce drastically the necessary period of time for removing binder materials from the preform, and further, enables the recovery of the binder materials for recycling. Further, the fluid isolated can be recycled to the compressor 3. Therefore, as shown in FIG. 1, the system utilizing the inventive process can be considered to be an approximation to a closed circuit.
In view of the foregoing, the inventive process can reduce the cost of energy, and therefore, is more economical and saves materials and energy. It can be said that the inventors found an extremely efficient process for removal of binder materials from the preform.
The following examples illustrate the practice of the invention, but should not be interpreted as limiting the scope and application.
EXAMPLE 1
15 Weight parts of binder (octadecanol or stearic acid) was added to 100 weight parts of alumina (having grain size of 1 to 10 μm), and mixed. The mixture was pressed in a small size liquid pressure press to the pressure of 700 Kg/cm 2 , into a moulding of preform. The moulding of preform was exposed to CO 2 or FREON®12 (chlorofluorocarbon) (Dichlorodifluoromethane) in supercritical state so as to remove the binder materials.
The conditions and results thereof are shown in Table 1.
The critical point of CO 2 fluid is at the critical temperature of 31° C., and at the critical pressure of 72.8 atm. The critical point of Freon 12 is at 112° C., and 40.7 atm.
TABLE 1__________________________________________________________________________ Weight of Removal Pressre Green body Flow Rate of Binder ExposureNo. Binder Fluid Temp. °C. Kg/cm.sup.2 G g l/min % Period__________________________________________________________________________ Hrs.1 Octadecanol CO.sub.2 100 65 10.07 191 0.2 2.12 Octadecanol CO.sub.2 45 200 11.32 200 70.3 2.23 Octadecanol Freon ® (chlorofluorocarbon) 12 120 120 11.69 260 94.7 2.84 Stearic acid CO.sub.2 45 200 10.35 235 85.0 2.55 Stearic acid Freon ® (fluorocarbon) 12 120 120 10.06 64 99.0 0.7__________________________________________________________________________
In Table 1, No. 1 was not in the supercritical state and therefore, the media was in a gas state, so that the removal of the binder materials could be effected only by the vapor pressure of the binder material. The result shows that most of the binder material could not be removed from the preform. Embodiments of Nos. 2 to 5 are within the scope of the claimed invention. In those examples, the preforms were exposed to the fluids in a supercritical state, and therefore, the results indicate that the removal of binder materials was increased without any deformation of the preform.
There is shown that there was found somehow difference in the efficiency to remove the binder material and the periods for removal among examples of Nos. 2 to 5. Those results are not limitative, for when the flow rate of the fluids is increased, the removal of the binder material can be improved, and the period for removal can be decreased.
EXAMPLE 2
Various organic materials were added to alumina powder and mixed, and the mixtures of the particulate materials were injected into a preform in a given shape. The shaped preforms were exposed to CO 2 in a supercritical state to remove the binder materials from the preform. The results are shown in Table 2.
When injection moulding is used for forming of the preform in a given shape, a variety of binder materials are used often in combination thereof under consideration of fluidability, formability and demouldability characteristics, and further, more amounts of binder materials are frequently used, and therefore, the removal by pyrolysis needs longer period of time.
There was found that such injected preform could be treated in much shorter period such as about 30 minutes to 3 hours for removal of binder materials by exposing to the fluid in a supercritical state, and any deformation of the preform could not be found.
TABLE 2__________________________________________________________________________ Weight of Flow Removal Exposure Temp. Pressure Green body Rate of Binder PeriodNo. Preform Fluid °C. Kg/cm.sup.2 G g l/min % Hrs.__________________________________________________________________________6 Al.sub.2 O.sub.3 :100 CO.sub.2 60 200 9.14 40 91.0 0.5stearyl alcohol:187 Al.sub.2 O.sub.3 :100 CO.sub.2 85 200 10.11 210 71.4 2.2stearyl alcohol:158 Al.sub.2 O.sub.3 :100 CO.sub.2 70 200 9.60 300 78.0 3.0paraffin 155:12stearic acid:2DEP: 19 Al.sub.2 O.sub.3 :100 CO.sub.2 45 200 10.05 270 70.0 2.8stearic acid:2stearyl alcohol:8paraffin155:810 Al.sub.2 O.sub.3 :100 CO.sub.2 60 200 10.59 150 83.0 1.5stearic acid:2stearyl alcohol: 10seratic :6__________________________________________________________________________
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The invention relates to a method of removing binder materials from a shaped preform (green body) in the preparation procedure for the manufacture of ceramics from particulate materials. The new method comprises exposing the green body to a supercritical fluid to dissolve the binder materials in the supercritical fluid without deforming the shape of the article. In the method, the binder materials can be removed without swelling of the article because the green body is not exposed to a rapid temperature increase and the binder does not volatilize in the body. In addition, the binder material can be removed in a drastically shorter period of time from the entire body.
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FIELD OF THE DISCLOSURE
[0001] The present disclosure relates generally to an improved device for use in masonry applications. In particular, the present disclosure relates to an adjustable masonry arch form to support masonry elements in an arched construction.
BACKGROUND
[0002] In building projects, such as residential homes and commercial buildings, ornamental masonry elements are often placed over/around various structural features for aesthetic purposes. This is especially common around windows and doors. As used in this specification, masonry elements/masonry shall mean stone, brick, or other earthen materials used for construction purposes, generally using mortar as a bond. The presence of masonry accents in a residential home can greatly increase its resale value, and provides the homeowner with the desired aesthetic look and feel he/she is seeking.
[0003] The process of installing masonry elements over and/or around a desired structural feature varies depending on the shape of the desired structural feature. In some cases, the top of the structural feature will be horizontal (horizontal construction). In other cases, the top of desired structural feature will have an arched component (arched construction). By arched component it is meant any structural feature that has a change in elevation at any point intermediate between the ends of the structural feature. In the case of horizontal constructions, the standard practice is to lay the masonry elements across a supporting horizontal beam (commonly referred to as a lintel) set in place over the structural feature, for example a window. The lintel can be made from steel, wood, or reinforced concrete, depending on the size of opening and weight to be supported. The lintel commonly rests on the masonry that is installed up the sides of the window. The masonry elements are then installed on the horizontal face of the lintel in the configuration desired. The lintel remains a part of horizontal construction above the window or door.
[0004] In arched constructions, this practice cannot be employed. As stated above, the materials that lintels are constructed from (steel, wood, or reinforced concrete) cannot be easily adapted to fit the contours of an arched construction. Therefore, other methods must be used to support the masonry elements that form a masonry arch in an arched construction. Several methods are typically used to support the masonry elements that form a masonry arch. The first method is to build an arch form, which is commonly constructed from plywood and dimensional lumber. The arch form must be constructed to exactly fit the contours of the masonry arch to be constructed, and is supported in place with wooden legs. The arch provides the surface to support the masonry elements forming the masonry arch while the mortar hardens. Once the mortar hardens, the arch form is removed and discarded. In addition, the mortar must generally be scratched or chiseled to conform to the appearance of the mortar forming the remainder of the structure.
[0005] The second method is to drive nails or similar items into the outer edge of the exterior of a structure to support the masonry elements that forms the masonry arch. In order to provide sufficient support for the masonry elements, the nails must be placed close together, which necessitates the use of a large number of nails. Once the mortar hardens, the nails are removed. The removal of the nails leaves multiple holes in the exterior molding that must be repaired by filling the holes and painting the surface
[0006] The third method is to support a section of lumber horizontal to the bottom edge of the masonry arch to be constructed. Once the section of lumber is in place, bricks or other material are stacked on the horizontal section of lumber to support the masonry elements that form the masonry arch. As is obvious, the bricks are placed in a jigsaw fashion until the proper height is reached to support each section of the masonry elements. This requires that the bricks be cut into smaller pieces to support various sections of the arch. In addition to being very time consuming, such a method leads to many bricks being wasted. In addition, the bricks can fall easily requiring the temporary form be reconstructed. Once the mortar hardens, the bricks and the horizontal section of lumber are removed.
[0007] A fourth method to support the masonry elements that form a masonry arch is to use prefabricated arch supports. These arch supports are shipped with the arch structure preformed. However, these items must be specially ordered since the configuration of masonry arches varies from application to application, making a “standard” prefabricated arch form impractical. As a result, these prefabricated supports are expensive. In addition, the prefabricated supports create other problems. Since the supports are prefabricated in the form of an arch, they are bulky to ship and store, further increasing their cost. In addition, these preformed supports are more susceptible to damage during shipping and storage. As a result, if the units are damaged, construction may be delayed while replacement supports are obtained.
[0008] Each of the methods discussed above suffer from several shortcomings. In general, the methods are tedious and time consuming to implement. As a result, the cost of the final construction can be increased dramatically. In addition, the arched constructions lack the strength of the horizontal constructions because of the lack of a solid lintel. In most cases, much of the weight of the masonry arch in supported directly by the structure over which the arch is installed, such as a door or window. This additional weight can cause damage. Therefore, what is needed is a device that will allow a masonry arch to be installed conveniently and economically. The device should be simple to use and not require the creation of complicated temporary structures that are expensive and time consuming to create. In addition, the device should eliminate the need to make costly repairs to the exterior of the structure caused by the installation process.
BRIEF DESCRIPTION OF THE FIGURES
[0009] [0009]FIG. 1 is a perspective view of one embodiment of the adjustable masonry arch of the present disclosure.
[0010] [0010]FIG. 2 is a perspective view of the adjustable masonry arch form of FIG. 1 being installed over an arched door.
[0011] [0011]FIG. 3 is a side, cutaway view of the adjustable masonry arch form of FIG. 1 as installed in an arched construction.
[0012] [0012]FIG. 4 is a front, partial cutaway view of the adjustable masonry arch form of FIG. 1 installed over an arched window.
SUMMARY
[0013] The adjustable masonry arch form of the present disclosure is an improvement over current devices available for installing masonry arches. The adjustable masonry arch form comprises a planar base section to support the masonry elements which will comprise the masonry arch, and a plurality of attachment means secured to the planar base for securing the form to a structure. In the embodiment illustrated, the attachment means is shown as a rounded flange. The adjustable masonry arch form is constructed from material rigid enough to support the masonry elements, but flexible enough to be bent to conform to any given arched construction. The adjustable masonry arch form is secured to the exterior of a structure by a securing means, such as screws, nails or staples. The masonry elements which will comprise the masonry arch are placed directly on the planar base of the form in the desired configuration and secured in the masonry arch by mortar. The form is left in position permanently, obviating the need to build a temporary arch support saving time and expense and obviating waste of materials, while providing additional strength to the arched construction. In addition, there is no repair required to the exterior surface of the structure.
[0014] Therefore, it is an object of the disclosure to provide an adjustable masonry arch form that is capable of being installed in any given arched construction at a construction site without the need to create or special order individually configured arch forms. It is another object of the disclosure to provide an adjustable masonry arch form that is permanently installed in an arched construction, thereby obviating the time consuming and wasteful practice of creating temporary forms, and which provide additional strength to the masonry arch. An additional object of the disclosure is to provide an adjustable masonry arch form such that the planar base and/or attachment means will not be deformed as the ach form is bent to conform to the contours of an arched construction. Yet another object of the disclosure to provide an adjustable masonry arch form that is economical to produce and simple to install, decreasing the overall cost of the finished arched construction. It is a further object of the disclosure to provide an adjustable masonry arch form that can be easily shipped, transported and stored, thereby minimizing the risk of damaging the form and avoiding costly construction delays caused by ordering replacement arch forms. It is also an object of the disclosure to provide an adjustable masonry arch form that will prevent damage to the structural features over which masonry arches are installed. Additional objects and advantages will become apparent through the drawings and descriptions that follow.
DETAILED DESCRIPTION
[0015] The adjustable masonry arch form 10 is illustrated in FIGS. 1 - 4 , where like numbers in the figures refer to like elements. As illustrated in FIG. 1, the form 10 is composed of a planar section 12 . The planar section 12 comprises longitudinal axis 14 , a front side 16 and a rear side 18 parallel to the axis 14 , and two ends 20 and 22 . The width of the planar section 12 is sufficient to support the masonry to be incorporated into the masonry arch. While the width can be varied as determined by individual applications as can be determined by one of ordinary skill in the art, in one embodiment the planar section 12 is 3 inches wide. For aesthetic purposes, it is desired that the width of the planar section 3 be slightly less than the width of the masonry elements to be incorporated into the masonry arch (as illustrated in FIG. 3). The form 10 can be manufactured in any length desired and can be cut to fit a given installation at the job site. A plurality of attachment means are secured to the rear side 18 . The attachment means are generally perpendicular to the axis 14 of the planar base 12 . In the embodiment illustrated, the attachment means are shown as flanges 22 . The flanges 22 may be of any desired configuration, but in the embodiment shown the flanges 22 are shown with rounded edges for ease of installation and to remove sharp edges which may cause injury to the installer. In one embodiment the flanges 22 each have an opening 24 for receiving a means to secure the form 10 to a structure. It is preferred that the opening 24 be centered on flange 22 for ease of use, but opening 24 may be placed anywhere on flange 22 .
[0016] The flanges 22 are placed at intervals along the planar section 12 . In one embodiment, the flanges 22 are placed 1 inch apart along the length of the form. By spacing the flanges 22 apart from one another, the form 10 can be bent to conform to the contours of a desired arched construction without deforming planar base 12 and/or the attachment means, in this case flanges 22 . In prior devices, when the form is made to conform to the contours of an arched construction, the device would be deformed at undesirable locations in response to the bending force applied. This deformation is often referred to as splaying or buckling. As a result of the splaying or buckling of prior devices, the masonry element could not be installed in a uniform and aesthetically pleasing manner. The spacing apart of flanges 22 along the rear side 18 also allows the form 10 to be bent without requiring excessive bending force to be applied, allowing the form 10 to be installed at a jobsite with no special equipment required. The width of each individual flange 22 is such that the flange 22 can receive a securing means to secure the form 10 to a structure, but narrow enough so that the flange 22 will not interfere with the flexibility of the form 10 . In one embodiment the width of the individual flange is 1 inch. The above spacing distances and flange widths are given as examples only, and other spacing distances and flange widths may be used as determined by one of ordinary skill in the art and should be considered within the scope of this disclosure.
[0017] The device 10 is made of a material that is rigid enough to support the masonry elements comprising the masonry arch, yet flexible enough to be bent to conform to the contours of an arched construction, typically over a window or door. A preferred material for construction of form 10 is 14 gauge steel, however, other materials may be used, including but not limited to high strength plastic or composite materials. Since the form 10 is flexible, it can be bent from its horizontal configuration to conform to the contours of an arched construction and secured in place at the site of use (illustrated in FIG. 2).
[0018] The form 10 can be made by a variety of methods, the following being provided as example only. The form 10 may be formed from a single piece of material, in this example 14 gauge steel. The single piece of steel may be stamp or die cut to form the individual attachment means, in this case flanges 22 , at the desired intervals along the newly formed rear side 18 . Once the flanges 22 are formed, the flanges 22 can be bent upward such that they are generally perpendicular to axis 14 of the planar base 12 . The flanges 22 are illustrated with rounded edges for ease of installation and to minimize sharp edges, however, any configuration of flanges 22 may be produced. Alternatively, individual attachment means, in this case flanges 22 , may be produced individually and secured to the rear side 18 of planar base 12 by any convenient means, such as by welding. The form 10 is produced in a horizontal configuration. The benefits of making the form 10 in the horizontal configuration include ease of transporting, shipping and storing the form 10 as compared to prefabricated forms. Since the arch is not prefabricated, much less space is required to ship, transport and store the form 10 . In addition, because the form 10 is made in the horizontal configuration out of a sturdy material, the form 10 is less likely to be damaged during shipping, transport and storage, thereby eliminating possible delay in construction caused by obtaining replacement forms. Furthermore, since the form 10 can be bent to conform to any arched construction, there is no need to maintain a supply of prefabricated arch forms for use on different types of arched constructions, greatly decreasing the cost of storage and maintaining the proper inventory.
[0019] As illustrated in FIGS. 2 - 4 , the form 10 is placed atop the molding of an arched construction over which the masonry arch is to be installed, illustrated best in FIG. 3 as molding 50 . The form 10 is then bent into shape over the molding 50 to conform to the shape of the molding 50 and provide a flat surface on which to place the masonry elements which will comprise the masonry arch. FIG. 2 shows the form 10 in its horizontal configuration ( 10 A) and after it is bent ( 10 B) to conform to the contours of the arched construction. The form 10 can be manipulated to fit any arched construction by simply cutting the form 10 to the desired length and bending the form 10 to conform to the contours of the desired arched construction. It is preferred that the form 10 be cut to the desired length before being bent to conform to the desired arched construction. Once the form is in place, the form 10 is secured to the exterior sheathing of a structure, illustrated as sheathing 52 in FIGS. 3 and 4, by a securing means. FIG. 3 shows the form 10 being secured to sheathing 50 by a nail 54 , however, other securing means, such as screws, staples, or bolts may be employed. Once the form 10 is secured, the flanges 22 may be covered with the appropriate waterproof construction paper to prevent seepage of water behind the form 10 .
[0020] As discussed above, there are several alternate methods of supporting masonry elements in an arched construction. In most of these methods, the masonry elements are placed directly on the molding of the window or door over which they will be installed. In the case of installation over windows, the weight of the masonry elements stresses the window such that the panes in the window may be damaged. For example, it is not uncommon for the seal in a double-paned window to break under the weight of masonry elements, which are applied directly on the molding of the window. The use of the form 10 removes the weight of the masonry elements from the window or door, thereby preventing damage to these components, further reducing the costs of construction.
[0021] Once form 10 is secured in place, masonry elements are then placed on the planar base 12 and arranged according to the specifications for the given arched construction. While any masonry elements may be used, FIG. 3 illustrates a typical brick 56 being installed on planar base 12 . FIG. 4 illustrates a vertically oriented paver 58 being installed on planar base 12 . The individual masonry elements are then secured in the desired arrangement by mortar or similar material. Once the mortar hardens, the installation of the masonry arch is complete. The form 10 remains as a part of the arched installation and it is not required to remove the form 10 . An additional advantage of the form 10 remaining a permanent part of the masonry arch is the form 10 provides a significant amount of strength to the masonry arch. As a result, the mortar holding the masonry arch together is less prone to crack as a result of normal settling of the structure and other factors. As a result, repair and maintenance cost may be significantly less in arched constructions having the additional strength afforded by form 10 , than in arched constructions without such additional strength. As discussed above, the width of the planar base 12 is les than the width of the masonry elements to be installed on planar base 12 such that planar base 12 is essentially invisible in the finished installation.
[0022] The above has described several embodiments of the adjustable masonry arch form in detail so that the form and its principles of operation may be understood. The above discussion should not be interpreted to exclude additional embodiments of the form. With respect to the above description, it should be considered that the optimal dimensional relationships for the various parts of the form, including variations in size, materials, shape, form, function and manner of operation, assembly and use, are readily apparent to one of ordinary skill in the art, and all equivalent relationships to those described above and illustrated in the figures are intended to be encompassed by the present disclosure. Therefore, the foregoing is considered illustrative only, and should not be understood to limit the scope of the disclosure to the exact construction and operation discussed and illustrated.
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An adjustable masonry arch form is disclosed. The adjustable masonry arch form comprises a planar base section to support the masonry elements which will comprise the masonry arch, and a plurality of attachment means secured to the planar base for securing the form to a structure. The adjustable masonry arch form is constructed from material rigid enough to support the masonry elements, but flexible enough to be bent to conform to any given arched construction without unwanted buckling of the form. The masonry elements which will comprise the masonry arch are placed directly on the planar base of the form in the desired configuration and secured in the masonry arch by mortar. The form is left in position permanently, obviating the need to build a temporary arch support saving time and expense and obviating waste of materials.
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BACKGROUND OF THE INVENTION
The present invention relates to a universal support that attaches to a conventional snare drum stand and is capable of being adjusted so that the drum is at a position desired by the performer.
A conventional stand for a snare drum has three support arms for supporting a hoop on the lower side of the snare drum. Each support arm is linked to the stand through a ball joint so that a performer can adjust the snare drum to a desired position and angle.
A significant disadvantage to this type of snare drum stand is that the hoop on the lower side of the snare drum is sandwiched between the support arm which causes a distortion in the sound emanating from the drum. To remedy this disadvantage, the snare drum is often not fixed to the stand but is merely placed on three support arms. However, since the snare drum is merely placed on the support arms, if the drum is to be moved, one must hold both the drum and the stand. Of course, there is always a possibility that a snare drum supported in this manner will fall off during a performance.
SUMMARY OF THE INVENTION
An object of the present invention is to overcome problems encountered with conventional drums stands. To this purpose the universal drum support of the present invention does not affect the sound of the drum supported on it, while it firmly holds the drum at the position and at the angle desired by the performer.
A further object of the present invention is to effect easy and quick positioning of the drum on the support.
Still a further object of the present invention is the ability to maintain the desired position of the universal support to the stand after the drum has been removed from the support and the stand has been folded for either storage or transportation.
The present invention is a universal support adapted for connection to an attachment member of a support stand, and for holding an elongated support at a desired position relative to the support stand. The universal support includes a receiving member, and a first press attached to the receiving member. The receiving member and the first press each have a contoured surface adapted to accommodate the support rod as it is sandwiched between the contoured surfaces of the receiving member and the first press. A second press is attached to the receiving member and spaced from the first press. The receiving member and the second press each have a contoured surface adapted to accommodate the attachment member of the support stand sandwiched between the contoured surfaces of the receiving member and the second press. The universal support is capable of independently accommodating the attachment member of the support stand and the elongated support.
The elongated support may itself be capable of supporting a drum. Thus, the angular displacement between the drum and the support stand is determined by the universal support.
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
For a fuller understanding of the nature and objectives of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings.
FIG. 1 is a side view of a snare drum being held by a universal support of the present invention.
FIG. 2 is a plan view of the snare drum of FIG. 1.
FIG. 3 is a side view of a bracket and a curved arm used to support the snare drum in conjunction with the universal support.
FIG. 4 is a cross-sectional view of the bracket of FIG. 3.
FIG. 5 is an enlarged front view of the universal support.
FIG. 6 is a side view of FIG. 5.
FIG. 7 is a cross-sectional view along the line 7--7 in FIG. 5.
FIG. 8 is a cross-sectional view along line 8--8 in FIG. 5.
FIG. 9 is a side view of the support stand, shown in FIG. 1, folded.
FIG. 10 is a cross-sectional view of the bracket shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, the universal support H of the present invention is installed at the top of a drum stand 50. A support rod 62 is attached to the universal support H at one end, and is attached at the other end to a bracket 61 of a snare drum 60. The support rod 62 can be adjustably fixed anywhere along its length to universal support H, and thereby adjusts the height of the snare drum 60 from the floor.
Bracket 61 has a curved arm 70 that surrounds the outer periphery of the upper hoop 91 of snare drum 60. Upper hoop 91 can be tightened about a drum 60. Curved arm 70 is connected to upper hoop 91 at three locations and it supports the drum 60 vis-a-vis the drum stand 50. A butterfly knob 71 tightens and loosens the bracket 61 on support rod 62.
Curved arm 70 is located on the lower side of the outer periphery of upper hoop 91. Upper hoop 91 is for the purpose of tightening the drum head 90 on its top side. Hoop installations 93, with installation holes 92, are provided on the outer periphery of upper hoop 91. Since there are a plurality of hoop installations 93 along the upper hoop 91, they distribute the load on snare drum 60 and thereby prevent any undesirable strain on the drum.
It is preferable if hoop installations 93 are separated as widely apart from each other on upper hoop 91 as is feasible. In addition, there can be more than these installations 93 on upper hoop 91 depending upon the size and weight of the drum 60. Snap fixtures 74 are on the side of the drum 60, and each snap fixture is actuated by a switch lever 75.
Curved arm 70 is curved in shaped and surrounds the outer periphery of the shell of drum 60, and comprises two arms 72 which extend from and are fixed on both sides of an installation plate 73. The length of curved arm 70 can be suitably determined by the size of the drum 60 it supports. However, for stability in supporting the drum 60, the arms 72 are typically of a length such that the curved arm 70 surrounds up to about half the outer periphery of drum 60.
A rubber or plastic stopper 76 is disposed at the bottom of installation plate 73. As shown in FIG. 4, stopper 76 abuts against the lower hoop 97 of drum 60 to prevent excessive shaking of drum 60.
As is shown in FIGS. 3 and 4, flange-shaped brackets 94 are soldered or screwed on the under side of curved arm 70, and are positioned thereon to correspond to the positions of hoop installations 93 on upper hoop 91.
Hoop installations 93 and brackets 94 are connected to each other by bolt installations 95. Thus, curved arm 70 is connected to upper hoop 91 by bolt installations 95 engaging brackets 94 and hoop installations 93.
Bolt installations 95 elastically link hoop installations 93 to brackets 94 by a vibration absorber 96 made of a vibration-absorbing material, such as rubber. The vibration absorber 96 absorbs the vibration of drum 60. As shown in FIG. 4, bolt installations 95 include a fastening element above and below the vibration absorber 96. An upper screw 95a extends upwardly from vibration absorber 96, and a rubber seat 98 engages upper screw 95a. Rubber seat 98 prevents vibration of the drum from being transmitted by the bracket and support.
Referring to FIG. 10, rubber seat 98 comprises a lower seat 98a that is fixed to upper screw 95a and an upper seat 98b that is removably installed on upper screw 95a. The upper screw 95a of bolt installation 95 passes through hole 92 of hoop installation 93 and thereby lower seat 98a abuts the lower side of hoop installation 93. Upper seat 98b is screwed to upper screw 95a, with the result that upper and lower seats 98a and 98b come in contact with each other at terminals 99 for each of the lower and upper seats 98a and 98b. At terminals 99 both the lower and upper seats 98a and 98b are tapered which minimizes contact of the lower seat 98a with hoop installation 93 at hole 92.
The terminal outer periphery of lower seat 98a and upper seat 98b are tapered and narrow in form as they engage each other at hole 92. By so shaping the upper and lower seats 98a and 98b the contact between rubber seat 98 and hoop installation 93 is kept at a minimum to reduce the transmission of vibrations.
Referring to FIG. 1, support stand 50 is a conventional support stand comprising a main body 52 and legs 53. The main body 52 includes a lower pipe 52a and an upper pipe 52b that is slidably inserted in lower pipe 52a, with the height of the support stand 50 being determined by the length that upper pipe 52b protrudes from lower pipe 52a. Once the support stand 50 is adjusted to its desired height, upper pipe 52b is fixed in place by a tightening bolt 52c. Spherical body 51 is installed on upper pipe 52b.
The end of each leg 53 is attached to the outer periphery of an annular body 54 which slidably engages lower pipe 52a in a freely rotatably manner. Approximately the center of each leg 53 is attached to the lower part of the lower pipe 52a through an arm 55.
As shown in FIG. 9, support stand 50 can be folded compactly when not in use or when it is being carried. Support stand 50 is shown with legs 53 attached to the outer periphery of annular body 54. Since annular body 54 is slidable along lower pipe 52a, a screw 56 is used to fix annular body 54 in position on lower pipe 52a.
Referring to FIGS. 5 through 8, the universal support H contains a ball receiving member 10, a ball press 20, a rod press 30, a spherical body tightening nut 40 and a rod tightening nut 45. The universal support H is attached to spherical body 51 of support stand 50.
Referring to FIGS. 5 through 7, the universal support H provides universal positioning for drum 60, because receiving member 10 along with ball press 20 retain spherical body 51 at almost any angular position, and because ball receiving member 10 along with rod press 30 adjustably retain support rod 62 at any position along its length. A concave surface 11 for accommodating spherical body 51, and a concave surface 12 for accommodating support rod 62 are formed on the interior of ball receiving member 10.
The interior concave surface 11 of ball receiving member 10 is formed in the same shape as the exterior surface of spherical body 51. Ball receiving member 10 has a first holder 13 disposed on the same side as concave surface 11. First holder part 13 is linked with a holder 23 of ball press 20 by a pin 22, thereby rotatably supporting ball press 20 on ball receiving member 10. More specifically, holder 23 is formed on the side of ball press 20 that corresponds to holder 13 of ball receiving member 10, so that holder 23 is rotatably connected to holder 13 by pin 22. Like concave surface 11, ball press 20 has an interior concave surface 21 which accommodates spherical body 51. Spherical body 51 is sandwiched between ball receiving member 10 and ball press 20. A threaded bolt 24 engaging a threaded tightening knob 40 is disposed through hole 14 of ball receiving member 10 and hole 25 of ball press 20 at a side opposite holder 13 and 23.
Referring to FIG. 8, ball receiving member 10 has the interior concave surface 12 formed at its upper end. The concave surface 12 is shaped to conform to the outer surface of the support rod 62. The support rod 62 is a bar-shaped body whose cross section is hexagonal. An interior concave surface 31 of rod press 30 is likewise shaped to conform to the outer surface of support rod 62.
A second holder 15 is provided on ball receiving member 10. Second holder 15 is linked with a holder 33 of the rod press 30 by a pin 32. Thus, support rod 62 is sandwiched between ball receiving member 10 and rod press 30, and is accommodated in their interior concave surfaces 12 and 31, respectively.
Threaded bolt 34 has a tightening head at one end and the other end engages a knob 45. Bolt 34 extends through a hole 16 in ball receiving member 10. By tightening knob 45 to bolt 34, support rod 62 is retained between ball receiving member 10 and rod press 30. An engaging step 17 is formed in ball receiving member 10 for engaging knob 45 when knob 45 is tightened. Thus, with rod press 30 having a concave surface 31 which accommodates support rod 62 together with concave surface 12 of ball receiving member 10, the two elements are easily tightened or loosened about support rod 62 by knob 45. Engaging step 17 assures proper tightening of knob 45. A spring 36, which extends along bolt 34, and a metal washer 37 are provided to prevent knob 45 from being loosened.
On the side of ball press 20 opposite holder 23, a threaded bolt 24 is provided. Bolt 24 is inserted into a tightening hole 25 of ball press 20 and extends through a hole 14 of ball receiving member 10, and is screwed to knob 40. Thus, bolt 24 is tightened by knob 40 to retain spherical body 51 sandwiched between ball receiving member 10 and ball press 20.
In universal support H, spherical body 51 is inserted between accommodating concave surfaces 11 and 21, and ball receiving member 10 and ball press 20 can be rotated about spherical body 51. As the knob 40 is screwed to bolt 24, the ball receiving member 10 and the ball press 20 are tightened, with their position held fixed about spherical body 51.
Rod press 30 has holder 33 on the same side as it has concave surface 31. Holder 33 corresponds to holder 15 of ball receiving member 10. Holder 33 and holder 15 are linked by pin 32. Thus, rod press 30 is rotatable to ball receiving member 10.
The tightening head of bolt 34 is positioned on rod press 30 opposite holder 33. Knob 45 is screwed to bolt 34, and support rod 62 is either tightened or loosened between ball receiving member 10 and rod press 30.
Support rod 62 can be retained anywhere along its length to ball receiving member 10 and rod press 30 by tightening tightening knob 45 to bolt 34. Tightening knob 45 engages step 17, with the consequence that the tightened position is firmly fixed.
By use of the universal support H, support rod 62 can be easily and accurately adjusted along its length by the performer. Also, the performer can mark the fixing position for support rod 62 on the rod's surface.
In the universal support H of the present invention, the support rod for a drum can be held in a fixed position by the ball receiving member 10 and rod press 30, yet it can be easily removed and reattached. Referring to FIG. 9, even if the support rod of the drum is removed from the universal support H, when the support rod is reattached, it will maintain its same angular position. The angular position of the support rod is determined by the engagement of universal support H to spherical body 51, and that engagement is not affected by the removal of the support rod from the universal support H.
Although the present invention has been described in relation to a particular embodiment thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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A universal support is provided wherein the angular adjustment provided by the universal support for an object supported thereby remains fixed even though the object, such as a drum, has been removed from the universal support. The universal support is capable of holding a support rod relative to a support stand having an attachment member. The universal support includes a receiving member, with a rod press and a support stand press each attached to the receiving member. The receiving member and the rod press each has a concave surface adapted to accommodate the rod support sandwiched between the contoured surfaces of the receiving member and the rod press. In addition, the receiving member and the support stand press each has a concave surface adapted to accommodate the attachment member of the support stand sandwiched between the concave surface of the receiving member and the support stand press. Thus, the universal support is capable of accommodating the attachment member of the support stand independently of the rod support.
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FIELD OF THE INVENTION
The present invention relates to formations penetrated by wells which are experiencing water influx due to casing problems, coning, channeling, fingering, or any other reservoir related cause of water influx. More particularly it relates to a method for the identification of the precise point of water influx.
It also relates to downhole video technology, to water influx identification using downhole video equipment, and to a method of replacing the clear fluid in the wellbore prior to video monitoring procedures with a fluid which is clear yet provides sufficient contrast to better facilitate the precise identification of water influx points in the well.
DESCRIPTION OF THE PRIOR ART
Oil field operators must frequently contend with the problem of excessive water influx in producing wells and of poor distribution profiles in water injection wells. Water shutoff represents an enormous expense in the oil industry. The major problem in performing water shutoff jobs is identifying the precise points of water influx.
In the production of hydrocarbons from a hydrocarbon-bearing formation there is normally provided a well which extends from the surface of the earth into the formation. The hydrocarbon-bearing portion of the formation may be overlain or underlain by a water-bearing portion of the formation.
The well may be completed by employing conventional completion practices such as running a cement casing in the well and forming perforations through the casing and cement sheaths around the casing, thereby forming an open production interval which communicates with the formation.
In the case of a hydrocarbon-bearing formation it is normally desirable to form the open production interval so that it communicates with the oil-bearing portion but does not extend into and communicate with the water-bearing portion. However, the open production interval which is formed in the well may inadvertently communicate with a water-bearing portion which is completed in the same wellbore as the hydrocarbon-bearing portion of the formation.
Even if there is no actual initial fluid communication between the open production interval and the water-bearing portions of the formation, such communication may develop during production of hydrocarbon from the hydrocarbon-bearing portion of the formation. For example, water may be drawn upwardly from the water-bearing portion into the oil-bearing portion about the well. This phenomenon is known as water coning. In the case of water coning, free water is produced in the well which results in a much higher water-to-oil ratio in the production stream than would be the case without the water coning.
A phenomenon called fingering can also occur where the viscosity of one fluid, such as water, causes the development of fingers or bulges which may be caused by points of minute heterogeneities in the reservoir. These fingers of displacing fluid tend to become extended in the direction of flow.
In situations where secondary recovery of oil is being accomplished by water flood, it is frequently found that areas of high permeability exist at points along the interior of the well into which flood water is being injected. Instead of providing the desired uniform sweep through the formation, the flood water channels through zones of high permeability, “thief zones”, and finds its way to a producing well without having served any useful purpose.
Casing problems are also quite common. In the case of an oil well, for example, after the steel casing or tubing has been in place for some time, rusting and occasional shifts in the earth will cause rupturing or uncoupling of the steel casing. Water can then enter the well at these points. When this happens, visual examination is necessary to identify precise point of water influx, the extent of the break or leak, and the feasibility of repairs. Accordingly, the visual examination of the walls of a well is frequently needed when applied to the above problems.
In other instances, exploration holes are drilled to locate mineral deposits such as oil and gas, ground water, and geothermal supplies, to check the integrity for nuclear waste depositories, and also to determine the potential for landslides in an unstable environment. In any of these situations it is often possible for a crack or rupture to allow the influx of water.
Methods are known in the art for monitoring wells and for locating and analyzing fluid influxes.
In U.S. Pat. No. 4,980,642, incorporated herein by reference in its entirety, there is described a method of detection of influx of fluids invading a borehole.
U.S. Pat. No. 5,070,949, incorporated by reference in its entirety, discloses a method of controlling a well drilling operation and monitoring drilling parameters to detect a fluid influx.
Closed circuit TV camera systems are also known in the art for visually examining the walls of a given borehole. In large diameter boreholes, a trained geologist can be physically lowered into the hole with a light source to visually examine the stratification, fracturing, and layering of the various geological formations down to which the borehole penetrates. In smaller diameter holes, this type examination is impossible. Accordingly, in smaller holes visual wall examination must be made with a moving picture borehole camera or with a closed circuit television video camera. Additionally, the bore shaft itself made by the borehole is often not in a vertical orientation and has a drift or deviation in azimuth from its true vertical. There are drift recorders which monitor and log the slanting or drifting of the borehole from its true azimuth. Inclinometers are known which determine deviation as well as drift, for example, by photographing from a plumb bob position against a compass background.
U.S. Pat. No. 4,855,820 describes an apparatus and method of visually examining the sidewalls of a borehole, including a downhole video tool lowered into the borehole by means of a cable and winch on the surface. The apparatus includes a wide angle video camera enclosed in its lower section. An upper section houses, for example, a power supply/triplexer, a telemetry board, an FM modulator video amplifier transmission board, gyro data interface board and a gyroscope for showing the directional orientation of the camera and apparatus in the borehole. The gyroscope orientation and the visual image of the portion of the sidewall viewed is transmitted to a video display monitor in an equipment van on the surface. The image on the screen includes a directional reference point so that the direction of a portion of the sidewall being viewed can be ascertained. The camera images are recorded by a video cassette recorder for a permanent record of the visualization of the entire length of the borehole. Various geological data can be extrapolated by this visualization by means of the fracturing and stratification which may be observed in a given borehole. Additionally, the probe can be used to inspect boreholes previously encased by steel tubing to detect any leaks or other deterioration in the tubing system.
Positively identifying the precise source of water influx is a key step in being able to successfully treat the problem. Furthermore, for video monitoring to be successful, clear fluids must be present across and adjacent to the targeted viewing interval. This creates a problem when trying to determine the point(s) where water entry is occurring because there is no contrast in the fluids, making it almost impossible to define water flow. That is, water is entering into a water phase. When exploration personnel review video tapes of actual footage recorded downhole, the lack of contrast in fluids when looking for water entry is very evident, especially at reduced producing rates. Thus far, no practical solution to the problem is known in the art. In actual situations in the field the lack of contrast in water at the point of entry negates the value of any information obtained by downhole video cameras. Logs obtained in situations such as described cannot be accurately interpreted. Based on the attempted interpretation of such logs, the perforations could have been either producing water or completely plugged and not contributing. Without some type of indication technique to better identify the water source the success ratio of using this tool as a diagnostic is greatly reduced.
With these problems in mind, it would constitute a distinct advance in the art if there were an effective, low cost method of treating fluid used to analyze water influx which would make the precise point of water influx much easier to detect.
SUMMARY OF THE INVENTION
In accordance with the foregoing the present invention is directed to any method known in the art for identifying water entry points in a well and to the improvement comprising: Prior to the steps for locating the water influx points, replacing the wellbore fluid with a fluid selected from:
a) water to which has been added a viscosifying agent, a coloring agent and, optionally, sufficient salt to increase the density; and in the alternative, a fluid comprising
b) a transparent water-insoluble solvent.
Either of these two fluids provide a distinct contrast between the injected fluid and the wellbore fluid and provide an improvement over anything presently available in the art.
In the first embodiment it has been discovered that neither the viscosifying agent nor the coloring agent alone sufficiently solves the problem, but with the two in combination it is possible to observe a distinct contrast. In the second embodiment the water-insoluble solvent enters the wellbore as small bubbles.
DETAILED DESCRIPTION OF THE INVENTION
The method of the present invention offers a cost effective solution to identifying the water entry points. It would be a valuable tool when employing downhole video services. Video monitoring of this type is discussed, for example, in U.S. Pat. No. 4,855,820, incorporated by reference herein in its entirety.
In the first embodiment of the present invention wellbore fluid is replaced prior to examination of the well with water to which a viscosifying agent, a coloring agent and, optionally, salt to increase density has been added.
The viscosifying agent can be any composition with a viscosity greater than water which would increase the internal resistance to flow of the water used to replace the wellbore fluid. It is necessary that one achieve some degree of turbulence caused by a more dense fluid mixing with a less dense fluid. Generally, suitable examples include polyacrylamides, celluloses and even starch.
In the present invention it was found that suitable viscosifying agents include hydrophilic polymers. Suitable examples include natural gums, (e.g. xanthangum) or chemically modified natural polymers, such as, for example carboxymethyl cellulose, methyl cellulose, hydroxyethyl cellulose, polyacrylamide, polyvinyl alcohol, ethylene oxide, and related compounds. Any of the hydrophilic polymers normally utilized for oil recovery operations are suitable.
In the examples herein the preferred hydrophilic polymer is hydroxyethylcellulose, a nonionic ether of cellulose which is soluble in hot or cold water, but is insoluble in organic solvents. It is stable in concentrated salt solutions and is nontoxic. The material is available commercially under several trademarks, including NATROSOL® 250 HHR. The 250 designation indicates a hydroxyethyl molar substitution of 2.5 and the HHR is an indication of the viscosity type. NATROSOL® is available from Hercules.
The amount of viscosifying agent will be in the range of 0.5 to 2% by weight, a preferred amount is 1%.
The coloring agent can be any agent which adds color. This may include any number of compounds including some organic salts. Particularly suitable coloring agents are selected from the group consisting of nitro colorants, azocolorants, triphenylmethane colorants, zanthene colorants, guinoline colorants, anthraquinone colorants, indigo color additive or pyrene color additive. Also useful are colored inorganic salts, phosphorescent dyes and related compounds. This includes a variety of red, orange, yellow, blue and green food dyes, as certified by the U.S. for coloring in foods, drugs and cosmetics. In the examples, good results were obtained using purple food-coloring dye.
Coloring agent should be added in an amount ranging from 0.1 to 2% by weight. The preferred range is 0.1 to 0.5 wt %.
The addition of inorganic salt to increase density may be indicated. Generally the most cost effective salt is NaCl. In this situation one generally would want to add sufficient salt to make the density of the wellbore fluid equal or a little greater than the density of the incoming water. The amount of salt added should be in the range of 1 to 33% by weight, preferably in the range of 20% to 30%.
In the second embodiment of the invention the wellbore fluid is replaced with a transparent water-insoluble solvent. Generally, suitable solvents are selected from the group consisting of halogenated hydrocarbon solvents, which can be aromatic, aliphatic, alicyclic, heteroyclic and combinations thereof. Suitable examples of solvent include halogenated hydrocarbons such as alkyl chloride, fluorobenzene, chlorobenzene, bromobenzene, o-dichlorobenzene and p-dichlorobenzene.
Suitable halogenated aliphatic compounds can also include halogenated alkanes and alkenes of 1 to about 8 carbon atoms, illustrated by such alkanes as carbon tetrachloride, carbon tetrabromide, bromoform, iodoform, iodoethane, 1,2-diiodoethane, 2-bromo-1-iodoethane, hexachloroethane, 1,1,1-trichloroethane, 1,1-bis (p-chlorophenyl) -2,2,2-trichloroethane, substituted 1,2-dibromoethane compounds.
The preferred solvent is bromobenzene and related water insoluble solvents.
To further illustrate the invention, the following examples are presented to illustrate the process described above, although this is supplied for the purpose of complete disclosure and is not intended to limit the scope of the invention in any way.
COMPARATIVE EXAMPLE I.
The following experiment was conducted to verify that the addition of a polymer and coloring agent would allow a downhole camera to identify water influx into the wellbore. A glass container with an inlet at the bottom was filled with water. Water was then flowed into the container and filmed with a black and white video camera from above the container, to simulate field conditions. When the video tape was played back the incoming water was not apparent. The glass container was then filled with an hydroxyethyl cellulose solution without a dye and the experiment was repeated. In this case the influx was apparent, but not striking. The glass container was then filled with purple colored hydroxyethyl cellulose solution and the experiment repeated. When the tape was played back the water influx was quite evident.
COMPARATIVE EXAMPLE II
In a well with incoming fluid of a maximum density of 1.1 g/ml, the wellbore fluid was replaced with a hydroexyethylcellulose solution and enough salt to raise the density to 1.2 g/ml. It was found that it was still difficult to determine the point of water influx.
The wellbore fluid was replaced again with coloring agent and sufficient salt to raise the density to 1.2 g/ml. The coloring agent alone was not sufficient to make apparent the point of entry of the water influx.
It has been found that neither coloration or increased viscosity alone allowed for easy identification of water entry into the wellbore. However, the combination of the two offered a definite contrast between the injected fluid and the wellbore fluid.
EXAMPLE III
In a well where incoming fluid had a maximum density of 1.1 g/ml, the wellbore fluid was replaced with a hydroxyethylcellulose solution to which a food-coloring dye and enough sodium chloride to raise the density to 1.2 g/ml had been added. Water influx could easily be seen during the logging process. After the camera was run the wellbore fluid could be produced.
EXAMPLE IV
In another example in a well to be analyzed for water influx, where incoming fluid had a maximum density of 1.1 g/ml, the wellbore fluid could be replaced with bromobenzene. When using bromobenzene in this manner the water will enter the wellbore as small bubbles in contrast to the surrounding liquid phase.
Although the invention has been described in terms of a series of specific preferred embodiments and illustrative examples which are believed to include the best mode for applying the invention known at this time, it will be recognized to those skilled in the art that various modifications may be made to the composition and methods described herein without departing from the true spirit and scope of the invention which is defined more precisely in the claims appended hereinafter below.
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An improved method to detect water influx using video monitoring of a cased wellbore is disclosed. A wireline well tool having a video camera and a light source is lowered into a selected borehole interval where water influx is suspected. The borehole fluid over the selected interval is displaced and replaced with either a water transparent mixture containing a viscosifying agent, a coloring agent and/or sufficient salt to increase mixture density; or a transparent water insoluble solvent. By use of either of these displacement fluids, the quality of video monitoring over the selected borehole interval for water influx, is enhanced.
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CLAIM OF PRIORITY
This application claims priority from U.S. Provisional Patent Applications Nos. 60/370,380 and 60/370,413 both filed Apr. 5, 2002.
BACKGROUND
Equalizers are an important element in many diverse digital information applications, such as voice, data, and video communications. These applications employ a variety of transmission media. Although the various media have differing transmission characteristics, none of them is perfect. That is, every medium induces variation into the transmitted signal, such as frequency-dependent phase and amplitude distortion, multi-path reception, other kinds of ghosting, such as voice echoes, and Rayleigh fading. In addition to channel distortion, virtually every sort of transmission also suffers from noise, such as additive white gausian noise (“AWGN”). Equalizers are therefore used as acoustic echo cancelers (for example in full-duplex speakerphones), video deghosters (for example in digital television or digital cable transmissions), signal conditioners for wireless modems and telephony, and other such applications.
One important source of error is intersymbol interference (“ISI”). ISI occurs when pulsed information, such as an amplitude modulated digital transmission, is transmitted over an analog channel, such as, for example, a phone line or an aerial broadcast. The original signal begins as a reasonable approximation of a discrete time sequence, but the received signal is a continuous time signal. The shape of the impulse train is smeared or spread by the transmission into a differentiable signal whose peaks relate to the amplitudes of the original pulses. This signal is read by digital hardware, which periodically samples the received signal.
Each pulse produces a signal that typically approximates a sinc wave. Those skilled in the art will appreciate that a sinc wave is characterized by a series of peaks centered about a central peak, with the amplitude of the peaks monotonically decreasing as the distance from the central peak increases. Similarly, the sinc wave has a series of troughs having a monotonically decreasing amplitude with increasing distance from the central peak. Typically, the period of these peaks is on the order of the sampling rate of the receiving hardware. Therefore, the amplitude at one sampling point in the signal is affected not only by the amplitude of a pulse corresponding to that point in the transmitted signal, but by contributions from pulses corresponding to other bits in the transmission stream. In other words, the portion of a signal created to correspond to one symbol in the transmission stream tends to make unwanted contributions to the portion of the received signal corresponding to other symbols in the transmission stream.
This effect can theoretically be eliminated by proper shaping of the pulses, for example by generating pulses that have zero values at regular intervals corresponding to the sampling rate. However, this pulse shaping will be defeated by the channel distortion, which will smear or spread the pulses during transmission. Consequently, another means of error control is necessary. Most digital applications therefore employ equalization in order to filter out ISI and channel distortion.
Generally, two types of equalization are employed to achieve this goal: automatic synthesis and adaptation. In automatic synthesis methods, the equalizer typically compares a received time-domain reference signal to a stored copy of the undistorted training signal. By comparing the two, a time-domain error signal is determined that may be used to calculate the coefficient of an inverse function (filter). The formulation of this inverse function may be accomplished strictly in the time domain, as is done in Zero Forcing Equalization (“ZFE”) and Least Mean Square (“LMS”) systems. Other methods involve conversion of the received training signal to a spectral representation. A spectral inverse response can then be calculated to compensate for the channel distortion. This inverse spectrum is then converted back to a time-domain representation so that filter tap weights can be extracted.
In adaptive equalization the equalizer attempts to minimize an error signal based on the difference between the output of the equalizer and the estimate of the transmitted signal, which is generated by a “decision device.” In other words, the equalizer filter outputs a sample, and the decision device determines what value was most likely transmitted. The adaptation logic attempts to keep the difference between the two small. The main idea is that the receiver takes advantage of the knowledge of the discrete levels possible in the transmitted pulses. When the decision device quantizes the equalizer output, it is essentially discarding received noise. A crucial distinction between adaptive and automatic synthesis equalization is that adaptive equalization does not require a training signal.
Error control coding generally falls into one of two major categories: convolutional coding and block coding (such as Reed-Solomon and Golay coding). At least one purpose of equalization is to permit the generation of a mathematical “filter” that is the inverse function of the channel distortion, so that the received signal can be converted back to something more closely approximating the transmitted signal. By encoding the data into additional symbols, additional information can be included in the transmitted signal that the decoder can use to improve the accuracy of the interpretation of the received signal. Of course, this additional accuracy is achieved either at the cost of the additional bandwidth necessary to transmit the additional characters, or of the additional energy necessary to transmit at a higher frequency.
A convolutional encoder comprises a K-stage shift register into which data is clocked. The value K is called the “constraint length” of the code. The shift register is tapped at various points according to the code polynomials chosen. Several tap sets are chosen according to the code rate. The code rate is expressed as a fraction. For example, a ½ rate convolutional encoder produces an output having exactly twice as many symbols as the input. Typically, the set of tapped data is summed modulo-2 (i.e., the XOR operation is applied) to create one of the encoded output symbols. For example, a simple K=3, ½ rate convolutional encoder might form one bit of the output by modulo-2-summing the first and third bits in the 3-stage shift register, and form another bit by modulo-2-summing all three bits.
A convolutional decoder typically works by generating hypotheses about the originally transmitted data, running those hypotheses through a copy of the appropriate convolutional encoder, and comparing the encoded results with the encoded signal (including noise) that was received. The decoder generates a “metric” for each hypothesis it considers. The “metric” is a numerical value corresponding to the degree of confidence the decoder has in the corresponding hypothesis. A decoder can be either serial or parallel—that is, it can pursue either one hypothesis at a time, or several.
One important advantage of convolutional encoding over block encoding is that convolutional decoders can easily use “soft decision” information. “Soft decision” information essentially means producing output that retains information about the metrics, rather than simply selecting one hypothesis as the “correct” answer. For an overly-simplistic example, if a single symbol is determined by the decoder to have an 80% likelihood of having been a “1” in the transmission signal, and only a 20% chance of having been a “0”, a “hard decision” would simply return a value of 1 for that symbol. However, a “soft decision” would return a value of 0.8, or perhaps some other value corresponding to that distribution of probabilities, in order to permit other hardware downstream to make further decisions based on that degree of confidence.
Block coding, on the other hand, has a greater ability to handle larger data blocks, and a greater ability to handle burst errors.
The following is a description of an improvement upon a combined trellis decoder and decision feedback equalizer, as described in U.S. patent application Ser. No. 09/876,547, filed Jun. 7, 2001, which is hereby incorporated herein in its entirety. More specifically, the present invention provides an improvement upon a transposed structure for a decision feedback equalizer (“DFE”), as taught by the concurrently filed U.S. Patent Application entitled “Transposed Structure for a Decision Feedback Equalizer Combined with a Trellis Decoder,” which is also hereby incorporated herein in its entirety. The transposed structure permits extremely fast and effective ghost cancellation, so that the equalizer provides a high quality signal resolution even during severe noise and channel distortion. However, the transposed filter structure disclosed in that application does not handle the “corner cases,” caused by the interruption in the data symbols presented by synchronization symbols in most digital signal. For example, the frame and field sync symbols in a digital television signal interrupt the data symbols. Thus, in order to employ a transposed structure DFE in a digital television receiver there is a need for an improvement upon the transposed filter structure to deal with those corner cases. The present invention is directed towards meeting this need, among others.
SUMMARY OF THE INVENTION
In a first embodiment the present invention provides a synchronization symbol re-inserter, comprising a trellis decoder and a mirrored symbol delay line. The trellis decoder comprises a plurality of decoding stages, each decoding stage having as output intermediate decoded symbols. The mirrored symbol delay line comprises a plurality of 3:1 multiplexers and a plurality of delay devices. Each of the plurality of 3:1 multiplexers has a multiplexer output, and each receives as input the intermediate decoded symbols from a following stage of the trellis decoder, and the intermediate decoded symbols from the current stage of the trellis decoder. For each of the plurality of 3:1 multiplexers, there is a delay device that receives as input one of the plurality of multiplexer outputs, and has a multiplexer output The multiplexer output of each of the delay devices other than a final multiplexer is fed to a following 3:1 multiplexer.
In a second embodiment the present invention provides a digital equalizer for interpreting a digital signal including convolutionally encoded symbols and synchronization symbols outside the convolutional code. The digital equalizer comprises a combined trellis decoder and DFE, wherein the synchronization symbols are re-inserted into the input of the DFE in order to restore time domain continuity created by removal of the synchronization symbols.
BRIEF DESCRIPTION OF THE DRAWINGS
Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself, and the manner in which it may be made and used, may be better understood by referring to the following descriptions taken in connection with the accompanying figures forming a part hereof.
FIG. 1 is an illustration of the equivalent N×D symbol delay line during the normal re-arrangement operation of the trellis decoder in an equalizer according to the present invention.
FIG. 2 is an illustration of the equivalent N×D symbol delay line during the re-arrangement operation in segment synchronization-related corner cases in an equalizer according to the present invention.
FIG. 3 is an illustration of the equivalent N×D symbol delay line during the re-arrangement operation in frame synchronization-related corner cases in an equalizer according to the present invention.
FIG. 4 is a diagram of a first embodiment synchronization symbol re-inserter according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the preferred embodiment and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alternations and further modifications in the invention, and such further applications of the principles of the invention as described herein as would normally occur to one skilled in the art to which the invention pertains, are contemplated, and desired to be protected.
The present invention provides an improvement on a transposed structure for a decision feedback equalizer (“DFE”). The transposed structure permits extremely fast and effective ghost cancellation, so that the equalizer provides a high quality signal resolution even during severe noise and channel distortion. Consequently, such a digital receiver will have clear reception under conditions where prior digital equipment would completely fail. The present invention provides a means to employ a high-performance DFE in a digital television application, by accounting for the interruptions in the data stream that are presented by the synchronization symbols that are used in the industry standard digital television protocols.
Those skilled in the art will appreciate that the synchronization symbols inserted into a digital television signal are outside of the chain coding. That is, the convolutional encoding is performed on the data stream first, and the synchronization symbols are inserted at the appropriate intervals in the resulting symbol stream. Consequently, the synchronization symbols in the received signal represent interruptions that, if not accounted for, will disrupt the temporal continuity of the symbols fed into the DFE.
Conceptually, a DFE needs to continuously take in N×D+M consecutive decoded symbol sequence in each symbol clock cycle and weigh all these symbols to produce the ghost estimate. Typically, each of the N+D+M decoded symbol inputs must incur exactly one more symbol clock cycle delay than the preceding one. This sequential symbol delay relationship is called “temporal continuity.” It will be appreciated that, when combined with the trellis decoder, the symbols with same time stamp may change their values because the trellis decoding process may modify some intermediate decoded symbols when they pass the current decoding bank.
In a non-combined DFE an accurate delay line of N×D+M symbols, where the symbols are delayed without changing their values, is sufficient to generate the decoded symbol sequence to be weighted. However, in a combined DFE the first N×D decoded symbols are held in the trellis decoder. When these symbols incur delay, their values are revised and as a result may be changed to symbols that are more likely to correspond to those in the original transmitted signal (according to the optimization assumptions of the decoder). Therefore the subsequent decoded symbols are not simply delayed copies of first decoded symbols, as is in an accurate delay line. The value changes cause the accurate delay line not to work with a combined DFE. On the other hand, regardless of value changes, there is an order in which these N×D decode symbols held in the trellis decoder can be re-arranged so that the consecutive decoded symbols do incur one symbol clock delay. This re-arranged sequence is a value-variable delay line, termed “an equivalent N×D symbol delay line.” After the first N×D symbols, there are the remaining M symbols. Each decoded symbol has its final value—the optimal value according to the decoder's solution. These symbols are delayed without value changes, therefore these M symbols compose an accurate delay line, and can be simply generated by a standard delay line. However, the first equivalent N×D symbol delay line is required.
In a DFE employing a multiple transposed pipeline structure, such as those shown in FIGS. 1 and 2 , the required temporal continuity is satisfied if the input to the 1st DFE pipeline (the decoded symbol from the 1st decoding state in the trace-back chain of the current bank) has the same time stamp as the un-decoded symbol being input to the trellis decoder, while the input to the 2d DFE pipeline (normally the decoded symbol from the 2d decoding states of the current bank) has a D symbol clock cycle delay, and so on through the input of the last DFE pipeline (normally the final decoded symbol), which has a N×D symbol delay. There must be exactly D symbol clock cycle delays between the consecutive input signals to a multiple transposed pipeline DFE.
As described in the concurrently filed application entitled “Transposed Structure for a Decision Feedback Equalizer Combined with a Trellis Decoder,” the N+1 decoded symbols fed to the DFE employing the multiple transposed pipeline structure are sufficient to generate all equivalent N×D+M decoded symbol delay lines. It will be appreciated that the N+1 decoded symbols inputs to the multiple transposed pipeline DFE are a sub-sequence of the overall equivalent N×D+M decoded symbol delay line.
In a digital television application, the temporal continuity is broken in the normal re-arranged sequence in several cases by the synchronization symbols inserted into the transmitted symbol stream. Unless these cases are specially handled, this will cause the ghost estimation from the DFE to be erroneous, because the decoded symbols to the DFE filter would appear at incorrect locations, and be weighted by erroneous taps. As previously mentioned, in the ATSC standard, the segment and frame synchronization symbols are outside the convolutional coding. Consequently, the trellis decoder must account for these symbols by interrupting normal operation, so that it is decoding the symbol stream produced by the encoding process. The specific “corner” cases to be specially handled are:
1. The segment synchronization symbols pass the cursor. The cursor symbol has the same time stamp as the currently input un-decoded symbol to the trellis decoder. When this happens the trellis decoder pauses decoding. Thus, the trellis decoder stops taking in new un-decoded symbols, tracing back, and updating the intermediate decoded results held in the inner decoding stages of its current bank. Nevertheless, it continues rotating banks. The suspension of decoding obviously breaks the temporal continuity in the resulting intermediate decoded results from the “frozen” decoding bank. 2. The “tail” region following the segment synchronization symbols. Once the segment synchronization symbols pass the cursor the trellis decoder resumes the decoding process. However, during the following N×D symbols the banks that were interrupted by the segment synchronization symbols do not keep a normal trace-back chain, wherein the time delay between two symbols stored in consecutive stages is equal. Consequently, when one of these banks is rotated to the current decoding bank the output intermediate decoded results contained in the trace-back chain break the continuity rule. 3. When the frame synchronization symbols arrive at the cursor. During the following N×D symbol clock cycles the trellis decoder pauses its decoding process. It stops taking in new un-decoded symbols, rotating banks, tracing back, and shifting the remaining intermediate decoded results held in the inner decoding stages of its current bank. Since no new symbol is decoded and no new decoded symbol is moved into the inner decoding stages the intermediate decoded results held in all banks become obsolete one by one, one in every symbol clock cycle. After N×D symbol clock cycles, the intermediate decoded results held in all banks have become obsolete for feeding to the first part of the DFE. These obsolete decoded symbols have time stamps earlier than frame synchronization, and have passed off their time window to feed into any DFE tap, when the DFE is no longer than the frame synchronization, which is the normal situation. 4. During the frame synchronization period the trellis decoder still pauses its decoding process; it does not take in new un-decoded symbols, rotate banks, or trace back or update the intermediate decoded results held in the inner decoding stages of its current bank. All the intermediate decoded symbols held in the trellis decoder become obsolete for feeding to the DFE. 5. After the frame synchronization symbols pass the cursor. During the following N×D symbol clock cycles after the last frame synchronization symbol passes the cursor the trellis decoder resumes the decoding process. It takes in new un-decoded symbols, and resumes rotating banks and tracing back among the inner decoding stages of its current bank. Since new symbols are decoded and new decoded symbols are moved into the inner decoding stages, the number of obsolete intermediate decoded results in all banks decreases by one in every symbol clock cycle. After N×D symbol clock cycles all of the obsolete decoded symbols are moved out of the trellis decoder, which then returns to the normal decoding process.
A mechanism is required to handle the above corner cases (together with the normal decoding process), which goes between the trellis decoder and the DFE. The normal decoding process is handled by a method of normal re-arrangement, while the corner cases are handled by separate methods. These methods mainly involve the re-insertion of synchronization symbols back into the re-ordered decoded symbol sequence generated by the normal re-arrangement method.
It will be appreciated that all cases fall into one of three general categories: normal operation, segment synchronization related corner cases, and frame synchronization corner cases. The following methods handle each of these three categories.
1. Normal Re-Arrangement
During normal operation all N×D inner intermediate decoded symbols held in the trace-back chains are re-arranged into an equivalent N×D symbol delay line in the order they went into the trellis decoder as input, as shown in FIG. 1 . As shown in FIG. 1 , the current decoding bank is denoted as “relative bank # 1 ,” the previous bank as “relative bank # 2 ,” and so on through bank #D—which, of course, is also the next decoding bank. T(i, j) denotes the intermediate decoded symbol stored in the j th stage of the trace-back chain, in relative bank #i, 1≦i≦D, 1≦j>N. In will be appreciated that the symbol T(i, j) incurs (j−1)D+(i−1) symbol delays after the cursor symbol. Consequently, the arrangement order is given by the syntax:
Equivalent_N × D_symbol_delay_line( )
{
for (j=1; j<N+1; j++)
for (i=1; i<D+1; i++)
T(i,j);
}
The data stored in the same stage of the trace-back chains (D symbols per stage) composes a temporally continuous delay line, shown by the arrow chain in FIG. 1 . The decoded symbols of this equivalent N×D symbol delay line are the first N×D symbols fed to the DFE.
2. Segment Synchronization Related Corner Cases
Firstly, the N×D inner intermediate decoded symbols in the trellis decoder are re-arranged into the equivalent N×D symbol sequence by the method of normal re-arrangement. The sequence is then divided into two pieces by the segment synchronization symbols—which are, of course, skipped by and not actually held within the trellis decoder. The missing segment synchronization symbols must be re-inserted between these two pieces to restore the temporal continuity of the delay line. In the process, the same number of symbols in the earlier piece—preferably, the earliest symbols—must be dropped to preserve the N×D symbol length of the delay line.
The above process produces a delay chain on the layout of the intermediate decoded symbols held in the trellis decoder, as shown in FIG. 2 . Due to bank jumping the decoded symbols stored in the trace-back chains in jumped banks that arrived before the segment synchronization symbols have an extra D symbol delays, shown as cells with slanted line shading in FIG. 2 . It will be appreciated that the symbol stored in cell T(i, j) incurs (j−1)D+(i−1)+D symbol clock cycle delays after the cursor symbol if it is one of these symbols, otherwise it incurs (j−1)D+(i−1) symbol clock cycle delays. In an ATSC standard system the segment synchronization is 4 symbols long. In the layout of the current symbol, if the symbol stored in cell T( 1 , 1 ) when the last segment synchronization symbol came to the cursor has moved on to the cell denoted by T(i 1 , j 1 ), (cell T(D, 2 ) in the example shown in FIG. 2 ), and the symbold stored in cell T( 1 , 1 ) when the first segment synchronization symbol came to the cursor has been moved to the cell denoted by T(i 2 , j 2 ), (cell T( 3 , 3 ) in the example shown in FIG. 2 ), the equivalent N 3 D symbol delay line is given by the syntax:
Equivalent_N × D_symbol_delay_line ( )
{
for (j=1; j<j 1 ; j++) {
for (i=1; i<N+1; i++) {
T(i,j);
}
}
j = j 1 ;
for (i=1; i<i 1 ; i++) {
T(i,j);
}
segment_sync_pattern;
j= j 2 ;
for (i=i 2 +1; i<D+1; i++) {
if (T(i,j−1) is a symbol which arrived before segment sync
in the jumped banks)
T(i,j−1);
else
T(i,j);
}
for (j=j 2 +1; j<N+1; j++) {
for (i=1; i<D+1; i++) {
if (T(i,j−1) is a symbol which arrived before segment sync
in the jumped banks)
T(i,j−1);
else
T(i,j);
}
}
}
In the example shown in FIG. 2 the dropped cells are T( 1 ,N), T( 2 ,N), T( 3 ,N), and T(D 4 ,N), shown as cells with a grid shading. The so acquired equivalent N×D symbol delay line, illustrated in FIG. 2 by the chain of arrows, is continuous in the time domain.
3. Frame Synchronization Related Corner Cases
Firstly, the N×D inner intermediate decoded symbols in the trellis decoder are again re-arranged into the equivalent N×D symbol sequence by the normal re-arrangement process. Then the corner cases related to frame synchronization must be addressed in two ways, separately.
This re-arrangement sequence, which occurs while the frame synchronization symbols are passing the cursor, is in itself an equivalent temporally continuous delay line, but it is frozen instead of being shifted. So the equivalent N 3 D symbol delay line is built from the received frame synchronization symbols followed by the equivalent N 3 D symbol sequence, then cut down to N 3 D symbols by dropping the other earliest symbols. If, in the layout of the current symbol the last data symbol before the frame sync is denoted by T(i 1 , j 1 ), (cell T(D, 2 ) in the example shown in FIG. 3 ), the equivalent N 3 D symbol delay line is given by the syntax:
Equivalent_N × D_symbol_delay_line ( )
{
arrived_frame_sync_sequence;
j = j 1 ;
for (i =i 1 ; i<D+1; i++) {
T(i,j);
}
for (j=j i +1; j<N+1; j++) {
for (i=1; i<D+1; i++) {
T(i,j);
}
}
}
The other corner case related to frame synchronization happens just after the last frame synchronization symbol passes the cursor. This means that the cursor symbol is a data symbol arrived after the frame synchronization symbols. The trellis decoder resumes its decoding process. The equivalent symbol sequence generated by the normal re-arrangement method is not in itself an equivalent delay line. This sequence is broken into two equivalent delay lines with a gap between them caused by the frame synchronization symbols—which are, of course, skipped by and not actually held within the trellis decoder. The missing frame synchronization symbols must be re-inserted back into the gap between these two pieces to restore the temporal continuity of the equivalent delay line. Then it is cut down to desired length of N×D by dropping the earlier symbols. The layout of intermediate decoded symbols held in the trellis decoder is shown in FIG. 3 . The earlier piece of the delay line includes the intermediate decoded symbols having an earlier time stamp than frame synchronization symbols, shown as cells without grid in FIG. 3 . The later piece is shown as cells with grid shading. The cells in the earlier piece incur an additional L symbol delay, where L denotes the length of frame synchronization plus that of two neighboring segment synchronizations. Assume the last data symbol before the frame synchronization is now moved to T(i 2 , j 2 ) in the layout of the current symbol, the equivalent N×D symbol delay line is given by the syntax:
Equivalent_N × D_symbol_delay_line ( )
{
for (j=1; j<j 2 ; j++) {
for (i=1; i<N+1; i++) {
T(i,j);
}
}
j = j 2 ;
for (i =1; i<i 2 +1; i++) {
T(i,j);
}
remaining_frame_sync_sequence;
}
Once again, the equivalent N×D symbol delay line is illustrated by the chain of arrows in FIG. 3 , and is continuous in the time domain.
Thus, the equivalent decoded symbol delay lines provided above always give N×D valid intermediate decoded symbols that satisfy the continuity requirement. When the N×D+M tap DFE is implemented in a transverse structure the equivalent N×D delay line is extended by an M-tap accurate delay line that shifts the final decoded symbol without modification. All of these N×D+M symbols are fed into the DFE. When it is implemented in a multiple transposed pipeline structure, only N+1 decoded symbols are fed into the DFE—specifically, those with a delay of 0 (that is, the first symbol), D, 2D . . . , and so on through N×D, which is the final decoded symbol.
One exemplary structure that employs these methods of covering the above corner cases in digital television receivers, such as ATSC DTV receivers, is shown in FIG. 4 , and indicated generally at 400 . The synchronization symbol re-inserter 400 , which combines the DFE (not shown) and the trellis decoder 420 , comprises a mirrored symbol delay line 410 . The mirrored symbol delay line 410 takes in only N intermediate decoded symbols from the trace-back chain of the current bank in the trellis decoder, and outputs equivalent N×D decoded symbol delay line that satisfies the continuity requirement. The mirrored symbol delay line 410 comprises N delay devices, shown as A 1 through AN in FIG. 4 , and no more than 2N 2:1 multiplexers, labeled B 3 through BN and C 1 through CN in FIG. 4 . Each of the delay devices A 1 -AN delays a decoded symbol by D symbol clock cycles. All of the multiplexers except C 1 and C 2 are organized into pairs to form 3:1 multiplexers; as shown, B 3 and C 3 together form a single 3:1 multiplexer, B 4 and C 4 form a 3:1 multiplexer, and so on through BN and CN. Each pair of adjacent delay devices after the first pair (that is, each pair starting with A 2 and A 3 , inclusive) is cascaded through one of the 3:1 multiplexers.
When the output symbol (Si, i=2, 3, . . . , N) of the previous delay device (A(i−1), i=2, 3, . . . , N) is indicated as a synchronization symbol the multiplexer Ci selects this delayed synchronization symbol. Otherwise, when in segment related corner cases, if the current decoding bank is one of the jumped banks, the 3:1 multiplexers Bi and Ci switch to the intermediate decoded symbol from the neighboring later stage (R(i−1), i=2, 3, . . . , N) when the symbol stored in the current stage (Ri, i=2, 3, . . . , N) arrived before the segment synchronization symbols. Otherwise, the 3:1 multiplexers Bi and Ci pass the output symbol of the current stage from the trellis decoder. It will be appreciated that the synchronization symbol has the highest priority, followed by the symbol from the neighboring later stage, while the symbol from the current stage has the lowest priority. Symbols with the higher priority always override the lower priority symbols.
The N multiplexed outputs (xi, i=2, 3, . . . , N) are fed into the next delay device (A(i), i=2, 3, . . . , N), and are also the input symbols fed to the multiple transposed pipeline DFE. The first multiplexer C 1 follows no previous delay device, so one of its symbol inputs comes from the synchronization symbol generator, which typically generates the predefinded frame or segment synchronization symbols when their stamp arrives.
The synchronization re-inserter 400 further comprises a composite synchronization indicator 470 . The composite synchronization indicator 470 is an independent single bit delay line, also used to determine whether the output symbol (S(i), i=2, 3, . . . , N) of a delay device (A(i−1), i=2, 3, . . . , N) is a synchronization symbol. All synchronization symbol indicators, including the segment synchronization indicator and the frame synchronization indicator, are connected to a logical or-gate to obtain a composite synchronization indicator. The composite synchronization indicator is then delayed by the N×D composite synchronization symbol indicator delay line 470 to give those delayed versions that match the output symbols (S(i), i=2, 3, . . . , N) of the delay devices in the mirrored symbol delay line 410 . Each of these delayed versions indicates whether the output symbol (S(i), i=2, 3, . . . , N) of a delay device is a synchronization symbol. They are connected to a logical or-gate with the original version, respectively, to select the delayed synchronization symbol (S(i), i=2, 3, . . . , N). The segment synchronization indicator and its delayed versions are connected by an or-gate by cascading or-gates (F(i), i=4, 5, . . . , N), to decide whether it is necessary to select the neighboring later stage (R(i−1), i=2, 3, . . . , N) instead of the current stage (R(i), i=2, 3, . . . , N). It will be appreciated that the multiplexer B 1 and B 2 can be optimized away; this causes the first two stages of the structure 400 to appear irregular.
During the normal re-arrangement process the N×D mirrored symbol delay line 410 keeps a mirrored version of the intermediate decoded symbols held by the trace-back chains of all banks in the trellis decoder. During corner cases, the mirrored symbol delay line 410 inserts the synchronization symbol correctly. Indeed, it is the equivalent N×D decoded symbol delay line. When fed to the transposed DFE only tap 0, D, 2D, . . . (N−1)D (shown as decoded symbol #1, #2, . . . #N respectively in FIG. 4 ), together with the final decoded symbol are needed.
In the case of an ATSC receiver, there are 12 trellis coding banks, and typically 16 stages of trace-back chains. Such a trellis decoder keeps 192 intermediate decoded results before it gives out the final decoded symbol. So in the above structure there are 16 delay devices, each covering 12 symbol clock cycles. In this case, N is 16 and D is 12 in FIG. 4 .
In addition to obtaining the intermediate decoded symbol outputs with re-inserted synchronization symbols this structure has another useful function. It can give out a training mode indicator, which is simply the finally delayed composite synchronization signal. This signal provides an ideal control to switch the equalizer between a training mode and a data directed mode.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the description is to be considered as illustrative and not restrictive in character. Only the preferred embodiments, and such alternative embodiments deemed helpful in further illuminating the preferred embodiment, have been shown and described. It will be appreciated that changes and modifications to the forgoing can be made without departing from the scope of the following claims.
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A digital equalizer for interpreting a digital signal including convolutionally encoded symbols and synchronization symbols outside the convolutional code comprises a combined trellis encoder and DFE. The synchronization symbols are re-inserted into the input of the DFE in order to restore time domain continuity created by removal of the synchronization symbols.
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FIELD OF THE INVENTION
This invention relates to disposable absorbent articles and, specifically, to a technique to maintain the integrity of the absorbent core of disposable absorbent articles which enables the absorbent core to maintain its integrity whenever moistened, wet, or stressed by rubbing or movement.
BACKGROUND OF THE INVENTION
In order to position, retain, or hold absorbent cores such as those in disposable absorbent articles the core has been adhered or glued in place. One method deposits an adhesive or glue-type material onto a backing sheet whereon the absorbent core is positioned and thereby fixed in a spacial relationship to the other portions of the absorbent article. As the absorbent core is positioned in contact with the adhesive, the fibers which are on the surface of the core and thereby in contact with the adhesive thus are permanently attached to the backing sheet or the layers and remain fixed relative thereto. However, since the core typically is formed of fluffed cellulose or other absorbent fibers and the individual fibers are not adhered to each other in any way, only those fibers contacted specifically by the adhesive and thus fixed in their position are confined against undesired movement if or whenever the article and core receive moisture. The remainder of the core is free to move or separate.
A significant problem with any absorbent article occurs because the fibers of the absorbent core tend to shift and pull apart and the absorbent core loses its integrity should the absorbent core become wet and/or forces are exerted against it. Forces typically come from the wearer or user of the article due to normal movement in activities such as walking, bending, sleeping or sitting.
With the loss of the integrity of this core, the capability of the absorbent core to absorb and hold fluids is significantly degraded.
The fibers tend to separate if wet and when engaged by forces; thus, gaps in the absorbent core may form and permit the accumulation of fluids in that region without adequate absorbency to accommodate the fluid quantity.
Even though absorbent cores heretofore have been enclosed within an envelope of material, typically pervious to liquids on at least one side, the absorbent core contained therein may and can lose its structural integrity when wet.
According to this invention, the integrity of the fiber absorbent core is maintained even when wet by limiting displacement of the fibers in this core. A plurality of columns inserted into the absorbent fiber core or pad limits or restricts the movement of the core. The columns restrict movement of the fibers engaged by the columns to a very short distance, that between adjacent columns. Thus the columns will not only resist movement and core separation but also act to maintain a fairly even distribution of fibers and, therefore, fairly uniform absorbency. The columns preferably are formed on a backing sheet of a material impervious to liquids. The columns also may be formed on a top sheet, the top sheet being positioned next to the user or wearer of the article. The top sheet column would be projecting away from the user or wearer.
The columns are preferably formed by a process known as gravure printing. The polymeric material used to form the columns is typically polyethylene for use on polyethylene sheets or polypropylene for use on polypropylene sheets. The polymeric material is heated to the glass transition temperature of the material, Tg, and transformed into a softened and semi-liquid mass which then is deposited into cells or apertures on a gravure printing drum. The drum is rotated into face-to-face engagement with the sheet upon which the columns are to be formed and the softened or semi-molten material is contacted with the supporting sheet. As the supporting sheet is thereafter separated from the gravure printing drum or plate, the softened material will tend to string or pull out into an elongated form prior to cooling below its glass transition temperature, Tg. As the material is pulled out or strung into a plurality of vertical prongs and subsequently hardens, the prongs then are cut with the hot wire. It is important that the hot wire be disposed at a position which allows stretching of the material to occur prior to the material being severed, thereby leaving a series of columns protruding from the support sheet. Prophetically, excess height of the columns could be trimmed away by means of mechanical cutters and trimmers or by means of a hot wire which extends transverse to the sheet, at a height to allow the desired column height.
The gravure printing roll is maintained in a substantially one-to-one velocity ratio with the backing sheet; and as the backing sheet is separated from the printing roll, the columns will be pulled substantially perpendicular to the backing sheet. Depending upon preference, the columns may be of any cross-sectional shapes such as circular, oval, round, rectangular or triangular. The base end of the column is deposited on and joined to the backing sheet, typically by fusing with the material of the backing sheet at the column/support sheet interface as the heat softens the backing sheet.
The distal end of the column also may be of various configurations. Typical configurations may include a bulbous end, a hooked end, or sheared to form a pile from the columns otherwise cut off at a desired height. All of the above type terminations of the distal end are suitable as are any other form or shape of the distal end which may be inserted into the fiber mass of the absorbent core.
The absorbent core itself typically is a fluffed mass of cellulose fibers but it should be understood that it may be made of shredded foam or any other absorbent material. The fluffed core typically is deposited onto the support layer and pressed onto the columns formed on the support layer. As the columns penetrate and protrude into the absorbent core, they tend to limit the movement of the fibers of the absorbent core in a plane substantially parallel to the support layer. Movement of the fibers in directions corresponding to the axis of the projection is restricted by the construction of the absorbent article. A top sheet of liquid pervious sheet material may be provided with columns in a manner similar to or identical to that generally described above with the columns faced towards and projected into the fibrous absorbent core.
The top and backing sheets of the article then may be joined to form an envelope containing the absorbent core; if desired, attachment or fastening means for holding the article on the wearer in a position intended for both efficiency and comfort may be provided.
Significant and advantageous benefits resulting from the invention include improved wet integrity and improved uniformity of absorbency.
This invention will be described in more detail with reference to examples which are illustrated in the accompanying drawings.
FIGS. 1 and 2 show perspective views of an absorbent garment which advantageously incorporates the subject invention.
FIGS. 3 and 4 detail sectional views of the absorbent articles, illustrated in FIGS. 1 and 2, taken along Lines 3--3 and 4--4, respectively.
FIG. 5 illustrates a device for forming columns on sheet material.
FIG. 6 is a typical column as well as a three axis reference diagram.
FIGS. 7A thru 7D illustrate various forms of columns which may be advantageously incorporated into the absorbent disposal articles.
FIG. 8 is a sectional view of a bed pad with columns exposed on the backing sheet for engagement with bedding.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiments of the invention are described below; referring initially to FIG. 1. A disposable diaper is illustrated. The diaper illustrated is of the type described in U.S. Pat. No. 3,860,003 issued to Kenneth Barclay Buell and commonly assigned herewith.
While a diaper is used for illustrative purposes, other disposable absorbent articles such as sanitary napkins or briefs can be fabricated using the invention described herein.
The foregoing U.S. Pat. No. 3,860,003 is incorporated herein by reference for the teaching of construction of a disposable absorbent article.
The disposable diaper of FIG. 1 is comprised of a backing sheet 12, absorbent core 14 and a top sheet 16. In addition, the disposable diaper 10 may further comprise attachment and retention tabs 18 to permit the attachment of the diaper 10 to the wearer as well as to retain it in the desired position relative to the wearer. The absorbent core 14 is preferably fabricated from a fluffed cellulose fiber pad 22 and may be contained within an envelope 19 formed of a liquid permeable sheet material 20. The liquid permeable sheet material 20 enveloping pad 22 may be manufactured of any material which is pervious to liquid, such as apertured film, woven or non-woven fabric. Formed onto one surface 21 of the enveloping material 20 are a plurality of columns 24 which project substantially perpendicular to the plane of the material forming the envelope 20. The columns 24 are physically attached or adhered to the surface 21 of the material 20 forming envelope 19 and project into the fibrous absorbent pad 22. The columns 24 do not significantly degrade the liquid pervious nature of material 20.
The absorbent core 14 is placed onto backing sheet 12 and then a top sheet 16 overlaid onto the backing sheet 12 and absorbent core 14. Top sheet 16 preferably is manufactured from materials which are hydrophobic, compliant, feel soft to touch, and nonirritating to the wearer's skin. A preferred top sheet could comprise polypropylene fibers having a denier of about 1.5, such as Hercules Type 151 polypropylene fibers marketed by Hercules, Incorporated of Wilmington, Del. Alternative materials for top sheets include porous foams, reticulated foams, apertured films, natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers) or a combination of natural and synthetic fibers.
The top sheet 16 then is joined around its periphery to the backing sheet 12 by gluing, fusing or ultrasonic bonding. Other joining techniques may be used so long as the joint could not become a source of irritation to the wearer.
FIG. 2 illustrates an alternative embodiment where the columns 24 are formed directly on backing sheet 12 in a pattern which generally would correspond to the shape of the absorbent pad 22. The pattern may be controlled by the gravure printing drum or plate to be described below. The absorbent pad 22 forming the absorbent core 14 typically is a fluffed mass of absorbent fibers, such as cellulose, which may be directly deposited onto the backing sheet 12 and columns 24. Thereafter, a top sheet 16 is overlaid onto the backing sheet 12 and the absorbent core 14. The face 17 of top sheet 16 which engages absorbent core 14 is similarly provided with columns 24 substantially identical to the columns 24 formed on backing sheet 12. The top sheet 16 and backing sheet 12 then are joined or fused at the margins 13 to envelop and contain core 14. The significant difference between the embodiments illustrated in FIG. 2 and FIG. 1 is the elimination of the separate envelope 19 in FIG. 2.
FIG. 3 is a partial sectional view of a disposable absorbent article such as a disposable diaper, disposable incontinence pad, sanitary napkins, panty liners or an absorbent bedding pad. The absorbent pad 22 is surrounded and contained by an envelope 19 having columns 24 extending from said envelope 19 into the pad 22 of fibers 23 thereon forming the absorbent core 14. The top sheet 16 and backing sheet 12 are illustrated as joined at periphery 13 by any desired and conventional technique, such as glue, heat fusing or ultrasonic bonding.
FIG. 4 illustrates a sectional view of a portion of an absorbent disposable personal article as in FIG. 3, wherein the top sheet 16 and backing sheet 12 each are provided with a plurality of columns 24 protruding from the surfaces of each of the sheets 16, 12, respectively, that project into the pad 22 of fibers 23 and that engage the fibers 23 which constitute at least a portion of the absorbent core 14. The absorbent core 14 in this embodiment does not have an envelope. Similar to the construction illustrated in FIG. 3, the margins of top sheet 16 and backing sheet 12 are joined or fused at a periphery 13.
The columns 24 which project from surfaces of top sheet 16 and backing sheet 12 preferably are formed by a gravure printing process. In the gravure printing process diagrammatically illustrated at FIG. 5, a backing roll 40 is provided to support sheet 42. Sheet 42 ultimately may become a backing sheet 12, top sheet 16 or envelope material 20 depending upon the type of sheeting selected and printed. One surface 41 of sheet 42 is engaged with gravure roller 44 which forms a nip 46 in cooperation with backing roll 40.
A reservoir 48 contains a quantity of materials, such as polyethylene or polypropylene dependent upon the material forming sheet 42, and is provided to supply the material contained in reservoir 48 to the cells or apertures 50 formed in the surface of gravure roller 44. A doctor blade 52 acts to prevent excessive quantities of the material within reservoir 48 from adhering to the surface 51 of gravure roller 44 at locations other than in cells or apertures 50. Backing roll 40 and gravure roller 44 rotate in the directions indicated by arrows 54 and 56, respectively, thereby transporting sheet 42 through the nip 46 and create continuous contact of a new portion of the surface of sheet 42 with the material from reservoir 48. The material, polyethylene or polypropylene or other suitable material, is heated to its glass transition temperature, Tg, and slightly above to transform the solid material into a thick semi-molten mass. As the heated material in the gravure cells or apertures 50 is contacted onto a face 41 of sheet 42, the heat contained therein will soften a minute region of the surface 41 of sheet 42, and the material contained in the gravure cells or apertures 50 will join to and be adhered or fused to sheet 42. As the gravure roller 44 is separated from sheet 42, the molten material from cells or apertures 50 will be pulled to form strings 25; upon cooling sufficiently below the glass transition temperature, Tg, of the material, strings 25 will be cut leaving a pile of columns 24 which project generally normal to the surface of sheet 42.
The columns 24 may project at an angle relative to sheet 42, but preferably have a component normal to the sheet 42. The columns 24 then may be trimmed by any suitable trimming device or technique, but the preferred approach is to use a hot wire 58 extended transverse to the direction of the movement of sheet 42 and displaced from the surface of sheet 42 by a distance to yield a plurality of columns 24 of substantially uniform height. The columns 24 then will be a form of stubble extending normally from the sheet 42.
The density of the columns 24 per square unit of measure will be a function of the number of gravure cells or apertures 50 formed into the printing surface 51 of printing drum 44. Alternatively, a screen, not shown, may be used and attached to the drum 44 to provide the gravure cells or apertures 50. Typical densities may range from as low as 144 columns per square inch to as high as 1600 columns per square inch, with a preferred density of approximately 400 to 600 columns per square inch. The apparatus described in FIG. 5 and its operation is substantially the same apparatus disclosed and described in U.S. Pat. No. 5,180,534 issued to Dennis A. Thomas, et al., and commonly assigned herewith and incorporated herein by reference.
The substantial difference in the two apparatuses is that the velocity ratio of the printing surface 51 of gravure roller 44 and the sheet 42 is maintained at a 1:1 ratio. This ratio tends to form the columns 24 in a substantially perpendicular orientation to the sheet 42. The process of U.S. Pat. No. 5,180,534 is modified such that the velocity ratio between the periphery of the gravure roller 44 and the sheet 42 is maintained at a 1:1 ratio, rather than the velocity differential disclosed in U.S. Pat. No. 5,180,534.
Referring now to FIG. 6, a typical column 24 is illustrated along with a segment of sheet 42 and additionally illustrates the terminal or distal end 60 of column 24. The distal end 60 in this illustration may result either from a clipping or shearing action or the use of the hot wire trimmer 58 as illustrated in FIG. 5. It is very possible, depending upon the temperature of the hot wire 58 and its relative location to the nip 46, that other forms of the tip 60 also may result from hot wire trimming.
As can be readily observed, with columns 24 extending upwardly from the sheet 42 if a fibrous absorbent core 24 is placed onto column 24 in a downward Z direction of movement, the column 24 will restrict the movement of the fibers 23 closely positioned to the column 24 and thus prevent movement in the XY plane. With movement constrained in the XY plane and additionally with a large number of similar columns 24 engaging the same or other fibers in the core 22, at least those fibers 23 near the surface of the core 22 become partially immobilized with the exception of movement in the Z direction.
Movement of fibers 23 in the Z direction is constrained by the fibrous absorbent core 22 being entrapped between a top sheet 16 and a backing sheet 12, as illustrated in any of FIGS. 1 thru 4.
The manufacture of the columns 24 may result in many different shapes, not only of the columns 24 but also of the tips 60 of the columns 24. Referring now to FIGS. 7A thru 7D, several different possible shapes of the columns 24A, 24B, 24C, and 24D are illustrated. The columns 24A thru 24D will be essentially free-formed during the manufacturing process. By the term free-form, it is intended to convey that there is no effort to make the columns 24A thru 24D conform to any precise shape or aspect ratio, but result from stringing the molten polymeric material after the molten polymeric material has contacted the sheet 42, which may subsequently be formed into top sheet 16, backing sheet 12, or material 20 of envelope 19, as illustrated in FIGS. 1 thru 4. It should be noted that the axis of the columns 24a thru 24d form an angle theta with respect to sheet 42. Angle theta is preferably 90 degrees but may vary acceptably therefrom to a limited amount. The angle is measured using the technique described in U.S. Pat. No. 5,180,534, and may satisfactorily deviate from the ideal 90 degrees by about 45 degrees resulting in an angle theta from 45 degrees to 90 degrees.
FIG. 7A illustrates a clipped distal end 60a either formed by mechanical shearing or by hot wire trimming, as previously described.
FIG. 7B illustrates a tip where the tip 60b as the natural result of the string 25 breaking during the manufacturing process.
Tip 60c as shown in FIG. 7C illustrates a tip formed by the material drooping or collapsing from its own weight, a result either of slow cooling after the string 25 has broken or by a hot wire trimmer 58 severing the column 24, with the material being sufficiently hot to effectively delay the cooling of the material below its glass transition temperature, Tg, thus permitting the softened and molten material to fall over forming a hook as in tip 60c.
FIG. 7D illustrates a bulbous termination 60d of column 24d. This form may also be the result of a hot wire trimmer 58 whereby the material immediately adjacent to the hot wire 58 is sufficiently heated or reheated to flow and coalesce into a bulbous form on the top 60d of the otherwise rigid column 24d.
Inasmuch as any of these forms may be projected into the fibrous mass of the absorbent fiber core 14 and then restrict the movement of pad 22 in the XY plane, parallel to the surface of sheet 42, any of these terminations 60, 60a, 60b, 60c, 60d are acceptable.
The height of the completed columns 24 as shown in FIG. 6 for columns 24a thru 24d may be as much as 21/2 to 3 millimeters, if the fiber absorbent core 14 is sufficiently thick or may be a fraction of a millimeter for a very thin core 14 with a preferred height of about one millimeter. The difference in the thickness in the cores 14 will depend to some extent upon the absorbency required for the particular article or the nature of the article. The use of the columns 24 to constrain movement and to preserve integrity of the absorbent core 14 may be advantageous not only in disposable diapers, but may also be used in catamenial products, bed pads and other absorbent articles wherein the integrity of the fiber absorbent core 14 must be maintained should the absorbent core 14 become wet, moist, or stressed.
An example of a catamenial product which may advantageously utilize the invention disclosed herein is disclosed and claimed in U.S. Pat. No. 4,950,264 issued to Thomas W. Osborn, III and commonly assigned herewith. This patent, U.S. Pat. No. 4,950,264 hereby is incorporated by reference herein for purposes of disclosure regarding the construction, fabrication and conformation of the disposal absorbent article disclosed therein. As with the disposable diaper 10 disclosed in FIGS. 1 or 2 of this specification, the absorbent pad 22 making up the absorbent core 14 may be made from any suitable absorbent material including wood pulp, creped cellulose wadding, absorbent foams, absorbent sponges, synthetic staple fibers, polymeric fibers, hydrogel forming polymer gelling agents, or any equivalent materials or combination of materials. The only requirement of the core 14 is that the columns 24 protruding from the sheet 42 as illustrated in FIG. 5 may be pressed into the core 14, regardless of whether the core 14 is contained such as by envelope 19 in FIG. 1 or is deposited as a loose batt or batting of material onto backing sheet 12 and overlaid by top sheet 16 as illustrated in FIG. 2.
For uses such as bed pads, it may be desirable to deposit the columns 24 onto both surfaces of a backing sheet 12 as shown in FIG. 8. The exposed columns 24 on the surface of backing sheet 12 will engage the bedding and resist slippage of the bed pad relative to the bedding. Nevertheless, a bed pad need not have columns 24 on the exposed surface of backing sheet 12.
It will be apparent to one skilled in the art that various other modifications and combinations of the columns 24, backing sheets 12, top sheets 16 and absorbent cores 14 may be fabricated into numerous different articles of an absorbent and disposable nature which may advantageously incorporate the integrity stabilization aspects of the present invention. Also, it will be apparent to one skilled in the art that minor modifications and changes may be made to different aspects of this invention and still fall within the scope of the appended claims.
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A technique to preserve absorbent core integrity in a disposable article is described.
Columns which protrude from the backing sheet of an absorbent disposable article or personal wear garment and which project into the fibrous mass of an absorbent core overlaid onto a liquid impervious backing sheet are disclosed. A top sheet which is pervious to liquids overlies the core of fibrous material encapsulating the absorbent core in cooperation with the backing sheet. The top sheet also may carry similar columns. These columns act to restrict the movement of the fibers in the absorbent core and, more particularly, to enhance and maintain the integrity of the absorbent core whenever wet and/or placed under stress. These columns serve to resist and to diminish any disintegration of the absorbent core.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to detecting circuits and, more particularly, to the detection of a direct current voltage in the presence of interfering alternating current and direct current voltages.
2. Description of the Prior Art
It is well-known to provide the detection of direct current voltages by means of voltage threshold devices which respond to voltages exceeding that threshold. Particular problems arise, however, in environments in which spurious voltages are also present and which must be discriminated against when detecting the desired voltage. Thus, direct current voltages of different polarity or of different magnitudes must be discriminated against as well alternating current voltages which may have components exceeding the test voltage. One such system is shown in U.S. Pat. No. 4,270,030 issued May 26, 1981 to S. J. Brolin et al.
In a telephone system environment, it is often necessary to detect a particular line voltage level while, at the same time, not to interfere with standard test responses such as leakage tests and foreign potential tests. The detector circuit must therefore not only respond correctly to the desired voltage, but also present a high enough impedance to permit standard leakage tests. In addition, the detector circuit must not feed voltages back into the telephone circuit which would cause false responses during a foreign potential test.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiment of the present invention, a voltage detector is provided which includes an alternating current filter section, a diode and a threshold voltage detector. The filter removes alternating current components while the diode isolates the circuit being tested from voltages generated in the detection circuit. The threshold detector insures that the direct current voltage being measured has a magnitude exceeding a specified preselected threshold.
One feature of the present invention is the ability of this detector circuit to present a very high impedance (the reverse bias impedance of a low leakage diode) to a negative potential placed on a telephone line circuit, thus providing compatability with leakage testing.
In accordance with another feature of the invention, the detector circuit is immune to alternating circuit voltages, such as induced 60 Hz voltages, and is not responsive to voltages of a proper polarity but of a lower magnitude than the test voltage.
Finally, the detector circuit of the present invention does not place any voltages on the line being tested which might be interpreted as foreign potentials.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a detailed circuit diagram of a telephone line circuit including the test voltage detector in accordance with the present invention; and
FIG. 2 is a detailed circuit diagram of the test voltage detector shown in block form in FIG. 1.
DETAILED DESCRIPTION
In FIG. 1 there is shown a detailed circuit diagram of a telephone line circuit comprising a hybrid coil 1 having two primary windings 2 and 3 and two secondary windings 4 and 5. A capacitor 6 is connected in series between primary windings 2 and 3. Windings 2 and 3 are connected to tip conductor 7 and ring conductor 8, respectively, which are connected to the central office appearance of a telephone line. Secondary windings 4 and 5 are connected in series to a pair of conductors 9 which, in turn, are connected, for example, to a pair gain system. As previously noted, such a pair gain system is shown in the S. J. Brolin et al patent.
Connected to primary winding 2 is a test voltage detector 30 having an input terminal 10 and an output terminal 21. Detector 30 detects the presence of a test voltage on tip conductor 7 having a magnitude which exceeds a threshold, e.g., 90 volts, and which is poled so as to be positive on tip conductor 7. Detector 30 is unresponsive to positive voltages of lower magnitude, is unresponsive to negative voltages on tip conductor 7 and is unresponsive to alternating current signals on tip conductor 7. The output of detector 30 at terminal 21 is utilized in the pair gain system to initiate test activities on the particular telephone circuit connected to conductors 7 and 8. As noted in the aforementioned S. J. Brolin et al patent, these tests may comprise local drop tests at the remote end of the pair gain system as well as tests of the pair gain system itself.
In FIG. 2 there is shown a detailed circuit diagram of the test voltage detector 30 shown in block form in FIG. 1. The voltage detector of FIG. 2 comprises an input terminal 10 to which is connected a resistor 11, the other end of which has a capacitor 12 connected to ground potential. The midpoint of resistor 11 and capacitor 12 is connected to the anode of a diode 13, the cathode of which is connected through a resistor 14 to the base electrode of transistor 15. The base electrode of transistor 15 is biased through a biasing resistor 16 to negative voltage source 17.
The emitter of transistor 15 is connected to ground potential. A diode 18, poled oppositely to the base-emitter junction of transistor 15, is connected between the base and emitter of transistor 15. The collector of transistor 15 is biased through biasing resistor 19 to positive voltage source 20. The collector of transistor 15 is connected to output terminal 21.
The circuit of FIG. 2 operates as follows: In the absence of an enabling voltage at input terminal 10, a current is drawn through diode 18 and resistor 16 to negative voltage supply 17. The voltage drop across diode 18 (approximately 0.6 volts) provides a reverse bias on the base of transistor 15 which keeps transistor 15 cut off. Under this condition, the voltage at output terminal 21 is the value of bias supply voltage 20. In order to perform a telephone line foreign potential test, it is important that the present detector circuit not cause voltages to appear on the connected telephone circuit. Diode 13 is forward biased during foreign potential tests, however, and provides a compensating voltage drop opposite to the voltage drop across diode 18; therefore, the net voltage fed back to input terminal 10 is essentially zero. Thus, the circuit of FIG. 2 does not interfere with foreign potential tests.
Alternating current components at input terminal 10 are filtered out by the combination of resistor 11 and capacitor 12 and thus are insufficient to trigger the detector circuit.
A positive voltage at input terminal 10 forward biases diode 13, causing a current to flow through resistors 11 and 14. The bias current flowing through diode 18 and resistor 16 must, however, be overcome by the current flowing through diode 13 before transistor 15 is triggered ON. The values of the circuit components are chosen such that this bias current is overcome only when the voltage at input terminal 10 exceeds the desired value. Thus, the threshold value is essentially determined by the values of resistors 11, 14 and 16 and power supply 17. When this threshold current is exceeded, transistor 15 is turned on and rapidly saturates to pull the voltage at output terminal 21 from the positive voltage of supply 20 to near ground potential. This shift in voltage levels at output terminal 21 represents the output of the detector and thus signals the presence of a positive voltage of the proper magnitude at input terminal 10.
It will be noted that the diode 13 in FIG. 2 is placed after, rather than before, the filter section comprising resistor 11 and capacitor 12. In this way, no nonlinear filtering or rectification of the alternating current components takes place in the circuit. In addition, the values of resistors 11 and 14 can be chosen so as to be sufficiently high that the detector of FIG. 2 presents a high impedance to the telephone loop connected to input terminal 10. As previously mentioned, the telephone loop is isolated from voltages generated in the circuit of FIG. 2 by the compensating voltage drops across diodes 13 and 18.
Appropriate values for the components of FIG. 2, when used to detect a test voltage equal to or exceeding 90 volts, are given in Table I.
TABLE I
R11=82.5K ohms
R14=82.5K ohms
R16=23.3K ohms
R19=100.0K ohms
C12=2.15 microfarads
Such a circuit can therefore be used to respond uniquely to a positive test voltage of 90 volts or more and yet be unresponsive to alternating current voltages, negative voltages, or positive voltages less than 90 volts.
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A direct current voltage detector is disclosed including a low-pass filter, an isolating diode and a threshold detector. The circuit is designed to be simple and inexpensive and causes no interference with foreign potential and leakage tests on a telephone line.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates broadly to prosthetic implants, and more particularly, to prostheses for human joints, such as the knee, implantable by means of arthroscopic as well as open surgical techniques.
2. Discussion of the Prior Art
Previous proposals for artificial knee prostheses including components for surgical implantation into a patient's knee are known in the art. The complexity of normal knee movement, however, has rendered the attainment of natural knee action quite difficult. More specifically, the natural knee joint includes the bottom part of the femur, constituted by the two condyles, the lower parts of which bear upon the complementary shaped upper surface plateaus of the tibia through the intermediary of cartilage or meniscus. Connection through the knee is provided by means of ligaments which also provide joint stability and assist in absorbing stresses applied to the knee. The femur, cartilage and tibia are normally subjected to significant compression loading in supporting the weight of the body.
Movement of the normal knee is not a true hinged joint about a single center but, rather, is a complex action including rocking, gliding and axial rotation. During the first part of the knee movement from full extension of the leg towards flexion, there is pivotal rotation of the tibia about the femur, which is then converted to a rocking movement wherein the femoral condyles roll posteriorly on the tibial plateaus. The rocking movement then changes to a combined sliding and pivoting movement wherein successive points on the femoral condyles slide forward on the tibial plateaus until full flexion is obtained. In other words, the flexion movement is polycentric, that is, about different centers which are not fixed in one position but lie in a somewhat spiral or polycentric pathway.
A variety of total knee prostheses have been proposed, essentially being of two broad types, hinged and non-hinged. Knee prostheses of the first category possess significant disadvantages in that they generally involve the removal of natural ligaments and only permit motion about a single axis as opposed to the controlled rotation and translation characteristic of a natural, healthy knee.
Knee prostheses of the second type generally include femoral components secured to the condylar surfaces of the femur, typically having cylindrical bearing surfaces, and tibial components fixed to the tibial plateaus, the femoral components bearing against the upper surfaces of corresponding tibial components. Examples of prostheses of the latter type are shown in U.S. Pat. No. 4,470,158 to Pappas et al; U.S. Pat. No. 4,211,228 to Cloutier; U.S. Pat. No. 4,207,627 to Cloutier; and U.S. Pat. No. 3,953,899 to Charnley.
In addition to total knee replacement, unicompartmental knee replacement is known wherein a single compartment of the knee is surgically restored. Typically, the medial or lateral portion of the tibio-femoral joint is replaced without sacrificing normal remaining structure in the knee. For instance, U.S. Pat. No. 4,340,978 to Buechel et al discloses a unicompartmental knee replacement device including a tibial platform secured to the tibia and having a track for receiving a bearing insert. A femoral component is attached to one of the condylar surfaces of the femur and is provided with a generally convex spherical inferior surface for engaging the superior surface of the bearing insert. Similar unicompartmental knee implants are shown in U.S. Pat. No. 4,743,261 to Epinette; U.S. Pat. No. 4,309,778 to Buechel et al; U.S. Pat. No. 4,193,140 to Treace; U.S. Pat. No. 4,034,418 to Jackson et al; and U.S. Pat. No. 3,852,830 to Marmor.
The non-hinged knee implants previously discussed, while possessing advantages over the hinged devices, nonetheless are characterized by numerous drawbacks. Many of the prior art prostheses require the removal of a great deal of bone from the femur and tibia in order to accommodate the implant, thus complicating and prolonging the surgical procedure and reducing the amount of bone available in reserve should subsequent restorative measures be required. Additionally, alignment of the prosthesis components is extremely difficult, and even small misalignments lead to an imbalance of the forces transmitted from the femoral component to the tibial component. The asymmetric distribution of load on the plateaus of the tibial component can result in tibial loosening and failure of the prosthesis. Moreover, inadequate fixation of the prosthesis can occur, possibly resulting in the prosthesis twisting loose from the implanted position.
The misalignment and anchoring problems associated with conventional prostheses are due in part to the fact that the prosthesis is secured in place by means of cement applied to the prosthesis after a trial fit and prior to actual fixation. Although the joint may have been precisely prepared to accept the prosthesis, and although the femoral and tibial components may have been accurately aligned during trial fitting, deviation from the desired location is apt to occur when the prosthesis is removed to place cement on the prepared bone surface and then replaced on the bone surface.
The prior art prosthetic devices have another disadvantage in that excess cement tends to escape from between the bone and the implant around the edges of the implant. The excess cement, if not removed, may deteriorate and crumble, thereby becoming a source of possible irritation. Additionally, cracking and breakage of the cement may lead to loosening of the cement bond, thus jeopardizing the integrity of the cemented parts. Therefore, additional steps are typically undertaken to remove the excess cement squeezed out during the surgical procedure.
Several of the prior art prosthetic devices previously referred to are illustrative of the foregoing deficiency. For example, Buechel et al ('978) is directed to a unicompartmental knee prosthesis wherein the prosthesis components must be removed after a satisfactory trial fit to allow cement to be placed on the bone surfaces. The components are then reintroduced into the surgical site, located in the pre-established position and firmly held in compression with the bone until complete polymerization has been obtained. Excess cement is removed from the edges of the prosthetic component by a scalpel and curette. Similarly, Charnley teaches inserting cement through a hole cut into the head of the tibia. The anterior end of the tibial component is then elevated to cause the posterior end to press into the tibia bone so as to close the posterior route of escape for the cement. Treace discloses a knee prosthesis for fixation to the femur including a curved body provided with a plurality of cement holding rings fixedly attached to and extending upwardly from the upper surface of the body. The femur must be prepared by drilling slots therein for receiving the cement holding rings subsequent to cement being injected into the slots.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to overcome the above mentioned disadvantages of the prior art.
Another object of the present invention is to provide a prosthesis permitting cement to be supplied between the prosthesis and the prepared tissue surface after the prosthesis has been positioned on the tissue surface.
A further object of the present invention is to provide a prosthesis which can be implanted utilizing arthroscopic surgical techniques.
An additional object of the invention is to utilize a rim to control rotation of a femoral prosthesis during fixation by cement.
The present invention has another object in that unicompartmental prosthetic total knee replacement can be performed with the use of modular tibial components, bearing inserts and femoral components.
Another object of the invention is to provide a tibial prosthesis receiving bearing inserts of varying thicknesses to provide accurate alignment.
According to the present invention, therefore, a prosthesis includes a body having a fixation surface for placement adjacent the surface of the tissue, such as bone, to which the prosthesis is to be affixed. A recess is formed in the fixation surface of the body such that, when the fixation surface is positioned adjacent the bone surface, the recess is substantially closed off by the bone surface to define a cement receiving chamber. Securing means such as a screw or post member secures the body member in position on the bone surface. A channel formed in the prosthetic body establishes communication between the cement receiving chamber and the exterior of the body member, and cement is introduced into the cement receiving chamber via the channel. Thus, the prosthesis may be cemented in place while in the desired position and secured against movement. The invention further contemplates a wall or rim extending from the fixation surface for penetrating the bone surface when the prosthesis is in position thereon so as to provide additional stability. The rim extends along and at least partially surrounds the recess to serve as a seal or trap for preventing release of cement from the cement receiving chamber thereby augmenting cement pressurization.
Some of the advantages of the present invention over the prior art are that the prostheses can be placed using arthroscopic surgical techniques, textured surfaces enhance the prosthesis-cement interface, the asymmetrical shape of the tibial prosthesis component provides optimal coverage of the tibial plateau, the modular design allows variation of final tibial thickness, the femoral prosthesis component does not interfere with the patella, two spaced tapered posts on the femoral prosthesis component provide rotational stability, a rim extending along a recess in the fixation surface of the femoral prosthesis component resists rotation of the implant and augments cement pressurization, a rim extending along a recess in the fixation surface of the tibial prosthesis component holds the implant in place and augments cement pressurization, and a portal or channel through the tibial and femoral prosthesis components allows placement of bone cement between the implant and the prepared bone surface after the implant has been accurately positioned on the bone surface without moving the implant.
Other objects and advantages of the present invention will become apparent from the following description of the preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the knee joint prosthesis of the present invention with the femur and tibia shown in phantom.
FIG. 2 is a top plan view of the tibial prosthesis component of the present invention.
FIG. 3 is a bottom plan view of the tibial prosthesis component of FIG. 2.
FIG. 4 is a cross-section of the tibial prosthesis component taken along line 4--4 of FIG. 2.
FIG. 5 is an enlarged fragmentary view taken along line 5--5 of FIG. 4.
FIG. 6 is a broken side view of the tibial prosthesis component with a bearing insert shown in phantom.
FIG. 7 is a top view of a bearing insert of the present invention.
FIG. 8 is a section of the bearing insert taken along line 8--8 of FIG. 7.
FIG. 9 is a bottom plan view of another embodiment of the tibial prosthesis component of the present invention.
FIG. 10 is a side view of a further embodiment of the tibial prosthesis component of the present invention.
FIG. 11 is a side view of the femoral prosthesis component of the present invention.
FIG. 12 is a top view of the femoral prosthesis component of FIG. 11.
FIG. 13 is an anterior view of the femoral prosthesis component of FIG. 11.
FIG. 14 is an enlarged fragmentary view in section taken along line 14--14 of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to prostheses for implant in the body and is particularly described in connection with a prosthesis or implant for the knee joint. A preferred embodiment for a knee joint prosthesis implant according to the present invention is shown in FIG. 1 and includes a tibial prosthesis component 12, a femoral prosthesis component 14 and a bearing insert 60. The tibial component 12 is affixed to a suitably prepared site on the upper plateau 16 of the tibia 18, shown in phantom. The femoral component 14 is affixed to a suitably prepared site on a condyle 20 of a femur 22, shown in phantom.
FIGS. 2-6 show a preferred embodiment of the tibial component 12 including a body 24 which, viewed from the top, has a generally asymmetrical, D-shaped configuration with an arcuate side wall 26 joined to a generally planar side wall 28 via curved side wall sections 29. The body 24 has a top or upper surface 30 connecting the upper edges of the planar side wall 28, the arcuate side wall 26 and the curved side wall sections 29. As best shown in FIG. 3, the body has a bottom or fixation surface 32 connecting the lower edges of the planar side wall 28, the arcuate side wall 26 and the curved side wall sections 29.
A cavity 34 is formed in the top surface 30 of the body 24 defined by a planar cavity side wall 36 joined to an arcuate cavity side wall 38 by curved cavity wall end sections 40 and a cavity bottom wall 42 joining the lower edges of cavity side walls 36, 38 and 40. An inwardly tapered through hole 44 is formed in the cavity bottom wall 42 and extends substantially perpendicularly through the body 24.
With particular reference to FIGS. 2 and 4, each curved cavity wall end section 40 has a lip 46 projecting from the curved cavity wall section into the interior of the cavity 34. As shown in detail in FIG. 5, the lip 46 has a chamfered surface 48 extending downwardly from the top surface 30 of the body at an angle of approximately 45°. The surface 48 terminates in a vertical cavity facing surface 50 which joins curved cavity wall section 40 via a horizontal surface 52. Curved cavity wall sections 40 extend downwardly from horizontal surface 52 to cavity bottom wall 42 at an angle of approximately 20° toward the interior of the cavity 34 such that lips 46 form grooves in the side wall curved end sections 40.
With reference to FIG. 6, it can be seen that the top surface 30 of the body 24 is generally flat except for a sloping surface 54 at an anterior portion extending from a straight edge 56 located on the top surface downwardly at an angle of approximately 30° with respect to the parallel top and bottom surfaces to meet the side walls of the body. A through hole 58 is formed in the anterior portion to extend through the body from sloping surface 54 to bottom surface 32 at an angle of approximately 60° with respect to the bottom surface 32 and perpendicular to surface 54.
A bearing insert 60 closely configured to the peripheral dimensions of the cavity 34, as defined by cavity side wall sections 36, 38 and 40, includes a body defined by a planar insert side wall 62 joined to an arcuate insert side wall 64 by curved insert wall end sections 66. The body has an upper surface 68 joining the upper ends of the insert side walls 62, 64 and 66, while the lower ends of the side walls are joined by a lower surface 70.
Upper surface 68 is slightly concave when viewed from the side, as shown in FIGS. 6 and 8. Each curved end section 66 is provided with a flexible protruding lip 72 extending upwardly and outwardly from the lower surface 70 toward the upper surface 68 at an angle of approximately 20° with respect to the end section 66, as best illustrated in FIG. 8, to terminate in an upper edge 73 spaced from the side wall curved end section 66. The insert 60 has a configuration mating with the configuration of cavity 34 and is received in the cavity 34, as shown in phantom in FIG. 6, with the insert bottom surface 70 resting on the cavity bottom wall 42, insert side walls 62, 64 and 66 in close abutment with the respective cavity side walls 36, 38 and 40 and the lips 72 engaged in the grooves beneath lips 46 to securely retain the insert in position within the cavity. A range of inserts ranging in thickness, for example, from approximately 8 mm to 15 mm as measured from the insert upper surface 68 to the insert lower surface 70, is provided so that the proper fit can be attained. The upper surface 68 of the insert will be elevated with respect to the top surface 30 of the tibial component body by varying amounts depending upon the thickness of the particular insert. Preferably, the bearing insert is integrally fabricated in a unitary manner of ultrahigh molecular weight polyethylene.
As particularly shown in FIG. 3, the fixation surface 32 of the body 24 has a recess 74 therein defined within the confines of the side walls 26, 28 and 29 of the body. A channel or portal 76 connects the recess 74 to the exterior of the body and extends from the recess 74 through the arcuate side wall 26 at the anterior portion of the body. The recess 74 and the channel 76 share a common end wall 78 which defines the depth to which the recess and channel extend above the bottom surface 32 into the interior of the body. A land 80 along the fixation surface 32 isolates the through hole 44 from the recess 74, while a land 82 along the fixation surface 32 isolates the through hole 58 from the recess 74. A rim 84 projects from the bottom surface 32 spaced from but following the curve of arcuate side wall 26 with an interruption at the location of channel 76. As is most clearly depicted in FIGS. 4 and 5, the rim 84 is triangular in cross-sectional configuration, with the apex of the triangle forming a sharp bottommost edge 86 for the body. The rim 84 defines a wall extending along the recess 74 and at least partially surrounding the recess.
The tibial component 12 is provided in a range of sizes, for example, with the dimension A of the body ranging from approximately 37.5 mm to approximately 54 mm and the dimension B ranging from approximately 21 mm to approximately 33 mm, as shown in FIG. 2, to accommodate a range of sizes for optimal coverage of the tibial plateau. The asymmetrical "D" configuration of the body further contributes to optimal tibial plateau coverage in order to present a contact area for the femoral component coinciding with that of a normal knee.
The tibial component 12 is particularly designed to be affixed to a suitably prepared tibial plateau through arthroscopic surgical techniques; however, the tibial component can be used in normal open surgery procedures for prosthetic knee replacement. In use, the body can be grasped by an appropriate surgical instrument and placed in position on the tibial plateau with the bottommost edge 86 resting upon the tibial plateau. Once the desired position for the body on the tibial plateau has been established, the body is affixed by a cancellous bone screw 88 inserted at an angle through hole 58 and into the anterior portion of the tibia as illustrated in FIG. 1. A second cancellous bone screw 90 can be inserted through the body into the tibia via through hole 44 if desired. The recess 74 formed in the bottom surface 32 of the body define, together with the tibial plateau, an enclosed cement receiving chamber which communicates with the exterior of the body through channel 76. A bone cement, preferably low viscosity methyl-methacrylate, is injected into the chamber through channel 76 to form a physical bond between the body and the tibial plateau. It can be seen, therefore, that the tibial component can properly be positioned prior to the application of cement and need not be moved or disturbed in any manner thereby assuring precise and accurate positioning. The cement can be inserted in the cement receiving chamber by means of a needle or syringe to be compatible with arthroscopic techniques. The rim 84 forms a seal around the cement receiving chamber with respect to the tibial plateau to augment filling of the cement receiving chamber, and the rim 84 penetrates the tibial surface to establish a seal preventing escape of cement from the chamber while the bottom surface 32 engages the tibial plateau. Additionally, the rim 84 stabilizes the position of the tibial component on the tibial plateau. The lands 80 and 82 along the bottom surface 32 isolate the respective fixation screws from the cement so that the screws can be removed, if necessary. The bottom surface 32 and the wall 78 of recess 74 are textured to enhance the interface between the body and the cement. The invention contemplates a right medial/left lateral orientation for the tibial component in addition to the left medial/right lateral illustrated herein. A suitable bearing insert 60 can be inserted after the body has been implanted, or the insert 60 can be mounted in the body prior to implanting the body.
Another embodiment of a tibial component according to the present invention is shown in FIG. 9 wherein a body 88 is essentially the same as body 24 except that through hole 44 has been eliminated and the recess 90 follows the arcuate wall 26, as does end wall 92. The body 88 thus accommodates only a single screw which, due to its position at the anterior portion of the implant, provides sufficient fixation.
A further embodiment of the present invention is shown in FIG. 10 and is essentially the same as the tibial component of FIG. 9 except that a post 96 depends from the end wall 92 of the recess 90 at substantially the same position as through hole 44 shown in FIG. 3. The post 96 is intended to be inserted into a corresponding drilled hole in the tibial plateau. Preferably, the post 96 is tapered to allow a press fit into the corresponding hole.
The femoral component 14 of the prosthesis of the present invention is illustrated in FIGS. 11-15 and includes a body 100 having a curved configuration defining an arcuate outer bearing surface 102 with an anterior or distal end 104 and a posterior end 106. The bearing surface 102 is generally polycentric, that is, the surface lies on arcs of circles having more than one center and more than one radius to approximate the natural articulating surface of a femoral condyle. The posterior end 106 curves somewhat sharply while the anterior end 104 curves somewhat gradually. In other words, the radius cf an imaginary circle in which the anterior end 104 lies is greater than the radius of an imaginary circle in which the posterior end 106 lies. Body 100 further includes an inner fixation surface which joins the bearing surface 102 at side and end edges. The fixation surface includes a planar posterior section 118, a planar chamfer section 120 and a planar distal section 122. The posterior and distal sections 118 and 122 are oriented substantially perpendicular with respect to each other, while chamfer section 120 is oriented at an angle of substantially 45° with respect to the posterior and distal sections.
As shown in the top view of the femoral component 14 in FIG. 12, the body 100 has a generally straight medial side edge 110 and a generally straight lateral side edge 112 parallel to edge 110 but about one half the length of the edge 110. The side edge 112 is joined to side edge 110 via a generally polycentric curved edge 114. An arcuate posterior edge 116 joins the opposite ends of the side edges 110 and 112. Side edge 110 extends along the sides of the posterior, chamfer and distal sections of the fixation surface. Side edge 112 extends along the sides of the posterior and chamfer sections and along a portion of the side of the distal section, the curved edge 114 extending along the remaining portion of the side of the distal section.
As shown in FIGS. 11 and 12, a recess 124 is formed in the chamfer section 120 and the distal section 122 of the fixation surface. A side wall 126 of the recess 124 generally follows the side edges 110, 112 and 114 of the body 100, running generally parallel thereto but separated therefrom by a portion of the fixation surface. The recess is provided with a bottom surface 128 and terminates along a bottom edge 130 of the posterior section 118. A channel 132 is formed in the bottom surface 128 of the recess 124 extending generally parallel to the side edge 110 of the body 100 in the distal section 122 and through the curved side edge 114 of the body to establish communication with the exterior.
Posts 136 and 138 project upwardly substantially perpendicular to bottom surface 128, preferably at an inclination of 5° from the plane of the posterior section 118. The posts 136 and 138 are generally cone-shaped and have respective tapered top ends 140 and 142. As depicted in FIG. 11, the post 136 is longer than the post 138, the post 138 being around two-thirds the length of post 136. A rim 144 projects from the fixation surface, spaced from but lying generally parallel to side edges 110, 112 and 114 of the body 100. As can be seen in FIG. 12, the rim 144 also lies generally parallel to the side wall 126 of the recess 124 so as to at least partially surround the recess 124 along the chamfer section 120 and the distal section 122. The rim 144 is preferably triangular in cross-sectional configuration to provide a relatively sharp edge 148 as was discussed in connection with rim 84 for the tibial component 12 and as shown in FIG. 14. A semi-circular indentation 150 is provided on each side of the body 100 in distal section 122 proximate side edges 110 and 112 as shown in FIGS. 11, 12 and 13.
The femoral component 14 is adapted to be positioned on a condylar surface of the femur after the surface has been suitably cut and shaped to conform to the fixation surface of the body 100. The femoral component may be positioned by means of open or arthroscopic surgical techniques with the indentations 150 engaged by a surgical tool for placement of the femoral component on the prepared femoral condyle. The posts 136 and 138 are fitted into drilled holes in the cut distal end of the femoral condyle, the tapered upper ends 140 and 142 of the posts allowing for a press fit. With the femoral component in the proper position on the femoral condyle, the rim 144 penetrates the bone to enhance securement and forms a seal with respect to the bone around the cement receiving chamber formed by the recess 124 and the surface of the bone. Cement is introduced into the chamber through the channel 132 by means of a syringe, a needle or the like as discussed in connection with the tibial component. The rim 144 inhibits rotation of the femoral component as do the posts 136 and 138. Preferably, the fixation surface and the recess bottom surface 128 are textured to enhance the interface between the femoral component and the cement. The tibial and femoral components are preferably fabricated of metal, the preferred material for the tibial component being implant grade titanium, and for the femoral component cobalt-chromium.
The surface 102 of the femoral component cooperates with the concave surface 68 of bearing insert 60 to allow the same freedom of movement afforded by a healthy knee. The nonmetallic insert 60 provides a bearing surface for the metallic femoral component similar to the cartilage in a natural knee joint. The plastic material from which the insert is fabricated provides a low coefficient of friction between the contacting surfaces and minimizes the rate of wear of the contacting surfaces of the components. As discussed in connection with the tibial component, it is contemplated that the femoral component be available in a number of sizes, and in right medial/left lateral and left medial/right lateral versions to prevent interference with the patella.
The knee joint prosthesis of the present invention can be used in conventional open, total knee replacement surgical procedures but is particularly useful for implant using arthroscopic surgical techniques due to the simplified cementing procedures and the stability permitted by the tibial and femoral prosthesis components coupled with the modular nature thereof and the use of bearing inserts of varying sizes to produce desired tibial thicknesses or heights. Method and apparatus for implant of the knee joint prosthesis of the present invention are disclosed in an application filed concurrently herewith by the same inventors, entitled "Methods and Apparatus for Arthroscopic Prosthetic Knee Replacement", the disclosure of which is incorporated herein by reference.
Inasmuch as the present invention is subject to many variations, modifications and changes in detail, it is intended that all subject matter discussed above or shown in the accompanying drawings be interpreted as illustrative only and not be taken in a limiting sense.
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A knee joint prosthesis includes tibial and femoral components and a bearing insert designed for unicompartmental prosthetic total knee replacement and can be implanted using arthroscopic surgical techiques. The tibial and femoral prosthesis components have channels or portals therethrough allowing supply of cement to the prosthesis-bone interface after the prosthesis has been positioned for implant. Recesses communicate with the channels and cooperate with the bone surfaces to form cement receiving chambers, and rims at least partially surround the recesses to penetrate the bone surfaces to stabilize the positions of the prostheses and form seals preventing cement from escaping from the prosthesis-bone interfaces.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on and incorporates by reference Japanese Patent Application No. 2003-275952, which was filed on 17. Jul. 2003.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a rotation angle sensor that includes a brushless resolver having a transformer and a magnetic rotor and to a method for winding a rotation angle sensor, and in particular, to a rotation angle sensor in which a rotor transformer winding and a magnetic rotor winding are wound with a single wire.
[0003] A brushless resolver has a transformer winding such that, in addition to the rotor and stator for excitation and detection, the resolver includes a transformer for a power supply. FIG. 5 shows an example.
[0004] FIG. 5 is a cross-sectional view of the structure on the rotor of a conventional resolver. The structure of the stator is omitted. FIG. 5 shows the rotor structure including a rotor 102 having bobbin 103 integrally formed with the rotation shaft 101 (the rotor winding is not shown in the drawing). FIG. 5 represents an improvement over a conventional rotor transformer structure in which the bobbin 103 from is formed separately from the rotation shaft 101 and combined later. The rotor winding and rotor transformer winding are individually formed, and then combined. (e.g., see Japanese patent publication JP H10-170306). Then, the rotor winding and rotor transformer winding are connected, and the connection is performed as described below.
[0005] FIGS. 6A and 6B show a conventional connection of the rotor winding and rotor transformer winding. FIG. 6A shows that a rotor having a magnetic rotor winding and a rotor transformer having a rotor transformer winding are mounted on a rotation shaft. FIG. 6B shows a state in which the lead wires of each winding shown in FIG. 6A are connected.
[0006] The coil bobbin 113 of the rotor transformer 112 is mounted on a winding machine (not shown in the drawing), and an electrical wire is coiled around the groove of the coil bobbin 113 for a predetermined number of times. Then the lead wire 122 a at the starting side of the winding and the lead wire 122 b at the ending side of the winding are temporarily fixed with an insulation tape (not shown in the drawing). Then, the lead wires 122 a , 122 b are led out from the winding machine.
[0007] Regarding the magnetic rotor 114 , a laminated rotor core 123 is mounted on the winding machine and the electric wire is coiled for a predetermined number of times on each of many magnetic poles of the rotor core 123 . The wire may be coiled directly on each magnetic pole or indirectly via a coil bobbin. Then, the lead wire 124 a at the start of the winding and the lead wire 124 b at the end of the winding are temporarily fixed with insulation tape, and then led out from the winding machine.
[0008] Next, a hollow rotation shaft 111 is inserted and fitted in the magnetic rotor 114 and the rotor transformer 112 . Then, as shown in FIG. 6A , the magnetic rotor 114 and the rotor transformer 112 are positioned at predetermined locations on the rotation shaft 111 . At that time, the magnetic rotor 114 and the rotor transformer 112 are arranged so that an opening 119 of the coil bobbin 113 of the rotor transformer 112 is located on the side of the coil bobbin 113 that faces the magnetic rotor 114 .
[0009] When the magnetic rotor 114 and the rotor transformer 112 are positioned properly, insulation tubes 128 are mounted on the lead wires 124 a and 124 b . Then, the starting lead wire 124 a and the ending lead wire 124 b of the magnetic rotor winding 121 are led into the groove of the coil bobbin 113 via the opening 119 . Then, while taking the polarity of the magnetic rotor winding 121 and rotor transformer winding 120 into account, the lead wires 124 a and 124 b of the magnetic rotor winding 121 are connected to the starting lead wire 122 a and ending lead wire 122 b of the rotor transformer winding 120 , so that a series circuit is formed. The insulation coating of the electric wire will not be damaged by the edge of the opening 119 due to the insulation tubes 128 .
[0010] In the case of FIG. 6B , the ending lead wire 124 b and the starting lead wire 122 a are connected with solder 126 . Similarly, the starting lead wire 124 a and the ending lead wire 122 b are connected with solder 127 . The soldered connections are made along insulation tape 125 , which is attached to the surface of the rotor transformer winding 120 , and fixed with resin. This method has the following problems.
[0011] Conventionally, a semi-finished product has been manufactured for each unit. That is, a semi-finished rotor component, in which the magnetic rotor winding is coiled and its lead wire is temporary fixed with tape, and a semi-finished rotor transformer component, in which the rotor transformer winding is coiled and its lead wire is temporarily fixed with tape, are individually formed. Then, an alignment process in which the rotation shaft is inserted in the components is carried out. The alignment is difficult because the finished winding may be mistakenly deformed by being pressed manually or the temporary insulation tape may detach, and the predetermined shape of the coiled winding may be destroyed.
[0012] In addition, when the lead wires of the magnetic rotor winding and the lead wires of the rotor transformer are connected, the lead wires of the magnetic rotor winding are covered with insulation tubes 128 and then fed through the opening 119 . Then, the lead wires 124 a , 124 b , 122 a , 122 b are connected at two junctions, and the two junctions are placed along the rotor transformer winding via insulation tape and fixed with resin. The process is difficult to carry out in a small space, and thus, long lead wires must be employed. Unlike the winding portion, the long lead wires may generate an irregular magnetic field that has an effect on the basic magnetic field, which is based on the designated number of windings, and may create an uneven weight distribution, which may cause oscillations during the rotation. Further, the long lead wires may cause a restriction such that the interval between the rotor transformer and magnetic rotor cannot be narrowed.
SUMMARY OF THE INVENTION
[0013] An objective of the invention is, by taking the above-mentioned problems into account, to provide a rotation angle sensor having a simple connection structure for the lead wires.
[0014] The present invention is mainly characterized in that, in order to reduce the number of connections between the lead wires of the magnetic rotor winding and rotor transformer to one, both windings are formed by a continuous coiling of a single electric wire. To allow the continuous coiling, a notch, through which the wire passes, is formed on the coil bobbin of the rotor transformer.
[0015] The invention is basically a rotation angle sensor characterized in that a coil bobbin of a rotor transformer, which has a notch on its side wall, and a laminated core of a magnetic rotor are arranged parallel to one another on a rotation shaft. A rotor transformer winding and a magnetic rotor winding, in which a single electric wire is continuously coiled on the coil bobbin of the rotor transformer and the laminated core of the magnetic rotor via the notch, are formed. The ends of the electric wire are connected via the notch and are fixed on the rotor transformer winding with resin.
[0016] The laminated core of the magnetic rotor has a plurality of magnetic poles, and the electric wire is continuously coiled on each magnetic pole.
[0017] In another aspect of the invention, the coil bobbin of the rotor transformer has annular grooves, and the grooves are arranged to accommodate the rotor transformer windings.
[0018] In another aspect of the invention, edges of the walls that define the notch are coated with a resin to provide the edges with a low friction surface. The resin is one that provides low friction contact. Thus, the wire will not be damaged by contact with the edges of the walls that define the notch
[0019] Therefore, in one aspect of the invention, the rotation angle sensor includes a coil bobbin of a rotor transformer, which has a notch on the side wall, and a laminated magnetic rotor core. The coil bobbin and the laminated core are located in a parallel relationship on a rotation shaft. A single electric wire is continuously coiled on the coil bobbin to form a rotor transformer. The same wire is continuously coiled on the laminated core to form a magnetic rotor winding. The wire passes from the rotary transformer to the magnetic rotor through the notch. First and second ends of the winding of the electric wire are connected through the notch and fixed on the rotor transformer winding with resin. Therefore, the rotor transformer winding and magnetic rotor winding are formed by a continuous winding of a single electric wire. In addition, only one connection is needed at only one location, allowing the length of electric wire to be shortened at only one place. Consequently, the electric effect and magnetic effect on the winding at the connection can be reduced compared to the prior art.
[0020] The laminated core of the magnetic rotor has magnetic poles, and in principle, only the projected magnetic poles are coiled, allowing machine winding. In addition, for the magnetic rotor winding, when all the magnetic poles are coiled, the end of the winding is directed back to the beginning of the winding, which allows continuous coiling with a single electric wire.
[0021] The coil bobbin of the rotor transformer has annular grooves, which extend at a right angle to the axis of the rotation shaft, and therefore, the rotor transformer winding which is a continuously coiled single electric wire, can be arranged in the grooves.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying figures, in which like reference numerals refer to identical or functionally similar elements throughout the separate views and which, together with the detailed description below, are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention.
[0023] FIG. 1A is a diagrammatic side view illustrating an initial stage of the winding process of the magnetic rotor and rotor transformer of the rotation angle sensor of the present invention;
[0024] FIG. 1B is a diagrammatic side view illustrating an intermediate stage of the winding process of the magnetic rotor and rotor transformer of the rotation angle sensor of the present invention;
[0025] FIG. 1C is a diagrammatic side view illustrating a late stage of the winding process of the magnetic rotor and rotor transformer of the rotation angle sensor of the present invention;
[0026] FIG. 2 is diagrammatic side view of a winding machine that uses the multi-joint robot of the present invention;
[0027] FIG. 3A is a diagrammatic side view of a further embodiment of the invention in which shield plates are fixed adjacent to the rotor transformer and the magnetic rotor;
[0028] FIG. 3B is an end view of a shield plate 52 ;
[0029] FIG. 3C is an end view of a sidewall 18 of a rotor transformer 12 .
[0030] FIG. 3D is an end view of a shield plate 51 ;
[0031] FIG. 4 is a partial cross sectional view of a side wall of the bobbin showing a resin coating on the notch;
[0032] FIG. 5 is a cross-sectional view of a rotor of a conventional resolver;
[0033] FIG. 6A is a diagrammatic side view illustrating an initial stage of a method of connecting lead wires of a magnetic rotor winding and a rotor transformer winding of a conventional resolver; and
[0034] FIG. 6B is a diagrammatic side view illustrating a later stage of a method of connecting lead wires of a magnetic rotor winding and a rotor transformer winding of a conventional resolver.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] FIG. 1 shows an initial stage of the winding process for a magnetic rotor 14 and a rotor transformer 12 of a rotation angle sensor of the present invention. FIG. 1A shows a laminated core 15 of the magnetic rotor 14 and a coil bobbin 13 of the rotor transformer 12 prior to initiation of coiling. FIG. 1B shows the laminated core 15 of the magnetic rotor 14 and the coil bobbin 13 of the rotor transformer 12 during the coiling process, and FIG. 1C shows the laminated core 15 of the magnetic rotor 14 and the coil bobbin 13 of the rotor transformer 12 after the coiling is completed. The rotation angle sensor includes a stator (not shown) and the magnetic rotor 14 for excitation and detection. In addition, the rotation angle sensor includes a stator transformer (not shown) and the rotor transformer 12 for the electric supply.
[0036] First, as shown in FIG. 1A , the coil bobbin 13 of the rotor transformer 12 and the laminated core 15 of the magnetic rotor 14 are fitted to a hollow rotation shaft 11 , which is made of a metal such as an aluminum alloy. Then the coil bobbin 13 and the laminated core 15 are positioned and fixed. The coil bobbin 13 is made of a magnetic substance, an aluminum alloy, or the like. Alternatively, the coil bobbin 13 of the rotor transformer 12 can be formed on the hollow rotation shaft 11 in advance.
[0037] The coil bobbin 13 of the rotor transformer 12 is arranged annularly on the surface of the rotation shaft 11 and its rim has a cross-sectional shape that resembles a squared U-shape.
[0038] The U shape is, as shown in the circled window of FIG. 1A , a bottom 16 and side walls 17 and 18 . On one side wall 18 , a notch 19 is formed to accommodate an electric wire (magnet wire). Preferably, the edges of the notch 19 are rounded or coated a resin 18 a with a small contact resistance, for example, Teflon (trademark), to prevent damage to the insulation coating of the electric wire (See FIG. 4 ). The notch 19 is shaped such that the magnetic flux generated due to the electric current flow in the rotor transformer winding 20 practically has no effect on a magnetic rotor winding 21 . When the coil bobbin 13 is formed by a magnetic substance, it forms a magnetic path and functions as an electromagnetic shield.
[0039] The laminated core 15 is, in the case of the embodiment of FIG. 1A , laminated with a predetermined number of silicon steel plates and fixed. The steel plates are punched in a shape that includes salient poles, or magnetic poles, and then fixed, and an insulator that also serves as a coil bobbin is mounted as required. The magnetic poles of the plates that form the laminated core 15 are skewed as shown. That is, the plates that form the laminated core 15 are slightly offset from one another to form the skewed poles as shown in FIG. 1A .
[0040] Next, the rotation shaft 11 , in which the positioning of the coil bobbin 13 of the rotor transformer 12 and the laminated core 15 of the magnetic rotor 14 is completed, is fixed on a winding machine (not shown in the drawing) and then, through a process using a multi-joint robot (not shown in the drawing) a first end 22 a of an electric wire 22 is temporarily fixed to the coil bobbin 13 of the rotor transformer 12 with insulation tape 26 . Then, with the multi-joint robot, the rotor transformer 12 is continuously coiled with the same piece of electric wire 22 . Then the same piece of wire 22 is coiled for a predetermined number of times and fed through the notch 19 of the bobbin 13 . Then, the same piece of wire 22 is coiled on the rotor transformer 12 and then on each of the magnetic poles 23 of the laminated core 15 of the magnetic rotor 14 in one direction for a predetermined number of times.
[0041] When all the magnetic poles 23 are coiled, a second end 22 b of the electric wire 22 of the magnetic rotor winding 21 is arranged in the coil bobbin 13 through the notch 19 of the coil bobbin 13 . Insulation tape 25 is attached on the rotor transformer winding 20 so that the winding will not come off and so that solder from the next process will not fall on the electric wire and break it.
[0042] The first and second ends 22 a , 22 b of the wire 22 are soldered together and arranged along the insulation tape 25 . Then, the solder joint is sealed with resin. The resin-sealed portion is arranged along the insulation tape, and then fixed with resin.
[0043] The winding direction of the rotor transformer winding 20 and the winding direction of the magnetic rotor winding 21 are significantly different; they are essentially transverse to one another. Therefore for the winding machine, for example, a vertical multiple-joint robot 31 is used. Multiple-joint robots are commercially available from a variety of companies and, in the present invention, the robot 31 can be appropriately selected from those available based on the circumstances.
[0044] FIG. 2 shows a winding machine 30 that uses the multi-joint robot 31 . In FIG. 2 , the winding machine 30 includes the multi-joint robot 31 and a work holder 39 that are arranged on a platform 42 . The position of the multi-joint robot 31 and work holder 39 can be changed on the platform 42 .
[0045] The multi-joint robot 31 of FIG. 2 has only three axes, however, the number of axes is determined in connection with the operation of the work holder 39 and a movable tip 36 . Often, a multi-joint robot with 6 axes is employed. The electric wire 32 is led to a nozzle 37 , which is arranged on the movable tip 36 of the multi-joint robot 31 through electric wire guides 33 , 34 and 35 , which are provided on the multi-joint robot 31 . The nozzle 37 can be either fixed or movable on the movable tip 36 . When the nozzle 37 is movable, the nozzle 37 is structured so that the installation angle of the nozzle 37 against the movable tip 36 is changed to carry out a regular winding, and it carries out the designated winding operation with an integrated motor (not shown in the drawing).
[0046] The work holder 39 has a control circuit and a driving source such as a motor that moves a chuck 38 rotationally and axially.
[0047] The multi-joint robot 31 and work holder 39 are connected with a cable 40 , and the required control is carried out by a controller 41 . The controller 41 includes a microcomputer that executes a program. The program includes a winding process routine. The winding process routine has a learning routine that includes a learning routine for the movable tip 36 , and in particular, it has a learning routine for the winding process of the magnetic poles of the laminated core 15 of the magnetic rotor 14 .
[0048] In the winding process, the rotation shaft 11 , on which are the coil bobbin 13 of the rotor transformer 12 and the laminated core 15 , is held by the chuck 38 of the work holder 39 as shown in FIG. 2 .
[0049] On a rear side of the multi-joint robot 31 , an electric wire reel (not shown in the drawing) is provided, and the electric wire 22 sent out from the reel passes through the wire guides 33 , 34 and 35 of the multi-joint robot 31 . Then, the wire 22 is led to the nozzle 37 , as shown. The electric wire 22 is supplied from the nozzle 37 via a tension setting mechanism (not shown in the drawing) so that the wire 22 has a constant tension.
[0050] By programmatically controlling the nozzle 37 while the chuck 38 of the work holder 39 is rotation controlled so that the tension of the electric wire 32 is constant, the electric wire 22 is coiled around the coil bobbin 13 . Once the number of windings for the coil bobbin reaches a predetermined number, the multi-joint robot 31 directs the wire 22 to the magnetic rotor 14 through the notch 19 . Then, the multi-joint robot 31 continuously coils the magnetic poles of the magnetic rotor 14 using the same single electric wire 22 . Note that the wire 22 passes through the notch 19 directly to one of the nearest poles of the magnetic rotor 14 so that the insulation coating of the wire 22 is not damaged by contact with the edges of the notch 19 .
[0051] The magnetic poles are coiled by moving the nozzle 37 around the magnetic poles of the laminated core 15 of the magnetic rotor 14 . The electric wire 22 sent out from the nozzle 37 is coiled from the base end (inner end) of each salient pole to the distal end, or from the distal end to the base end in a single line, and then it is coiled in a plurality of layers.
[0052] When the nozzle 37 passes through the slot between the magnetic poles, it moves in a slanted state and is inclined outwards from the salient poles, so that the nozzle 37 can coil without contacting the distal ends of the magnetic poles.
[0053] By moving the nozzle 37 around each magnetic pole using the multi-joint robot 31 , the angle and moving speed of the nozzle 37 can be freely adjusted depending on the rounding position. Therefore, damage to the insulation coating of the electric wire 32 is prevented, which allows multiple-layer coiling of the electric wire 32 . When the winding of the laminated core of the magnetic rotor 14 is completed, the wire 22 is lead through the notch 19 to the coil bobbin 13 , and then the winding process by the multiple-joint robot 31 is completed.
[0054] Once the winding is completed, both ends 22 a , 22 b of the single electric wire 22 are soldered in the coil bobbin 13 in the rotor transformer 12 , and then fixed with resin.
[0055] With regard to the winding of the multi-joint robot, continuous coiling of a single electric wire for the magnetic rotor winding and the rotor transformer winding with different winding directions is accomplished. In addition, it is possible to coil 3 or more windings in different directions, and they are similarly carried out.
[0056] In addition, if a flyer is used instead of a multi-joint robot, the function of the work holder should be enhanced and, at a minimum, the winding direction is matched to the direction of the operation.
[0057] FIGS. 3A, 3B , 3 C and 3 D show an alternative embodiment in which shield plates 51 , 52 provide electromagnetic shielding.
[0058] FIG. 3A shows an embodiment like that of FIG. 2 in which a rotor transformer winding and magnetic rotor winding are made with a single electric wire in a predetermined form, and the ends are soldered and fixed with resin. In this embodiment, a first shield plate 51 is provided on the rotation shaft 11 between the rotor transformer 12 and magnetic rotor 14 , and a second shield plate 52 is provided on a side of the magnetic rotor 14 that is opposite to the shield plate 51 . Thus, the magnetic rotor 14 is located between the first and second shield plates 51 , 52 .
[0059] Using the first shield plate 51 and the second shield plate 52 , the effect of the magnetic field of the rotor transformer 12 on the magnetic rotor 14 and the effect of an external magnetic field and external noise can be practically nullified. Note that the first shield plate 51 includes a notch 53 to permit passage of the wire 22 . The position of the notch 19 of the sidewall 18 of the bobbin 13 and the notch 53 of the first shield plate are selected so that the effect of the magnetic field and noise will not be increased.
[0060] The notches 19 , 53 are located so that they do not overlap in the axial direction. That is, the angular position and length L of the notch 19 is chosen so that the notch 19 does not align in the axial direction with the notch 53 . Accordingly, there is no magnetic flux passing through both of the notches 19 , 53 .
[0061] The distance of the first shield plate 51 from the rotor transformer winding 20 and the magnetic rotor winding 21 is, in principle, determined according to electric characteristics such as the SN ratio of the magnetic rotor winding. In addition, the distance is determined by the precision of the winding machine. In FIG. 3 , two shield plates 51 , 52 are provided. However, the number can be increased or decreased as required. The positions of the notches of the shield plates shall be set as described above.
[0062] Even when providing a shield plate, there is a single electric wire winding so that there is a single process for the electric wire. Therefore the structure is simple, manufacturing is easy and the electrical properties are improved.
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A rotation angle sensor and a method of winding a rotation angle sensor involve a single electrical wire that is wound from a rotor transformer to a magnetic rotor. The magnetic rotor is axially spaced on a shaft from the rotor transformer. A notch is formed in a wall of a bobbin of the rotor transformer to permit the wire to pass from the rotor transformer to the magnetic rotor. The ends of the single wire are electrically connected together at a junction, and the junction is fixed to the rotor transformer with resin.
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This application is a division of application Ser. No. 07/348,754 filed Apr. 24, 1989, now U.S. Pat. No. 5,178,987.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to radiation-sensitive mixtures useful as negative-working resist compositions containing at least one novolak resin and selected benzannelated acetic acids as the photoactive compound. Furthermore, the present invention also relates to substrates coated with these radiation-sensitive mixtures as well as the process of imaging and developing these radiation-sensitive mixtures on these substrates.
2. Description of Related Art
Photoresist compositions are used in microlithographic processes for making miniaturized electronic components such as in the fabrication of integrated circuits and printed wiring board circuitry. Generally, in these processes, a thin coating or film of a photoresist composition is first applied to a substrate material, such as silicon wafers used for making integrated circuits or aluminum or copper plates of printed wiring boards. The coated substrate is then baked to fix the coating onto the substrate. The baked coated surface of the substrate is next subjected to an image-wise exposure of radiation. This radiation exposure causes a chemical transformation in the exposed areas of the coated surface. Ultraviolet (UV) light, electron beam and X-ray radiant energy are radiation types commonly used today in microlithographic processes. After this image-wise exposure, the coated substrate is treated with a developer solution to dissolve and remove either the radiation-exposed or the unexposed areas of the coated surface of the substrate.
There are two types of photoresist compositions--negative-working and positive-working. When negative-working photoresist compositions are exposed image-wise to radiation, the areas of the resist composition exposed to the radiation become more insoluble to a developer solution (e.g. a cross-linking reaction occurs) while the unexposed areas of the photoresist coating remain relatively soluble to a developing solution. Thus, treatment of an exposed negative-working resist with a developer causes removal of the non-exposed areas of the resist coating and the creation of a negative image in the photoresist coating. On the other hand, when positive-working photoresist compositions are exposed image-wise to radiation, those areas of the resist composition exposed to the radiation become more soluble to the developer solution (e.g. a decomposition reaction occurs) while those areas not exposed remain relatively insoluble to the developer solution. Thus, treatment of an exposed positive-working resist with the developer causes removal of the exposed areas of the resist coating and the creation of a positive image in the photoresist coating.
After this development operation, the now partially unprotected substrate may be treated with a substrate-etchant solution or plasma gas mixture and the like. The etchant solution or plasma gas mixture etches the portion of the substrate where the photoresist coating was removed during development. The areas of the substrate where a positive photoresist coating still remains are protected and, thus, an etched pattern is created in the substrate material which corresponds to the photomask used for the image-wise exposure of the radiation. Later, the remaining areas of the positive photoresist coating may be removed during a stripping operation, leaving a clean etched substrate surface.
Positive-working photoresist compositions are currently favored over negative-working resists because the former generally have better resolution capabilities and pattern transfer characteristics.
Photoresist resolution is defined as the smallest feature which the resist composition can transfer from the photomask to the substrate with a high degree of image edge acuity after exposure and development. In many manufacturing applications today, resist resolution on the order of one micron or less is necessary.
In addition, it is generally desirable that the developed photoresist wall profiles be near vertical relative to the substrate. Such demarcations between developed and undeveloped areas of the resist coating translated into accurate pattern transfer of the mask image onto the substrate.
Still further, many current negative photoresist formulations also swell when subjected to development steps, thereby causing image distortion. And, negative photoresists generally require an organic developer solution. The employment of such organic materials creates special handling and disposal problems for the photoresist fabricator.
On the other hand, positive photoresist formulations are not favored for all commercial applications. For example, positive photoresists such as those based on novolak resins and orthonaphthoquinone diazide photosensitizers have certain processing limitations when their imaging is carried out in the deep ultraviolet region of the light spectrum. In this class of positive resists, both ingredients absorb light from the deep ultraviolet region and, thus, the photoresist requires increased input of radiation to compensate for the unwanted light absorptions.
Accordingly, there is a need for a better negative-working photoresist formulation which overcomes the deficiencies of current negative-working photoresists, especially in the area of the deep UV light region where positive-working resists have limitations as to commercialization. The present invention is believed to be an answer to that need.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a radiation-sensitive mixture useful as a negative-working photoresist composition comprising the admixture of:
(a) at least one novolak-type resin; and
(b) a photoactive benzannelated acetic acid selected from the compounds of formula (I): ##STR2## wherein X is either an oxygen, sulfur or --C--H 2 .
Moreover, the present invention also encompasses the process of coating substrates with these radiation-sensitive mixtures and then imaging and developing these coated substrates.
Still further, the present invention also encompasses said coated substrates (both before and after imaging) as novel articles of manufacture.
DETAILED DESCRIPTION
The preferred photoactive (also called "sensitizer") benzannelated acetic acid is xanthene-9-carboxylic acid. This compound is also known as 9H-xanthene-9-carboxylic acid, xanthenecarboxylic acid, or xanthanoic acid and it's Chemical Abstracts Registry Number is 82-07-5. Its structure is shown by Formula II: ##STR3##
Its sulfur analog is known as thioxanthene-9-carboxylic acid or 9H-thioxanthene-9-carboxylic acid and its Chemical Abstract Registry Number is 17394-14-8.
The photoactive benzannelated acetic acid is then combined with a novolak resin or resins to make radiation-sensitive mixtures useful as negative-working photoresist compositions. The term "novolak-type resins" is used herein to mean any novolak resin which is conventionally used in photoresist compositions. Suitable novolak resins include phenol-formaldehyde novolak resins and cresol- formaldehyde novolak resins, preferably having a molecular weight of about 500 to about 30,000, more preferably from about 1,000 to about 20,000. These novolak resins are preferably prepared by the condensation reaction of phenol or cresol with formaldehyde and are characterized by being light-stable, water-insoluble, alkali-soluble and film-forming. The preparation of examples of such suitable resins is disclosed in U.S. Pat. Nos. 4,377,631; 4,529,682; and 4,587,196, all of which issued to Medhat Toukhy and are incorporated herein by reference in their entireties.
The proportion of the above sensitizer compound in the radiation-sensitive mixture may preferably range from about 1 to about 30 percent, more preferably from about 5 to about 25 percent by weight of the non-volatile (e.g. non-solvent) content of the radiation-sensitive mixture. The proportion of novolak resin in the radiation-sensitive mixture may preferably range from about 70 to about 99 percent, more preferably, from about 75 to 95 percent of the non-volatile (e.g. excluding solvent) content of the radiation-sensitive mixture.
These radiation-sensitive mixtures may also contain conventional photoresist composition ingredients such as solvents, actinic and contrast dyes, anti-striation agents, plasticizers, speed enhancers, and the like. These additional ingredients may be added to the novolak resin and sensitizer solution before the solution is coated onto the substrate.
The resins and sensitizers may be dissolved in a solvent or solvents to facilitate their application to the substrate. Examples of suitable solvents include ethyl cellulose acetate, n-butyl acetate, xylene, ethyl lactate, propylene glycol alkyl ether acetates, or mixtures thereof and the like. The preferred amount of solvent may be from about 50% to about 500% by weight, more preferably, from about 100% to about 400%, based on combined resin and sensitizer weight.
Actinic dyes help provide increased resolution by inhibiting back scattering of light off the substrate. This back scattering causes the undesirable effect of optical notching, especially where the substrate is highly reflective or has topography. Examples of actinic dyes include those that absorb light energy at approximately 400-460 nm [e.g. Fat Brown B (C.I. No. 12010); Fat Brown RR (C.I. No. 11285); 2-hydroxy-1,4-naphthoquinone (C.I. No. 75480) and Quinoline Yellow A (C.I. No. 47000)] and those that absorb light energy at approximately 300-340 nm [e.g. 2,5-diphenyloxazole (PPO-Chem. Abs. Reg. No. 92-71-7) and 2-(4-biphenyl)-6-phenyl-benzoxazole (PBBO-Chem. Abs. Reg. No. 17064-47-O)]. The amount of actinic dyes may be up to ten percent weight levels, based on the combined weight of resin and sensitizer.
Contrast dyes enhance the visibility of the developed images and facilitate pattern alignment during manufacturing. Examples of contrast dye additives that may be used together with the radiation-sensitive mixtures of the present invention include Solvent Red 24 (C.I. No. 26105), Basic Fuchsin (C.I. 42514), Oil Blue N (C.I. No. 61555) and Calco Red A (C.I. No. 26125) up to ten percent weight levels, based on the combined weight of resin and sensitizer.
Anti-striation agents level out the photoresist coating or film to a uniform thickness. This is important to ensure uniform radiation exposure over the film surface. Anti-striation agents may be used up to five percent weight levels, based on the combined weight of resin and sensitizer. One suitable class of anti-striation agents is non-ionic silicon-modified polymers. Non-ionic surfactants may also be used for this purpose, including, for example, nonylphenoxy poly(ethyleneoxy) ethanol; octylphenoxy (ethyleneoxy) ethanol; and dinonyl phenoxy poly(ethyleneoxy) ethanol.
Plasticizers improve the coating and adhesion properties of the photoresist composition and better allow for the application of a thin coating or film of photoresist which is smooth and of uniform thickness onto the substrate. Plasticizers which may be used include, for example, phosphoric acid tri-(β-chloroethyl)-ester; stearic acid; dicamphor; polypropylene; acetal resins; phenoxy resins; and alkyl resins up to ten percent weight levels, based on the combined weight of resin and sensitizer.
Speed enhancers tend to increase the solubility of the photoresist coating in both the exposed and unexposed areas, and thus, they are used in applications where speed of development is the overriding consideration even though some degree of contrast may be sacrificed, i.e. in negative resists while the unexposed areas of the photoresist coating will be dissolved more quickly by the developer, the speed enhancers will also cause a larger loss of photoresist coating from the exposed areas. Speed enhancers that may be used include, for example, picric acid, nicotinic acid or nitrocinnamic acid at weight levels of up to 20 percent based on the combined weight of resin and sensitizer.
The prepared radiation-sensitive resist mixture, can be applied to a substrate by any conventional method used in the photoresist art, including dipping, spraying, whirling and spin coating. When spin coating, for example, the resist mixture can be adjusted as to the percentage of solids content in order to provide a coating of the desired thickness given the type of spinning equipment and spin speed utilized and the amount of time allowed for the spinning process. Suitable substrates include silicon, aluminum or polymeric resins, silicon dioxide, doped silicon dioxide, silicon resins, gallium arsenide, silicon nitride, tantalum, copper, polysilicon, ceramics and aluminum/copper mixtures.
The photoresist coatings produced by the above described procedure are particularly suitable for application to thermally grown silicon/silicon dioxide-coated wafers such as are utilized in the production of microprocessors and other miniaturized integrated circuit components. An aluminum/aluminum oxide wafer can be used as well. The substrate may also comprise various polymeric resins especially transparent polymers such as polyesters and polyolefins.
After the resist solution is coated onto the substrate, the coated substrate is baked at approximately 70° to 115° C. until substantially all the solvent has evaporated and only a uniform radiation-sensitive coating remains on the substrate.
The coated substrate can then be exposed to radiation, especially ultraviolet radiation, in any desired exposure pattern, produced by use of suitable masks, negatives, stencils, templates, and the like. Any conventional imaging process or apparatus currently used in processing photoresist-coated substrates may be employed with the present invention.
The exposed resist-coated substrates are next developed in alkaline inorganic or organic developing solution. Immersion development is preferred. This solution is preferably agitated, for example, by nitrogen gas agitation during immersion. Examples of alkaline inorganic developers include aqueous solutions of tetramethylammonium hydroxide, sodium hydroxide, potassium hydroxide, choline, sodium phosphates, sodium carbonate, sodium metasilicate, and the like. Examples of organic developers include isopropanol alone or mixed with methyl isobutylketone or mixtures of methyl ethyl ketone, ethanol and isopropanol and the like. The preferred developers for this invention are aqueous solutions of tetramethylammonium hydroxide.
Alternative development techniques such as spray development or puddle development, or combinations thereof, may also be used.
The substrates are allowed to remain in the developer until all of the resist coating has dissolved from the unexposed areas. Normally, development times from about 30 seconds to about 3 minutes are employed.
After selective dissolution of the coated wafers in the developing solution, they are preferably subjected to a deionized water rinse to fully remove any remaining undesired portions of the coating and to stop further development. This rinsing operation (which is part of the development process) may be followed by blow drying with filtered air to remove excess water. A post-development heat treatment or bake may then be employed to increase the coating's adhesion and chemical resistance to etching solutions and other substances. The post-development heat treatment can comprise the oven baking of the coating and substrate below the coating's softening point.
In industrial applications, particularly in the manufacture of microcircuitry units on silicon/silicon dioxide-type substrates, the developed substrates may then be treated with a buffered, hydrofluoric acid etching solution or plasma gas etch. The resist compositions of the present invention are believed to be resistant to a wide variety of acid etching solutions or plasma gases and provide effective protein for the resist-coated areas of the substrate.
Later, the remaining areas of the photoresist coating may be removed from the etched substrate surface by conventional photoresist stripping operations.
The present invention is further described in detail by means of the following examples. All parts and percentages are by weight unless explicitly stated otherwise.
EXAMPLE 1
PREPARATION OF PHOTORESIST FORMULATION
3.52 grams of Xanthene-9-carboxylic acid were mixed with a solution comprising 15.00 grams mixed 45% m- and 55% p-cresol formaldehyde novolac resin (weight average M.W. of about 4929) and 51.84 grams of ethyl lactate. The bottle was then rolled for 12 hours at room temperature until all the solids were dissolved. The resulting resist solution was then filtered through a 0.2 micron pore size filter using a Millipore microfiltration system (a 100 ml. barrel and a 47 mm. disk were used). The filtration was conducted in a nitrogen atmosphere under a gauge pressure of 10 pounds per square inch.
EXAMPLE 2
COATING OF PHOTORESIST COMPOSITION ONTO A SILICON WAFER
Approximately three mls. of the filtered resist composition in Example 1 was spin-coated with a Model 5110-C single head spinner manufactured by Solitec, Inc. (Santa Clara, Calif.) onto a thermally grown silicon/silicon dioxide-coated wafer of four inches in diameter and having 5400 Angstroms of silicon dioxide on its upper surface which was primed with 20% by volume hexamethyldisilazane (HMDS)/80% by volume xylene solution. The resist was applied to a static wafer. Then, the wafer was rotated to an initial spinning velocity of 500 revolutions per minute for 3 seconds, followed by acceleration at 2,000 revolutions per second to a final spinning velocity of 1,500 revolutions per minute for 30 seconds. This spinning operation evenly spread the photoresist over the upper surface of the wafer to produce an even thin film. The coated wafer was then subsequently baked at 100° C. on a vacuum applied hot plate for 60 seconds. The photoresist film thickness was then measured to be approximately one micron with a Dektak IIa profilometer unit manufactured by Sloan Technology (Santa Barbara, Calif.).
EXAMPLE 3
DEEP-UV IMAGE-WISE EXPOSURE OF 100° C. BAKED COATED WAFER
The wafer baked at 100° C. in Example 2 was image-wise exposed to deep-UV light wavelengths between 220-250 nm using a Canon Model PLA-501F aligner (Lake Success, N.Y.) equipped with a Xenon-mercury UV lamp and CM250 cold mirror for a twenty five second exposure time in the hard contact mode. The deep-UV wavelengths were passed through a quartz Series 1 multidensity resolution target from Detric Optics, Inc. (Hudson, Mass.). Eight-tenths of a micron features were confirmed on the target using scanning electron microscopy. The intensity at the wafer plane was measured to be 8.62 mW/cm 2 with a Mimir Instruments Inc. (Santa Clara, Calif.) Model 100 Powermeter equipped with a detector for measurement at 254 nm.
EXAMPLE 4
DEVELOPMENT OF EXPOSED RESIST COATED WAFER
The resist coated wafer exposed according to Example III was then held with Teflon tweezers and immersed in a 500 milliliter polypropylene container containing 25% by volume WAYCOAT Positive MIF Developer solution (Olin Hunt Specialty Products, Inc., West Paterson, N.J.) in water. This WAYCOAT solution is an aqueous solution of tetramethylammonium hydroxide. The wafer was allowed to remain immersed in the developer solution while the container was moved in a circular motion for fifty five seconds. Then the wafer was rinsed in deionized water for one minute and dried in a stream of filtered nitrogen. The unexposed areas of the photoresist film were developed therefore producing a negative image.
The developed and exposed wafer was then examined to determine the photospeed of the photoresist film and small feature sizes.
Photospeed of the resist was determined by looking at each of the developed areas of the resist coating corresponding to different percent transmittance windows of the SERIES I target. Photospeed of this resist was calculated by multiplying the exposure energy at the wafer plane (8.62 milliwatts per square centimeter), the lowest percent transmittance window of the target at which the resist fully coated, and the full transmittance time (twenty five seconds) and then dividing by 100.
Examination of fine features was done using a Nikon optical microscope with one thousand times magnification.
The first panel to be fully coated was the 25.1% window corresponding to a photospeed of 54.1 millijoules per centimeter squared at 254 nm. The optical microscope revealed eight-tenths micron lines.
The measured photospeed and fine feature size indicates this photoresist formulation which was baked at 100° C. and imaged in the Deep-UV range should provide excellent resolution and, thus, appears suitable for commercial applications where these baking temperatures are employed.
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A radiation-sensitive mixture useful as a negative-working photoresist composition comprising:
(a) at least one novolak resin; and
(b) a photoactive benzennelated acetic acid selected from formula (I): ##STR1## wherein X is either an oxygen, sulfur or --C--H 2 .
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. Ser. No. 08/965,548, filed Nov. 6, 1997, now U.S. Pat. No. 6,121,980 the disclosure of which is expressly incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to the synthesis of adhesive compositions and more particularly to the synthesis of telechelic polymers of selected narrow molecular weight distribution for use in adhesives, coatings, and like applications. For present purposes, “telechelic” polymers are polymers that contain reactive end groups. “Polytelechelic” (co)polymers, then, contain two or more reactive pendant groups which often are end groups. For present purposes, “polymers” include homopolymers and copolymers (unless the specific context indicates otherwise), which may be block, random, gradient, star, graft (or “comb”), hyperbranched, or dendritic. The “(co)” parenthetical prefix in conventional terminology is an alternative, viz., “(co)polymer” means a copolymer or polymer, which includes a homopolymer.
Conventional free radical polymerization leads to synthesis of polymers with a fairly broad molecular weight distribution, Mw/Mn (weight molecular weight/number molecular weight), or polydispersity, in the range of 2.5 to 3. Number molecular weight (Mn) relies on the number of molecules in the polymer, while weight molecular weight relies on the weight of the individual molecules. See, e.g., Solomon, The Chemistry of Organic Film Formers , pp. 25, et seq., Robert E. Krieger Publishing Co., Inc., Huntington, N.Y. (1977), the disclosure of which is expressly incorporated herein by reference. The basic theory that applies to the control of the growth of the polymer chains and Mw/Mn ratios in a free-radical initiated polymerization reaction is well documented in the literature by P. J. Flory, JACS , Vol. 96, page 2718 (1952).
State of the art practice used to prepare polymers with a narrow molecular weight distribution in the range of, say, 1.05 to 1.4, rely on living polymerization techniques, such as anionic and cationic polymerization. These ionic living polymerization techniques have several limitations including, for example, restrictions on the types of monomers that can be polymerized, low temperature and purity process requirements, the inability to synthesize high molecular weight polymers, etc. Because of these constraints, ionic polymerization processes are limited to the synthesis of polymers based on styrene, isoprene, isobutylene, and like monomers to produce synthetic elastomers and thermoplastic rubbers.
Telechelic polymers prepared from either living polymers or condensation polymers, such as polyesters, for example, tend to be of low molecular weight, typically on the order of several hundreds to several thousands (e.g., 500-10,000). This low molecular weight limitation makes conventional telechelic polymers impractical for a variety of applications including, for example, adhesives.
Recent work on atom transfer radical polymerization (ATRP) has shown the potential of using this pseudo-living polymerization technique to prepare high molecular weight polymers based on acrylic monomers, vinyl monomers, and other common monomers which polymers exhibit a fairly narrow molecular weight distribution, say, in the range of 1.05 to 1.5. Molecular weights up to 10 5 have been claimed to have been synthesized by ATRP techniques. See Patten, et al., “Radical Polymerization Yielding Polymers with Mw/Mn ˜1.05 by Homogeneous Atom Transfer Radical Polymerization”, Polymer Preprints , pp. 575-576, No. 37 (March 1996); Wang, et al., “Controlled/”Living” Radical Polymerization. Halogen Atom Transfer Radical Polymerization Promoted by a Cu(I)/Cu(II) Redox Process”, Macromolecules 1995, 28, 7901-7910 (Oct. 15, 1995); and PCT/US96/03302, International Publication No. WO 96/30421, published Oct. 3, 1996, the disclosures of which are expressly incorporated herein by reference.
BRIEF SUMMARY OF THE INVENTION
Disclosed is a method for preparing adhesive polymers which commences with the formation of a poly-telechelic polymer of narrow molecular weight distribution (Mw/Mn), say from about 1-3, by polymerizing one or more radically-polymerizable monomers in the presence of a transition metal, a ligand, and an initiator, under atom or group transfer radical polymerization conditions. In this polymerization step, OH groups are contained on one or more of said initiator, an initiating monomer, a polymerizable monomer, a terminating monomer, or combinations thereof, that is, (i) one or more of the initiator, an initiating monomer, a hydroxy monomer, or combinations thereof; on (ii) one or more of a hydroxy monomer, a terminating monomer, or combinations thereof; or on (iii) one or more of the initiator, an initiating monomer, or terminating monomer, or combinations thereof. The poly-telechelic polymer, then, is chain extended with a chain extension agent, such as a polyisocyanate, to form the adhesive polymer.
Regression analysis reveals that the adhesive properties of the chain extended polymers is dependent primarily upon the Mn of the telechelic polymer and the hydroxyl monomer and/or initiator used in forming the telechelic polymers. Data demonstrating such adhesive properties is set forth herein.
DETAILED DESCRIPTION OF THE INVENTION
In the polytelechelic polymer formation step of the process, atom or group transfer radical polymerization conditions are used. Such conditions can be found described in, for example, the art cited above and incorporated herein be reference. Included in this step are a transition metal, a ligand, and an initiator.
Preferred transition metals are Cu +1 , and Co +1 , although many other transition metals have been disclosed in the art and may find advantage in the present invention. Cu +1 halides, for example, arc described with respect to catalyzed reactions of organic polyhalides with vinyl unsaturated compounds are well known by Bellus, Pure and Applied Chemistry , Vol. 57, No. 12, pp. 1827-1838 (1985). Complexing of transition metal halides with organic ligands as part of the initiator system is described in U.S. Pat. No. 4,446,246, for example. Cu +1 halide-bipyridine complexes with active organic halide compounds are described to react with vinyl unsaturated compounds by Udding, et al., J. Organic Chemistry , Vol. 59, pp. 1993-2003 (1994). Organocobalt porphyrin complexes (alkyl cobaloximes) are described in the polymerization of acrylates by Wayland, et al., JACS , Vol. 116, pp. 7943-7966 (1994). Cu +1 carboxylate complexes formed from thiophene carboxylates are described by Weij, et al., Polymer Preprints , Vol. 38, No. 1, pp. 685-686 (April 1997). The disclosures of the foregoing references are expressly incorporated herein by reference.
The generation of radical intermediates by reacting some transition metal species, including salts and/or complexes of Cu, Ru, Fe, Va, Nb, and others, with alkyl halides, R-X, is well documented (see Bellus, Pure & Appl. Chem ., 1985, 57, 1827; Nagashima, et al., J. Org. Chem ., 1993, 58, 464; Seijas, et al., Tetrahedron , 1992, 48(9), 1637; Nagashima, et al., J. Org. Chem ., 1992, 57, 1682; Hayes, J. Am. Chem. Soc ., 1988, 110, 5533; Hirao, et al., Syn. Lett ., 1990, 217; Hirao, et al., J. Synth. Org. Chem ., (Japan), 1994, 52(3), 197; Iqbal, et al., Chem. Rev ., 94, 519 (1994); Kochi, Organometallic Mechanisms and Catalysis , Academic Press, New York, 1978. Moreover, it also is known that R-X/transition metal species-based redox initiators, such as Mo(CO) 6 /CHCl 3 , Cr(CO) 6 /CCL 4 , Co 4 (CO) 12 /CCl 4 , and Ni[P(OPh)) 3 ] 4 /CCl 4 , promote radical polymerization (see Bamford, Comprehensive Polymer Science , Allen, et al., editors, Pergamon: Oxford, 1991, vol. 3, p. 123). The participation of free radicals in these redox initiator-promoted polymerizations was supported by end-group analysis and direct observation of radicals by ESR spectroscopy (see Bamford, Proc. Roy. Soc ., 1972, A, 326, 431). The disclosures of the foregoing references are expressly incorporated herein by reference.
Ligands useful in the polytelechelic polymer formation step of the process also have been disclosed in the literature, such as set forth above. Such ligands most readily are halides; although, bipyridyls, mercaptides, triflates (CuOSO 2 CF 3 , J. Am. Chem. Soc ., 95, 1889 (1973), incorporated herein by reference), olefin and hydroxyl complexes (see, Cotton and Wilkinson, Advanced Inorganic Chemistry , 3 rd Ed. Chapter 23, John Wile & Sons, New York, N.Y. (1972; “Inorganic and Organometallic Photochemistry”, M. S. Wrighton, Editor, ACS-Advances in Chemistry Series , 168 (1978); and Srinivasan, J. Am. Chem. Soc ., 85, 3048 (1963), incorporated herein by reference) can be used as necessary, desirable, or convenient. The disclosures of the foregoing references are expressly incorporated herein by reference.
Initiators also have been disclosed in the literature. Representative of such initiators include, for example, 2-hydroxyethyl 2-bromopropionate, 2-hydroxyethyl 4-bromopropionate, methyl 2-bromopropionate, 1-phenyl ethyl chloride, 1-phenylethyl bromide, chloroform, carbon tetrachloride, 2-chloropropionitrile, lower alkyl (C 1 -C 6 ) esters of 2-halo-lower alkyl carboxylic acids (e.g., ethyl 2-bromoisobutyrate), α, α′-dichloroxylene, α, α′-dibromoxylene, hexakis(α-bromomethyl)benzene, and like. Obviously, halide initiators have been taught by the art to be preferred and such initiators serve quite efficaciously in the present invention. It should be observed, further, that photoinitiators also can be used, such as taught by M. P. Greuel, “Living Free-Radical Polymerization Using Alkyl Cobaloximes as Photoinitiators”, Doctoral Thesis, University of Akron, December 1992. The disclosures of the foregoing references are expressly incorporated herein by reference.
Referring now to radically-polymerizable monomers, broadly, such monomers include any ethylenically unsaturated monomer or oligomer which can be (co)polymerized in the presence of a the initiator. In adhesives technology, acrylic or acrylate compounds find wide acceptance in industry. Another suitable class of ethylenically unsaturated compounds are vinyl compounds, while a third broad class are compounds containing backbone ethylenic unsaturation as typified by ethylenically unsaturated polyester oligomers. For terminating or capping the polymer ends with OH functionality, monomers modified to contain such functionality are used in the polymerization step of the present invention.
Referring with more particularity to reactive acrylic or acrylate monomers or oligomers, a variety of monoacrylate monomers find use in accordance with the present invention. Monoacrylates include, for example, allyl (meth)acrylate, C 1 -C 22 alkyl and cycloalkyl (meth)acrylates, such as, for example, butyl acrylate, 2-ethylhexyl acrylate, isooctylacrylate, amyl acrylate, lauryl acrylate, iso-propyl acrylate, and the like, and corresponding monomethacrylates which include, for example, benzyl methacrylate, stearyl methacrylate, decyl methacrylate, cyclohexyl methacrylate, and the like, and mixtures thereof. The foregoing monomers are merely representative and not limitative of the list of acrylate and methacrylate monomers suitable for use in the present invention as those skilled in the art will appreciate.
Other suitable reactive compounds for use in the present invention include, for example, acrylated epoxy resins, acrylated silicone resins, acrylated polyurethane resins, and the like and mixtures thereof. Such acrylate-functional compounds are well known in the art and little more about them need be stated here.
Hydroxyl-containing acrylic monomers include hydroxyl derivatives of those monomers named above (e.g., hydroxy ethyl acrylate or hydroxy ethyl methacrylate), and the like, and mixtures thereof.
Hydroxy-functional initiators can be used in order to cap one end of the polymer (i.e., initiate the polymer). Alternatively, a pre-monomer can be used to start the polymerization which then proceeds with non-functional monomers. The other end of the polymer can be terminated with such functionality by choice of monomer which can be functional or a functional monomer (for example, allyl alcohol) can be post-polymerization added to cap the polymer with desired hydroxyl functionality. In this regard, it will be appreciated that the efficiency of hydroxyl incorporation into the telechelic (co)polymers is much greater when a hydroxy initiator or hydroxy initial monomer is used, rather than end-capping with a functional monomer, as those skilled in the art will appreciate. Mono and di-hydroxyl functional telechelic (co)polymers are preferred for use in the present invention; although, high functionality may be useful on occasion as is necessary, desirable, or convenient.
Polyisocyanates, preferably diisocyanates, are conventional in nature and include, for example, hexamethylene diisocyanate, toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), m- and p-phenylene diisocyanates, bitolylene diisocyanate, cyclohexane diisocyanate (CHDI), bis-(isocyanatomethyl) cyclohexane (H 6 XDI), dicyclohexylmethane diisocyanate (H 12 MDI), dimer acid diisocyanate (DDI), trimethyl hexamethylene diisocyanate, lysine diisocyanate and its methyl ester, isophorone diisocyanate, methyl cyclohexane diisocyanate, 1,5-napthalene diisocyanate, xylylene and xylene diisocyanate and methyl derivatives thereof, polymethylene polyphenyl isocyanates, chlorophenylene-2,4-diisocyanate, and the like and mixtures thereof. Triisocyanates and high-functional isocyanates also are well known and can be used to advantage; although, diisocyanates are presently preferred. Aromatic and aliphatic diisocyanates, for example, (including biuret and isocyanurate derivatives) often are available as pre-formed commercial packages and can be used to advantage in the present invention. As with conventional urethane reactions, there should be a slight to moderate excess of isocyanate equivalents compared to the hydroxyl equivalents of the telechelic (co)polymers being chain extended.
The chain extended poly-telechelic polymers find wide use in formulating adhesives. Such adhesive polymers retain bond strength by dint of their higher molecular weight, but also exhibit good peel properties as do lower molecular weight polymers while still maintaining desired viscosities of prior art adhesives. Thus, the chain extended adhesive polymers exhibit a combination of bond strength which is expected of high molecular weight polymers, while also exhibiting peel properties expected of much lower molecular weight polymers. Such peel properties and good viscosities are believed to result because of the narrow molecular weight distribution of the poly-telechelic polymer intermediates synthesized in accordance with the precepts of the present invention.
The compounding of the inventive adhesive polymers into useful adhesive formulations follows conventional processing and handling which are well known to the skilled artisan. In this application, all units are in the metric system unless otherwise expressly indicated. Also, all citations are expressly incorporated herein by reference.
EXAMPLES
GENERAL PROCEDURES
Raw Materials
Butyl acrylate (BA), 4-hydroxybutyl acrylate (HBA), methyl 2-bromopropionate (2-MPN), 1-bromoethyl benzene (1-BEB), allylalcohol (AllylOH), 5-hydroxypentene (Pentene-OH), copper bromide (CuBr), and bipyridine were obtained from Aldrich Chemicals and used without further purification. 2-bromopropionic acid and anhydrous ethyleneglycol also were purchased from Aldrich Chemicals.
Hydroxy-Containing Initiator Synthesis Methods
2-Hvdroxyethyl 2-Bromopropionate (2-H2PN)
Dicyclohexylcarbodimide (4.1 g, 20 mmol), anhydrous ethylene glycol (5.0 g, 81 mmol), and pyridine (1 ml, 12 mmol) were charged into a vial. Acetone (14 ml) and 2-bromopropionic acid (1.5 ml, 16.7 mmol) were added while cooling the vial down with an ice bath to control the exothermic reaction. After stirring the vial's contents overnight, undissolved by-products were removed by filtration. To the filtered reaction mixture were added AcOEt (20 ml) and saturated NaCl water (15 ml) followed by shaking well. The reaction mixture separated into 2 layers. The upper AcOEt layer was washed with dilute HCI once and saturated NaCl water (15 ml) two more times and then dried with MgSO 4 . After removing MgSO 4 , AcOEt was rotary evaporated to obtain a crude product. This crude product was purified by silica gel chromatography (eluent: AcOEt:hexane=1:1 by weight) to yield 1.4 g (43% yield) product.
2-Hydroxyethyl 4-Bromopropionate (2-H4PN)
The foregoing procedure was repeated using 1,4-butanediol as the starting material and anhydrous ethyleneglycol.
EXAMPLES 1-12
Typical Polymerization Method
Table 1, Examples 1-12
2-MPN, HBA (Example 2)
BA (12.8 g, 100 mmol) was charged into a four-neck flask equipped with a mechanical stirrer, N 2 inlet, cooling condenser, and rubber septum. Bipyridine (400 mg, 2.56 mmol) and Cu(I)Br (123 mg, 0.86 mmol) were added to the flask. The flask was purged with N 2 for at least 1 hour after which 2-MPN initiator (96 μl, 0.86 mmol) was injected into the flask through the rubber septum at ambient temperature. The reaction mixture then was stirred while being heated up to 110°-120° C. for 6 hours.
After verifying that the conversion ratio (dried polymer weight/neat reaction polymer weight) exceeded 95%, HBA (130 μl, 0.94 mmol) was bulk added through the rubber septum at 110°-120° C. The reaction solution then was heated for another 3 hours after which heating ceased. The crude polymer was diluted with ethyl acetate (50 ml) and then washed with diluted aqueous HCl three times and saturated aqueous NaCl three times followed by drying with anhydrous MgSO 4 . After filtering out MgSO 4 and removing ethyl acetate, the polymer residue was dried by a vacuum pump at 50° C. overnight.
2-H2PN, Pentene-OH (Example 12)
BA (25.6 g, 200 mmol) was charged into a four-neck flask equipped with a mechanical stirrer, N 2 inlet, cooling condenser, and rubber septum. Bipyridine (840 mg, 5.38 mmol) and Cu(I) Br (257 mg, 1.79 mmol) were added to the flask. The flask was purged with N 2 for at least 1 hour after which the bromo initiator, 2-H2PN (400 mg, 1.79 mol), was injected into the flask through the rubber septum at ambient temperature. The reaction mixture then was stirred for 6 hours while being heated up to 110°-120° C.
After verifying that the conversion ratio (dried polymer weight/neat reaction polymer weight) exceeded 95%, penteneOH (1.54 g, 17.9 mmol) was bulk added through the rubber septum at 110°-120° C. The reaction solution then was heated overnight after which heating ceased. The crude polymer was diluted with ethyl acetate (50 ml) and then washed with diluted aqueous HCl three times and saturated aqueous NaCl three times followed by drying with anhydrous MgSO 4 . After filtering out MgSO 4 and removing ethyl acetate, the polymer residue was dried overnight by a vacuum pump at 50° C.
TABLE 1
Hydroxy-Containing Polymers
OH
Mn
Example No.
Monomer
Initiator*
Comonomer
Terminator
(calculated)
Mw
Mw/Mn
1
BA
2-MPN
—
—
43,567
69,701
1.60
(B-4-1)
(12.8 g,
(0.27 mmol)
(47,650)
Comparative
100 mmol)
2
BA
2-MPN
HBA
—
15,538
34,491
2.22
(B-8-2)
(12.8 g,
(0.90 mmol)
(0.94 mmol)
(14,450
100 mmol)
3
BA
1-BEB
HBA
—
16,170
30,319
1.88
(B-19-1)
(12.8 g,
(0.88 Mmol)
(0.94 mmol)
(14,580)
100 mmol)
4
BA
1-BEB
HBA
—
16,041
33,274
2.08
(B-24-1)
(25.6 g,
(1.79 mmol)
(2.67 mol)
(14,580)
200 mmol)
5
BA
2-MPN
—
AllylOH
14,677
28,399
1.94
(B-13-1)
(12.7 g,
(0.9 mmol)
(1.47 mmol)
(14,400)
100 mmol)
6
BA
1-BEB
—
AllylOH
15,209
26,923
1.77
(B-48-1)
(25.6 g,
(1.76 mmol)
(excess)
(14,600)
200 mmol)
7
BA
2-H2PN
—
—
13,255
31,482
3.02
(B-39-1)
(12.8 g,
(0.9 mmol)
(14,500)
100 mmol)
8
BA
2-H4PN
—
—
12,850
31,193
2.43
(B-45-1)
(12.8 g,
(0.89 mmol)
(14,600)
100 mmol)
9
BA
2-H4PN
HBA
—
15,103
26,861
1.78
(B-49-1)
(12.8 g,
(0.89 mmol)
(0.91 mmol)
(14,800)
100 mmol)
10
BA
2-H4PN
—
AllylOH
14,956
33,234
2.22
(B-46-1)
(25.6 g,
(1.78 mmol)
(29.4 mmol)
(14,700)
200 mmol)
11
BA
2-H2PN
—
AllylOH
84,926
214,519
2.53
(B-52-1)
(12.8 g,
(1.0 mmol)
(110 mmol)
(126,000)
100 mmol)
12
BA
2-H2PN
—
PenteneOH
21,897
34,889
1.60
(B-56-1)
(25.6 g,
(200 mmol)
(17.9 mmol)
(14,600)
200 mmol)
*Ratio of Initiator/CuBr/Bipyridine was fixed at 1 mol eq/1 mol eq/3 mol eq.
Example 1 synthesis is a control run in that neither the initiator nor any monomer contained hydroxy functionality, nor was the polymer terminated with a hydroxy terminating monomer. The polymers synthesized in Examples 2-4 both were synthesized using hydroxy functional co-monomers; although, the initiator did not contain hydroxy functionality. The polymers synthesized in Examples 5-6 were both initiated with non-hydroxy functional initiators and neither contained any hydroxy functional co-monomers; although, each was polymer was terminated with allyl alcohol. The polymers synthesized in Examples 7-8 were initiated with a hydroxy functional initiator, although, none of the monomers contained hydroxy functionality. The polymers synthesized in Examples 9-10 both were initiated with hydroxy functional monomers. In Example 9, however, a hydroxy functional co-monomer was used and in Example 10, the polymer was terminated with allyl alcohol. Finally, the polymers synthesized in Examples 11-12 were both initiated with a hydroxy functional initiator and terminated with either allyl alcohol (Example 11) or with pentene alcohol (Example 12).
EXAMPLES 13-24
Typical Chain Extension Procedure
Table 2. Examples 13-24
Example 14 (below)
The polymer synthesized in Example 2 (Mn=15, 538, 1.35 g, 0.087 mol, 0.092 mmol OH equivalents) was charged into a reaction vial and diluted with tetrahydrofuran (THF) (1.6 ml). Added thereto were 1 wt-% dibutyltin dilaurate (DBTL) in THF (120 mg, 1.9 μmol) and 10 wt-% 4,4′-methylenebis(phenyl isocyanate) (120 mg, 0.048 mmol, 0.096 mmol NCO equivalents, NCO/OH ratio in reaction mixture of 1.0) followed by stirring for 2 hours under heating at 60° C. The molecular weight of the resulting product was determined by gel permeation chromatography using polystyrene as the standard.
Following the general procedures detailed above, the polymers synthesized as reported in Table 1 were chain extended with 4,4′-methylenebis(phenyl isocyanate) to produce polymers which have utility in formulation adhesive compositions. The chain extension results are reported in Table 2, below
TABLE 2
Chain Extension by Reaction of Polymers of Table 1 (Examples 1-12) with Diisocyanates
Chain
Extension
Table 1
Table 1 Data
NCO/OH
Chain Extension Data
Ex. No.
Ex. No.
Mn
Mw
Mw/Mn
(eq)
Mn
Mw
Mw/Mn
13
1
43,567
69,701
1.60
—
—
—
No Reaction
14
2
15,538
34,491
2.22
1.0
25,036
50,558
2.02
15
3
16,170
30,319
1.88
1.2
22,983
108,529
4.72
16
4
16,041
33,274
2.08
1.2
23,761
287,627
12.11
17
5
14,677
28,399
1.94
1.2
15,865
35,338
2.23
18
6
15,209
26,923
1.77
1.4
18,523
33,706
1.82
19
7
13,255
31,482
3.02
1.4
18,274
55,090
3.02
20
8
12,850
31,193
2.43
1.2
16,607
57,084
3.44
21
9
15,103
26,861
1.78
2.0
46,587
259,875
5.18
22
10
14,956
33,234
2.22
1.5
27,148
73,219
2.70
23
11
84,926
214,519
2.53
1.4
106,001
334,315
3.15
24
12
21,897
34,889
1.60
1.8
48,438
252,259
5.22
The results reported in Table 2 indicate that a variety of hydroxy-containing polymers can be produced that have Mw/Mn values ranging between about 1.6 and 3.0. These results further demonstrate that chain extension of the hydroxy-containing polymers in Table 1 produces new polymers that have Mw/Mn values that range between 1.82 and 12.11. Although, the Mw/Mn values of the chain extended polymers do not exhibit the narrowness in number that their corresponding hydroxy functional telechelic (co)polymers from they are derived do, such chain extended (co)polymers indeed display very unusual adhesive properties as data presented below will demonstrate. Polymers that do not contain hydroxyl functionality (Example 1 in Table 1 and Example 29 in Table 2) do not react with the diisocyanate chain extenders.
EXAMPLE 25
Finally, the non-chain extended polymers synthesized in Examples 11 and 12 (Table 1), and the chain extended versions (same MDI isocyanate as in the previous examples) thereof synthesized in Examples 23 and 24 (Table 2), were tested for their adhesive qualities by measuring their tack by the Polyken Tack Test (see, for example, U.S. Pat. No. 4,183,834 for test details, the disclosure of which is expressly incorporated herein by reference). Additionally, two conventional polymers (identified as Reference 1 and Reference 2) were synthesized from the same ingredients as used in Examples 11 and 12, except that they were conventionally synthesized by free-radical addition polymerization. The results recorded are set forth in Table 3, below.
TABLE 3
Tack
Test No.
Mn
Mw
Mw/Mn
(grams/cm 2 )
1-Example 11
84,926
214,519
2.53
261
1-Example 23
106,001
334,315
3.15
128
2-Example 12
21,897
34,889
1.60
320
2-Example 24
48,438
252,259
5.22
284
Reference 1
22,732
57,467
2.53
142
Reference 2
122,157
320,608
2.62
55
These results demonstrate that the inventive polymers have good tack when synthesized, as expected. When they are chain-extended with an isocyanate, tack decreases, as expected; however, increased molecular weight conventionally translates into stronger bonds. Unexpectedly, it will be observed that the inventive isocyanate-extended telechelic polymers retained a much higher adhesive strength at the higher molecular weights. This is unexpected. For example, compare the tack results for Test No. 1—Example No. 23 and Reference 2. These polymers have about the same molecular weight; yet, the inventive polymer displays a tack of 128 g while the comparative polymer displays a tack of only 55 g. Moreover, the peel strength of the inventive isocyanate-extended telechelic polymers can be tailored by judicious selection of monomer ingredients and degree of reaction.
Thus, the inventive isocyanate-extended telechelic polymers can be synthesized to higher molecular weights to retain their strength by dint of the increased molecular weight, while also retaining a much high peel strength that heretofore would be expected of much lower molecular weight polymers. Truly, an unusual blend of performance characteristics are demonstrated by these data.
EXAMPLES 26-32
Additional hydroxy-functional block copolymers and their chain extended derivatives were synthesized by the procedures described above, as follows:
TABLE 4
Example
Monomers*
Initiator
Terminator
Mn
Mw
Mw/Mn
26
BA/MMA/BA
2-H2PN
Allyl OH
23,000
44,000
1.9
(1.8 mmol)
(110 mmol)
27
BA/STY/BA
2-H2PN
Pentene OH
23,000
50,000
2.19
(1.8 mmol)
(210 mmol)
*STY is styrene
TABLE 4
Example
Monomers*
Initiator
Terminator
Mn
Mw
Mw/Mn
26
BA/MMA/BA
2-H2PN
Allyl OH
23,000
44,000
1.9
(1.8 mmol)
(110 mmol)
27
BA/STY/BA
2-H2PN
Pentene OH
23,000
50,000
2.19
(1.8 mmol)
(210 mmol)
*STY is styrene
A comparison between the melt viscosities and cohesive strengths of conventional hot melt acrylic polymers and the new hot melt polymers described in Table 6 is set forth below.
TABLE 6 a
Relative Melt
Relative Cohesive
Example
Polymer
Viscosity b
Bond Strength c
30
Ref. 2
1
1
(Table 3)
31
26
3.2
2
(Table 5)
32
27
2.8
3
(Table 5)
a The data has been normalized to 1 based on the reference sample.
b The higher the relative melt viscosity ratio, the greater the ability of the polymer to melt and flow.
c The higher the relative cohesive bond strength relative number, the greater the bond strength of the hot melt adhesives adhered to two pieces of aluminum metal.
Now, the only significant difference between polymer 26 and polymer 27 is the alcohol used to terminate the structure. It is believed that the pentene alcohol may be a mixture of pentene alcohols where branched species are present. It is believed that such branching is responsible for the different adhesive performances reported herein. Note, that the reported tack data in Table 3 also shows a marked difference in adhesive performance between those polymers terminated with allyl alcohol and those terminated with pentene alcohol.
When end-capping the telechelic (co)polymer, is conceivable that the inefficiencies of such process may produce a mixture of hydroxyl-capped (co)polymer and initial telechelic (co)polymer. Such mixture may be termed a “self-assembled” adhesive because a balance of properties is achieved in situ by the synthesis steps (mixture of components) rather than by blending different components as is conventional in adhesive formulation technology. Based on these results, it is believed that the relative tack value, Mn and Mw of the chain extended polymers, can be predicted based on the Mn of the initial telechelic polymers synthesized as disclosed herein.
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Disclosed is a method for preparing adhesive polymers which commences with the formation of a poly-telechelic polymer of narrow molecular weight distribution (Mw/Mn) by polymerizing one or more radically-polymerizable monomers in the presence of a transition metal, a ligand, and an initiator, under atom or group transfer radical polymerization conditions. In this polymerization step, OH groups are contained on one or more of said initiator, an initiating monomer, a polymerizable monomer, a terminating monomer, or combinations thereof. The poly-telechelic polymer, then, is chain extended with a polyisocyanate to form the adhesive polymer.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 61/359,189 filed Jun. 28, 2010 and titled Power Input Electrical Connector.
FIELD OF THE INVENTION
This application relates to the field electrical connectors. More particularly, this application relates to connectors used to connect the electrical wiring harnesses of over-the-road trailers, and in particular, trailers connected in double trailer arrangement.
BACKGROUND OF THE INVENTION
Semi-trailer tractor trucks also known as a semi, or tractor-trailer, will frequently be configured to tow a second semi-trailer behind the first in a configuration known as a “double trailer”. In such a configuration it is necessary that the tail lamps, running lamps, brake lights, and signal lights of the towed trailer be connected into the tractor so proper illumination and turn and brake signals are operating on the rear-most trailer. This is typically accomplished by providing a wiring harness that travels the length of the first trailer to communicate electrical signals generated by the tractor to the rear-most trailer. The wiring harness allows the rear-most trailer to be connected into the electrical system of the tractor thereby receiving the electrical impulses that cause illumination of the tail lamps, running lamps, brake lights, and signal lights of the towed trailer. The wiring harness must be affixed to the trailer and at the front and/or rear of the trailer. The end terminal or socket of the wiring harness must be installed into a portion of the frame of the trailer. Generally, such installation comprises the placement of the receptacle or socket (typically known as an SAE standard J560 connector) within a round hole or void that has been made in a front or rear metal frame piece of the trailer. It will be appreciated that a first end of the wiring harness has an electrical connector located in an opening on the forward facing surface of the trailer, (or workpiece) and is commonly referred to as the “Nose Plug.” A second electrical connector is located in an opening on the rearward facing surface of the trailer and may be referred to as the “Tail Plug.” Both plugs or receptacle or sockets are defined in SAE specification J560. The connector at the rear of the trailer is suitable for connecting another tandem trailer and serves as the power output connector to the trailer in-tow or dolly in-tow.
The challenge in trailer wiring is ensuring a waterproof seal at the trailer's power connector. The electrical connector is exposed to all forms of weather and highway driving speeds and vibrations. This environment and these conditions make it essential that any connector be sealed against the elements and that the integrity of such sealing against the elements be maintained during installation to avoid corrosion of the connector and wiring harness. Generally, this requirement for excluding moisture and dirt has resulted in wiring harnesses that are fully formed with integral receptacles or socket and with molded plastic covers that extend the length of the wiring harness and the receptacles. Therefore, installation of a wiring harness requires either insertion of one end of the harness through a mounting hole in the trailer frame and pulling the 30 to 60 feet of wire through the hole or having a connector that can be mounted in the hole from the back-side of the hole. The first of these installation methods can result in the scraping and cutting of the wiring harness on the edges of the metal in which the hole or void is made.
Therefore, it would be beneficial to have a receptacle or socket that allows for rear installation of the socket onto the trailer frame to avoid pulling the whole of the wiring harness through the hole in the trailer frame. It would be a further benefit if the socket is integrally sealed against moisture with the wires or electrical leads that are attached to the connector. It would be a further benefit if the means for attaching the connector avoids the creation of entry points for moisture of areas that will retain moisture and lead to corrosion of the electrical components and connections of the socket or connector.
SUMMARY OF THE INVENTION
The present electrical connector comprises a standard J560-type receptacle or connector with a sealed, molded plastic unitary cover that extends over the length of the wire bundle and over the connector body to provide a moisture proof housing. The front of the connector is provided with surrounding collar that is separable into at least two segments, a detachable retaining clip segment and a non-detachable lip segment. The detachable retaining clip, when removed, reduces the overall dimension of the connector exterior to permit the insertion of the connector through a hole, void or opening in a trailer frame that is dimensioned to receive a SAE standard J560 connector therein. Once the non-detachable lip segment of the connector is inserted through the hole, void or opening in the trailer frame the retaining clip may be reattached to form a collar to retain and secure the connector within the a hole, void or opening and to the trailer frame.
DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 shows a front and right side perspective view of the assembled electrical connector having the retainer clip 12 in position on the connector body to form a collar;
FIG. 2 is a cross-section view taken along line 2 - 2 of FIG. 1 and showing retainer clip 12 in position on connector body 14 with terminals 16 inserted into apertures 18 of connector body 14 and showing a wiring harness 20 having conductors 22 extending therefrom and connecting with terminals 16 surrounding wiring harness 20 and connector body 14 is over-mold cable retainer 24 ;
FIG. 3 is a front and right side perspective view of electrical connector 10 in a partially exploded view showing retainer clip 12 separated from connector body 14 and showing electrical connector 10 in an installed environment in which a void or hole 26 is provided in a work piece 28 and connector body 14 is passed through void 26 to then allow installation of retainer clip 12 on the opposite side of the bulkhead from cable retainer 24 ;
FIG. 4 shows a rear and left side perspective view of the connector body 14 of FIG. 1 with the terminals wiring harness retainer clip and cable retainer removed and showing the seven apertures 18 of one embodiment for receiving terminal 16 therein and showing cavity 30 on connector body 14 , which receives finger 32 that projects from retainer clip 12 (see FIG. 3 ) and showing shoulder 34 which contacts retainer clip 12 to support retainer clip 12 and showing seating trough 36 on connector body 14 , which receives ridge 38 of retaining clip 12 therein to assist in retaining connector body 14 within void 26 of bulkhead 28 . Also shown are grooves 40 at the rear of apertures 18 , which receive terminal retention tabs 42 of terminal 16 therein;
FIG. 5 shows a front elevation view of connector body 14 showing apertures 18 therein which receive terminals 16 and showing flange receivers 44 therein which receive spring flanges 46 of terminal 16 to prevent rearward movement of terminal 16 within connector body 14 . Access voids 48 are shown which allow the plastic material that forms over-mold cable retainer 24 to flow through connector body 14 during formation of the over-mold cable retainer;
FIG. 6 shows a front top and left side perspective view of retainer clip 12 with securing apertures 50 therein;
FIG. 7 shows a rear bottom and right side perspective view of retainer clip 12 ;
FIG. 8 shows a front top and right side perspective view of terminal 16 ;
FIG. 9 shows a front and left side perspective view of electrical connector 10 with retaining clip 12 removed; and
FIG. 10 shows a front and right side exploded view of electrical connector 10 and also showing connector seal 52 which is formed simultaneously with the formation of over-mold cable retainer 24 as plastic material forming over-mold cable retainer 24 is forced through access voids 48 in connector body 14 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
As required, detailed embodiments of the present inventions are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be 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.
Referring now to FIG. 1 , electrical connector 10 is shown completely assembled but not shown installed as it would be for use in a structure requiring an electrical connector. Electrical connector 10 is generally comprised of a retainer clip 12 which connects to a connector body 14 with the retainer clip 12 being removable and installable as needed to permit insertion of connector body 14 through an aperture or hole in a structure such as a truck trailer.
Referring now to FIG. 10 , the component parts of electrical connector 10 and their relationships to one another will be described. In FIG. 10 , electrical connector 10 is shown in an exploded view. Connector clip 12 is shown space above the position it connects to on connector body 14 . Terminals 16 are shown just prior to their insertion into terminal apertures 18 of connector body 14 . A wiring harness 20 having conductors 22 is shown in position for connection to terminals 16 . Over-mold cable retainer 24 is shown removed from connector body 14 and connector seal 52 is shown separated from connector body 14 . It will be appreciated by those skilled in the art that after the assembly of wiring harness and conductors 22 to terminal 16 and the insertion of terminal 16 into connector body 14 that a liquid plastic material is then injected into a mold form containing the connector body and the terminals and the wiring harness. A liquid plastic material is injected to form the shape of over-mold cable retainer 24 . During the formation process of over-mold cable retainer 24 , a portion of the injected liquid plastic is allowed to pass through access voids 48 in connector body 14 (best seen in FIG. 5 ) to provide the formation of connector seal 52 simultaneously with the formation of over-mold cable retainer 24 . Therefore a simultaneously molded unitary structure comprised of over-mold cable retainer 24 and connector seal 52 is constructed. It will be appreciated by those skilled in the art that the presence of connector seal 52 prevents moisture and debris from coming in contact with the terminals of electrical connector 10 when a complementary male connector is inserted into the female electrical connector 10 shown in the present embodiment.
Referring now to FIG. 2 , the construction of electrical connector 10 is shown in cross-section view wherein it may be seen that terminals 16 are inserted into apertures 18 which are provided within connector body 14 . As will be discussed hereinafter, terminal 16 are securely mounted within apertures 18 and structures are present to prevent both rotation of 16 within apertures 18 and the rearward movement of terminals 16 out of apertures 18 after the insertion of terminal 16 into the back end or rear of connector body 14 . It is shown in FIG. 2 that conductors 22 are connected to terminal 16 with such connection being made by soldering or welding connectors 22 to the surface of a flat spade extension from the rear of terminal 16 , or alternatively, conductor 22 may be crimped into connection with terminal 16 using a crimp connection 54 as is shown in FIG. 8 .
Still referring to FIG. 2 , conductors 22 are contained within wiring harness 20 which serves to maintain the seven conductors of the present embodiment in a single manageable group. Retainer clip 12 is shown in position on connector body 14 in FIG. 2 and the entirety of connector body 14 having terminal 16 therein with conductors 22 connected thereto and the wiring harness grouping of conductors 22 all being surrounded by the plastic of over-mold cable retainer 24 as a result of the injection molding process to produce over-molding cable retainer 24 and connector seal 52 .
Referring now to FIG. 3 , the method of use and installation of electrical connector 10 will be described. One typical use of electrical connector 10 is to install the electrical connector into a pre-existing wall or bulkhead of a vehicle such as a truck trailer. In a typical application, electrical connectors of the type to which electrical connector 10 belongs are installed in tandem tractor-trailer configurations wherein power and signal light and brake light connections must be communicated from a first trailer to a second trailer. In view of the long length of the wiring harnesses used in such an application and the need to have a weather resistant cable connection it is advantageous to avoid feeding a long length of wiring harness through an aperture. Also, it is advantageous to avoid disassembly of the electrical connector to install it on the vehicle or bulkhead or workpiece involved. The reason for this will be apparent to those skilled in the art. The feeding of long lengths of wiring harness through apertures can result in the scraping of the covering of the wiring harness and potential cutting of the wiring harness and insulating material around conductors thereby compromising the integrity of the wiring harness. The assembly and disassembly of the electrical connector to permit its mounting on the vehicle or workpiece will compromise the weather resistant nature of the assembly such assembly and disassembly requires removable parts with connecting crevices which can permit the intrusion of dirt and moisture into the device thereby compromising the quality of the electrical connections. Therefore, the present structure is designed with these issues in mind to provide a complete sealed integrally formed structure which does not require assembly or disassembly of the electrical connector and related components for installation into the workpiece or vehicle. Further, the manner of installation avoids the need to feed the entire length of wiring harness through an aperture which may have sharp edges which could scrape and cut and compromise the quality of the insulation on the conductors.
In FIG. 3 , a workpiece or bulkhead or vehicle surface 28 is shown in broken lines indicating it to be environmental structure. Also is shown a void or hole or aperture 26 in the workpiece which is sized to permit the passage of connector body 14 of electrical connector 10 there-through once retaining clip 12 has been removed from connector body 14 . Also shown in FIG. 3 are secondary voids 56 , which permit insertion of a fastener therethrough to enable securing of electrical connector 10 to bulkhead 28 once installation and assembly of electrical connector 10 is complete. Upon insertion of electrical connector 10 (without retaining clip 12 ) through void 26 in bulkhead 28 , lip 58 extending downwardly from the bottom of connector body 14 becomes positioned on the opposite side of the void 26 from the remainder of connector body 14 . Lip 58 serves to properly orient connector body within void 26 to position the structures of connector body 14 which connectably mate with retaining clip 12 on the outside of the void 26 . It will be noted that for purposes of this description, the location “outside the void” will be taken to mean on a first side of the bulkhead 28 in which the void 26 is established and the phrase “inside the void” will mean the position on a second side of bulkhead 28 . Upon seating of lip 58 outside void 26 , and on a first side of bulkhead 28 , it will be possible to connect retainer clip 12 to those portions of connector body 14 , which also are positioned outside of void 26 by the seating of lip 58 against bulkhead 28 outside of void 26 . These additional parts and features of connector body 14 will be described hereinafter in detail, but they generally can be described as those features of connector body 14 which are adapted to receive therein retainer clip 12 and to mate with structures on retaining clip 12 to seat and lock retainer clip 12 to connector body 14 and thereby to seat and lock electrical connector 10 within void 26 on bulkhead 28 with certain features of electrical connector 10 outside void 26 and certain features of electrical connector 10 inside void 26 .
As may be seen in FIG. 3 , the features that are generally inside void 26 on a second side of bulkhead 28 are over-mold cable retainer 24 and wiring harness 20 and conductors 22 and terminal 16 and terminal apertures 18 and the features that are outside void 26 , on a first side of bulkhead 28 , are retaining clip 12 , lip 58 , seating trough 36 , cavity 30 and shoulder 34 of lip 58 . Once connector body 14 has been positioned as previously described in void 26 , bulkhead 28 and retaining clip 12 is attached to connector body 14 , the resultant structure will appear as is shown in FIG. 1 (however FIG. 1 does not show the environmental structure of FIG. 3 ). It will be appreciated by those skilled in the art that securing apertures 50 of retaining clip 12 align with secondary voids 56 of bulkhead 28 to permit passage of a fastener therethrough to complete the installation of electrical connector 10 on bulkhead 28 of a vehicle or trailer or other structure.
Still referring to FIG. 3 , it now can be appreciated that the structure shown in FIG. 9 are those portions of electrical connector 10 which are manipulated as a unit for insertion through void 26 in bulkhead 28 . FIG. 9 also provides yet another view of shoulder 34 and cavity 30 and seating trough 36 which receive finger 32 and ridge 38 of retainer clip 12 and which serve to provide a positive connection between connector body 14 and retainer clip 12 and prevent retraction of connector body 14 back through void 26 in bulkhead 28 once retaining clip 12 is installed.
Referring now to FIGS. 4 and 5 , the structure of connector body 14 will be described in additional detail. In FIG. 4 a first end 60 of connector 14 is shown having terminal apertures 18 therein. Terminal apertures 18 receive terminals 16 and secure terminals 16 within apertures 18 by grooves 40 which receive terminal retention tabs 42 . The tabs 42 engage in grooves 40 and by such connection to connector body 14 eliminate any rotational movement of terminal 16 around the longitudinal axis of terminal 16 . In this manner, rotational forces on the connection between terminal 16 and conductors 22 is provided and integrity of the soldering or crimping connection between conductors 22 and terminal 16 is enhanced. Also shown in FIG. 4 are two retaining ridges 62 which extend outwardly from the central longitudinal axis of connector body 14 . It will be appreciated by those skilled in the art that these features operate to provide protrusions that are surrounded by the liquid plastic that is injected to form over-mold cable retainer 24 . Protrusions 62 operate to assist in securing the connection between container body 14 and over-mold cable retainer 24 to prevent slippage and separation between container body 14 and over-mold cable retainer 24 after the formation of the cable retainer. This is of particular importance as these features are adjacent to access voids 48 in container body 14 which allow the flow of liquid plastic material therethrough to permit the formation of connector seal 52 within the receptacle area 64 of container body 14 .
Still referring to FIG. 5 , the front of terminal apertures 18 is shown. Flange receivers 44 are positioned in terminal apertures 18 . Flange receivers 44 are provided to capture therein spring flanges 46 which extend from terminal 16 . It can be appreciated by those skilled in the art that upon insertion of terminal 16 into apertures 18 of connector body 14 that spring flanges 46 become slightly depressed as they move through terminal apertures 18 . Upon coming into contact with flange receivers 44 which are larger than the general diameter of terminal apertures 18 , spring flanges 46 can return to their original position and become captured within receivers 44 . This capture of spring flanges 46 within flange receivers 44 operates to prevent the subsequent rearward withdrawal of terminal 16 from engagement with terminal apertures 18 . In this manner rearward directed stresses transmitted via wiring harness 20 and/or over-mold cable retainer 24 to the connection of terminal 16 within terminal apertures 18 is resisted and the integrity of electrical connector 10 is enhanced.
Referring now to FIGS. 6 and 7 , retainer clip 12 will be more fully described. In FIG. 6 , retaining clip 12 is shown having securing apertures 50 extending therethrough to permit the passage of fasteners therethrough for the securing of electrical connector 10 onto a workpiece 28 or bulkhead of a truck 28 after assembly of retaining clip 12 onto connector body 14 has been completed. Retaining clip 12 is provided with ridge 38 which extends from retaining clip 12 for connection into seating trough 36 of connector body 14 ( FIG. 4 ). It will be appreciated by those skilled in the art that ridge 38 fits into seating trough 36 and therefore separate forward motion or rearward motion of retaining clip 12 with respect to connector body 14 is inhibited. Also shown in FIG. 6 is finger 32 which projects outwardly from ridge 38 and which is intended for reception within cavity 30 on connector body 14 . As cavity 30 is a further intrusion into the surface of connector body 14 as compared to the distance of intrusion provided by seating trough 36 , it will be appreciated that as connector clip 12 is guided into seating trough 36 of connector body 14 that finger 32 rides along flat segment 36 A of seating trough 36 after which finger 32 of retaining clip 12 is forced into cavity 30 on connector body 14 by retaining clip 12 . This forcing of finger 32 into cavity 30 is achieved as the insertion of retaining clip 12 into seating trough 36 causes an outward expanding forced to be delivered to retaining clip 12 as it passes along the track created by seating trough 36 and flat segment 36 A. Upon finger 32 reaching cavity 30 , finger 32 is pressed inwardly to relieve the outward, expansive pressure that has been delivered to retaining clip 12 by movement past the diameter of connector body 14 . The forces involved here are generated by the presence of a finger 32 on each side of retainer clip 12 thus providing of opposed fingers 32 on either side of retaining clip 12 (best seen in FIG. 7 ). This gap between fingers 32 as indicated by Arrow A is narrower than the diameter of flat segments 36 A on either side of connector body 14 . This different spacing therefore causes the slight expansion of retaining clip A as it is inserted onto connector body 14 and results in the inward movement of fingers 32 into cavities 30 of connector body A to positively capture retaining clip 12 on connector body 14 . As previously described, once retaining clip 12 is seated and captured by connector body 14 , fasteners may be passed through securing apertures 50 and through workpiece 28 to secure electrical connector 10 to the workpiece.
Referring now to FIG. 8 , terminal 16 will be described in greater detail. Terminal 16 is formed of an electrically conductive material such as a metal and is provided with spring flanges 46 , which are captured within flange receivers 44 of connector body 14 . Terminal 16 also is provided with terminal retention tabs 42 which, upon installation of terminal 16 within connector body 14 , become inserted into grooves 40 to prevent pull out of terminal 16 within terminal apertures 18 of connector body 14 . As previously described, the function of spring flanges 46 is to provide a positive capture of spring flanges 46 within flange receivers 44 and to thereby prevent the withdrawal of terminals 16 from terminal apertures 18 of connector body 14 . In FIG. 8 , the embodiment of terminal 16 is shown with a crimp connection 54 which has first and second legs 54 A and 54 B which receive conductor 22 therebetween upon which legs 54 A can be pressed against conductor 22 to capture conductor 22 therebetween for positive electrical connection.
Once the connector system is securely attached to the trailer, a power cord can be connected to a forward mounted J560 connector to provide trailer power from the tractor power. Alternatively a power cord can be attached to a rear mounted J560 connector to provide power to tandem trailer or converter dolly.
In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
Certain changes may be made in embodying the above invention, and in the construction thereof, without departing from the spirit and scope of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not meant in a limiting sense.
Having now described the features, discoveries and principles of the invention, the manner in which the inventive electrical connector is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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A wiring harness electrical connector is provided having a detachable and re-attachable mounting system to permit the attachment of the connector on a frame surface of a semi-trailer, or workpiece, from the rear or interior side of the of the frame or workpiece without disruption to the integrally formed and moisture proof encasing of the connector.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to variable compliance assemblies and more particularly to a variable compliance assembly for an automatic assembly operation utilizing a fluid spring for providing multi-directional compliance movement of a gripper member or similar device.
The uses of robots in the assembly of close-fitting mechanical parts has become widespread. The assembly of close-fitting mechanical parts, however, usually has predetermined tolerances between the workpiece and the receiving part. Compliance assemblies enable a workpiece to be inserted into a receiving part when the centerlines of the workpiece and the receiving part are not exactly collinear with one another to minimize assembly forces and the possibility of jamming or destruction of parts due to machining inaccuracy, parts variation, and fixturing tolerances.
Several compliance assemblies have attempted to resolve variation in centerlines between a workpiece and a receiving part. U.S. Pat. No. 4,276,697 (Drake and Simunovic) discloses a compliance assembly utilizing a multi-stranded cable having an elastomeric collar for providing compliance movement in the assembly. U.S. Pat. No. 4,155,169 (Drake and Simunovic) discloses a compliance assembly utilizing deformable members for providing compliance movement in the assembly. U.S. Pat. No. 4,098,001 (Watson) discloses a compliance assembly utilizing deflectable members for providing compliance movement in the assembly. Also, a technical paper entitled "Using Compliance In Assembly--An Engineering Approach To Float", CASA MS79-873, by Drake, Spencer, and Simunovic discloses compliance assemblies utilizing springs and elastomeric shear pads for providing compliance movement in the assembly.
The above-described assemblies, however, have several disadvantages. Springs, cables, deformable members, and deflectable members are subject to fatigue failure. The failure of these elements in turn causes the automatic assembly operation to be stopped for a repair period which, in turn, stops production. The above assemblies are also highly complicated, include several moving parts, and involve precision tooling in the manufacturing of the assemblies. The resilient elements are assembled on the compliance assemblies at very precise angles, making the compliance assemblies complicated and costly to manufacture.
The present invention overcomes the disadvantages of the prior art by providing a relatively simple and relatively inexpensive variable compliance assembly. The new and improved variable compliance device of the present invention includes a housing having an interior chamber and a base member positioned in the housing and seated on a surface of the interior chamber. Generally, the base member is secured to a gripper and provides the gripper with multi-directional compliance movement. The variable compliance assembly further comprises a fluid spring associated with the housing and the base member for providing the base member with multi-directional compliant movement to correct for lateral, out-of-square, or other misalignment, and for returning the base member to a normal, self-centering seating position. A passageway in the housing is also disclosed for transfer of pressurized fluid to and from the interior of the fluid spring to enable the fluid spring to have varying degrees of pressure and compliance.
Other objects and advantages of the present invention will become apparent to one skilled in the art in view of the following specification, accompanying drawing, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a variable compliance assembly in accordance with the present invention;
FIG. 2 is the view of FIG. 1 with the variable compliance assembly in a displaced position;
FIG. 3 is a cross-sectional view of FIG. 1 taken along lines 3--3; and
FIG. 4 is a schematic view of a control system for the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a cross-sectional view of a variable compliance assembly is shown and designated by reference numeral 10. The compliance assembly 10 includes a housing 12, having an interior chamber 14, positioned on a wrist 16 of a robot arm 18. A base member 20 is positioned in the interior chamber 14 of the housing 12. A fluid spring 22 is secured to the housing 12 and base member 20 for providing the base member 20 with multi-directional compliance movement in the housing 12 and for returning the base member 20 to a normal resting position.
The normal resting position of the base member 20 is illustrated in FIG. 1. A passage 24 in the housing 12 enables a pressurized fluid source 13 (FIG. 4) to communicate with the interior chamber 25 of the fluid spring 22. Generally a gripper device 26 having gripper fingers 28 and 29 is secured onto the base member 20 by conventional means into recess 21 of the base member 20. The gripper fingers 28 and 29 are operatively associated with the gripper device 26 for grasp, release, insertion, and transport of the workpiece 30.
The housing 12 includes a top wall 32, which is securely fastened to the wrist 16 by conventional means such as a bolt 31 extending from the wrist 16 and threadably inserted into an aperture 33 in the wall 32. The housing 12 further includes an annular sidewall 34 depending substantially perpendicular from the periphery of the top wall 32 and an annular flange 36 depending angularly from and continuous with the sidewall 34. The top wall 32, sidewall 34, and flange 36 define the outer boundary of the interior chamber 14.
The top wall 32 has a projection 38 to secure the fluid spring 22 to that wall 32. The projection 38 has a peripheral flange 40 which retains the upper portion of the spring 22 as noted below. The top wall 32 also contains the passage 24 bored through the top wall 32 and the projection 38 to communicate a pressurized fluid source 13 (above atmosphere) with the interior 25 of the fluid spring 22.
The free depending end 37 of the flange 36 defines a circular opening 39 which enables the base member 20 project outwardly from the housing 12. The interior surface of the flange 36 forms a frustoconical seating surface 42 for the base member 20. An aperture 44 is formed in the flange 36 to hold a pin 46 in the housing 12. The pin 46 controls rotational movement of the base member 20 relative to rotational movement of the housing 12. The base member 20 has a notch 54, best seen in FIG. 3, for enabling the housing pin 46 to insert into the base member 20 for limiting independent rotation of the base member 20. As the base member 20 rotates in the housing 12, the walls of the notch 54 abut against pin 46 limiting the rotation of the base member 20 with respect to the housing 12. Thus, the notch 54 may provide the base member 20 with a limited degree of independent rotation inside of the housing 12 if rotation is not a factor. If rotational alignment must also be taken into consideration, such as with a square part, the notch 54 would conform to the pin to permit no relative rotation between the housing 12 and the base member 20.
The base member 20, projecting through the housing opening 39, has an overall frustoconical shape including an angular sidewall 48 which matingly seats on the interior surface 42 of the housing flange 36 and a projection 50. This angular arrangement enables the base member 20 to have free sliding movement upon the interior surface 42 of the housing flange 36. The projection 50 provides the base member 20 with a surface for securing the fluid spring 22 onto the base member 20 and has a peripheral flange 52 to retain the lower portion of the spring 22 as will be noted below. Generally, the projecting member 50 is of a cylindrical shape.
The fluid spring 22 is comprised in the described embodiment of a resilient bellows 56. The bellows 56 may be manufactured from any resilient material, preferably an elastomeric material. The bellows 56 is secured to the projections 38 and 50 of the housing top wall 32 and base member 20, respectively, by rings 58 and 60 acting against the flanges 40 and 52 of the projections 38 and 50, respectively to secure the upper portion of the bellows 56 to the housing 12 and the lower portion of the bellows 56 to the base member 20.
The interior of the bellows 56 may communicate with the pressurized fluid source 13 via passage 24 and a control system 70. Referring to FIG. 4, a schematic view of a control system 70 is illustrated for pressurization of the bellows 56 of the fluid spring 22. The bellows 56 should be pressurized at a higher pressure, providing a stiffer, more expanded bellows 56, as shown in FIG. 4, when the robot arm 16 transfers a workpiece 30 from station to station. The stiffer bellows 56 enables the base member 20 to be rigidly secured in the housing 12, reducing compliant movement of the base member 20 during the transfer period during which the assembly 10 is moved over a relatively large distance at a relatively rapid rate than compared to when the assembly is used at a work station, where the bellows 56 should be in a low pressure state at the robot arm 16 inserts, grasps, or releases a workpiece 30. In the low pressure state, as shown in FIGS. 1 and 2, the bellows 56 provides the base member 20 with multi-directional compliance movement within the housing 12. The amount of compliance can be varied as desired with variance in the pressure of the fluid passing to or released from the bellows 56.
The control circuit 70 includes first and second solenoid control valves 72 and 74 and high pressure and low pressure relief valves 76 and 78. The first solenoid valve 72 has a first position 80 for enabling high pressure fluid (approximately 5 psi in the described embodiment) to enter into the bellows 56 to expand the bellows 56 and provide the base member 20 with a rigid, less compliant position, as seen in FIG. 4. In this position, the source 13 communicates via conduits 71 and 73 with the high pressure relief valve 76 which in turn communicates via conduit 75 with the first solenoid valve 72, which, in first position 80, communicates with passageway 24 via conduit 77. Low pressure fluid is blocked off by a plug 85 associated with the first solenoid valve 72.
The first solenoid valve 72 has a second position 82 for enabling low pressure fluid (approximately 2 psi in the described embodiment) to enter the bellows 56 and provide the bellows 56 with a low pressure, more compliant, limp position as seen in FIGS. 1 and 2.
Low pressure fluid enters into the bellows 56 when the first solenoid valve 72 is actuated to its second position 80 and the second solenoid valve 74 is disposed in its first position 84. In this position, the source 13 communicates via conduits 71 and 79 with the lower pressure relief valve 78 which in turn communicates via conduit 81 with the second solenoid valve 74. A conduit 83 also extends from the second valve 74 to the first valve 72 which communicates with conduit 77 and passage 24 when the solenoid 72 is in its second position 82. High pressure fluid is blocked off by the plug 85 associated with the solenoid valve 72.
The bellows 56 can be evacuated to the atmosphere when the first solenoid valve 72 is in its second position 82 and the second solenoid valve 74 is in its second position 86. This evacuation position provides the bellows 56 with a means for rapid evacuation of the bellows 56 so that the pressure inside of the bellows 56 may be changed rapidly from high pressure to low pressure for accommodating the bellows 56 in its expanded and limp positions, respectively. In this position, the source 13 is blocked off and the bellows 56 via conduits 24 and 77 communicates with conduit 83 via valve 72 and conduit 87 via valve 74. Conduit 87 is vented to the atmosphere at port 91. Port 91 may also be connected as a third source of pressurized air.
The check valves 76 and 78 prevent the high and low pressure fluids from exceeding their predetermined levels. If the pressure of the fluid exceeds the predetermined level, the relief valves 76 and 78 automatically release the fluid entering the system to maintain the desired pressure.
Now referring back to FIGS. 1 and 2, a receiving part 90 is shown. The receiving part 90 has a chamfer 92 and a receiving portion 94 for receiving the workpiece 30. In FIG. 1, the line 96 associated with the center of the workpiece 30 is collinear with the line 98 associated with the center of the receiving part 90. In this case, the workpiece 30 should insert into the receiving part 90 with no apparent compliance problem, although the cone of compliant movement of the center of compliance of a workpiece is shown in dashed lines in FIG. 1. The center of compliance of a workpiece is known in the art as the point on a workpiece where a lateral force causes only a lateral deflection and a torque or moment causes only a rotational deflection.
Turning to FIG. 2, illustrating when the lines 96 and 98 associated with the centers of the workpiece 30 and receiving part 90, respectfully, are not collinear. When this is the case, a compliance problem exists which the compliance assembly 10 corrects.
Generally, in the compliance process the workpiece 30 comes into contact with the chamfer 92 of the receiving part 90. The robot arm 16 forces the workpiece 30 toward the receiving part to insert the workpiece 30 into the receiving portion 94 of the receiving part 90. At this time, the bellows 56 (in a limp state) and the base member 20 (seated on the flange interior surface 42) move to insert the workpiece 30 into the receiving part 90. The movement of the base member 20 occurs by the base member sidewall 48 sliding upon the flange interior surface 42 until proper compliance is achieved and the workpiece 30 is inserted into the receiving part 90.
The conical shape of the base member 20 and interior surface 42 of the flange 36 provides the compliance assembly 10 with multi-directional compliant movement so that a lack of collinear alignment in any direction between the workpiece 30 and the receiving part 90 may be corrected. In addition, the fluid spring 22 may provide the compliance assembly 10 with some limited axial movement, if desired. Once the workpiece 30 has been deposited in the receiving part 90 and the gripper fingers 28 and 29 release the workpiece 30, the bellows 56 will return and self-center the base member 20 to its normal seating position.
Generally, pressurized air (above atmosphere) is used as the working fluid since pressurized air can be rapidly moved in and out of the interior of the bellows 56. However, hydraulic fluid could be used as the working fluid with satisfactory results where weight and speed are less important considerations.
While the above summarizes the present invention, it will become apparent to those skilled in the art that modifications, variations and alterations may be made without deviating from the scope and spirit of the present invention as described and claimed herein.
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A variable compliance assembly is disclosed for use in automatic assembly operations. The variable compliance assembly includes a housing having an interior chamber; a base member, positioned on the surface of the interior chamber, moveable in a multi-directional fashion; a fluid spring operably associated with the housing and base member for controlling the multi-directional movement of the base member and for returning the base member to a normal, self-centering seating position; and a mechanism for associating a pressurized fluid source with the fluid spring to vary the amount of control exerted by the fluid spring on the base member.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improvements in techniques for the formation of felts, and in particular thick felts such as those used for heat and sound insulation.
2. Background of the Prior Art
The formation of felts from fibers carried by a gaseous current is traditionally carried out by passing this current through a perforated receiving conveyor which holds back the fibers. To bond the fibers to each other, a binder is sprayed over the fibers in the course of their path to the receiving conveyor. This binder is subsequently hardened, for example by a heat treatment.
This technique is employed in particular for the production of mineral fiber felts. Hereinafter the formation of felts from fibers of vitreous materials is exclusively referred to due to the importance of this type of production but the invention is nevertheless applicable to all processes of producing felts, whether from mineral or from organic fibers.
One of the difficulties encountered in the preparation of these felts is connected with the uniform distribution of the fibers within the felt. The gaseous current carrying the fibers normally has a cross section of limited width which is a function, in particular, of the apparatus used for the production of the fibers. Moreover, the gaseous current normally does not cover the whole width of the conveyor, and the fibers are not uniformly distributed.
Various means have been proposed for improving the distribution of the fibers on the conveyor. One of the most useful of these means is of the type described in U.S. Pat. No. 3,134,145. It consists of passing the gaseous flux carrying the fibers through a guide duct. This duct is movable and is subjected to an oscillating movement which alternately directs the gaseous flux from one edge to the other of the conveyor receiving the fibers.
If the operating conditions are suitably chosen, the fibers are deposited by these means over the whole width of the conveyor.
In practice, however, it has been found that a strictly uniform distribution is very difficult to obtain. Deviations of the mass of fibers per unit surface area of as much as 15% or more from the mean value are encountered in samples taken at different points over the width of the felt. It is therefore necessary to improve the practical execution of this technique of distribution in order to reduce as much as possible the variations found in the distribution of the fibers.
It is an object of this invention to provide an improved technique for the distribution of fibers in the formed felts.
The invention particularly has the object of providing a process whereby variations in distribution appearing in the course of operation can be corrected.
The invention also has the aim of enabling the correction in the variations of fiber distribution to be carried out automatically.
SUMMARY OF THE INVENTION
These objects are achieved by means of the invention, according to which the parameters determining the oscillating movement of the guide duct may be varied during the course of operation. Permanent measures for the distribution of the fibers within the form felt also enable the conditions for the best possible distribution to be re-established at each instant through feedback according to pre-established corrections as a function of the deviations detected in relation to the desired distribution.
By continuously measuring the density of fiber distribution in the felt being formed, distributional errors can be corrected during operation by altering the distribution mechanism, the continuous feedback resulting in a quickly dampened amplitude of irregular distribution.
The invention also proposes a set of means for carrying out the regulation of distribution by the method indicated above.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in detail below with reference to the annexed sheets of drawings, in which
FIG. 1 is a schematic view of an installation for the formation of fiber felts viewed transversely to the direction of transport of the receiving conveyor.
FIG. 2 is a partial view of FIG. 1 on an enlarged scale, showing more precisely the construction of the apparatus for distribution of the fibers.
FIG. 3 is a schematic view showing an arrangement for measuring the mass of fibers per unit surface area.
FIG. 4 is an overall schematic view illustrating how the system of distribution of fibers of the invention is regulated.
FIGS. 5a, 5b, 5c and 5d illustrate schematically four types of configuration of distribution of the fibers across the felt.
FIG. 6 shows a form of combination of measures for demonstrating the fundamental characteristics of the distribution measured.
FIG. 7 represents an example of the evolution of distribution of fibers when the means for regulation according to the invention are carried out.
FIG. 8 represents another example, analogous to that of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
The installation for the formation of felts shown in FIG. 1 comprises an apparatus for the formation of fibers, a receiving arrangement and distributing means.
In this figure, the apparatus for formation of the fibers is of the type in which the material to be fiberized is projected in the form of fine filaments from a centrifuge having a multiplicity of orifices. The filaments are then carried and attenuated by a gaseous current directed vertically downwards. The gaseous current is normally at a high temperature enabling the filaments to be maintained under suitable conditions for attenuation.
The fibers carried by the gaseous current form a sort of film 2 around and above the centrifuge 1.
This method of formation of fibers has been the subject of numerous publications. A detailed description of the operating conditions and apparatus may be found, in particular, in French Pat. No. 78 34616.
It is to be understood that this invention is not limited to a particular mode of formation of fibers but covers all techniques in which a felt of fibers is formed from fibers carried by a gaseous current. The example of formation of fibers by this technique of centrifugation has been selected because of its wide importance in the industrial field.
In this type of formation, the film of fibers contracts under the centrifuge for reasons pertaining to the geometry of the fiberizing device. The gaseous current carrying the fibers subsequently expands when it comes into contact with the surrounding atmosphere.
It should be noted that this expansion of the gaseous current is an entirely general phenomenon independent of the original form of the current and hence of the method of formation of fibers employed.
The gaseous current carrying the fibers is directed into a container 4 the base of which is formed by a perforated conveyor 3. This container is enclosed laterally so that the gaseous current cannot be evacuated except by passing through the perforated conveyor 3.
Walls 5 channel the flow of gas laterally. These walls may be movable, as indicated in FIG. 1. Such walls have the advantage that they may be continuously freed from any fibers which may adhere to them, especially if the fibers have been sprayed with a binder composition in their path towards the conveyor. The straying assembly is not shown in the drawing.
Observation of the gaseous current carrying the fibers shows that the expansion of the current takes place relatively slowly. In the case under consideration, the current adopts a conical form with an apical angle A of the order of 20°. The felts produced frequently have a width of more than 2 meters and since the current is originally fairly narrow, it is obviously not possible to obtain a sufficiently wide flow to cover the whole surface of the conveyor. This is shown in FIG. 1.
Underneath the conveyor 3, gas enters the box 6, which is maintained at a lower pressure than the container 4 by suction means (not shown).
The box 6 is arranged so that this suction takes place across the whole width of the conveyor 3, thereby avoiding the formation of undesirable turbulences in the container 4. This uniform suction to a certain extent also favors uniform ditribution of the fibers, the zones of the conveyor already charged with fibers having a greater resistance to the passage of gas, thereby opposing the accumulation of additional fibers.
The equilibrium which tends to become established on the conveyor by the presence of the fibers is, however, insufficient in itself to achieve suitable distribution on a conveyor which is very much wider than the gaseous current. The accumulation of fibers is greater at the center of the conveyor, that is to say, in the direct path of the gaseous current than at the sides.
An oscillating guide duct 8 is arranged in the path of the gaseous current for the purpose of improving the distribution of fibers. The current is channeled by the duct 8 which is so designed that its oscillations deflect the current, causing it to sweep over the width of the conveyor 3.
The guide duct 8 is placed in the upper part of the container 4, as far away as possible from the conveyor so that the changes in direction to be imparted to be gaseous current will be as small as possible. The gaseous current is also preferably channeled when its geometry is clearly defined, that is to say, as close as possible to the fiber forming device.
FIG. 2 shows in more detail the guide duct 8 and the mechanism animating it in an arrangement according to the invention.
In prior techniques, and in particular in U.S. Pat. No. 3,134,145, the movement of the guide duct for the gaseous flow is obtained from a motor and a mechanical transmission comprising a cam and a set of links.
Improvements have been developed comprising a mechanism formed by a set of gears, the whole arrangement having the effect of producing a more complex movement of the duct. This movement comprises, for example, a higher speed of displacement in the end positions than in the mid-position.
The device for distribution of the fibers must be regulated with great precision. It will be seen in the examples of practical application of the invention that a very slight change in the parameters defining the movement of the guide duct causes a very significant change in the distribution. In the known apparatus, these adjustments are carried out by the operators before production is started. Interventions when production has already started are not entirely impossible but are difficult and temporarily interfere with the production process. In practice, these interventions are carried out only when very serious faults in distribution occur.
The apparatus used according to this invention, on the other hand, enables modifications in the operating conditions to be carried out without interrupting or even disturbing the production process. These modifications may therefore be carried out as often as desired. Even relatively small faults in distribution may be corrected so that products with substantially improved quality may be obtained.
In FIG. 2, the upper part of the guide duct has the form of a truncated cone slightly widening out in the direction of the fiber forming apparatus. This increase in width facilitates the channeling of the attenuating gas emitted from an annular attenuating device 10 at the periphery of the centrifuge 1.
The duct 8 is supported on two pivots 11 engaging on bearings fixed to mountings (not shown). The axis of rotation is placed sufficiently high on the duct so that the position of the opening of the duct in relation to the gaseous current is only slightly modified by the oscillation.
The oscillating movement is produced by a motor assembly which in the example illustrated consists of a hydraulic jack 9. This driving arrangement is obviously not the only one which may be used. An electric or electromechanical assembly, for example, could be provided to ensure both the oscillating movement of the duct 8 and the modification in the parameters determining this movement.
The movement is communicated to the duct 8 by a hinged mechanical transmission comprising the rod 16 of the jack 9, an arm 14, a link 13 and another arm 12 firmly connected to the duct 8.
The arm 14 pivots on an axle 15 mounted on bearings arranged on a fixed framework (not shown). The rod 16 of the jack 9 is connected to the arm 14 by a joint 22.
The jack 9 is supported on a framework 26 by pivots 27 allowing it a certain clearance in rotation in a vertical plane.
The link 13 hinged to the arms 12 and 14 in the form represented constitutes a deformable parallelogram with these arms. The two arms therefore move identically. Other, similar forms of assembly would obviously be possible within the scope of this invention. This particular arrangement has the advantage of simplifying the determination of the position of the duct 8, this determination playing some part, as will be seen herinafter, in the regulating process according to the invention.
The arrangement for the transmission of movement comprises a series of regulating means enabling the geometry of movement to be determined with precision. The conventional means for this type of assemby have not been illustrated.
The jack 9 has a double action. It may therefore be subjected to a reciprocating movement. Such a movement may also be obtained with two single action opposing jacks but a double action jack is preferable for convenience of operation.
The operation of the jack 9 is controlled by a proportional distributor indicated at 17 which regulates the rate supply of fluid into the jack and is associated with a hydraulic center supplying fluid under pressure, indicated by the block 28.
The excursion of the jack 9 and the construction of the mechanical transmission are chosen so that the oscillation of the guide duct 8 may respond to any requirements encountered in practice. In other words, the limits of the movement, indicated, for example, in FIG. 1 by the angle B formed by the axis of the conduit in its two end positions, are such that the gaseous current would extend beyond the whole width of the conveyor if it did not strike the lateral walls 5.
The use of a hydraulic jack offers great facility for controlling movement. The amplitude may, of course, be modified or the end positions may be modified while maintaining the same amplitude. The speed may also be varied.
The movement which may be imparted to the jack 9 and therefore communicated to the guide duct 8 may follow any desired plan. For example, the jack may be subjected to an operating program in which the speed varies in the course of one oscillation according to a complex law, and variations in several of the parameters determining the movement, such as speed, frequency, amplitude and end positions, may be combined.
All these modifications are carried out without interruption of the movement, by suitable control of the proportional distributor.
The hydraulic jack constitutes a preferred means according to the invention due to its sturdiness and flexibility of use, although other means may equally well be used to produce this type of variable movement as indicated above.
The distribution device used according to this invention is thus well-adapted to frequent corrections in the mode of distribution such as may appear necessary in the course of production of the felts.
No matter what precautions are taken, the dispersion of fibers on the conveyor is subject to numerous chance factors. It would obviously be very difficult to maintain a perfectly stable gaseous flow inside the container 4. Considerable induced currents develop in addition to the current carrying the fibers. Furthermore, a single container normally contains a plurality of fiber forming devices each with its own gaseous current which influence each other. Consequently, and in spite of the suction under the conveyor, the container 4 is the site of vigorous turbulences. In addition to these factors causing irregularity in the gas flow, there may in some cases be an accidental lack of uniformity in the suction.
Whatever the causes, experience has shown that irregularities in the transverse distribution of the fibers appear in the course of operation and persist for relatively long periods so that it becomes desirable to modify the operating conditions of the guide duct with a view to re-establishing greater uniformity.
Another advantage of the use according to this invention of hydraulic means for actuating the guide duct is that it enables automatic control to be employed. As the variations mentioned above occur irregularly and are not predictable, it is very desirable that corrections should be made as soon as a fault in distribution is detected.
Measurement of the distribution of the fibers in the formed felt may be carried out by various methods. In the context of automatic regulation, the methods used should operate continuously and not disturb production.
One preferred method consists of measuring the absorption of radiation, in particular of X-rays, but other methods capable of determination of relative density and distribution could equally well be envisaged.
The method of measuring by absorption of X-ray is preferred when the felt is thick, in other words when there is considerable absorption. For thinner and therefore less absorbent fiber layers, such as the products referred to as "films," a method of measurement using beta radiation for example, may be preferred.
The method of measuring the mass of fibers per unit surface area on the felt by X-ray absorption is carried out according to this invention in accordance with clearly specified particulars.
Thus the apparatus used for measurement should be situated at a point on the production chain suitable for providing a significant measurement.
On leaving the receiving container 4, the formed felt is frequently loaded with moisture, in particular from a solution of binder sprayed on the fibers. Water may also be sprayed on the path of the fibers to cool the attenuating gas and the fibers carried by it. Water, which strongly absorbs X-rays may therefore substantially modify the results of measurement if it is not uniformly distributed. It is therefore advantageous to carry out the measurement at a point along the production line where the felt is free from moisture.
The measurement of the mass of fibers per unit surface area is therefore preferably carried out at the exit from the container in which the binder treatment is carried out.
If, however, the accumulated fibers carry only little moisture or if this moisture is well-distributed, the measurement may be carried out before treatment, as soon as the fibers leave the receiving container.
When measurement is carried out after treatment with the binder, it would take place at a relatively great distance from the location where distribution of the fibers takes place. Between the deposition of the fibers on the conveyor belt and their passage to the point of measurement, several minutes may elapse, even as much as 10 minutes. This delay, which is thus introduced systematically in the operation of regulating the distribution according to the measured faults in uniformity, is, however, no great disadvantage. As is shown in the examples below, the means of regulation according to the invention may be used to correct faults in distribution which manifest themselves over relatively long periods compared with the delay in question. Furthermore, in the course of production, the irregularities are normally progressive. If they are correctd as soon as they appear, the deviations normally remain relatively minor and do not interfere with production.
The measurements should be carried out over the whole width of the felt, and the measuring apparatus is therefore designed to be displaceable transversely to the felt.
FIG. 3 is a schematic representation of a measuring apparatus used according to the invention.
In this figure, the felt 7 passes through a frame 29 the upper, transverse part of which supports a source 30 of radiation emitted in the direction of the felt 7.
The emitting source 30 is movably mounted on rollers. It is displaceable transversely by a system of chains (not shown) in the frame.
A displaceable receiver 31 in the lower transverse part is situated opposite the emitting source. The receiver is moved identically to the source, also be a system of chains.
A single driving assembly in the box 32 ensures perfectly synchronized movement of the source 30 and receiver 31.
The radiation emitted is partially absorbed by the felt, and the fraction of radiation reaching the receiver is measured.
The measurements are carried out during displacement of the apparatus and each measurement corresponds to a fraction of the width of the felt over which the apparatus sweeps.
The duration of each measurement, and consequently the width of the fraction analyzed, may be chosen according to the use which is to be made of these measurements.
The measurements should be carried out over such fractions of the width of the felt that the discontinuous structure of the fibrous material does not prevent significant values being obtained. The minimum width of the "sample" over which the measurement is carried out is a function of the mass per unit surface area of the felt. The denser the felt, the smaller is the minimum width of sample.
For felts having a mass per unit surface on the order of 1 to 3 kg/m 2 , a width of measurement of a few millimeters to a few centimeters, up to about 10 centimeters, is sufficient.
In practice, as will be seen later, regulation of the apparatus distributing the fibers can only be carried out on a limited number of parameters. A large number of measurements is therefore only purposeful to the extent that it provides additional possibilities in the treatment of these measurements.
FIG. 4 shows schematically the arrangement for regulating the felt forming installation insofar as it relates to the distribution of fibers.
The figure shows a single device for the formation of fibers. This type of installation normally has 6 to 12 such devices aligned along the conveyor 3 in the container 4.
In the case of installations comprising several fiber forming devices, each such device is advantageously equipped with a distributing system of the type used according to the invention. The movement of these devices may be identical or not, as the case may be. The devices are generally, but not necessarily, subjected to a movement of the same frequency and the movements need not necessarily by synchronized.
The amplitude and mean direction may also be adjusted to vary from one device to another.
When automatic regulation is carried out according to this invention, it may act on one or more than one device of the same installation.
The felt 7 leaving the container 4 is taken up by the conveyor 20 moving at the same speed as the conveyor 3. The felt passes through a stove 19 where it is subjected to a circulation of hot air to polymerize the binder.
At the exit from the stove 19, the dry felt enters the X-ray absorption measuring device 21.
The regulating circuit employed is as follows:
The measuring device 21 transmits the magnitudes corresponding to the absorption of the analyzed "sample" and the position of this sample on the felt to a computer indicated at 23.
The computer 23 also receives information on the operation of the distributing device by means of the regulating assembly represented by the block 24. In particular, the computer receives signals relating to the position of the guide duct 8. This position may be registered, for example, by a potentiometric detector 18 (FIG. 2) which follows the movement of rotation of the arm 14 about the axle 15.
The computer 23 may also receive information relating to the speed of displacement of the felt 7 by means of a control system 25 regulating the speed of the conveyors.
The computer compares these informations with a set of data in its memory in terms of the deviations found and produces instructions which are transmitted to the regulating assemblies 24 and 25. These assemblies then modify, respectively, the operation of the distributing apparatus and the speed of the conveyors.
As already indicated above, the parameters available for controlling the distribution of fibers are few in number.
The speed of advance of the conveyors is able to modify the mass per unit surface area of fibers in a general manner but not the transverse distribution. The overall quantity of fibers is normally determined at the moment when these fibers are formed, for example by regulating the quantity of material to be fiberized, assuming that the speed of the conveyor remains constant.
The presence of an assembly for measuring the mass per unit surface area of felt, however, provides the means for automatic control of the speed as indicated above. For this purpose, the computer 23 is instructed to integrate the local measurements in order to determine the mass per unit surface area over the whole felt. A comparison of the results obtained with an imposed value commands the acceleration or deceleration of the conveyors according to whether this mass is found to be greater or less than the imposed value.
The parameters which determine the operation of the distributing duct 8, and hence the transverse distribution of the fibers, are the frequency of oscillation, the amplitude of oscillation and the mean direction.
The frequency is an important factor for obtaining good distribution of the fibers on the conveyor. When felts with a large mass of fibers per unit surface area are to be formed, several successive depositions of fibers are normally superimposed on each other, each obtained from one of a series of devices in alignment as described above. In that case, the frequency has less influence above a certain relatively low minimum threshold. For lighter weight felts, precise regulation of the frequency is much more important for the final result.
The frequency should generally be sufficient to ensure that the whole surface of the moving conveyor is effectively covered by the flow carrying the fibers. When several fiber forming devices are put into operation for producing one felt, however, it is not absolutely necessary for each flow to completely cover the surface. It is sufficient in that case if all the devices together effectively produce a complete covering.
It is, however, not advantageous to increase the frequency excessively. The improvement which could thereby be obtained is not substantial and is in any case limited by the inertia of the film of fibers. It is found that beyond a certain frequency, the movement of the gaseous current can no longer folow the movement imposed on the guide duct. Effective regulation of the distribution of the fibers then becomes impossible.
The frequency may be regulated, for example, as a function of a previously determined optimum for each mass per unit surface area value. The frequency regulation may then be combined with the regulation of the speed of movement of the conveyor as a function of the mean mass per unit surface measured over the whole width of the felt.
The amplitude and median direction of movement of the guide duct directly determine the transverse distribution of the fibers. The use of guide ducts in conventional methods has enabled single results to be isolated to show how the different parameters affect the distribution. The modification in median direction while the amplitude remains constant gives rise to a displacement in the deposition of fibers in the same direction as this modification. Bearing in mind the presence of the lateral walls, this displacement in fact results in an increase in the mass of fibers per unit surface area on the side to which this displacement is directed. Similarly, it is found that an increase in the amplitude of movement favors the deposition of fibers along the edges of the conveyor at the expense of the center, and conversely.
The measurements carried out on the mass of fibers per unit surface area and their treatment by the computer have in particular the object of obtaining the best possible control of these two parameters. Models of distribution have therefore been drawn up, to which the answers correspond, the whole arrangement beig stored in the memory of the computer.
Four basic forms of distribution have been distinguished. These four distributions are represented schematically in FIGS. 5a, 5b, 5c and 5d. These figures show the deviation in mass per unit surface area from the mean value over a transverse section of the felt. For the mean value, the deviation is zero. These four forms correspond, respectively, to the gaseous current shifted to the left (FIG. 5a), shifted to the right (FIG. 5b), at too high an amplitude of oscillation (FIG. 5c) and too low an amplitude (FIG. 5d).
The correction to be imposed upon the operation of the guide duct is determined by comparing the measurements, processed and evaluated as described, with these four models.
Processing of the measurement comprises, firstly, the collection of several measurements corresponding to successive passages at the same position in the width of the felt. The mean value deduced therefrom is then a more complete and precise image of the effective distribution in the zone under consideration. The measurements are also regrouped by sectors, which are then evaluated. The choice of sectors and their respective evaluation is determined by tests so that the values obtained will be representative of the distribution and the corrections carried out will result in an effective improvement.
The processing of these values is also chosen as far as possible to reflect all the configurations or dimensions of the installations equipped with these regulating systems.
A preferred method of regrouping measurements of the mass of fibers per unit surface area is indicated in FIG. 6. In this method, for example, the width of the felt L is divided into four sectors which partially overlap. The regrouped, evaluated measurements in these four sectors ensure that excessive importance is not given to measurements corresponding to the sides of the felt compared with the center part.
Other methods of processing, could, of course, be employed. Tests in each case show the significance of the method studied for resolving the problems encountered in practice.
EXAMPLES
By way of example, tests have been carried out on a pilot installation for the formation of felt from glass wool. This installation contained only one fiber forming device. These examples are not intended to limit the invention.
I.
The fiber forming device and the arrangement of guide duct and driving system are of the type represented in FIG. 2.
In this installation, the felt has a width of 2.40 m. It has a mass per unit surface area of 1 kg/m 2 .
Since only a single fiber forming device is used, the speed of the receiving conveyor is relatively low, being 5.25 m/min.
The felt leaving the receiving chamber passes through a stove.
At the exit from the stove, the felt passes through an X-ray absorption measuring device using americium 241 as its source. This movable source passes over the whole width of the felt in 32 seconds. Sixty-four measurements are taken in the course of each movement over the width of the felt. The values are registered together with their position.
A sliding mean is established over the last 8 passages of the X-ray probe.
The values are grouped into four bands I, II, III, IV as indicated in FIG. 6.
The regulation is carried out on the basis of the mean values obtained for these four bands according to the method described above.
Beween two successive corrections, it is necessary to take into account the delay between the formation of the felt and the measurement. In this case, this delay is 10 minutes. It is also necessary to take into account the time corresponding to at least eight successive passages of the X-ray probe over the formed felt subsequent to the preceding correction in order to obtain the eight fixed measurements.
In these tests, the corrections are carried out systematically at intervals of 18 minutes.
FIG. 7 shows the evolution in the distribution of fibers over a lateral strip of felt of a width of 30 cm. The corresponding value is then the mean of eight measurements for each of the eight measurements for each of the eight successive passages, amounting to a total of 64 measurements.
The graph shows the relative deviation in density of the strip under consideration compared with the mean mass per area over the whole width of the felt. The moment at which corrections are carried out is indicated by a vertical bar.
The initial movement of the guide duct corresponds to an amplitude defined by the half angle B of 8.7° and a median direction making an angle of +0.8° with the vertical. The frequency of oscillation, which remains unchanged during the tests, is 60 forward and return movements per minute.
Initially, that is to say, before the first corrections, the deviation from the mean varies from +15 to +7%. After two corrections, this deviation is rapidly reduced to less than 5%. It is thereafter constantly below 5% in relative value, and after the fifth correction, it falls to less than 3%.
The improvement thus obtained is remarkable.
It should also be noted that if the mass per unit area of the lateral strip chosen has been corrected, similar measurements carried out on other fractions of the felt show that over the felt as a whole, the deviations are maintained at a value below 5% of the mean value. In other words, corrections carried out which have succeeded in improving the distribution over the outer strip have not been to the detriment over the distribution of the remainder of the felt.
The correction introduced according to this invention is an extremely precise operation. At the end of the fifth correction applied, the amplitude of movement of the guide duct is 8.14° and the median direction makes an angle of -0.5° with the vertical. The modifications imposed on the movement are thus very small.
These modifications indicate the degree of sensitivity of the distribution to the parameters of movement of the distribution duct and what difficulty could be encountered in arriving at a regulation of equal quality if it were carried out manually, supposing that the device actuating the guide duct could be corrected in this manner.
II.
FIG. 8 also reproduces a regulating test carried out on the same device as previously described.
These measurements correspond to eight separate strips across the width of the felt. The measurements for the strips 1, 2, 4, 7 and 8 have been represented by way of indication.
This example is of interest since in this case the distribution was originally particulary irregular. Thus adjacent strips 1 and 2 or 7 and 8 have deviations of which one is positive and the other negative in relation to the mean.
In the present case, the mean mass per unit area is 1.3 kg/m 2 .
The half angle B defining the amplitude of movement is initially 12.35° and the deflection from the vertical is initially -10.61°.
The corrections are indicted on the time scale by a vertical bar.
It should be noted that after two corrections, the deviations for all the values, including those that are initially the worst (+18% for strip 2, -12% for strip 8) have been brought within an interval of from +5% to -5%. The values subsequently remain within this interval.
At the fourth correction, the half angle B is 12.72% and the median direction is -10.25°. As in the example illustrate in FIG. 7, the variations leading to an improvement in the distribution of the fibers are extremely small.
The invention has been disclosed with respect to particular embodiments and examples. Particularly, specific fibers, mechanics and values have been identified which are not intended to limit the invention unless so indicated. Variations will occur to those of ordinary skill in the art without the exercise of inventive faculty, and remain within the scope of the invention as claimed below.
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A process for the improvement in the distribution of fibers in a fiber felt formed by retention of fibers entrained in a gaseous current is disclosed, along with apparatus suitable for practicing that process. The gaseous current is caused to pass through an oscillating guide duct, the frequency, amplitude and median direction of the oscillation, or at least one of those aspects, may be automatically regulated and altered in response to sensed variations in the distribution of the fiber. The distribution variations are measured by determining relative absorption of radiation across different portions of the width of the felt in comparison with the mean value of that distribution.
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This application claims priority from provisional application Ser. No. 60/628,623, filed Nov. 17, 2004, the entire contents of which are incorporated herein by reference.
BACKGROUND
1. Technical Field
This application relates to a rotational thrombectomy wire for clearing thrombus from native vessels.
2. Background of Related Art
In one method of hemodialysis, dialysis grafts, typically of PTFE, are implanted under the patient's skin, e.g. the patient's forearm, and sutured at one end to the vein for outflow and at the other end to the artery for inflow. The graft functions as a shunt creating high blood flow from the artery to the vein and enables access to the patient's blood without having to directly puncture the vein. (Repeated puncture of the vein could eventually damage the vein and cause blood clots, resulting in vein failure.) One needle is inserted into the graft to withdraw blood from the patient for transport to a dialysis machine (kidney machine); the other needle is inserted into the graft to return the filtered blood from the dialysis machine to the patient. In the dialysis machine, toxins and other waste products diffuse through a semi-permeable membrane into a dialysis fluid closely matching the chemical composition of the blood. The filtered blood, i.e. with the waste products removed, is then returned to the patient's body.
Over a period of time, thrombus or clots may form in the graft. Thrombus or clots may also form in the vessel. One approach to break up these clots and other obstructions in the graft and vessel is the injection of thrombolytic agents. The disadvantages of these agents are they are expensive, require lengthier hospital procedures and create risks of drug toxicity and bleeding complications as the clots are broken.
U.S. Pat. No. 5,766,191 provides another approach to breaking up clots and obstructions via a mechanical thrombectomy device. The patent discloses a basket having six memory wires expandable to press against the inner lumen to conform to the size and shape of the lumen. This device could be traumatic if used in the vessel, could denude endothelium, create vessel spasms and the basket and drive shaft could fracture.
U.S. Pat. No. 6,090,118 discloses a mechanical thrombectomy device for breaking up clots. The single thrombectomy wire is rotated to create a standing wave to break-up or macerate thrombus. U.S. Patent Publication No. 2002/0173812 discloses another example of a rotational thrombectomy wire for breaking up clots. The thrombectomy wire has a sinuous shape at its distal end and is contained within a sheath in a substantially straight non-deployed position. When the sheath is retracted, the distal portion of the wire is exposed to enable the wire to return to its non-linear sinuous configuration. The wire is composed of stainless steel. Actuation of the motor causes rotational movement of the wire, creating a wave pattern, to macerate thrombus. The device of the '812 patent publication is effective in atraumatically and effectively breaking up blood clots in the graft and is currently being marketed by Datascope, Inc. as the Pro-Lumen* thrombectomy catheter. In the marketed device, the wire is a bifilar wire, composed of two stainless steel wires wound side by side with a metal tip and an elastomeric tip at the distalmost end.
Although the sinuous wire of the '812 publication is effective in proper clinical use to macerate thrombus in dialysis grafts, it is not suited for use in native vessels. The device is indicated for use in grafts, and if improperly used the wire can kink or knot, and perhaps even break. The wire can also bend, making it difficult to withdraw after use, and can lose its shape. Additionally, the wire would be abrasive to the vessel and the vessel could get caught in the interstices of the wire. It could also cause vessels spasms which can cause the vessel to squeeze down on the wire which could break the wire. Similar problems would occur with the use of the device of the '118 patent in native vessels.
The need therefore exists for a rotational thrombectomy wire which can be used to clear clots or other obstructions from the native vessels. Such wire could advantageously be used not only in native vessels adjacent dialysis grafts but for deep vein thrombosis and pulmonary embolisms.
SUMMARY
The present invention advantageously provides a rotational thrombectomy wire for breaking up thrombus or other obstructive material in a lumen of a native vessel.
The present invention provides a rotational thrombectomy wire comprising an inner core composed of a flexible material and a multifilar outer wire surrounding at least a portion of the inner core. The outer wire includes at least first and second metal wires wound side by side and having a sinuous shaped portion at a distal region. The inner core at a distal portion has a sinuous shaped portion within the sinuous portion of the outer wire. The inner core limits the compressibility of the multifilar wire. The multifilar wire is operatively connectable at a proximal end to a motor for rotating the wire to macerate thrombus within the vessel.
In a preferred embodiment, the inner core is composed of nylon material. In another embodiment, the inner core is composed of shape memory material wherein the inner core assumes its sinuous shape in the memorized configuration. In another embodiment, the core comprises at least two twisted wires of stainless steel.
The thrombectomy wire preferably further includes a polymeric material surrounding at least a distal portion of the multifilar wire. In a preferred embodiment, the polymeric material comprises a shrink wrap material attached to the multifilar wire. In another embodiment, the polymeric material is a coating over the multifilar wire.
The thrombectomy wire preferably comprises a flexible and blunt tip positioned at a distal end.
The inner core can have in one embodiment an enlarged distal end to form a connection portion and a metal tip secured to a distal end of the multifilar wire has a recess to receive the enlarged end of the inner core to frictionally engage the inner core.
In one embodiment, the first and second metal wires are wound together such that the coils of the first wire occupy the space between adjacent turns of the second wire and the coils of the multifilar outer wire have an inner diameter approximately equal to an outer diameter of the inner core.
The present invention also provides a rotatable thrombectomy wire for breaking up thrombus or other obstructive material in a lumen of a vessel comprising a multifilar outer wire including at least two metal wires wound side by side and operatively connectable at a proximal end to a motor for rotating the wire to macerate thrombus. The multifilar wire has a sinuous shaped portion at a distal region. A polymeric material surrounds at least a region of the sinuous portion of the multifilar outer wire to block the interstices of the multifilar wire.
In a preferred embodiment, the polymeric material comprises a shrink wrap material. In another embodiment, the polymeric material is a coating over the bifilar wire.
The present invention also provides a thrombectomy apparatus for breaking up thrombus or other obstructive material comprising a handle, a sheath, a battery, a motor powered by the battery, and a sinuous thrombectomy wire having at least one wire wound to form a coil and an inner core composed of a material to limit the compressibility of the coil. The coil has a sinuous portion and surrounds at least a distal region of the inner core. The inner core has a sinuous portion within the sinuous portion of the coil. The sinuous portion of the inner core and first and second wires are movable from a straighter configuration within the sheath for delivery to a sinuous configuration when exposed from the sheath.
In a preferred embodiment, a polymeric material surrounds at least a distal portion of the coil to cover the interstices of the coil. In one embodiment, the core is composed of a shape memory material wherein the memorized position of the core has a sinuous configuration. In another embodiment, the core is composed of Nylon. In another embodiment, the core is composed of at least two twisted wires of stainless steel.
The present invention also provides a method for breaking up thrombus or other obstructive material in a native vessel comprising:
providing a thrombectomy wire having an inner core composed of a flexible material and at least one outer wire surrounding at least a portion of the inner core, the outer wire has a sinuous shaped portion at a distal region and the inner core has a sinuous shaped portion within the sinuous portion of the outer wire, and a polymeric material surrounding at least a distal portion of the at least one outer wire to block the interstices of the at least one outer wire;
delivering the wire to the lumen of the native vessel such that the sinuous shaped portions of the inner core and bifilar outer wire are in a more linear configuration within a sheath;
exposing the sinuous portion of the inner core and the at least one outer wire; and
actuating a motor operatively connected to the thrombectomy wire so the sinuous portion of the at least one outer wire contacts the inner wall of the native vessel to macerate thrombus in the vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiment(s) of the present disclosure are described herein with reference to the drawings wherein:
FIG. 1 is a side view in partial cross-section of a first embodiment of a thrombectomy wire of the present invention shown inside a catheter sleeve for delivery;
FIG. 2 is a schematic view illustrating motorized rotation of the wire and a port for fluid delivery;
FIG. 3 is a schematic side elevational view of the sinuous portion of the thrombectomy wire to depict a first embodiment of the inner core positioned therein;
FIG. 4 is an enlarged cross-sectional view of the distalmost region of the rotational thrombectomy wire of FIG. 3 ;
FIG. 5 is schematic side elevational view of the sinuous portion of the thrombectomy wire to depict a second embodiment of the inner core positioned therein; and
FIG. 6 is an enlarged side view of the distalmost region of the rotational wire of FIG. 5 ;
FIG. 7 is a schematic side elevational view of the sinuous portion of the thrombectomy wire to depict a third embodiment of the inner core positioned therein; and
FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 7 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now in detail to the drawings where like reference numerals identify similar or like components throughout the several views, FIGS. 3 and 4 illustrate a first embodiment of the thrombectomy wire of the present invention. The thrombectomy wire, designated generally by reference numeral 10 , includes a core 20 , a bifilar wire (coil) 30 , and shrink wrap 50 . The bifilar wire 30 is formed by two stainless steel wires 32 , 34 , wound together. As shown they are wound side by side so the cross-sectional area or diameter “a” of the wire fills the space between adjacent turns of the other wire. For example, turns 32 a and 32 b are filled by respective turns 34 a , 34 b as shown. Preferably the bifilar wire 30 has a length of about 30 inches and a diameter of about 0.030 inches to about 0.040 inches and more preferably about 0.035 inches. When used in deeper native vessels, e.g. deep veins of the legs or pulmonary circuit, the wire 30 can have a length of about 52 inches. Other dimensions are also contemplated.
The distal region 16 of the bifilar wire 30 is formed into a sinuous or s-shape to contact the vessel wall as the wire rotates.
Although in the preferred illustrated and described embodiments, the outer wire is a multifilar wire in the form of a bifilar wire (two wires), a different number of wires could be wound to form the outer wire component of the thrombectomy wire of the present invention. In yet another embodiment the outer wire can comprise a single wound wire.
The bifilar wire 30 is preferably cold formed into an over-formed s-shape. The bifilar wire is heated, for example at about 670 degrees Fahrenheit, which removes residual stresses and changes the shape of the “s” so it warps back to its desired shape. This stress relief process makes the wire more dimensionally stable.
A tip 80 , preferably composed of rubber, Pebax, or other elastomeric materials, is mounted at the distalmost tip of the wire 10 to provide the wire 10 with an atraumatic distal tip to prevent damage to the vessel wall during manipulation and rotation of the wire. A metal tip 60 is attached by laser welding or other methods to the distal end of the bifilar wire 30 . The metal tip 60 has an enlarged dumbbell shaped head 62 to facilitate attachment to tip 80 . The flexible tip 80 is attached by injection molding over the machined tip. Other attachment methods are also contemplated.
With continued reference to FIG. 4 , a core 20 is positioned within the bifilar wire 30 and preferably has an outer diameter E substantially equal to the inner diameter D of the coil. The core at a distal portion has a sinuous shaped portion within the sinuous shaped portion of the outer wire 30 , corresponding to and formed by the sinuous shape of outer wire 30 . In one embodiment, the core extends the entire length of the bifilar wire 30 and this is shown in the schematic drawing of FIG. 3 . The core 20 can alternatively have a length of about 4-5 inches so it extends through the distal linear portion and sinuous portion of the wire 30 . That is, in such embodiment, the core extends through the portion of the wire that is exposed from the sheath and used to macerate thrombus. It is also contemplated that the core can extend within a shorter or longer length of the bifilar wire.
The core 20 is composed of a flexible material which will limit the compressibility of the wire 30 during use. The core in the embodiment of FIG. 3 is composed of Nylon, and preferably a drawn Nylon monofilament. Other possible materials include, for example, Teflon, polypropylene, PET, and fluorocarbon. The Nylon provides a non-compressible material to limit the compressibility of the wire 30 during use. That is, as noted above, the Nylon core preferably has a diameter E to fill the inside of the coil 30 , e.g. a diameter of about 0.008 inches to about 0.013 inches, and preferably about 0.012 inches. (Other dimensions are also contemplated.) This enables the coil (bifilar wire) 30 to compress only to that diameter. By limiting compressibility it strengthens the wire as it reduces its degree of elongation if it is under torque. It also prevents bending or knotting of the wire which could otherwise occur in native vessels. It increases the torsional strength of the wire and also strengthens the wire to accommodate spasms occurring in the vessel. An enlarged distal head, such as ball tip (not shown), can be provided on the core 20 to fit in a recess of machined tip 60 . As an alternative, core 20 can be attached by adhesive at the tip, welded, crimped, soldered or can alternatively be free floating.
The shrink wrap material 50 covers a portion of the bifilar wire 30 proximal of the flexible tip 80 to block the interstices of the coil and provide a less abrasive surface. As shown in FIG. 4 , the distal end of the shrink wrap abuts the proximal end of the tip 60 . The shrink wrap can be made of PET, Teflon, Pebax, polyurethane or other polymeric materials. The material extends over the exposed portion of the wire 30 (preferably for about 3 inches to about 4 inches) and helps to prevent the native vessel from being caught in the coil and reduces vessel spasms. Alternatively, instead of shrink wrap, a coating can be applied to the coil formed by the bifilar wire to cover the interstices.
FIGS. 5 and 6 illustrate an alternate embodiment of the thrombectomy wire of the present invention, designated generally by reference numeral 100 . Wire 100 is identical to wire 10 of FIG. 1 , except for the inner core 120 . It is identical in that it has a bifilar wire 130 , a shrink wrap 170 , an elastomeric tip 180 and metal, e.g. stainless steel, tip 160 .
In this embodiment, the core 120 is composed of a shape memory material, preferably Nitinol (a nickel titanium alloy), which has a memorized configuration of a sinuous or s-shape substantially corresponding to the s-shape of the bifilar wire 130 . In the softer martensitic state within the sheath, core 120 is in a substantially linear configuration. This state is used for delivering the wire to the surgical site. When the wire is exposed to warmer body temperature, the core 120 transforms to its austenitic state, assuming the s-shaped memorized configuration. Cold saline is delivered through the catheter during delivery to maintain the core 120 in this martensitic state; the warming occurs by exposure to body temperature to transform the core 120 to the memorized state. Such memorized s-shape helps maintain the s-shape of the bifilar wire 130 during use. Cold saline can also be delivered to the core 120 at the end of the procedure to facilitate withdrawal.
The Nitinol core 120 , like the Nylon core 20 , is not compressible so it will also limit the compressibility of the bifilar wire 130 . The Nitinol core 120 also will increase the stiffness of the wire 100 , thereby reducing the chance of knotting and kinking and increase the strength of the wire to accommodate any spasms in the vessel. Its shape memory helps hold the amplitude of the bifilar wire 130 during use to maintain its force against the clot for maceration upon rotation. It preferably extends about 4-5 inches so it extends through the distal linear portion and sinuous portion of the wire 130 , terminating at end 122 . Alternately it can extend a shorter or longer length within the wire 130 , or even the entire length as shown in the schematic view of FIG. 5 . It preferably has an outer diameter of about 0.008 inches to about 0.013 inches, and more preferably about 0.012 inches, corresponding to the inner diameter of the coil. Other dimensions are also contemplated.
In another embodiment, a stainless steel braid, cable, or strand of wires twisted together provides the inner core member to limit compressibility of the coil (bifilar wire) and provide increased stiffness, strength and other advantages of the core enumerated above. This is shown in the embodiment of FIGS. 7 and 8 where wire 200 has inner core 220 of seven twisted stainless steel wires. A different number of twisted wires is also contemplated. The other elements of the wire 200 , e.g., outer bifilar wire 230 , metal tip 260 , tip 280 shrink wrap 250 , etc., are the same as in wires 10 and 100 described herein.
The rotational thrombectomy wires 10 , 100 and 200 of the present invention can be used with various thrombectomy catheters to macerate thrombus within the vessel. The rotational thrombectomy wire 10 (or wire 100 or 200 ) is contained within a flexible sheath or sleeve C of a catheter as shown in FIG. 1 . Relative movement of the wire and sheath C will enable the wire 10 to be exposed to assume the curved (sinuous) configuration described below to enable removal of obstructions, such as blood clots, from the lumen of the vessel.
A motor powered by a battery is contained within a housing to macerate and liquefy the thrombus into small particles within the vessel lumen. This is shown schematically in FIG. 2 . Wire 10 (or 100 or 200 ) is operatively connected to the motor. Operative connection encompasses direct connection or connection via interposing components to enable rotation when the motor is actuated. The curved regions of the wire 10 or ( 100 or 200 ) are compressed so the wire (including the distal region 16 , 116 or 216 , respectively) is in a substantially straight or linear non-deployed configuration when in the sheath C. This covering of the wire 10 (or 100 or 200 ) by sheath C facilitates insertion through an introducer sheath and manipulation within the vessel. When the flexible sheath C is retracted, the wire is exposed to enable the wire to return to its non-linear substantially sinuous configuration for rotation about its longitudinal axis within the lumen of the vessel.
Fluids, such as imaging dye can be injected through the port D into the lumen of the sheath C in the space between wire 10 (or 100 or 200 ) and the inner wall of the sheath C, and exiting the distal opening to flow into the vessel. This imaging dye provides an indication that fluid flow has resumed in the vessel. The lumen of the sheath can also receive cold saline to cool the Nitinol core 120 as described above.
The rotational thrombectomy wires 10 , 100 and 200 of the present invention can also be used with the thrombectomy catheters having one or more balloons such as the balloon described in the '812 publication. The wires 10 , 100 and 200 can further be used with other thrombectomy catheters.
While the above description contains many specifics, those specifics should not be construed as limitations on the scope of the disclosure, but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision many other possible variations that are within the scope and spirit of the disclosure as defined by the claims appended hereto.
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A rotatable thrombectomy wire for breaking up thrombus or other obstructive material comprising an inner core composed of a flexible material and an outer wire surrounding at least a portion of the inner core. The outer wire has a sinuous shaped portion at a distal region. The inner core limits the compressibility of the outer wire. The outer wire is operatively connectable at a proximal end to a motor for rotating the wire to macerate thrombus.
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BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a ball bat with improved shock and vibration dampening. More particularly, the present invention relates to a ball bat with a handle, a barrel, and a socket assembly interposed between the handle and barrel. The socket assembly allows the barrel and handle to move relative to each other, which dampens shock and vibration.
(b) Description of the Prior Art
Baseball and softball are very popular sports in the United States, Japan, Cuba, and elsewhere. Ball bats and similar implements which impart or receive impact forces transmit the shock and vibrations of impact to the handle of the bat, causing the hands of the user to receive an uncomfortable or painful sensation. This sensation is more pronounced when the impact occurs on an area of the bat outside of the center of percussion or “sweet spot” of the bat.
The problem of this sensation being transferred to a user is well known in baseball. Fear of pain or discomfort may decrease the user's confidence and enthusiasm, impairing his or her performance in the sport. This problem is especially troublesome for individuals first learning the game or children.
Shock absorbing ball bats are known in the prior art, but each have their drawbacks. For example, a large number of parts and complex construction may make such ball bats more expensive than a conventional ball bat. For ball bats including composite materials, a complex shock absorbing system may require separate curing steps for different components of the ball bat. Other methods of producing shock absorbing ball bats may by applicable only to bats with metal barrels. Accordingly, what is needed is a simple, reliable, and cost-effective design that is effective in reducing the uncomfortable sensation produced by impact on the ball bat.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel design for a ball bat which decreases the shock and vibration resulting from an impact so as to minimize the discomfort of the user of the ball bat.
The present invention relates to a ball bat with improved shock and vibration dampening. More particularly, the present invention relates to a ball bat with a handle, a barrel, a notch, and a socket assembly adjacent to the notch and interposed between the handle and barrel. The socket assembly comprises a socket and a wedge. The inner surface of the barrel and outer surface of the handle are contoured to retain the generally toroidal socket. The socket includes a central channel sized to receive the handle. The socket allows the barrel and handle to move relative to each other, which dampens shock and vibration.
The wedge is located between the barrel and handle, restricting the relative movement between the handle and barrel when a ball is struck. The degree of restriction of relative movement between the handle and barrel can be varied by selecting the thickness of the wedge and the material from which the wedge is constructed. In some embodiments, the notch includes a ring disposed coaxially around the handle which acts cooperatively with the wedge to restrict the relative movement between the handle and barrel. In this embodiment, the notch may also include fill material, such that the barrel, ring, fill material, and handle, provide a substantially continuous and smooth exterior surface for the ball bat.
In one embodiment, the vibration dampening ball bat of the present invention comprises a barrel including a tapered end, a handle, a socket assembly interposed between the barrel and handle, the socket assembly including a socket and a wedge, whereby the barrel and handle are capable of moving relative to each other about the socket, the movement being restricted by the wedge. In this embodiment, the socket has a generally toroidal shape and includes a central channel, the wedge has a truncated generally conical shape and includes a small diameter end and a central channel, and the socket is attached to the small diameter end of the wedge, whereby the handle is serially positioned within the central channel of the socket and the central channel of the wedge.
In another embodiment, the vibration dampening ball bat of the present invention comprises a composite barrel including a tapered end, a composite handle, a socket assembly interposed between the barrel and handle, the socket assembly including a socket attached to a wedge, a notch located adjacent to the socket on a side opposite the wedge, and a ring positioned around the handle and located in the notch, whereby the barrel and handle are capable of moving relative to each other about the socket, the movement being cooperatively restricted by the wedge and ring.
In a further embodiment, the present invention comprises the method of making a vibration dampening ball bat, namely (a) providing a hollow composite barrel having a tapered end, the barrel being comprised of composite material, (b) providing a socket assembly, the socket assembly comprising a wedge having a large diameter end and a small diameter end and a socket attached to the small diameter end, (c) providing a hollow handle sized to fit within the socket assembly, (d) placing the socket assembly abut the barrel, such that the large diameter end is abut the tapered end, (e) drawing the tapered end over the socket assembly, and (f) inserting a portion of the handle into the socket assembly, whereby the barrel and handle are capable of moving relative to each other about the socket, the movement being restricted by the wedge. This embodiment may include the additional steps (g) creating a notch in the ball bat, the notch located at a longitudinal station adjacent to the socket on a side opposite the wedge, (h) positioning a ring around the handle, the ring located in the notch, whereby the ring restricts the movement between the barrel and handle in cooperation with the wedge, and (i) placing fill material in the notch, such that the barrel, ring, fill material, and handle, provide a substantially continuous and smooth exterior surface for the ball bat.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings, wherein:
FIG. 1 depicts a first embodiment of a ball bat;
FIG. 2A-2C depict a knob-end view, a cross-sectional view along lines 2 - 2 , and an end-end view of a socket;
FIG. 3A-3C depict a knob-end view, a cross-sectional view along lines 3 - 3 , and an end-end view of a wedge;
FIG. 4A-4C depict a knob-end view, a cross-sectional view along lines 4 - 4 , and an end-end view of a socket assembly;
FIG. 5 depicts a cross-sectional view of the transition region of a first embodiment of a ball bat along lines 5 - 5 of FIG. 1 ;
FIG. 6 depicts a second embodiment of a ball bat; and
FIG. 7 depicts a cross-sectional view of the transition region of a second embodiment of a ball bat along line 7 - 7 of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1-3 , a first embodiment of the ball bat 10 of the present invention is shown having an end 12 , a barrel 14 including a tapered end 16 , a transition region 18 , a handle 20 , a knob 22 , and a notch 24 . A socket assembly 26 comprising a socket 28 and a wedge 30 is interposed between the barrel 14 and handle 20 , adjacent to the notch 24 .
As shown in FIGS. 2A , 2 B, 2 C, and 5 , the socket 28 is pre-molded into a generally toroidal shape with a central channel 34 sized to snugly accept the handle 20 . In one embodiment, the socket 28 has an outer diameter of about 1.25 inches (3.18 cm), an inner diameter of about 0.87 inches (2.29 cm), and a length of about 0.55 inches (1.40 cm). The outer curve of the socket 28 is a segment of a circle with a diameter of 1.26 inches (3.20 cm). The inner curve of the socket 28 is a segment of a circle with a diameter of 0.98 inches (2.49 cm). The height of the socket varies from about 0.19 inches (4.83 mm) at the center to about 0.07 inches (1.78 mm) at the edges. In a preferred embodiment, as shown in FIGS. 2B , 2 C, 3 , and 5 , the socket 28 includes a notch 32 . The notch 32 has a length of about 0.1 inches (2.54 mm) and a height of about 0.04 inches (1.02 mm). The socket 28 may be made of any suitable material, such as, for example, a hard nylon.
The wedge 30 is pre-molded into a truncated, generally conical shape having a large diameter end 36 and a small diameter end 38 . The wedge 30 includes a central channel 42 sized to snugly accept the handle 20 . In a preferred embodiment, as shown in FIGS. 3A , 3 B, 3 C, and 5 , the wedge 30 includes a notch 40 located in the small diameter end 38 . The length of the wedge 30 is about 2 inches (5.08 cm). The small diameter end 38 has a diameter of about 1.1 inches (2.79 cm). The diameter of the wedge 30 remains constant for a length of 0.1 inches (2.54 mm), defining the length of the notch 40 , then increases along a curve with a radius of 0.05 inches (1.27 mm) to a diameter of 1.2 inches (3.05 cm). The diameter of the wedge 30 then increases at a 6.5 degree angle to a diameter of about 1.70 inches (4.32 cm) at the large diameter end 36 . The central channel 42 has a 1 inch (2.54 cm) diameter at the small diameter end 38 , which decreases in diameter at a 5 degree angle for a length of about 0.57 inches (1.45 cm) to a diameter of 0.9 inches (2.29 cm). The central channel 42 maintains a constant diameter of 0.9 inches (2.29 cm) for a length of about 1.08 inches (2.74 cm), then increases in diameter at a 45 degree angle for a length of about 0.35 inches (8.9 mm) to the large diameter end 36 . In this embodiment, the outer surface of the wedge 30 corresponds with the inner surface of the transition region 18 of the ball bat 10 . The wedge 30 may be made of any suitable material, such as, for example, rubber, or preferably, ethylene propylene diene monomer (“EPDM”) rubber with a hardness between 40-50 Shore A, ideally about 45 Shore A.
The socket assembly 26 is made by attaching the socket 28 to the small diameter end 38 of the wedge 30 such that the handle 20 may serially fit inside the central channel 34 of the socket 28 and the central channel 42 of the wedge 30 . As shown in FIGS. 4B and 5 , the socket 28 contacts the wedge 30 such that the notch 40 of the wedge 30 is inserted within the notch 32 of the socket 28 . The wedge 30 may be secured to the socket 28 by any suitable method, such as, for example bonding with an adhesive. In a preferred embodiment, the notch 32 of the socket and notch 40 of the wedge 30 are bonded together using a cyanoacrylate adhesive.
The handle 20 is a mostly constant diameter hollow tube. The handle 20 may be manufactured using common manufacturing techniques.
For example purposes only, a composite handle 20 may be made by rolling at least one flat sheet of pre-impregnated composite fiber (“pre-preg”) around a mandrel, thereby making a tube with an outer diameter appropriately sized for a ball bat handle. In a preferred embodiment, the sheet of pre-preg comprises two layers of graphite pre-preg with fibers angled +/−15 degrees from the longitudinal with one layer orientated at a negative angle to the other layer. Two layers of pre-preg with a height of about 0.005 inches (0.127 mm) and fibers angled 90 degrees from the longitudinal are wrapped around the last 7.87 inches (20.0 cm) of the handle 20 at the end opposite the knob 22 .
The barrel 14 is a mostly constant diameter hollow tube with a tapered end 16 . In one embodiment, the barrel is made of composite material. The composite barrel may be manufactured using common manufacturing techniques.
For example purposes only, a composite barrel 14 may be manufactured by spirally rolling 24 layers of high aspect ratio parallelogram-shaped pieces of pre-preg, each layer having a height of about 0.005 inches (0.127 mm), on a rolling mandrel with the fibers oriented longitudinally, thereby making a tube with an outer diameter appropriately sized for a ball bat barrel. The parallelograms are rolled up such that each layer has a butt joint with itself and such that on one end all the layers stop at the same longitudinal station but on the other end, each layer is about one centimeter shorter than the previous layer, creating a tapered end 16 . In one embodiment, the layers are angled +/−37 degrees from the longitudinal with each layer orientated at a negative angle to the previous layer.
A finishing mandrel includes a constant diameter section and a tapered section. After being rolled up, the barrel 14 is transferred to the constant diameter section of the finishing mandrel. The socket assembly 26 is temporarily attached to the finishing mandrel by affixing the large diameter end 36 of the wedge 30 to the end of the tapered section of the finishing mandrel. Latex banding about one inch (2.54 cm) wide and 0.05 inches (1.27 mm) high is wrapped around the tapered end 16 of the barrel 14 . The tapered end 16 is then slowly drawn down the tapered section of the finishing mandrel, over the wedge 30 and over the socket 28 , such that the tapered end 16 stops at the same longitudinal station as the socket 28 . The latex banding is then removed and ribbons of pre-preg about 0.5 inches (1.27 cm) wide are wound around the lay-up directly above the socket assembly 26 , forming a thickness of about 20 layers of pre-preg, each layer having a height of about 0.005 inches (0.127 mm). By being formed directly over the socket assembly 26 , the inner surface of the barrel 14 is contoured to retain the socket assembly 26 , as shown in FIG. 3 .
The barrel 14 is removed from the finishing mandrel and a portion of the handle 20 is inserted. The handle 20 serially contacts the socket 28 and wedge 30 of the socket assembly 26 , but does not contact the barrel 14 , as shown in FIG. 5 . The handle 20 is retained within the socket 28 and wedge 30 by mechanical interference. In some embodiments, the handle 20 may be attached to the wedge 30 , such as, for example, by bonding with an adhesive. The barrel 14 and handle 20 are capable of moving relative to each other about the socket 28 , which dampens shock and vibration. The wedge 30 is located between the barrel 14 and handle 20 , restricting the relative movement between the handle 20 and barrel 14 . The degree of restriction of relative movement between the handle 20 and barrel 14 can be controlled by selecting the thickness of the wedge 30 and the material from which the wedge 30 is constructed.
The exterior surfaces of the barrel 14 and handle 20 do not provide a substantially continuous and smooth surface for the outer surface of the transition region 18 , as shown in FIGS. 1 and 5 . Instead, a generally triangular shaped notch is formed in the transition region 18 of the ball bat 10 . The notch 24 is perpendicular to the long axis of the ball bat 10 and formed at a station whereby the notch 24 is adjacent to the socket 28 . The notch 24 has a maximum depth of about 0.25 inches (6.35 mm) adjacent to the socket 28 , with the depth of the notch 24 decreasing in the direction of the knob 22 . The notch 24 allows for greater relative movement between the handle 20 and the barrel 14 .
An inflatable bladder is inserted into the ball bat 10 assembly and a standard knob 22 is applied using techniques common in the industry. The bladder is inflated, expanding the barrel 14 and handle 20 . The expansion of the handle 20 causes the outer surface of the handle 20 to conform to the inner surface of the socket 28 and wedge 30 , as shown in FIG. 5 . In particular, the handle 20 forms a concave “saddle” shape conforming to the inner surface of the socket 28 which mechanically locks the handle 20 within the barrel 14 . The assembly then is placed into a ball bat-shaped mold under pressure and heated to cure the ball bat, using standard techniques known in the art. Both the handle 20 and barrel 14 are cured at the same time, consequently only one composite cure cycle is needed for the ball bat 10 . After curing, an end 12 , such as a standard end cap, is applied using techniques common in the industry.
With reference to FIGS. 6-7 , a preferred second embodiment of the ball bat 110 of the present invention is shown having a barrel 14 including a tapered end 16 , a transition region 18 , a handle 20 , and a notch 24 . A socket 28 and a wedge 30 are interposed between the barrel 14 and handle 120 , adjacent to the notch 24 .
This second embodiment of a ball bat 110 is constructed in a similar manner as the first embodiment of a ball bat 10 , but further includes a ring 144 coaxially placed around the handle 20 , in the notch 24 , such that the ring 144 abuts the socket 28 and the tapered end 16 of the barrel 14 . The height of the ring 144 is preferably equal to the depth of the notch 24 and the width of the ring is about 0.212 inches (5.38 mm). The ring 144 may be made of any suitable material, such as, for example, rubber, or preferably, EPDM rubber with a hardness between 40-50 Shore A, ideally about 45 Shore A. The ring 144 is preferably constructed from the same material as the wedge 30 . The ring 144 acts cooperatively with the wedge 30 to restrict the relative movement between the handle 20 and barrel 14 about the socket 28 . The degree of restriction of relative movement between the handle 20 and barrel 14 can be controlled by modifying the material from which the ring 144 is constructed. The remaining volume of the notch 24 may be filled with a fill material 146 , such as, for example, adding sufficient pre-preg to fill the remaining volume of the notch 24 before the cure cycle. In this preferred second embodiment, the notch 24 is filled by the ring 132 and fill material 146 such that the barrel 14 , ring 144 , fill material 146 , and handle 20 , provide a substantially continuous and smooth exterior surface for the transition region 18 of the ball bat 110 , as shown in FIGS. 6 and 7 .
The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications can be made by those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims.
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The present invention relates to a ball bat with improved shock and vibration dampening. More particularly, the present invention relates to a ball bat with a handle, a barrel, and a socket assembly interposed between the handle and barrel. The socket assembly allows the barrel and handle to move relative to each other, which dampens shock and vibration.
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BACKGROUND OF THE INVENTION
The present invention relates generally to stabilizers used in self-steering axle suspension systems for wheeled vehicles. More particularly, the present invention relates to a rotary damper used as a stabilizer in self-steering axle suspension systems for wheeled vehicles to suppress oscillations during travel of the vehicle and to control the steerability of the self-steering axle suspension system.
Self-steering axle suspension systems in the medium and heavy duty truck and semi-trailer industry are known. Typically, such suspensions are made self-steering by adjusting the pitch or caster angle of the wheels so that the drag of the wheels as the vehicle proceeds in the forward direction causes the suspension (including the wheels of the system) to steer automatically in response to steering of the (typically front) steering axle of the vehicle and in response to steering created by other vehicle motion such as vehicle cornering (i.e., as the vehicle goes into a turn). Typical of self-steering axle suspension systems are those referred to as pusher, tag or trailing axles found on trucks and semi-trailers. They may be of the liftable or non-liftable type.
In most self-steering axle suspensions in common use, a pair of dampers is used to suppress (dampen) oscillations during automatic steering at the self-steering axle resulting from travel of the vehicle. Typically, such dampers are in the form of conventional shock absorbers either with, or without, an external auxiliary coil spring. Such devices are often referred to as stabilizers for the self-steering axle suspension systems and they control the steerability of the suspension. In such a damper, a cylinder is provided which houses a fluid reservoir that is almost completely filled with an incompressible hydraulic fluid. This cylinder is separated into two chambers by a piston having an orifice, or orifices, in its head, thus to form a flow path between the two chambers, but which otherwise seals the two chambers against fluid flow therebetween. Dampening is accomplished by attaching one end of the stabilizer (usually by a piston rod connected to the piston head) to one of the components of the steering assembly of the suspension and the other end of the stabilizer to the axle beam structure of the suspension or vehicle. Since the orifice(s) in the piston head restricts flow between the two chambers as the piston slides in the cylinder due to oscillations experienced during vehicle operation (e.g. road shocks and wheel shimmy), such oscillations are appropriately dampened and tracking is stabilized.
FIG. 1 illustrates a conventional self-steering axle suspension system generally designated by reference numeral 10 . Conventional self-steering axle suspension system 10 includes linear stabilizers generally designated 12 , 14 . Stabilizers 12 , 14 are in the form of a pair of laterally extending shock absorbers 16 , 18 having auxiliary coil springs 20 , 22 . Stabilizers 12 , 14 are each mounted, at one end, to a bracket, which in turn, is mounted to a laterally extending axle beam and, at another end, to a steering assembly component such as the steering arm of the steering knuckle (as shown). Stabilizers 12 , 14 supress steering oscillations during road travel of the vehicle and control the steerability of the self-steering axle suspension system 10 . The coil springs 20 , 22 provide a self-centering feature in known manner. Stabilizers 12 , 14 are positioned in opposite orientations such that they are mirrored about the vehicle centerline in order to control the steering action and self-centering in both directions for the vehicle.
Linear stabilizers, such as those illustrated in FIG. 1 as reference numerals 12 , 14 are relatively heavy, expensive, bulky and require high maintenance. With regard to the latter drawback, linear stabilizers are subject to damage due to road debris and the like. For this reason, enclosed housing designs have been implemented; however, such designs have only reduced but have not eliminated the maintenance required for linear stabilizers. In addition, maintenance operations, especially out in the field, are cumbersome and correspondingly difficult and time consuming.
In view of the foregoing, there is a need for a relatively lightweight self-steering axle suspension system stabilizer. There is also a need for a relatively inexpensive self-steering axle suspension system stabilizer. Further, there is a need for a relatively compact self-steering axle suspension system stabilizer. Moreover, there is a need for a self-steering axle suspension system stabilizer that requires little maintenance and is relatively easy to maintain.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a self-steering axle suspension system utilizing a rotary damper acting directly about the king pin centerline on one side of the vehicle in a manner such that the rotary damper constitutes a rotary stabilizer. The rotary stabilizer is coaxially aligned with the king pin centerline. The rotary stabilizer is used to control the steerability of the self-steering axle suspension system. The rotary stabilizer may also have a self-centering axle mechanism incorporated therein. The present invention is also directed to a rotary stabilizer component used in a self-steering axle suspension system.
A rotary stabilizer designed in accordance with the principles of the present invention and used in a self-steering axle suspension system is preferably relatively lightweight, translating into increased payload capacity and more readily permitting compliance with relevant bridge weight and stress laws and regulations. The stabilizer is preferably relatively inexpensive, having fewer components than conventional stabilizers used in self-steering axle suspension systems. In addition, only a single stabilizer is required for control of the steerability of the suspension system in both steering directions. The stabilizer is preferably compact, fitting tight in relation to the axle or axle beam and acting directly about the king pin centerline. The stabilizer is preferably relatively low maintenance insofar as it includes a fully-enclosed housing and it is mounted above the axle in a position where it is less likely to be subjected to road debris and the like. Maintenance of the stabilizer is also relatively easy, as it is positioned above the king pin centerline in coaxial relationship therewith and is positioned above the axle or axle beam, permitting its relatively simple installation, removal and replacement. The stabilizer preferably includes material that resists velocity motion and the accompanying oscillations that would otherwise occur during road travel of the vehicle. The stabilizer also preferably includes material that provides for self-centering of the self-steering axle suspension system.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
Reference has been and will frequently be made to the following figures, in which like reference numerals refer to like components, and in which:
FIG. 1 is a perspective view of a self-steering axle suspension system using conventional linear stabilizers;
FIG. 2A is an elevational view of a self-steering liftable axle suspension system shown in its ground engaging position;
FIG. 2B is an elevational view of the same self-steering liftable axle suspension system shown in its lifted position;
FIG. 3 is a perspective view of the self-steering liftable axle suspension system shown in FIGS. 2A and 2B and shown as being designed in accordance with the principles of the present invention;
FIG. 4 is a perspective view of a rotary stabilizer designed in accordance with the principles of the present invention and being designed for use in a self-steering axle suspension system;
FIG. 5 is another perspective view of the rotary stabilizer shown in FIG. 4 being partially cut away to illustrate internal features thereof;
FIG. 6 is a perspective view of a portion of the self-steering axle suspension system shown in FIG. 2 ;
FIG. 7 is another perspective view of the portion of self-steering axle suspension system shown in FIG. 6 ;
FIG. 8 is a perspective view of a portion of a self-steering axle suspension system having another embodiment of a rotary stabilizer designed in accordance with the principles of the present invention;
FIG. 9 is sectional view of the portion of the self-steering axle suspension system shown in FIG. 8 taken along line 9 - 9 thereof;
FIG. 10 is perspective view of the rotary stabilizer shown in FIG. 8 ;
FIG. 11 is a top plan view of the rotary stabilizer shown in FIG. 8 ;
FIG. 12 is an elevational view of the rotary stabilizer shown in FIG. 8 ; and
FIG. 13 is a horizontal sectional view of the rotary stabilizer shown in FIG. 8 showing the interior of the housing thereof.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 2A , 2 B and 3 illustrate a self-steering axle suspension system generally indicated by reference numeral 30 . The illustrated self-steering axle suspension system 30 is a self-steering auxiliary lift-axle type of suspension system having a parallelogram, trailing arm geometry. The axle suspension system 30 is preferably a relatively lightweight suspension designed to permit compliance with any applicable bridge weight and stress regulations, such as the Federal Bridge Formula associated with relevant laws and regulations applicable within the United States of America.
While suspension system 30 is described as having these additional features, it will be appreciated that the present invention applies to all self-steering axle suspension systems for wheeled vehicles.
The suspension 30 illustrated in the figures is representative of an embodiment of the steerable, wheel-bearing lift axle suspension systems disclosed in U.S. Pat. No. 5,403,031 and U.S. Pat. No. 5,620,194. The entire disclosure of U.S. Pat. No. 5,403,031 and the entire disclosure of U.S. Pat. No. 5,620,194 are hereby incorporated herein by reference.
With respect to suspension system 30 , the majority of the components positioned on one side of the vehicle will have correspondingly similar components positioned on the other side. Accordingly, in this description, when reference is made to a particular suspension component, it will be understood that a similar component is present on the opposite side of the vehicle, unless otherwise apparent. It will be appreciated that like elements are duplicated on opposite sides of the vehicle centerline.
As shown, suspension system 30 includes a pair of longitudinally extending parallel beams 34 , 36 on each side of the vehicle, preferably constructed as cast aluminum beams. Beams 34 , 36 are pivotally connected at their forward ends in known manner by pivots 38 , 40 to a side rail frame hanger bracket 42 which, in turn, is fastened to a longitudinal frame member 44 for the vehicle. Frame member 44 extends longitudinally and preferably has a C-shaped cross-section in conventional manner.
Parallel beams 34 , 36 are also pivotally connected at their rearward ends to an axle seat 46 by pivots 48 , 50 . Pivot 48 preferably includes an eccentric cam 52 designed to permit adjustment of the caster angle, permitting self-steering operation of the suspension system. Adjustment of the caster angle is made by turning eccentric cam 52 the requisite amount. The adjustable caster angle is typically oriented within the range of about positive three degrees to positive six degrees from the king pin centerline.
Axle seat 46 is mounted onto a laterally extending fabricated axle 54 having a hollow axle body 56 and gooseneck portions 58 on each end of the axle body (see FIG. 3 ). An inline lift air spring 60 is mounted to beams 34 , 36 through brackets 62 , 64 , which in turn are fastened to beams 34 , 36 . A vertical ride air spring 66 is mounted on axle seat 46 and connected to frame member 44 through upper air spring bracket 68 .
Steering knuckles 70 are rotatably mounted on opposite ends of the axle 54 by king pin assemblies (not shown) in known manner. King pins are used to mount the steering knuckles to the axle at 71 , as shown in FIG. 3 . Each steering knuckle 70 includes a steering arm 72 , and a laterally extending tie rod 74 links the steering arms 72 of the steering knuckles 70 mounted on opposite sides of the vehicle.
Referring to FIGS. 3 and 6 , at least one of the steering knuckles 70 includes an upper plate 76 for mounting a rotary stabilizer 78 used to control the steerability of the suspension system. The rotary stabilizer 78 is preferably mounted on the upper plate 76 of the steering knuckle 70 by bolts or similar fasteners. The stabilizer 78 includes a central shaft 80 that preferably is coaxially aligned with the king pin used for mounting its adjacent steering knuckle 70 to that end of the axle 54 . The shaft 80 is fixedly connected to the axle 54 , preferably by a bracket 82 secured thereto and preferably secured to the gooseneck portion 58 of the axle 54 .
When one rotary stabilizer 78 is used (as shown), total weight and cost are minimized. When a rotary stabilizer is mounted on each side of the axle beam, size per stabilizer is minimized, translating into better packaging.
FIG. 2A illustrates suspension 30 in its lowered or ground-engaging position, as opposed to its lifted or raised position, which is illustrated in FIG. 2B . Raising and lowering of suspension 30 is accomplished by the expansion and contraction of the inline lift air springs 60 and the vertical ride air spring 66 . By expanding the vertical air spring 66 and exhausting the inline air springs 60 , the wheels are lowered into engagement with the ground surface, which is shown in FIG. 2A . By expanding inline air springs 60 and exhausting vertical air spring 66 , the wheels are lifted from engagement with the road surface, which is shown in FIG. 2B . The control of fluid in the air springs 60 , 66 for accomplishing the lifting and lowering of the wheels is conventional and well known in the art.
Referring to FIG. 4 , rotary stabilizer 78 includes a mounting base 84 having a generally planar construction. Mounting base 84 preferably has a generally round shape with the addition of ear-like protrusions 86 spaced approximately ninety degrees from adjacent protrusions 86 . A mounting bore 88 is preferably machined within each protrusion 86 to permit the rotary stabilizer 78 to be mounted to the upper plate 76 of the steering knuckle 70 by appropriate fasteners (see FIG. 3 ).
The rotary stabilizer 78 includes a housing 90 . Shaft 80 is positioned within housing 90 and extends axially in relation thereto. A portion of shaft 80 extends axially out of housing 90 and is exposed from the housing, as shown. The housing is generally cylindrical and preferably forms a unitary construction with mounting base 84 of stabilizer 78 . The mounting base 84 and the housing 90 are together rotatably maneuverable about the shaft 80 , as further described.
Referring to FIG. 5 , as shown, the housing 90 of the rotary stabilizer 78 is partitioned into two or more fixed volume chambers 92 A, 92 B sized to accommodate the wheel cut specifications for the self-steering axle suspension system 30 in both directions. The wheel cut specification for the self-steering axle suspension system 30 illustrated in FIG. 3 is twenty-eight degrees. Under such circumstances, the chambers 92 A, 92 B illustrated in FIG. 5 preferably are sized to include an arc angle of about sixty degrees. Chamber 92 A serves as a fluid reservoir for viscous material such as an incompressible hydraulic fluid, and its boundaries are defined by radially extending walls within housing 90 and the top and bottom walls of the housing. It will be appreciated that the top surface of the mounting base 84 for the stabilizer 78 may serve as the bottom wall of the housing 90 for this purpose.
As further shown, panes 96 A, 96 B are preferably associated with chambers 92 A, 92 B, respectively, and partition each such chamber into two variable volume sub-chambers. The sum of the variable volume sub-chambers for a particular chamber 92 A, 92 B is equal to the total volume of the chamber.
Each pane 96 A, 96 B preferably projects radially from the shaft 80 and preferably bisects the arc angle for its associated chamber 92 A, 92 B when the suspension system is in its resting (centered) position. The panes 96 A, 96 B may be formed with the shaft 80 as a unitary component, or alternatively may be secured to the shaft 80 by appropriate means. Pane 96 A includes orifices 100 to provide for a fluid flow path during steering of the suspension system 30 , which controls the steerability of the suspension system. Pane 96 B may or may not include orifices, as desired.
As further shown, rotary stabilizer 78 also preferably includes resilient members 102 used for self-centering. Resilient members 102 may be formed with an elastomer-type material. For illustrative purposes, resilient members 102 are shown as being rubber cushion inserts having orifices or holes to permit their expansion and compression. However, it will be appreciated that the resilient members may take a variety of forms, such as, for example, air bladders, coil springs, etc. In the illustrative embodiment, the rubber cushion inserts 102 are positioned under compression within chamber 92 B on opposite sides of pane 96 B.
Referring now to FIGS. 6 and 7 , as shown, the mounting base 84 and housing 90 of the rotary stabilizer 78 are fixedly mounted to the steering knuckle 70 , specifically to the upper plate 76 thereof. In addition, the shaft 80 of the rotary stabilizer 78 is fixedly mounted to the axle 54 through its bracket 82 (shown as being fastened to the gooseneck portion 58 of the axle 54 ) and is aligned with the king pin along its centerline.
In operation, when the vehicle corners, a force is imparted upon the self-steering axle suspension system 30 , causing the suspension system to steer in the appropriate direction. At this time, the steering knuckles 70 rotate about their respective king pins. At least one of the linked steering knuckles 70 carries the mounting base 84 and the housing 90 of the rotary stabilizer 78 . As the housing 90 of the stabilizer 78 rotates about its shaft 80 , the volumes of the variable volume sub-chambers within fluid reservoir chamber 96 A vary in accordance with the steering direction and cause the viscous fluid to flow through the orifices 100 of the radially extending pane 96 A, which, with shaft 80 and pane 96 B, remains stationary relative to the axle. In addition, during such steering action, one of the rubber cushion inserts 102 is also further compressed when its associated radially extending wall defining one of the boundaries of chamber 92 B rotates with the housing towards the pane such that the wall presses against the insert. When this happens, the insert 102 is further compressed between that wall and pane 96 B and its resilient nature tends to prevent further compression. As a result, there is additional control of the steerability of the system 30 by limiting free movement of the steering knuckles.
Upon straightening of the vehicle, however, the steering force imparted on the self-steering axle suspension system 30 is reduced to such an extent that the spring back force imparted on pane 96 B by the force differential between the overly compressed rubber cushion insert 102 and the expanded (less compressed) rubber cushion insert 102 on the opposite side of pane 96 B will overcome such steering force and cause the rotary stabilizer 78 to return to its resting (centered) position in a controlled manner due to the viscous fluid return flow through the orifices 100 of pane 96 A.
It will be appreciated by those skilled in the art that the self-steering and self-centering of the rotary stabilizer used in the above illustrated embodiment of the present invention may be tuned by varying, for example, the size of the stabilizer, the size of the chambers, the number of pane orifices, the size of the pane orifices, the material and configuration of the resilient members, and the composition of the viscous material.
FIGS. 8-13 illustrate an alternative embodiment of a rotary stabilizer identified generally by reference numeral 110 shown mounted on the upper plate of a steering knuckle used in association with a self-steering axle suspension system. Rotary stabilizer 110 includes an outer housing element 112 , an inner housing element 114 and a central shaft 116 . The central shaft 116 is preferably keyed to the inner housing element 114 . Central shaft 116 may be used as a king pin, as shown. The outer housing element 112 may include protrusions 118 (one of which is shown in FIG. 8 ). Each protrusion 118 may have a mounting bore 120 machined through it to permit mounting of rotary stabilizer 110 to an upper plate member of a steering knuckle, as shown. Viscous material 115 is contained in the space within outers housing element 112 and inner housing element 114 . In preferred embodiments, the viscous material surrounds a rotor element extending radially from inner housing element.
In operation, when the vehicle corners, a force is imparted upon the self-steering axle suspension system, causing the suspension system to steer in the appropriate direction. At this time, the steering knuckles mounted on opposite ends of the axle rotate about their respective king pins, which in this preferred illustrated case at least one of which may be the central shaft 116 , as shown. At least one of the linked steering knuckles carries the outer housing element 112 of the rotary stabilizer 110 . As the outer housing element 112 rotates in relation to the inner housing element 114 and the keyed shaft 114 , the viscous material 115 acts in shear to provide resistance to the rotary motion of the steering knuckle resulting in smooth motion and controlled steering of the self-steering axle suspension system.
Alternatively, any of several self-steering mechanisms may be used to cause the rotary stabilizer 110 to return to its resting (centered) position in a controlled manner, as desired. As one example, when the steering knuckle rotates about the king pin/central shaft, it may bear against a leaf spring having sufficient force to cause the steering knuckle to return to the resting position upon straightening of the vehicle.
It will be appreciated by those skilled in the art that while this invention has been described with reference to certain illustrative embodiments, it will be understood that this description shall not be construed in a limiting sense. Rather, various changes and modifications can be made to the described embodiments without departing from the true spirit and scope of the invention, as defined by the following claims. Furthermore, it will be appreciated that any such changes and modifications will be recognized by those skilled in the art as an equivalent to one or more elements of the following claims, and shall be covered by such claims to the fullest extent permitted by law.
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A self-steering axle suspension system utilizing a rotary damper coaxially aligned with and acting directly about the king pin centerline on one side of the vehicle is disclosed. When used as such, the rotary damper constitutes a rotary stabilizer. The rotary stabilizer is used to control the steerability of the self-steering axle suspension system and has a self-centering axle mechanism incorporated therein.
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BACKGROUND OF THE INVENTION
The present invention relates to a cover for use in yarn twisting machine.
When operating multiple twisting machines such as a double twisting machine or a quadruple twisting machine, a principal problem has been deterioration of working environments on account of fly waste scattering from a yarn balloon or noises caused by rotation of the yarn twisting machine which is noticeably inferior in these regards in comparison with other types of machines used in the art of fibers.
To overcome the abovementioned problems, a method has been proposed and employed in recent years wherein a yarn twisting machine is enclosed as a whole by a cover. This method has solved the problem of noises sufficiently, but it has not been an adequate solution to the problem of exhaust of the fly waste. In this method, exhaust of fly waste is effected by means of an uprising spiral air stream caused by rotation of a rotary disk inside a yarn twisting space sealed by said cover from an air exhaust. More often than not, however, the air stream caused by the rotation of the rotary disk is not adequate enough to turn into a strong uprising air stream to arrive at the air exhaust. When the air stream is not exhausted in this manner, the fly waste is likewise not exhausted with the result that it often accumulates on a feed yarn or entangles with a balloon yarn. This, in turn, causes the balloon yarn to agitate the sealed air inside the cover and elevates the temperature inside the cover to lead further to change of moisture and deterioration of the yarn properties as the eventual consequence.
SUMMARY OF THE INVENTION
It is therefore the first object of the present invention to provide a cover for use in a yarn twisting machine which eliminates the abovementioned defects of prior covers by generating a smoothly rising air stream inside the cover.
When a yarn twisting machine is enclosed entirely by the cover, however, procedures of changing the feed yarn or of threading the yarn into spindles become difficult.
It is therefore the second object of this invention to provide a cover which facilitates the above-mentioned procedures during the operation.
Yarn balloons generated in a multiple twisting machine exert substantial influences over the yarn properties after the twisting. If the tensile strength of the yarn balloon is too strong, for example, the yarn causes fluffs because of friction at the time of passing through the yarn guides, and if it is too weak, the yarn likewise causes fluffs because of friction as the yarn entangles with the outer periphery of a yarn feed pot. In the worst case, it causes breaking of the yarn.
It is therefore important to always set the ballooning of the yarn at a most optimum value in accordance with the conditions of yarn twisting. The tensile strength of the yarn balloon varies in accordance with rotational speed of the spindle, count number of the yarn to be twisted or changes of other twisting conditions.
It is therefore the third object of this invention to provide a cover including structure for readily adjusting the tensile strength of the yarn balloon.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a longitudinal section view of the cover of the present invention and a twisting machine therein;
FIG. 2 is an enlarged section view of the cover taken substantially along the lines II--II of FIG. 1;
FIG. 3 is an enlarged partial section view of the upper portion of the cover similar to the view shown in FIG. 1; and
FIG. 4 is a reduced perspective view of the cover of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be explained in further detail with respect to a double twisting machine as a typical embodiment by referring to the accompanying drawings.
In FIG. 1, the numeral 1 is a rotary disc which is rotated by means of a belt 2. The numeral 3 is a yarn feed pot, and a tension device is expressed by the numeral 4. All these components together make up a yarn twisting machine 5.
The numeral 6 denotes a cover to enclose the overall twisting machine composed of a balloon cover whose internal lower surface section is shaped so as to define a curved surface 7. The curved surface becomes narrower extending downwards and is connected to an upwardly diverging surface forming a taper 8 which is concentric with the rotary disc 1 and functions as a balloon limiting device. It is advisable to shape the transverse cross-section of the curved surface 7 to be annular and to merge with the taper 8 so as to generate a uniform uprising air stream. At a position above the upper section of the cover 6 where the balloon yarn does not get in touch with it, there is provided an air exhaust port 9 which is connected to a main duct 10 extending the entire longitudinal length of a machine support.
A centrifugal air stream generated by rotation of the rotary disc 1 strikes against the downwardly truncated curved surface 7 and is thereby converted into an uprising air stream 11. In order to ensure the generation of a smooth uprising air stream by means of the curved surface 7, it is desirable to locate the lower edge 33 of the curved surface 7 at a position lower than the lower edge section 34 of the rotary disc 1.
The uprising air stream 11 turns into an uprising swirling air stream 13 which is lead out from the air exhaust port 9 into the main duct 10 together with fly waste generated inside the yarn twisting space 12. The other end of the main duct 10 is connected to a suction device (not shown). The fly waste is collected and piled up at a predetermined location by means of suction of the suction device. The lower section of the main duct 10 is formed to include an L-shaped belt cover 14 which covers up a belt-running chamber 15 to muffle noises. The numeral 16 is a packing which interlockes the air exhaust port 9 and the main duct 10.
The upper section of the balloon cover is cut off to define a slant truncated open surface 17 which is covered by a cover lid 18 to render the twisting yarn space airtight. The open surface 17 is shaped as a slant surface such that the front section thereof is lower than the rear section, and the open area thereof is larger than the cross-sectional area of the tapered surface. The arrangement in this fashion ensures easier feed yarn change, threading of the yarn and so forth.
The cover lid 18 is pivotally connected to lugs 19 disposed protrudingly at both sides of the upper section of the balloon cover 6 by a pin 20. Thus, the cover lid 18 can be opened upwardly as shown in phantom in FIG. 1 at the time of changing the feed yarn, threading the yarn and the like.
As shown in FIG. 3 in further detail, there is provided a pin 22 protruding from a support section 21 of the cover lid 18 which supports a rod 25 past through a hole 24 bored on a covering plate 23 at the upper section of the balloon cover 6. Between the bearing section of the rod 25 and the covering plate 23, there is inserted a compression spring 26. When the cover lid 18 is closed as shown by full lines in FIGS. 1 and 3, this spring 26 urges the cover lid 18 around the pin 20 in a counter-clockwise direction whereby the cover lid 18 is pressed firmly to the slant open surface 17. When the cover lid 18 is opened as shown by dotted lines in FIGS. 1 and 3, the spring 26 urges the cover lid 18 in a clockwise direction around the pin 20 whereby the cover lid 18 is hit and retained by a stopper 27 disposed on the covering plate 23.
The cover lid 18 further has a hole 28 bored at its center into which a cylinder 29 is fitted slidably so as to guide the yarn. Positioning of the cylinder is readily adjustable in the hole 28 by means of an O-ring 30 fitted therein. In this manner, the position of the cylinder 29 with respect to the cover lid 18 can be regulated readily when twisting conditions are somehow changed so as to thereby change the height (H) of the balloon as indicated by dotted lines in FIG. 3 and set the tensile strength of the yarn balloon to an optimum value. The numerals 31, 32 stand for yarn guide members disposed respectively at the upper and lower edges of the cylinder 29. Provision of a scale on the outer surface of the cylinder makes it easy to determine the tensile strength of the yarn balloon.
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The present invention relates to a cover for enclosing an overall multiple-twisting machine. The cover comprises a balloon cover and a cover lid which is capable of opening or closing. The balloon cover includes a cylindrical tapered inner surface diverging upwardly and has an air exhaust port therewith.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to work areas and workshops, and more particularly, to a portable, compact folding workshop which includes an enclosure or cubicle defined by multiple, hinged panels which support cabinets, shelves, lighting and pegboards for storing tools, equipment and supplies. The panels forming the enclosure can be locked to secure the tools, equipment and supplies inside the enclosure when the workshop is in folded configuration and is not in use. In a preferred embodiment of the invention the enclosure is open at the top and bottom and consists of four panels mounted on rollers to more easily facilitate moving of the enclosure and opening of the panels on the connecting hinges to provide access to the cabinets and shelves, and to the tools, equipment and supplies, for functional use of the workshop. When in folded, stored configuration the portable workshop occupies a relatively small space and can be easily deployed in a garage or carport or even in the corner of a room inside the home, and when deployed for use the work area is no larger than a conventional work bench of similiar facility. The portable workshop of this invention is designed to provide maximum expediency in the use of hand and power tools in a workshop environment which occupies minimum space.
2. Description of the Prior Art
Efforts to conserve space by using portable furniture and other folding, compact items of a functional or decorative nature are well known in the prior art. U.S. Pat. No. 150,194, to H. J. Barrett, discloses a "Folding, Portable Bar" which includes a central portion having folding side members in order to facilitate storage of the bar in a minimum of space. A similiar "Portable Bar" is disclosed in U.S. Pat. No. 2,260,586 to R. I. Sheldon, which bar is characterized by a center support having hinged drop leaves supported by outwardly extending side members. U.S. Pat. No. 1,348,073, to M. P. Almy, discloses a portable screen which is likewise comprised of a central support member having shelves therein and folding wings or outer portions to facilitate use of the screen in functional position with the wings unfolded, and in storage configuration, with the wings in folded position against the center portion. U.S. Pat. No. 3,353,885, to H. C. Hanson, discloses an "Expansible Multi-Purpose Cabinet" which includes telescoping cabinet portions which can be slidably displaced to provide a work area, with accessory members which unfold and open to deploy a mirror and provide access to interior shelves within the major support members. A similiar "Display Case" is disclosed in U.S. Pat. No. 1,336,899, to W. H. Gallagher, which display case includes a central support member having interior shelves and outwardly folding side members or wings which can be unfolded and deployed on hinges for decorative purposes. French Pat. No. 1,444,175 discloses a folding cabinet having multiple interior storage compartments and two major folding portions which are hinged at one edge and open to provide access to the interior compartments. The major cabinet members close on the hinges to facilitate storage of the cabinet in a minimum of space. U.S. Pat. No. 2,870,459, to R. F. Zabielski, discloses an item of folding furniture which includes a major support member having a pair of folding side members hingedly attached at opposite edges, with one of the side members further including shelves and a hinged desk top and supporting doors which open beneath the desk top to support the desk top when in functional position. One or more cots can be deployed from storage in the major support member between the two folding side members when the folding side members are deployed on the hinges away from the major support member.
In recent years due to the high rate of inflation and increased costs, there has been a growing trend toward economy of space and the undertaking of home projects individually, rather than by use of skilled labor provided by contractors. This trend is particularly noteworthy with regard to the "do it yourself" home projects, which usually require a work space or area of sufficient size to handle the projects in question. Since the average home contains little extra space to accommodate such projects, they sometimes go unattended, or must be accomplished by skilled labor at a high cost.
Accordingly, it is an object of this invention to provide a new and improved, portable, compact workshop which is characterized by an enclosure or cubicle formed of multiple, hinged panels, which enclosure, when in folded, stored configuration, can be closed and locked or otherwise secured, and can be opened to provide access to cabinets, shelves, work space and tools contained within the enclosure.
Another object of this invention is to provide a new and improved portable workshop having an enclosure characterized by an open top and bottom and having multiple, hinged panels mounted on rollers to facilitate moving of the enclosure and opening and closing of the panels, which enclosure, in functional configuration, opens to provide access to shelves and cabinets mounted in cooperation with the supporting panels, and in closed configuration, can be locked to secure tools, supplies and materials within the enclosure.
Yet another object of the invention is to provide a new and improved workshop which is characterized by a cubicle-type enclosure defined by four hinged panels mounted on rollers and adapted for locking or securing into the cubicle configuration when not in use in order to conserve space, and which opens into a generally linear spatial arrangement to provide access to pegboards, cabinets, shelves, and a horizontal work space attached to the panels.
Yet another object of the invention is to provide a new and improved portable, compact workshop which can be stored in a minimum of space and used substantially anywhere, and which in a preferred embodiment is characterized by an enclosure shaped by four hinged, wheeled panels of substantially the same size which can be closed to secure tools and materials inside the enclosure when in stored configuration, and opened into a substantially linear arrangement on the hinges when in functional configuration, to provide access to shelves, cabinets, and a horizontal work space which is extended by a hinged counter adapted to be folded into a substantially horizontal position between cabinets attached to the panels.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a new and improved, portable and compact workshop which is characterized by an enclosure or cubicle defined by four hinged panels, two of which panels are hinged together along adjacent edges and are each provided with a panel facing disposed along the opposite edges for hinged attachment to the other panels, which panels can be folded on the hinges into an open top and bottom cubicle in stored configuration, and opened into a substantially linear spatial arrangement to provide access to shelves, cabinets and pegboards attached to the panels and containing tools and supplies, when in functional configuration. In a preferred embodiment the panels are mounted on rollers and are provided with a folding counter spanning the cabinets to increase the available horizontal work area.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by reference to the accompanying drawings wherein:
FIG. 1 is a perspective view of a preferred embodiment of the portable workshop in folded configuration;
FIG. 2 is a perspective view of the portable workshop illustrated in FIG. 1, with one of the four hinged panels in open configuration;
FIG. 3 is a perspective view of the portable workshop illustrated in FIGS. 1 and 2, with the panels further deployed on hinges to a partially open configuration;
FIG. 4 is a front elevation of the portable workshop, with the panels deployed in a fully open, linear and functional configuration;
FIG. 5 is a front elevation, partially in section, of the door panel of the portable workshop;
FIG. 6 is a perspective view, partially in section, of a preferred work support leg and brace design for a work support member;
FIG. 7 is a perspective view, partially in section, of a preferred folding counter for extending the horizontal working area in the portable workshop; and
FIG. 8 is a sectional view, taken along lines 8--8 in FIG. 4, more particularly illustrating the folding counter design.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawings, the portable workshop of this invention is generally illustrated by reference numeral 1, and is illustrated in folded, stored configuration where it occupies a minimum of space. Portable workshop 1 includes an enclosure or cubicle, generally illustrated by reference numeral 2, which is defined by a door panel 3 and a cooperating closure panel 8, which are both mounted on rollers 14, as illustrated. A set of three hasps 6, are each hingedly attached in spaced relationship to the unhinged edge of closure panel 8, and a lock 7 secures the center one of hasps 6 to a conventional eyelet secured to the door panel 3, in conventional fashion. In a preferred embodiment of the invention the door panel 3 is attached to a panel facing 4 by means of panel hinges 5, closure panel 8 is in turn attached to a second panel facing 4, by means of additional panel hinges 5, and each panel facing 4 is rigidly secured to one of rear panels 9, respectively, which are hinged together at adjacent edges, as hereinafter described.
Referring now to FIGS. 2 and 3 in sequence, the door panel 3 and closure panel 8 are partially opened on panel hinges 5, and rear panel hinges 10 are illustrated as attached to the inside surfaces of rear panels 9, to facilitate closing and opening of the rear panels 9. In a most preferred embodiment of the invention the rear panels 9 are each provided with a pegboard 12 on the inside surfaces and a single cabinet 16 is attached to one of the rear panels 9, while a double cabinet 19 is attached to the opposite one of rear panels 9, as illustrated in FIG. 3. Furthermore, shelves 34 are secured to the inside surfaces of door panel 3 and closure panel 8, respectively, and a pair of lights 13, are mounted on the rear panels 9 above the pegboards 12. Single cabinet 16 is provided with a horizontially-mounted single cabinet top 21, and the double cabinet 19 includes a double cabinet top 20 in substantially the same plane as single cabinet top 21, to provide divided horizontal work spaces when the portable workshop 1 is fully deployed, as hereinafter described. Both the single cabinet 16 and double cabinet 19 are provided with cabinet compartments 17 for storage of tools, supplies and equipment, as deemed expedient by the user. Furthermore, in a preferred embodiment the single cabinet 16 is also provided with a drawer 18 for additional storage capacity.
Referring now to FIGS. 1-4 of the drawings, in another most preferred embodiment of the invention the rollers 14 are secured to roller mounts 15, which are attached to the door panel 3, closure panel 8 and the rear panels 9, respectively, and rollers 14 are also provided on the bottom of single cabinet 16 and double cabinet 19, to more easily facilitate moving the portable workshop, both from one location to another and from the closed to the open configuration, and back to the closed mode, as illustrated in the opening sequence in FIGS. 1-4.
Referring now to FIGS. 2, 3, 4 and 7 of the drawings, in yet another most preferred embodiment of the invention, a hinged counter 23 is provided in the portable workshop 1 to make available a horizontal work space or area between the double cabinet top 20 of double cabinet 19 and the single cabinet top 21, of single cabinet 16. The counter 23 is attached to the single cabinet 16 by means of a counter hinge 29, and counter 23 can be deployed on counter hinge 29 from a non-functional position rearwardly toward single cabinet top 21, to a substantial alignment with double cabinet top 20 and single cabinet top 21. When so disposed in functional position, the counter 23 rests on the counter support 30, attached to double cabinet 19, as illustrated in FIGS. 4 and 7. In order to facilitate a full range of motion from a functional position in alignment with the double cabinet top 20 and the single cabinet top 21 as illustrated in FIG. 4, the counter 23 includes a counter segment 24, which is attached to the counter 23 by means of a counter segment hinge 25. A handle 28 is attached to the counter segment 24 to provide a means for manipulating the counter segment 24 on the counter segment hinge 25, to permit counter 23 to clear the pegboard 12 located above single cabinet 16, as the counter 23 moves in an arc past the pegboard 12, and past any tool or tools which may be suspended on the pegboard 12 in the arc. In another most preferred embodiment of the invention a cabinet spacer 31 is removably provided in spacer brackets 32, located on single cabinet 16 and double cabinet 19, respectively. The cabinet spacer 31 serves to maintain the proper distance between single cabinet 16 and double cabinet 19 when the portable workshop 1 is in deployed and functional configuration, as illustrated in FIG. 4, in order that counter 23 might be hingedly folded to bridge the distance between double cabinet top 20 and single cabinet top 21.
Referring again to FIG. 4 of the drawing, when the portable workshop 1 is in fully deployed and functional configuration, easy access is provided to the cabinet compartments 17 in single cabinet 16 and double cabinet 19, to the drawer 18 in single cabinet 17, and to the shelves 34 and the pegboards 12, for efficient use of the portable workshop 1.
In yet another preferred embodiment, electrical boxes 35 are provided above the double cabinet top 20 and single cabinet top 21, respectively, and mounted on each panel facing 4, in order to conveniently make use of power tools. Wiring 36, illustrated in phantom, connects the electrical boxes 35 with a central plug 22, illustrated in FIG. 1, which can be plugged into an extension cord or other conduit to supply electricity to the portable workshop 1.
Referring now to FIGS. 5 and 6 of the drawing, in a still further preferred embodiment of the invention the work support legs 37 and work support brace 38 of an auxiliary work support 33 are mounted on door panel 3, and work support 33 can be assembled from work support legs 37 and the cooperating work support brace 38, as illustrated in FIG. 6, to provide an additional working surface for use in connection with the portable workshop 1. As further illustrated in FIG. 6 the work support brace 38 is provided with brace ribs 40, which are spaced to register with a cooperating leg slot 39, provided in work support legs 37, to shape and support each end of the work support 33.
Referring again to the drawings, it will be appreciated by those skilled in the art that the portable workshop 1 can be shaped from multiple panels to provide a geometric enclosure of desired character. However, in a most preferred embodiment, four such panels are used, and the door panel 3, with the cooperating panel facing 4, the closure panel 8, also with the adjacent panel facing 4, and each of the rear panels 9 are about 4 feet by 8 feet in size respectively, to define an enclosure 2 which occupies a space of about 16 square feet when in folded configuration. Furthermore, various desired sizes, configurations and locations of shelves 34 and pegboards 12 can be provided inside the portable workshop 1 and mounted to the door panel 3, closure panel 8 and the rear panels 9, respectively, according to the particular needs and desires of the user. For example, while the lights 13 are illustrated as florescent lighting in the drawings, it will be appreciated that incandescent lights or other lighting known to those skilled in the art, can also be used as desired. Furthermore, the location, number and size of the single cabinet 16 and double cabinet 19 can also be varied to suit the particular needs of the user. However, in a most preferred embodiment of the invention it has been found that the specific spatial orientation of the utility means, such as the single cabinet 16 and double cabinet 19 on the rear panels 9, respectively, illustrated in the drawings is particularly advantageous when used in cooperation with the folding counter 23, to provide maximum horizontal work space and still facilitate the folding function of the portable workshop 1. Other utility means and modifications, which include a second work support 33 attached to the inside surface of the closure panel 8, and a vise secured to the double cabinet top 20 or single cabinet top 21, as well as storage jars or receptacles carried by the shelves 34, can be provided, in non-exclusive particular, according to the knowledge of those skilled in the art.
As heretofore described, the portable workshop of this invention can be used both outside and inside the home, and is particularly well adapted for garage and carport use in homes which are either sparsely provided with, or are not equipped with a workshop, work bench or storage facilities such as cabinets, shelves and pegboards, to accommodate tools, supplies and equipment. The portable workshop can be completely deployed in linear configuration, as illustrated in FIG. 4 of the drawings, or it can be partially opened, as illustrated in FIGS. 2 and 3 to provide shelter from wind in cold weather when the workshop is used outside.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention.
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A portable, compact and fully equipped workshop which includes enclosure or cubicle characterized by four hinged panels mounted on rollers and containing interior cabinets, shelves and lighting, and further including a hinged counter positioned inside the enclosure and raised when the panels are in folded configuration. The counter can be deployed in horizontal position to provide additional work space when the panels are opened to provide access to the cabinets and shelves. Various hand and power tools, as well as miscellaneous supplies and equipment can be stored in compartments provided in the cabinets and on the shelves, and the panels can be locked into the folded configuration to secure the tools, supplies and equipment inside the enclosure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] This invention relates to storage containers, specifically to such containers that store various small articles
[0005] Organizing and storing small items has always been a problem for people like homeowners, handymen, carpenters, machinists, chefs and many others. They are frequently wasting time searching for particular items necessary to finish a task. Items at home are many times mixed and misplaced in junk drawers or in containers such as jars, cans, bags, and boxes. Countless hours are also wasted in organizing and storing items for future use.
[0006] Transporting such items also presents problems, since open containers may not be overturned without spillage. In addition, common storage methods are inefficient with regard to space utilized, and many unnecessary containers are usually required for carrying materials.
[0007] Since common storage containers are fixed in volume, unrelated materials are often combined within them in order to utilize the space available more efficiently. Screws, buttons, nails, brackets etc. will end up in the same jar, and must be identified and separated when wanted. A jar with a few screws in it wastes space, but adding nails creates its own set of problems.
[0008] Many products are currently available which organize, store and provide accessibility to small items. Such things as tool cabinets and medicine chests are designed to separate and differentiate their contents for storage. While these products have had some degree of success, they all lack certain qualities that are essential to people who need secure, compact, segregated, and convenient storage that affords easy identification of their stored items; e.g. carpenters who must organize types of screws, nails, bolts, etc.
[0009] The instant invention provides several advantages to its user. The contents are visible, so time is not wasted in finding items. The organizer has segmented compartments that can store and divide a variety of articles and keep them securely divided when the container is in any orientation. The device provides for the efficient use of storage capacity, with minimal empty space. Additionally, the contents of the organizer are easily dispensed, with no commingling of articles from adjacent compartments.
[0010] The instant containing device utilizes longitudinal dividers which create separate chambers accessible from the top or sides. Many embodiments are presented herein to describe different aspects of its novel feature. These embodiments have all the advantages described previously, allowing efficient use of space, organization, easy identification, portability, simple dispensing and secure containment.
[0011] A preferred embodiment of the container is a transparent closeable cylinder having separating vanes rotatably communicated around a central longitudinal axis of the cylinder, creating a number of wedge-shaped compartments which are independent of each other and are radially adjustable as to size. The vanes are contoured to match the contour of the container walls to prevent mixing of the items between adjacent chambers. Since all of the compartments are completely enclosed, the container may be turned in any orientation without spilling or commingling of the contents from chamber to chamber. The size-adjustable compartment principle of this embodiment is novel and unique and is not taught in any prior art.
[0012] The proposed container may be constructed with simple materials, such as plastics, for inexpensive production and efficient use.
[0013] Because the vanes, or separators, are radially adjustable, materials requiring smaller volume are automatically stored in a smaller wedge because chambers holding materials requiring more space will widen to accommodate those materials. In this manner, the device is very efficient in the use of space, while keeping the contents separated according to category.
[0014] This embodiment has a further advantage in that it allows the contents to be readily viewed through the transparent sidewalls. By rotating the device around the central axis, all the contents are instantly visible in a sequential compartment after compartment manner. Presently used storage methods, such as small utility cabinets having transparent plastic drawers, require bending and provide poor visibility of the drawer contents, which are usually only viewable from the front. Cabinets are typically large, and hold very little. In addition, these holders are not easily moved, since the enclosed materials spill when the cabinet is tilted or inverted. The instant invention stores materials more securely and does not waste space.
[0015] Although specifically designed molded holders, such as closeable drill bit cases with sized cavities for each bit, meet many needs previously discussed, they are necessarily large and limited in their storage capacity. These molded cases typically leave no options for storing other related materials, only those materials for which the case is expressly designed. The instant device can provide a number of highly visible compartments of variable volume and are thereby more practical, especially for adding related materials.
[0016] None of the prior art presented herein teaches variable volume for storage.
[0017] Prior art such as U.S. Pat. Nos. 3,498,471, 3,441,033, 6,364,125 and 6,378,533 do not afford easy identification of the articles that they organize. It is necessary for users to label or memorize the contents. Furthermore, in some cases, removal of stored articles is complicated and time consuming. The cosmetic jar of U.S. Pat. No. 6,378,533 shows a horizontally compartmentalized container. The advantages described herein, such as visibility, security, accessibility, and simplicity of the present invention are obvious over this prior art, U.S. Pat. Nos. 3,498,471, 3,441,033, and 6,378,533 also teach lateral storage of materials and need pivoted movement to access those materials.
[0018] U.S. Pat. Nos. 5,626,266, 6,318,602 and 522,693 do not permit an assortment of items to be stored and are limited in their design because they must remove the entire contents of their container at one time.
[0019] U.S. Pat. No. 5,797,491 describes a tool carrier which is not fully enclosed, therefore contents will spill when tipped or overturned. Although providing segmented compartments, they are made of fabric and cannot visually display the contents of the carrier. Furthermore, this carrier is quite cumbersome, and not convenient for transport.
[0020] U.S. Pat. Nos. 5,277,329, 5,344,024 and 5,027,972 have the same shortcomings and are somewhat complicated in their general structure. The case of U.S. Pat. No. 5,344,024 does not teach a separate access to cells which lie within. The entire lid must be raised to add or remove articles. Secure enclosure of the other compartments therefore falls very short of the instant device, which provides access to individual compartments within the container from the exterior, without disturbing the integrity of the remaining compartments.
[0021] Further embodiments of the present invention are described herein since it may be designed for a variety of uses. Fixed longitudinal separators are described, with compartments that may be permanently sized according to expected use of enclosed materials, with secure enclosure and access from the top or sides. None of the prior art provides all of these elements of the instant device: complete secure enclosure, portability, simple access, readily visible identification, and variable volume of chambers.
[0022] Although presently used containers exist having separate internal chambers with independent access means, such as weekly pill dispensers, these devices lack the shape and storage capacity provided by a device as presented herein. The embodiments of the instant invention have large storage capacity relative to the access cavity, they are more easily viewable, and they represent a structure which is generally more easily handled and durable than such existing devices. These valuable features are not obvious, evidenced by the lack of such devices for storage of articles today. Embodiments of the present device produce unforeseen advantages for storage of materials.
[0023] None of the prior art teaches a secure longitudinal compartmental container which offers individual accessibility from the exterior which maintains the integrity of the remaining compartments.
[0024] In short, the prior art or commonly used containers in use today do not anticipate the individual or combined advantages described in the present device. Some of these advantages are:
[0025] Easy and quick dispensing of contents
[0026] Portability and rugged security of contents
[0027] Efficient use of storage space
[0028] Simplicity of manufacture
[0029] Practical mass production of inexpensive construction material
[0030] Storage for a variety of items and materials
[0031] Design can be altered to accommodate both small and large storage volumes
BRIEF SUMMARY OF THE INVENTION
[0032] In accordance with the present invention a storage container comprises a top, a base and a substantially cylindrical body with at least one enclosed radially distributed rotatable separator and an access means that facilitates the storage of small items. The advantages of the instant invention are visibility of stored items, accessibility, easy transport, and variable volume storage. This invention is intended to provide a secure, efficient, and useful storage device.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0033] In the drawings, closely related figures have the same number but different alphabetic suffixes.
[0034] [0034]FIG. 1 illustrates a preferred embodiment of the container.
[0035] [0035]FIG. 2 illustrates the top view of the lid with rotatable disk.
[0036] [0036]FIG. 3 illustrates an independent unit of pivotable separators with rotating means.
[0037] [0037]FIGS. 4 and 5 illustrate differing views of the lid with divided access door entry.
[0038] [0038]FIG. 6 illustrates a view of the lid with flexible restraining bar access system for divided access doors.
[0039] [0039]FIG. 7 illustrates an adjustable access entry using upper and lower slotted access disks.
[0040] [0040]FIGS. 8 and 8 a illustrate an embodiment of the invention with a sidewall aperture.
[0041] [0041]FIGS. 9 a and 9 b illustrate differing views of a primary rotatable separator which is centrally notched to accommodate secondary rotatable separator.
[0042] [0042]FIG. 9 c illustrates a hinged embodiment of primary and secondary separators.
[0043] [0043]FIGS. 9 d and 9 e illustrate top views of the primary and secondary separators.
[0044] [0044]FIG. 10 illustrates a doublet embodiment of storage containers.
[0045] [0045]FIG. 11 illustrates a doublet embodiment of storage containers having both fixed and adjustable separators.
DETAILED DESCRIPTION OF INVENTION
[0046] [0046]FIG. 1 illustrates a preferred embodiment of the device. Top 10 , tubular cylindrical body 20 and base 30 form a secure container.
[0047] Top 10 is comprised of a threaded retaining rim 40 having threads 50 matching those threads on cylindrical body 20 so it may be screwed on in a manner similar to a common jar. Holding lip 60 allows movement of rotatable disk 70 when retaining rim 40 is loosened, similar to the design of common mason jars. Flap 80 covers access hole 90 which rotates to a desired position when rotatable disk 70 is turned. Sidewalls 100 of tubular cylindrical body 20 are optionally transparent and may be constructed from a variety of materials, including plastic or glass.
[0048] Internally, pivotable separators 110 having hinges 120 are rotatably communicated with axle 130 , which longitudinally extends from base 30 to top 10 along a central longitudinal axis. Axle 130 is optionally affixed to base 30 at a central point 140 thereby facilitating the free rotation of separator 110 . Separators 110 are substantially rigid and flat and extend radially from axle 130 to sidewalls 100 and longitudinally from base 30 to top 10 . Edges of separators 110 are shaped to closely conform to the interior contour of base 30 , sidewalls 100 and top 10 so that they may be rotated easily yet prohibit stored material from transferring around the edges of these partitions.
[0049] Any number of separators 110 may be used, depending upon the intended use of the device. As can be seen, two adjacent separators 110 , base 30 , top 10 and sidewall 100 create a wedge-shaped compartment 150 within the container which confines materials to that compartment 150 . Since separators 110 are pivotable in this embodiment, an angular movement of separator 110 changes the volume of compartment 150 . This feature permits storage of differing quantities and sizes of materials within compartments 150 .
[0050] Since cylindrical body 20 of the device is transparent, items stored within are easily identified from the exterior as the container is rotated. Because of gravitational principles, separators tend to flip as the container is rotated while in a horizontal orientation, further facilitating identification of stored materials.
[0051] A closer view of the top 10 of the embodiment is shown in FIG. 2. Finger catch 160 protrudes from rotatable disk 70 simplifying rotation by providing a location where lateral force may be effectively applied.
[0052] To access a particular compartment 150 within the container, rotatable disk 70 is turned to a position whereby access hole 90 is aligned with compartment 150 . Flap 80 is frictionally closed over access hole 90 during storage and snapped open when addition or dispensing of materials is required. Flap 80 rotates around pivot pin 170 so that rear element 180 extends downward as the forward portion of flap 80 is deployed upward. Rear element 180 is sized and shaped to extend sufficiently downward and laterally to prevent the two pivotable separators 110 forming the compartment 150 from moving into the access hole 90 opening. In this manner, only one compartment 150 is accessible at a time and materials will not mix with other compartments when the container access hole 90 is open. Since rear element 180 extends downward into compartment 150 when flap 80 is deployed, the top edge of a pivotable separator 110 will prevent flap 80 from deploying if pivotable separator 110 is beneath flap 80 . In this way, access may only occur when separators 110 are spaced sufficiently wide and are properly aligned.
[0053] A particular compartment may be widened if the device is horizontally oriented and the desired compartment is faced upward. Gravity forces the materials within the compartments to compress downward, thereby widening the uppermost compartment 150 . Once this compartment 150 is of sufficient width, flap 80 may be raised and rear element 180 thereafter restrains adjacent separators 110 , allowing access. This secured access to one compartment is maintained, regardless of orientation of the device, while flap 80 is deployed.
[0054] This embodiment, therefore, provides visibility, security, adjustable volume and access to compartmentalized materials. It is also envisioned that the internal structure of this invention is marketable as an independent device. As shown in FIG. 3, pivotable separators 110 , and pivoting means 190 form an independent unit which may be inserted into an existing appropriate container in order to longitudinally compartmentalize that container. The unit may be designed to have dimensions which allow insertion and conformation to standardized containers such as jars and coffee cans, thereby forming longitudinally compartmentalized containers having many of the benefits presented in the instant described embodiments. Other embodiments of the interior structure of the present device are presented hereafter, all of which may also obviously be designed to be marketed independently.
[0055] It is obvious that form and structure changes may be made to the embodiment, such as having a sliding flap on the top, having a one piece top, having separators which hang over a central tube as rotating means, or curving the sidewalls of the tubular body while keeping it equidistant from the central axis for aesthetic purposes, without changing the basic concept presented herein.
[0056] Another embodiment of a top-located access to the interior chambers is illustrated in FIGS. 4 and 5 which show the lid in open and closed positions from different angles. Divided access doors 200 are of a size and shape to snugly cover pie-shaped access hole 90 and have finger tabs 210 which protrude slightly and communicate with top 10 by frictionally snap-fitting into snap depressions 220 when divided access doors 200 are closed. Top 10 rotates freely when divided access doors 200 are closed but remains in loose contact with the top of pivotable separators 110 , so that materials do not intermingle when the device is inverted during use.
[0057] Divided access doors 200 have springable access hinges 230 that allow pivoting around access hole sides 240 when divided access doors 200 are forced downward or finger tabs 210 are lifted. Access to an internal compartment is possible only when two adjacent separators 110 are positioned wider than the dimensions of the access hole 90 , since separators 110 will prevent downward movement of divided access doors 200 otherwise. Once the access hole 90 is rotated to the correct position, divided access doors 200 are forced downward or finger tabs 210 are lifted to provide access to a desired compartment. Divided access doors 200 restrain the two separators forming the compartment while material is added or removed from that compartment. This feature insures that material in all other compartments remains separate and secure when the desired compartment is accessed and the device is turned in any orientation. Closure occurs when finger tabs 210 are depressed and thereafter snapped. Finger tabs 210 also provide grip for easy rotation of top 10 .
[0058] It may be noted herein that it is difficult to overfill a compartment when loading through access hole 90 , since any material that interferes with closure of divided access doors 200 must first be removed. This insures that enough space is available for divided access doors 200 to pivot freely at a later time.
[0059] Rather than gaining access through divided access doors 200 as previously described, FIG. 6 illustrates a flexible restraining bar 250 which forces divided access doors 200 apart when depressed. Flexible restraining bar 250 bends over fulcrum 260 when depressed and is firmly attached at end point 270 to top 10 . While flexible restraining bar 250 is held down, separators 110 are held apart by divided access doors 200 . When released, flexible restraining bar 250 returns to a neutral position and divided access doors 200 are forced to a closed position by flexure of springs 275 .
[0060] A further embodiment of adjustable access to an internal chamber of a container is illustrated in FIG. 7 wherein lower slotted access disks 280 and upper slotted access disk 290 are stacked and have pie-shaped notches 300 which provide access to a particular chamber within the device when pie-shaped notches 300 are aligned by rotation. Lower slotted access disk 280 is overlapped by upper slotted access disk 290 having retaining lip 310 which is rotatably pressure fit over cylindrical body 20 having wide rim 320 . In this embodiment upper slotted access disk 290 necessarily has a larger diameter than lower slotted access disk 280 in order to fit around retaining rim 320 and hold lower slotted access disk 280 in place. It may be noted that upper slotted access disk 290 has characteristics similar to those of presently used safety medicine bottle tops, which design is obviously envisioned for use in the present device but not presented herein.
[0061] An embodiment of a sidewall aperture for dispensing enclosed material is illustrated in FIGS. 8 and 8 a . Turning ring 330 is rotatably mounted on grooves 340 on cylindrical body 20 and has a slidable cover 350 over sidewall aperture 360 . Turning ring 330 is shaped and wide enough to be flush with the interior surface of sidewall 100 . In this manner, mixing of enclosed materials is prevented and structural integrity of the container is maintained. This embodiment illustrates that sidewall access to the longitudinal chambers within the container is feasible and embodiments having this feature are envisioned.
[0062] [0062]FIGS. 9 a and 9 b illustrate an embodiment of the present invention having primary rotatable separator 370 which is centrally notched to accommodate communication with a secondary rotatable separator 380 . This design is direct in nature, in that there are few moving parts, the rotatable separators simply fit together as illustrated. The means for pivoting is the notched communication between these separators. Interior chambers formed by this embodiment are more limited, since those chambers laterally opposite of each other are affected by rotational movement of the separator. By hinging at least one of the separators, as shown in FIG. 9 c, chambers produced are somewhat independent of movements of other separators. Vanes 390 are hinged around pin 400 but still form a primary notch 410 which accepts secondary notch 420 of rigid divider 430 . FIG. 9 d illustrates an overhead view of this embodiment with dashed arrows showing possible movements of vanes 390 . It may be seen that chamber volume is variable up to one half of the total volume in this embodiment.
[0063] A slotted embodiment of the device is not limited to four compartments. As can be seen in FIG. 9 e, additional dividers may be structured to accommodate a variety of positions and sizes of chambers. Straight divider 440 is appropriately notched to accept two angled dividers 450 . It is obvious that a multitude of notched embodiments are possible.
[0064] Since the present invention is longitudinally compartmentalized, an embodiment, as illustrated in FIG. 10, may be created to afford additional storage space and provide a unitary container which is easy to carry. This doublet embodiment simply connects two of the previously described embodiments in a base to base relationship wherein tops 10 are at opposing ends and afford access to interior compartments. It is possible to construct this embodiment with either pivotable or immovable separators or a combination of both. In this illustration, upper pivotable separators 460 move independently of lower pivotable separators 470 .
[0065] The bases may either be permanently affixed or designed to be disconnected and reconnected as necessary by common snapping or threading means. It is envisioned that standardized dimensions of containers will allow combinations of different items to be transported and stored. For instance, one day a handyman may need metal screws and a certain assortment of brackets, another day he may need metal screws and nails. By disconnecting the container holding the brackets and connecting the container holding nails, he creates a single, transportable container for his needs on each day. By storing items in a number of single containers which are compatible for combining in a base-to-base manner, the user may transport the items he/she needs in fewer carrying units. It may be noted that such an embodiment is envisioned to have bases which are attachable and detachable, so that two devices holding materials may be mated temporarily to form a unit for transporting purposes and may thereafter be detached or attached to other devices. It is obvious that a similar arrangement is designable for compatibly connecting tops and bases to form connected stacks of the device.
[0066] [0066]FIG. 11 illustrates another doublet embodiment having both fixed separators 505 and pivotable separators. Some of the compartments extend from top to opposing top-such as long compartment 480 , halfway-such as half compartment 490 , or somewhere in between-such as short compartment 500 . Long compartment 480 is shown to be fixed, while the others are adjustable. Arrows indicate the possible adjustable movement of pivoting partitions 510 , allowing variations in volume of those affected compartments.
[0067] An example of a use for such a design is a common ratchet set. Bits may be stored in smaller chambers, but the ratchet driver itself is long and would be stored in a long fixed chamber.
[0068] The present invention has many obvious advantages over prior art. It represents a novel approach to storage of a variety of materials and its novelty is evidenced by the absence of any similar carrying and storage methods in use today.
[0069] Not only does the instant device have specific novel aspects, the combined effect of these novel features present an unobvious invention which is not anticipated in the prior art or in present usage.
[0070] It has advantages over other storage methods such as in this partial listing:
compact storage durability visible storage lightweight not spillable holds a variety of materials simple and variable design inexpensive and simple to manufacture categorized materials kept accessibility to stored materials separated may be sized to meet needs
[0071] The device is envisioned for use in containing the following partial list of materials;
miscellaneous change tools samples fasteners sewing needs craft supplies drill bits, other bits art supplies collectibles teaching supplies- chalk, tacks etc. snacks desk supplies candy keys pills training supplies- band aids, tape etc.
[0072] It has been shown that the referenced prior art does not anticipate this device and that this device has advantages over presently existing storage methods. Since similar embodiments of the present device are not available in the present environment and the instant device represents a useful item having many advantages, it follows that it is novel in nature and unobvious.
[0073] Although the descriptions herein contain 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 the invention, thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
[0074] Reference Numerals in Drawings
10 top 20 tubular cylindrical body 30 base 40 retaining rim 50 threads 60 holding lip 70 rotatable disk 80 flap 90 access hole 100 sidewall 110 pivotable separators 120 hinges 130 axle 140 central point 150 compartment 160 finger catch 170 pivot pin 180 rear element 190 pivoting means 200 divided access doors 210 finger tabs 220 snap depressions 230 access hinges 240 access hole sides 250 flexible restraining bar 260 fulcrum 270 end point 275 springs 280 lower slotted access disk 290 upper slotted access disk 300 pie-shaped notches 310 retaining lip 320 wide rim 330 turning ring 340 grooves 350 slidable cover 360 sidewall aperture 370 primary rotatable separator 380 secondary rotatable separator 390 vane 400 pin 410 primary notch 420 secondary notch 430 rigid divider 440 straight divider 450 angled dividers 460 upper pivotable separator 470 lower pivotable separator 480 long compartment 490 half compartment 500 short compartment 510 pivoting partitions
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A closeable container for storing and protecting materials having internal partitions extending radially and longitudinally creating at least two independent adjustable internal chambers within which stored materials are kept separated and are individually accessed for adding and dispensing purposes. In a substantially cylindrical embodiment of the instant device, separators forming the internal compartments are rotatable, thereby allowing adjustment of the volume of the internal compartments to accommodate dimensionally or quantitatively differing material. The compartments of the container automatically adjust volume as materials are added or dispensed. A variety of access means are presented which preclude commingling of materials between compartments during access. Transparent sides facilitate identification of stored materials within the chambers. The device is simple in design and inexpensive to produce and is envisioned to have a wide variety of uses for convenient and efficient storage.
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TECHNICAL FIELD
[0001] The present invention relates to a laser cladding method that belongs to the art of laser processing.
BACKGROUND
[0002] Hydraulic support columns are key components in mining equipment. In China, hydraulic support columns are commonly surface treated using chromium plating, so as to prevent the surface from rusting and to prevent corrosion. However, the abrasion performance of the plated chromium layer is poor, and usually, there may be peeling and scaling of the plated chromium layer after 1 to 1.5 years. Therefore, the surface of the column may be corroded by emulsion, so that the usage of the hydraulic support may be affected.
[0003] A laser cladding method for a mining hydraulic support column is disclosed in Chinese Patent No. CN101875128B, by which three layers of metallurgy materials are clad under particular laser cladding process conditions, so that the problems about the abrasion performance and the anti-corrosion performance of the mining hydraulic support column surface are solved with the service life thereof increased. The detailed technical solution therein includes performing preheating after the mining hydraulic support column is surface treated, and then plating a bottom layer, a middle layer and a surface layer in sequence with alloy powder material for cladding. The chosen alloy powder material for cladding for the bottom layer includes 0.1% of C, 3.2% of Si, 0.5% of Mn, 10.2% of Cr, 8.8% of Ni, 0.8% of Nb, 0.1% of B, 0.5% of P and residual amount of Fe.
BRIEF SUMMARY
[0004] In the abovementioned laser cladding method, the laser used is a carbon dioxide laser, i.e., a laser functioning with carbon dioxide as gain medium. However, when a carbon dioxide laser is being used to perform laser cladding, the laser beam coming out from the carbon dioxide laser irradiates the hydraulic support column, and energy absorption and utilization efficiency of laser beam is very low. Also, electric energy consumption in the process is relatively large.
[0005] In order to solve these technical problems, in the present invention, a laser cladding method is provided with which energy absorption and utilization efficiency of laser beam is increased, the electric energy utilization efficiency is increased, and power consumption is reduced.
[0006] The following are the technical solutions provided by the present invention.
[0007] Solution 1 is a laser cladding method that uses a laser beam emitted from a semiconductor laser to melt alloy powder for laser cladding on the surface of a hydraulic support column, so that a laser cladding layer is formed.
[0008] Solution 2 is the laser cladding method according to solution 1, changed in that the distance from a laser beam outlet of the semiconductor laser to the surface of the hydraulic support column is in the range of 150-250 mm, and the power density of the laser beam emitted from the semiconductor laser is above 109.38 W/mm 2 .
[0009] Solution 3 is the laser cladding method according to solution 2, changed in that the distance from the laser beam outlet of the semiconductor laser to the surface of the hydraulic support column is in the range of 190-220 mm, and the power density of the laser beam emitted from the semiconductor laser is above 112.63 W/mm 2 .
[0010] Solution 4 is the laser cladding method according to solution 3, changed in that the alloy powder for laser cladding is supplied at a speed of 38-40 g/min, and the diameter of the alloy powder for laser cladding is in the range of 44-178 μm. Further, the laser beam is a rectangular spot with a length of 16 mm and a width of 2 mm, and the linear scanning velocity of the laser beam is in the range of 540-780 mm/min, with the scanning direction of the laser beam perpendicular to the length direction of the rectangular spot.
[0011] Solution 5 is the laser cladding method according to solution 1, changed in that the alloy powder for laser cladding includes 0.01-0.15% of C, 0.5%-1.0% of Si, 0.4%-0.8% of Mn, 17.5%-19.5% of Cr, 21%-25% of Ni, and a residual amount of Fe and unavoidable impurities. The content of each element above is a content of weight percentage.
[0012] Solution 6 is the laser cladding method according to solution 1, changed in that the alloy powder for laser cladding includes 0.05%-0.20% of C, 1.0%-1.5% of Si, 0.4%-0.8% of Mn, 15.0%-15.8% of Cr, 4.0%-4.5% of Ni, and a residual amount of Fe and unavoidable impurities. The content of each element above is a content of weight percentage.
[0013] Solution 7 is the laser cladding method according to any one of solutions 1-6, changed in that the outer diameter of the hydraulic support column is in the range of 200-400 mm.
[0014] Solution 8 is the laser cladding method according to solution 7, changed in that the outer diameter of the hydraulic support column is in the range of 350-400 mm.
[0015] With the laser cladding method according to solution 1, the energy absorption and utilization efficiency of the laser beam is high, and because of high energy transition efficiency of the semiconductor laser, the electric energy utilization efficiency is increased with power consumption reduced.
[0016] In addition, in the solutions of the present invention, since a semiconductor laser is used, the continuous working time can be very long. For example, in an implementation process, the continuous working time can exceed 15000 hours. However, when a carbon dioxide laser is used, then the continuous working time is shorter because commonly a vacuum pumping operation needs to be performed once in every 24 hours.
[0017] With the laser cladding methods according to solutions 2-3, good process parameters are selected, i.e., the cooperative relationship between the distance from the laser beam outlet of the semiconductor laser to the surface of the hydraulic support column and the power density of the laser beam emitted from the semiconductor laser is optimized, so that laser cladding is performed effectively.
[0018] Solution 4 is a detailed embodiment, wherein many process parameters are defined, so that precise operating process parameters are provided to those skilled in the art.
[0019] With respect to the hydraulic support column obtained according to solution 5, because of the specific composition of the laser cladding layer, a good surface hardness, a long service life, a high bonding strength between the cladding layer and the metallic body, and a good salt spray resistance can be obtained. The hardness of the cladding layer on the surface of the hydraulic support column can exceed 30 HRC, the service life in mines is over 5 years, the bonding strength between the cladding layer and the metallic body can exceed 310 MPa, and the salt spray resistance can be maintained for over 96 hours.
[0020] With respect to the hydraulic support column obtained according to solution 6, on one aspect the hydraulic support column has all of the performance results of the hydraulic support column obtained according to solution 5. For example, the service life in mines is over 5 years, the bonding strength between the cladding layer and the metallic body can exceed 310 MPa, and the salt spray resistance can be maintained for over 96 hours. Moreover, the hardness of the cladding layer can exceed 45 HRC. Also, the cost is low because of the low content of Ni.
[0021] With the laser cladding method according to solutions 7 and 8, a preferable outer diameter of the hydraulic support column is given. Also, it is better for the outer diameter of the hydraulic support column to be larger. This is because that when the outer diameter of the hydraulic support column is larger, the outer surface of the column will be more close to a plane, and then the energy of the laser beam emitted from the semiconductor laser will be distributed more evenly on the surface of the hydraulic support column. But on the other hand, the outer diameter of the surface of the hydraulic support column should not be too large. This is because larger clamping means and larger carrying means are needed if the outer diameter of the hydraulic support column is too large. Therefore, the outer diameter of a preferable hydraulic support column is in the range of 200-400 mm, more preferably 350-400 mm. An even cladding could be achieved and loads for the other devices can be reduced when the outer diameter is within the above ranges.
DETAILED DESCRIPTION
[0022] The solutions of the present invention will be described in detail with reference to the embodiments, so that the solutions of the present invention will be more apparent to those skilled in the art.
First Embodiment
[0023] The embodiment is a laser cladding method for mining hydraulic support column.
[0024] The hydraulic support column used in the embodiment is a mining hydraulic support column used by XINJULONG ENERGY CO., LTD. of XINWEN MINING GROUP. The column is a hydraulic support column with a body of 27 SiMn and a diameter of 300 mm.
[0025] The laser cladding is performed with the following method.
[0026] 1. Performing the process of rust removing and the process of texturing of the mining hydraulic support column.
[0027] 2. Mounting the mining hydraulic support column into a laser process machine which is a semiconductor laser process machine, i.e., a laser process machine with a semiconductor laser.
[0028] 3. Under the cooperation of the rotary motion of the main shaft and the feeding motion of the linear shaft of the laser head, powder feeding and laser cladding are carried out simultaneously in one process step. The output power of the semiconductor laser is 4000 W, the distance from the laser beam outlet of the semiconductor laser to the surface of the hydraulic support column is 200 mm, the linear scanning velocity of the laser beam is 540 mm/min, and the laser beam is a 16*2 rectangular spot (with a length of 16 mm and a width of 2 mm). The cladding is performed in a scanning cladding manner.
[0029] The adopted composition for laser cladding is in powder form with particle size in the range of 44-178 μm. The composition includes 0.05% of C, 1.5% of Si, 0.4% of Mn, 15.8% of Cr, 4.0% of Ni, and a residual amount of Fe and few unavoidable impurities. The alloy powder for laser cladding is fed at the powder feeding speed of 38-40 g/min.
[0030] 4. Performing the machining.
[0031] In an embodiment, the total installed power of the semiconductor laser is 45 KW (kilowatt), the continuous power output of the semiconductor laser is 4000 W, the absorption efficiency of metallic material (i.e., the absorption efficiency of the column) is 80%, the dimensions of the semiconductor laser are 260 mm×118 mm×450 mm, the weight of the semiconductor laser is 27 kg, and the continuous working time can achieve 15000 hours.
[0032] In an embodiment, the heat absorbed by the metallic material is 3200 KW.
[0033] The following are performance indices tested in the experiments and tests to the obtained column.
[0034] 1. No cracks.
[0035] 2. The hardness of the cladding layer can exceed 45 HRC, the service life in mines is over 5 years, the bonding strength between the cladding layer and the column body can exceed 310 MPa, and the salt spray resistance can be maintained for over 96 hours.
[0036] With regard to the service life, the column has been promoted and used in XINJULONG ENERGY CO., LTD. of XINWEN MINING GROUP with good effects. The column has been used at the mining face for four years without any quality problem.
[0037] With regard to the experiment of salt spray resistance, China National Standard GB/T10125-1997 is adopted, and the reagent used in the experiment is aqueous solution of sodium chloride with a concentration of 50g/L±5g/L, a PH value of 6.5-7.2, and a temperature of 35° C.±2° C.
[0038] The cost is low because of the low content of Ni in the embodiment.
Second Embodiment
[0039] The embodiment is a laser cladding method for a mining hydraulic support column.
[0040] The hydraulic support column used in the embodiment is a mining hydraulic support column used by XINJULONG ENERGY CO., LTD. of XINWEN MINING GROUP. The column is a hydraulic support column with a body of 27 SiMn and a diameter of 400 mm.
[0041] The laser cladding is performed with the following method.
[0042] 1. Performing the process of rust removing and the process of texturing of the mining hydraulic support column.
[0043] 2. Mounting the mining hydraulic support column into a laser process machine which is a semiconductor laser process machine.
[0044] 3. Under the cooperation of the rotary motion of the main shaft and the feeding motion of the linear shaft of the laser head, powder feeding and laser cladding are carried out simultaneously in one process step. The output power of the semiconductor laser is 4000 W, the distance from the laser beam outlet of the semiconductor laser to the surface of the hydraulic support column is 250 mm, the linear scanning velocity of the laser beam is 600 mm/min, and the laser beam is a 16*2 rectangular spot (with a length of 16 mm and a width of 2 mm). The cladding is performed in a scanning cladding manner.
[0045] The adopted composition for laser cladding is in powder form with particle size in the range of 44-178 μm. The composition includes 0.15% of C, 1.0% of Si, 0.8% of Mn, 15.0% of Cr, 4.5% of Ni, and a residual amount of Fe and unavoidable impurities. The alloy powder for laser cladding is fed at the powder feeding speed of 38-40 g/min.
[0046] 4. Performing the machining.
[0047] It should be noted that in the embodiment, the total installed power of the semiconductor laser is 45 KW (kilowatt), the continuous power output of the semiconductor laser is 4000 W, the absorption efficiency of metallic material is 80%, the dimensions of the semiconductor laser are 260 mm×118 mm×450 mm, the weight of the semiconductor laser is 27 kg, and the continuous working time can achieve 15000 hours.
[0048] The following are performance indices tested in the experiments and tests to the obtained column.
[0049] 1. No cracks.
[0050] 2. The hardness of the cladding layer can exceed 45 HRC, the service life in mines is over 5 years, the bonding strength between the cladding layer and the column body can exceed 310 MPa, and the salt spray resistance can be maintained for over 96 hours.
Third Embodiment
[0051] The embodiment is a laser cladding method for a mining hydraulic support column.
[0052] The hydraulic support column used in the embodiment is a mining hydraulic support column used by XINJULONG ENERGY CO., LTD. of XINWEN MINING GROUP. The column is a hydraulic support column with a body of 27 SiMn and a diameter of 300 mm.
[0053] The laser cladding is performed with the following method.
[0054] 1. Performing the process of rust removing and the process of texturing of the mining hydraulic support column.
[0055] 2. Mounting the mining hydraulic support column into a laser process machine which is a semiconductor laser process machine.
[0056] 3. Under the cooperation of the rotary motion of the main shaft and the feeding motion of the linear shaft of the laser head, powder feeding and laser cladding are carried out simultaneously in one process step. The output power of the semiconductor laser is 4000 W, the distance from the laser beam outlet of the semiconductor laser to the surface of the hydraulic support column is 250 mm, the linear scanning velocity of the laser beam is 600 mm/min, and the laser beam is a 16*2 rectangular spot (with a length of 16 mm and a width of 2 mm). The cladding is performed in a scanning cladding manner.
[0057] The adopted composition for laser cladding is in powder form with particle size in the range of 44-178 μtm. The composition includes 0.15% of C, 1.0% of Si, 0.8% of Mn, 18.0% of Cr, 22.0% of Ni, and a residual amount of Fe and unavoidable impurities. The alloy powder for laser cladding is fed at the powder feeding speed of 38-40 g/min.
[0058] 4. Performing the machining.
[0059] It should be noted that in this embodiment, the total installed power of the semiconductor laser is 45 KW, the continuous power output of the semiconductor laser is 4000 W, the absorption efficiency of metallic material is 80%, the dimensions of the semiconductor laser are 260 mm×118 mm×450 mm, the weight of the semiconductor laser is 27 kg, and the continuous working time can achieve 15000 hours.
[0060] The following are performance indices tested in the experiments and tests to the obtained column.
[0061] 1. No cracks.
[0062] 2. The hardness of the cladding layer can exceed 30 HRC, the service life in mines is over 5 years, the bonding strength between the cladding layer and the column body can exceed 310 MPa, and the salt spray resistance can be maintained for over 96 hours.
Embodiment for Comparison
[0063] The embodiment is a laser cladding method for mining hydraulic support column.
[0064] The hydraulic support column used in the embodiment is a mining hydraulic support column used by XINJULONG ENERGY CO., LTD. of XINWEN MINING GROUP. The column is a hydraulic support column with a body of 27 SiMn and a diameter of 300 mm.
[0065] The laser cladding is performed with the following method.
[0066] 1. Performing the process of rust removing and the process of texturing of the mining hydraulic support column.
[0067] 2. Mounting the mining hydraulic support column into a laser process machine which is a carbon dioxide laser process machine, i.e., a laser process machine with a carbon dioxide laser.
[0068] 3. Under the cooperation of the rotary motion of the main shaft and the feeding motion of the linear shaft of the laser head, powder feeding and laser cladding are performed in synchronization in one process step. The output power of the carbon dioxide laser is 8000 W, the distance from the laser beam outlet of the laser to the surface of the hydraulic support column is 300 mm, the linear scanning velocity of laser is 480 mm/min, and the laser beam is a 15*2.5 rectangular spot (with a length of 15 mm and a width of 2.5 mm). The cladding is performed in a scanning cladding manner.
[0069] The adopted composition for laser cladding is in powder form with particle size in the range of 44-178 μm. The composition includes 0.02% of C, 1.5% of Si, 0.4% of Mn, 15.8% of Cr, 4.0% of Ni, and a residual amount of Fe and unavoidable impurities. The alloy powder for laser cladding is fed at the powder feeding speed of 38-40 g/min.
[0070] 4. Performing the machining.
[0071] It should be noted that said carbon dioxide laser is a laser functioning with carbon dioxide as gain medium and lighting by means of transition of the carbon dioxide among energy bands. In this embodiment, the total installed power of the carbon dioxide laser is 175 KW, the continuous power output of the carbon dioxide laser is 8000 W, the absorption efficiency of metallic material (i.e., the absorption efficiency of the column) is 40%, the dimensions of the carbon dioxide laser are 2500 mm×1500 mm×2300 mm, the weight of the carbon dioxide laser is 4000 kg, and the continuous working time is 24 hours because a vacuum pumping process needs to be performed once in every 24 hours for such laser.
[0072] In this embodiment, the heat absorbed by the metallic material is 3200 KW.
[0073] It can be seen that the carbon dioxide laser is large in size and inconvenient to operate. In addition, the continuous power output of the carbon dioxide laser cannot be lowered to 4000 W, so that power consumption cannot be decreased significantly.
[0074] The following are performance indices tested in the experiments and tests to the obtained column.
[0075] 1. No cracks.
[0076] 2. The hardness of the cladding layer can exceed 45 HRC, the service life in mines is over 5 years, the bonding strength between the cladding layer and the column body can exceed 310 MPa, and the salt spray resistance can be maintained for over 96 hours.
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In a laser cladding method, a laser beam is emitted from a semiconductor laser to melt alloy powder for laser cladding on the surface of a hydraulic support column. The semiconductor laser is a laser functioning with semiconductor material as gain medium and lighting by means of semiconductor material transition among energy bands. The hydraulic support column is mainly made of alloy steel of 27 SiMn. With the laser cladding method, the energy absorption efficiency of laser beam can be increased, and the energy utilization efficiency is increased, so that the power consumption is saved reduced.
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FIELD OF THE INVENTION
[0001] The invention relates to a multifunction device for endoscopic surgery, in particular an instrument which combines water jet surgery and high-frequency surgical applications in a single device.
BACKGROUND OF THE INVENTION
[0002] Minimally invasive surgery is a generic term for operative interventions with minimal trauma. It has always been the objective of operative treatment to bring about rapid recovery with minimal discomfort after the operation. At the start of the 1990s, laparoscopic and endoscopic surgery initially established themselves only as simple operative interventions, but later also established themselves for carrying out complex operations.
[0003] Nowadays, a differentiation is made between laparoscopic surgery and endoscopy. In laparoscopic surgery, the same interventions are, for all intents and purposes, made as with open surgical methods. However, the largest difference as compared to conventional interventions is that the area to be operated on is reached by significantly smaller incisions than with the conventional open surgery methods.
[0004] In contrast, in endoscopy, a doctor can gain a good view into the natural body cavities and hollow organs of the patient, identify illnesses and possibly also treat them immediately without large-scale surgical intervention. To this end, flexible or rigid endoscopes are used to examine the organs and e.g. look at their mucous membrane. For this purpose, there are also endoscopes with different outer diameters, lengths, biopsy channel diameters and functions. Moreover, so-called interventional endoscopy is no longer used exclusively in diagnosis, but is also frequently used in the treatment of a wide range of illnesses.
[0005] Typical applications for laparoscopic surgery and/or interventional endoscopy are, for example, a selective tissue separation by high-frequency (HF) or water jet surgery and haemostasis (coagulation) or vascular sealing by HF forceps or electrodes. Furthermore, surgical forceps are also used for dissection or biopsy removal of tissue, or also only for tissue preparation or fixing.
[0006] Endoscopic mucosal resection (EMR), in which tumors with large surface areas in the gastrointestinal tract are removed, is carried out for example, with the help of water jet technology, whereby HF surgery is used for haemostasis (coagulation). In this case, the blood vessels, which were previously separated selectively from the tissue with water jet technology, are securely sealed in a targeted manner with HF forceps.
[0007] In water jet surgery, an extremely fine laminary water jet is used which, as it were, pushes apart the tissue and forms an expansion space. Soft tissue can, in principle, be dissected at a low pressure, whereby tissue with high elasticity or large expansion, such as for example, blood vessels, escape the water jet and are thus protected.
[0008] In contrast, in HF surgery, electrical energy is converted into heat and is thus able to separate biological tissue and also bring about haemostasis. Therein, it is mainly thermal effects which are utilized. Temperatures of 60° C. to 70° C. in the region around the HF surgery electrode lead to protein coagulation. The term coagulation is used to refer to this process. This “welding effect” can be used, for example, to stop bleeding.
[0009] During separation, as a result of a higher current density, temperatures of over 100° C. are achieved such that the fluid evaporates in an explosive manner, the space is enlarged and the cell membrane “bursts.” Further, cells located in the direction of electrode movement follow this effect, as a result of which the desired incision or separation of the tissue is achieved.
[0010] In HF surgery, a differentiation is also made between monopolar and bipolar application technology. In the case of monopolar application technology, the flow of current takes place from a HF surgery electrode, through the biological tissue and to a neutral electrode, which is usually positioned on a large surface area on the patient. In contrast to this, in the case of bipolar application technology, the HF current does not flow across the body of the patient to a neutral electrode. In the case of bipolar forceps or clamps, an active electrode and a neutral electrode are arranged directly opposite one another, whereby the HF current only flows from the active electrode to the neutral electrode. This results in very short current paths and defined coagulation regions with a low power requirement.
[0011] During an operation (e.g., EMR) various instruments are frequently required for gripping, rinsing, separating and/or coagulating tissue and have to be interchanged correspondingly in the working channels. However, the continuous interchange of instruments requires a lot of time and can significantly extend the length of an operation.
[0012] A multifunction device, which comprises for example, an HF manual instrument for bipolar coagulation, cutting and gripping as well as a rinsing tube and suction tube additionally accommodated in a protective tube, is known from DE 42 42 143 C2. The tubes (rinsing, suction) which are accommodated in a protective tube, however, do not enable any selective separation of HF and water jet surgery and require, among other things, additional space since they are attached parallel to the electrodes on the manual instrument.
[0013] Furthermore, DE 100 56 238 A1 describes a device with a jaw mechanism for tube shaft instruments for the removal of intracorporal tissue samples which can be sucked away through a tube shaft in the proximal direction. The open jaw passage can additionally be used for rinsing or sucking away or also for the introduction of coagulation electrodes, lenses or other operational probes. However, the instruments and probes used must be correspondingly interchanged during the intervention.
[0014] It is therefore desirable to have available a multifunction device for endoscopic surgery which can be universally used and takes up little space.
SUMMARY
[0015] Embodiments of the invention include a multifunction device for endoscopic surgery with a supply means for the supply of at least one fluid and forceps or a clamp which comprise forceps-shaped electrodes with jaw parts for HF surgery, whereby the supply means is formed to dissect tissue by means of a fluid jet at or in a jaw part.
[0016] Embodiments of the invention also include a device for water jet surgery and HF electrodes formed for coagulation and/or for cutting in or at forceps or a clamp such that the multifunction device for surgery occupies no more space than a conventional HF instrument or conventional forceps or clamps.
[0017] As a result, a multifunction device for surgery is provided which combines the advantages of water jet surgery, in particular dissection by means of a fluid jet, with the advantages of HF surgery, in particular HF cutting and thermal coagulation, in forceps or a clamp and which is not larger than a conventional HF instrument.
[0018] One advantage of the multifunction device according to embodiments of the invention thus lies in particular in that, with the help of a single multifunction device for surgery, the functions of selective cutting, gripping and thermal coagulation of tissue can be carried out without the need to change instruments during the intervention. As a result, operating times, costs and the risk for the patient in terms of the length of intervention can be minimized.
[0019] According to a first embodiment, the endoscopic multifunction device for surgery includes forceps-shaped electrodes with a rigid part and a movable jaw part, whereby the supply means is formed for dissection by means of a fluid jet at or in the rigid jaw part. Herein, the rigid jaw part offers a simple possibility for integrating the supply means in one of the jaw parts and controlling it in accordance with the application.
[0020] The jaw part containing the supply means further includes an end piece which protrudes out of the distal end of the jaw part, whereby the end piece of the supply means is formed as a monopolar electrode which is suitable for the dissection and/or coagulation of tissue. The end piece of the supply means not only acts as a monopolar HF electrode for dissection of tissue but also acts as an outlet nozzle for precise cutting by water jet surgery.
[0021] The monopolar electrode preferably includes a circularly formed disc and/or a hemispherical attachment located at the distal end of the end piece of the supply means. This attachment simplifies HF cutting in all directions.
[0022] The end piece is furthermore movable relative to a longitudinal axis of the rigid jaw part. As a result, it is achieved that the length of the electrode can be adapted according to the desired use.
[0023] In another disclosed embodiment, at least one outlet of the supply means is arranged at the inside of the rigid jaw part opposite the movable jaw part such that at least one fluid jet can be discharged in the direction of the movable jaw part. As a result, it is achieved that precise tissue separation can be brought about in a simple manner, which is advantageous for example, in the case of partial liver resection. The tissue can be held in place by the jaw parts at the same time as resection. Furthermore, the jaw part opposite the outlet of the supply means offers, among other things, protection against the at least one fluid jet, which is discharged with very high pressure.
[0024] In a further disclosed embodiment, the at least one outlet of the supply means may be displaceable relative to a longitudinal axis of the rigid jaw part. As a result, it is achieved that the fluid jet can be displaced relative to the tissue fixed by the two jaw parts and the tissue separation is thus facilitated.
[0025] Furthermore, the at least one outlet of the supply means may be located in a recess of the rigid jaw part arranged parallel to a longitudinal axis of the multifunction device for surgery and/or the movable jaw part comprises a recess arranged parallel to the longitudinal axis of the multifunction device for surgery, which recess is opposite the at least one outlet of the supply means. As a result, it is achieved that the at least one outlet is kept free during separation by the fluid jet and additional fixing of the tissue to be separated and the exiting fluid can be discharged via the recesses.
[0026] in a further disclosed embodiment, the forceps or clamp is formed as biopsy forceps such that the multifunction device for surgery can be used for biopsy removal.
[0027] It is furthermore possible that the jaw parts of the multifunction device for surgery are prestressed by a spring element and as a result are held open. As a result, the function of gripping and coagulation is facilitated since the jaw parts only have to be actively closed but open again automatically as a result of the spring element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] In the following, the invention will now be described in more detail with reference to an exemplary embodiment, which will be explained in more detail with reference to the enclosed drawings.
[0029] FIG. 1 illustrates a simplified view of a typical use of an embodiment of a multifunction device for surgery, wherein a blood vessel is freely prepared by the fluid jet and can subsequently be separated and coagulated.
[0030] FIG. 2 illustrates a perspective view of an embodiment of a multifunction device for surgery according to the invention.
[0031] FIG. 3 illustrates a perspective view of a further embodiment of a multifunction device for surgery according to the invention with a fixed supply means.
[0032] FIG. 4 illustrates a perspective view of a further embodiment of a multifunction device for surgery according to the invention with a movable supply means.
[0033] FIG. 5 illustrates a sectional view along line V-V in FIG. 3 .
[0034] FIG. 6 illustrates a side view of a further embodiment of a multifunction device for surgery according to the invention which is formed as biopsy forceps.
[0035] FIG. 7 illustrates a side view of a further embodiment of a multifunction device for surgery according to the invention, whereby the rigid jaw part is represented as a functional section.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The same reference numbers are used in the following description for identical parts and parts with identical effects.
[0037] In the exemplary embodiment shown in FIGS. 1 and 2 , a multifunction device for surgery 10 with forceps or a clamp with, in each case, a movable jaw part 100 and a rigid jaw part 101 is shown. Jaw parts 100 , 101 are also formed as bipolar electrodes. A circular disc-shaped monopolar electrode 103 is attached to an end piece 102 a of a supply means 102 integrated within rigid jaw part 101 and for formation of a fluid jet 2 of a fluid (e.g., NaCl solution). The multifunction device for surgery is formed in this case such that it can selectively dissect for example, tissue around a blood vessel 1 without damaging the blood vessel 1 . After free preparation, blood vessel 1 is separated with bipolar electrodes 100 , 101 of the forceps or clamp and “welded” by coagulation. Jaw parts 100 , 101 formed as electrodes are in this case used for tissue separation as a result of a higher current flow between bipolar electrodes 100 , 101 and the resultant higher temperatures. In addition, jaw parts 100 , 101 formed as forceps or a clamp enable gripping or holding and thus enable preparation of the tissue, organ or blood vessel to be operated on. All the functions cited above are available with the multifunction device for surgery according to the invention without requiring a change in instrument. This can significantly reduce operating times and as a result minimize risks for the patient. Moreover, the forceps or clamp can be electrically isolated towards the outside in a further advantageous configuration.
[0038] Moreover, the means for supplying a fluid 102 with a correspondingly lower pressure of the fluid jet can also be used for injection or rinsing. Depending on the application, HF electrode 103 can be formed as a needle, hook, spatula, hemisphere, disc or in any other advantageous form. Moreover, HF-electrode 103 can be integrated into rigid jaw part 101 such that it is movable relative to a longitudinal axis of the rigid jaw part. Multifunction device for surgery 10 can furthermore be formed as a rigid or flexible instrument.
[0039] A further exemplary embodiment of the invention is shown in FIGS. 3 , 4 and 5 . This exemplary embodiment is particularly suitable for precise separation of tissue such as for example, in the case of partial liver resections. At least one outlet 204 of a supply means 202 for a fluid is arranged on an inside of rigid jaw part 201 which is opposite movable jaw part 200 such that at least one fluid jet 2 can be discharged in the direction of movable jaw part 200 with suitable pressure. In use, the open multifunction device for surgery 20 is moved with a sliding movement in the direction of the tissue and the tissue is separated by the at least one fluid jet. Outlets 204 are arranged in a recess 203 of rigid jaw part 201 in order to prevent blocking by the tissue. Movable jaw part 200 can also act as protection for tissue in the immediate vicinity against fluid jets 2 which are discharged with high pressure and thereby prevent a perforation of in-situ tissue parts. The fluid jet impacting on the movable jaw part is drained off by recess 205 ( FIG. 5 ). FIG. 4 shows an embodiment with an outlet 204 a which is displaceable relative to a longitudinal axis of rigid jaw part 102 a.
[0040] The exemplary embodiment shown in FIG. 6 shows a multifunction device for surgery 30 with biopsy forceps specially formed for biopsy and which includes a rigid jaw part 301 and a movable jaw part 300 . A supply means 302 for a fluid jet of a fluid (e.g., NaCl solution) is integrated in rigid jaw part 301 . End piece 302 a of supply means 302 protrudes out of rigid jaw part 302 , whereby a circular disc-shaped monopolar electrode 303 is formed at the end of end piece 302 a . The monopolar electrode at the end of end piece 302 a may also have any other shape which is advantageous for HF cutting. The function of the gripping mechanism, which is known per se, of the biopsy forceps is, in this case, marked by arrows. The hidden parts of the gripping mechanism are shown by dashed lines. The exemplary embodiment according to the invention shown in FIG. 6 has the advantage that tissue parts can be selectively separated by HF or water jet surgery and thereafter immediately received with jaw parts 300 , 301 of biopsy forceps 30 and transported away. In the case of low current strengths, monopolar electrode 303 could also be used for coagulation.
[0041] A further exemplary embodiment of the invention is shown in FIG. 7 . Movable jaw part 400 is prestressed by a spring element 404 such that it is held open. Furthermore, FIG. 7 shows a section through a rigid jaw part, whereby a supply means 402 and a nozzle 405 formed at the end of supply means 402 are integrated into the rigid jaw part 401 for forming a fluid jet. Rigid and movable jaw parts, 401 , 400 are formed as bipolar electrodes for the coagulation of tissue and can also be used as HF cutting electrodes in the case of a corresponding current strength.
[0042] It should be pointed out here that all the above described parts and in particular the details illustrated in the drawings are essential for the invention alone and in combination. Adaptations thereof are the common practice of persons skilled in the art.
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A multifunction device for endoscopic surgery including a supply means for the supply of at least one fluid and forceps or a clamp which comprise forceps-shaped electrodes with jaw parts for high-frequency surgery. The supply means is formed to dissect tissue by means of a fluid jet at or in a jaw part of the forceps or clamp. The multifunction device is one for both water jet surgery and high-frequency coagulation and/or cutting that occupies no more space than a conventional high-frequency instrument or conventional forceps or clamps.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation-in-part of co-pending application Ser. No. 11/677,412, filed Feb. 21, 2007.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is generally related to the field of food processing, and, more specifically, to a batter applicator with an adjustable tilt control for a submerger or coating mechanism.
[0004] 2. Description of the Related Art
[0005] A batter applicator is used to coat food products in a controlled fashion so as to provide a uniform coating for a wide range of batter viscosities. Batter applicators may be employed to apply batter to many types of food products, e.g., chicken, vegetables, etc. Typically, the food is run through the batter applicator device wherein the food is submerged in a tank of batter or passed through a curtain of batter as it passes through the batter applicator. The purpose of the submerger and the curtain of batter is to insure that the food material is thoroughly coated with the batter.
[0006] In some cases, it is desirable to change the spacing between the main batter tank and the submerger or mechanism used to generate the curtain of batter. For example, such adjustments may be made due to processing different types of food of differing size and shape and/or using different types of batter, perhaps with differing viscosities. In prior art batter application devices, such spacing adjustments were typically accomplished by manually removing or loosening four bolts (or other mechanical fasteners) that supported the submerger or curtain generating mechanism and vertically repositioning the submerger or curtain generating device. Thereafter, the four bolts had to be re-inserted and/or retightened. Such a system for achieving the desired spacing was difficult for many reasons. For example, such a system required the machine operator to have and keep up with a separate tool for adjusting the bolts. The operator also had to move from side to side of the machine to make the necessary adjustments. Additionally, maintaining the submerger or curtain device level was difficult as all four bolts had to be adjusted equally. Moreover, using the prior art machine, such spacing adjustments were difficult to make while the machine was in use.
[0007] The present invention is directed to an apparatus for solving, or at least reducing the effects of, some or all of the aforementioned problems.
SUMMARY OF THE INVENTION
[0008] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.
[0009] In one illustrative embodiment, a batter applicator with an adjustable coating mechanism is disclosed which comprises a frame, a main batter tank, a structure comprising at least one of a submerger and an overflow structure that is adapted to be positioned proximate the main batter tank and actuatable means for tilting the structure relative to a reference horizontal surface.
[0010] In another illustrative embodiment, the batter applicator comprises a frame, a main batter tank, a structure comprising at least one of a submerger and an overflow structure that is adapted to be positioned proximate the main batter tank and a lifting device comprising a plurality of lift pins that are adapted to adjust the tilt of the structure relative to a reference horizontal surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:
[0012] FIG. 1 is a perspective view of one illustrative embodiment of a batter applicator in accordance with the present invention;
[0013] FIGS. 2A-2B are perspective side views of the main tank and frame of the illustrative batter applicator disclosed herein;
[0014] FIG. 3 is a perspective view of an illustrative submerger that may be employed with various embodiments of the present invention;
[0015] FIGS. 4A-4D are various views of an illustrative lifting device that may be employed with the present invention; and
[0016] FIGS. 5A-5C are various views of another illustrative lifting device that may be employed with the present invention.
[0017] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Illustrative embodiments of the present subject matter are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
[0019] The present subject matter will now be described with reference to the attached figures. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.
[0020] FIGS. 1 and 2 A- 2 B are perspective views of an illustrative batter applicator apparatus 10 that may be employed in the food industry to apply batter to a food product. As will be recognized by those skilled in the art after a complete reading of the present application, the devices disclosed herein may be employed with a variety of different foods, e.g., poultry and vegetables, and thus should not be considered as limited to use with any particular type of food. Moreover, the batter applicator 10 described herein may be employed to apply a variety of different batters to different food products.
[0021] The apparatus 10 generally comprises a frame 12 , a food inlet 14 , a food outlet 16 and a control panel 18 . The apparatus 10 further comprises a main batter tank 19 , an overflow tank 20 , a conveyor 22 , an electric motor 24 to drive the conveyor 22 and a pump 25 .
[0022] In the illustrative embodiment depicted in FIG. 1 , the apparatus 10 further comprises an overflow structure 26 that is adapted to provide a curtain of batter material through which the food must pass as it moves from the food inlet 14 to the food outlet 16 . The overflow structure 26 comprises a generally plate-like body 28 , associated piping 30 , and support brackets 27 coupled to the body 28 . The overflow structure 26 further comprises a batter inlet 31 . In operation, the pump 25 is used to supply batter to the batter inlet 31 of the overflow structure 26 through a hose (not shown) that is coupled to both the pump 25 and the batter inlet 31 . Batter is supplied to the pump 25 via a hose (not shown) coupled to the overflow tank 20 .
[0023] Also depicted in FIG. 1 is a support bracket 29 that is operatively coupled to or engages a plurality of lift pins 56 . The operation of the lift pins 56 will be described later. The upper surface 23 of the support bracket 29 is adapted to engage the underside of the support bracket 27 . The overflow structure 26 further comprises a plurality of guides 34 having a guide hole 36 formed therein. The guides 34 are integrally formed with or coupled to the plate-like body 28 . The apparatus 10 further comprises a plurality of guide pins 32 attached to the frame 12 . As will be described more fully below, the overflow structure 26 is free to move vertically relative to the frame 12 of the apparatus 10 . During such vertical movement, the guide pines 32 and the guides 34 maintain the overflow structure 26 in its proper horizontal location.
[0024] Of course, those skilled in the art will understand that the particular details of the overflow structure 26 is provided by way of example only. Many variations as to the shape and configuration of the overflow structure 26 are possible without deviating from the scope of the present invention.
[0025] The illustrative batter applicator 10 depicted in FIG. 1 is provided with the overflow structure 26 and is designed to provide a curtain of batter as food passes through the apparatus 10 . However, as will be recognized by those skilled in the art after a complete reading of the present application, the device disclosed herein may be employed to raise or lower other structures associated with a batter applicator 10 . For example, FIG. 3 depicts an illustrative submerger device 40 that may be employed with the device disclosed herein. Such submerger devices 40 are well known to those skilled in the art and may have a variety of shapes and configurations. Thus, the details of the illustrative submerger device 40 depicted herein should not be considered a limitation of the present invention. In some cases, multiple structures, such as the overflow structure 26 and the submerger device 40 , may be raised or lowered as a single unit, or they may be raised or lowered independently.
[0026] In general, the purpose of the submerger device 40 is to insure that food is submerged in the batter in the main batter tank 19 as the food progresses through the batter applicator 10 . The illustrative submerger device 40 depicted herein comprises a frame 42 that is comprised of flanges 43 and a plurality of guide holes 46 formed in the flanges 43 . The guide holes 46 are adapted to guidingly engage the guide pins 32 (see FIG. 1 ) on the frame 12 of the batter applicator 10 . The submerger device 40 further comprises an electric motor 47 adapted to drive a plurality of drive sprockets 48 . The submerger device 40 further comprises a plurality of idler rollers 49 . In operation, a belt (not shown) is positioned around the idler rollers 49 and drive sprockets 48 and rotated as food passes through the batter applicator 10 . This action insures that food is submerged in the main batter tank 19 and is fully coated with batter.
[0027] FIGS. 4A-4D are various views of the lift device 50 of the present invention. The lift device 50 generally comprises a frame 51 of various structural members 53 , a plurality of lift pins 56 , having end surfaces 70 , an actuator device 52 , e.g., a hand wheel, a shaft 55 , a gear box 57 and a screw lift assembly 58 . Of course, the size, shape and configuration of the various components of the lift device 50 may vary depending upon the particular application. Thus, the illustrative details depicted herein for the lift device 50 should not be considered a limitation of the present invention. In one illustrative embodiment, the gear box 57 may be a miter gear box having a 1:1 gear ratio. Of course, gear boxes with different gear ratios may be employed. The lift pins 32 may have any desired diameter, e.g., 0.5-1.5 inches.
[0028] As shown in FIGS. 4B and 4C , the gear box 57 and shaft 55 are operably coupled to the frame 12 . For example, the gear box 57 may be fastened to a support member 12 A of the frame 12 by a plurality of mechanical fasteners. One end of the shaft 55 may be coupled to the frame 12 via a bearing flange 59 , which allows the shaft 55 to rotate therein.
[0029] As shown in FIG. 4D , the center structural member 53 C of the lifting device 50 may be operatively coupled to the screw lift assembly 58 via a threaded block 72 . The threaded block 72 is coupled to the center structural member 53 C by a plurality of mechanical fasteners 74 , e.g., screws, bolts, etc. As the screw lift assembly 58 is rotated, via the actuator device 52 and gear box 57 , the frame 51 travels up or down the screw lift assembly 58 via the engagement of the threaded block 72 . The movement of the frame 51 causes a corresponding movement of the lift pins 56 . It should be understood that although an illustrative hand wheel is depicted, the actuator device 52 may be a portion of a device or structure that is capable of causing movement of the lift pins 56 .
[0030] In operation, the lift device 50 is used to raise or lower a structure, e.g., the overflow structure 26 or the submerger 40 , relative to the main batter tank 19 of the batter applicator 10 . In some embodiments, the end surfaces 70 of the lift pins 32 may directly engage some portion of the structures to be moved relative to the main batter tank 19 , e.g., the end surfaces 70 may engage the underside of the flanges 43 of the submerger 40 . In the illustrative example depicted in FIG. 1 , the end surfaces 70 of the lift pins 32 engage or are attached to the bottom surface 29 A of the support brackets 29 that, in turn, engage the brackets 27 of the overflow structure 26 . The lift pins 56 extend through openings 39 (see FIGS. 2A-2B ) formed in the frame 12 of the batter applicator 10 . Depending upon the particular application, the end surface 70 of the lift pins 56 may only engage a portion of the structure to be lifted, or they may actually be coupled to another structure, such as the structure 29 depicted in FIG. 1 . Ultimately, the lift pins 56 may directly engage the member to be lifted (as in the illustrative example employing the submerger 40 ) or they may indirectly engage the structure to be lifted via a variety of intermediate members, such as the bracket 29 that engages the underside of the flanges 27 on the overflow structure 26 as shown in FIG. 1 . In the embodiment where the submerger device 40 is employed, the end surface 70 of the lift pins 56 is adapted to engage the underside of the flanges 43 of the frame 42 . Thus, when reference is made to the lift pins 56 being operatively engaged or operatively coupled to another structure, it should be understood that such language is intended to cover direct coupling between the lift pins 56 and such a structure or indirect coupling via one or more intermediate structures between the lift pin 56 and such a structure.
[0031] In operation, an operator of the batter applicator 10 may raise or lower a structure, e.g., the overflow structure 26 or the submerger 40 , or a combination of both, relative to the main batter tank 19 by rotating the hand wheel 52 . A measuring device or bracket 33 (see FIGS. 1 and 4B ) is provided to accurately determine the vertical position of the lifted structure relative to some point of reference, e.g., the bottom of the main batter tank 19 . As the hand wheel 52 is rotated, the frame 51 and lift pins 56 travel upward on the screw lift 58 . In turn, the end surfaces 70 of the lift pins 56 operative engage and cause upward movement of the desired device or structure, e.g., the overflow structure 26 or the submerger 40 . The guide pins 32 and guards or openings 34 , 46 act to maintain the moved structure in the desired horizontal position.
[0032] FIGS. 5A-5C are various views of another lift device 50 A of the present invention. The lift device 50 A provides additional capabilities relative to the lift device 50 shown in FIGS. 4A-4D . The lift device 50 A contains many structural similarities to the lifting device 50 . Thus, only a brief review of some aspects of the lift device 50 A will be described, with the understanding that like reference numbers refer to similar structures. The lift device 50 A generally comprises a frame 51 of various structural members 53 , a plurality of lift pins 56 A, having end surfaces 70 , an actuator device 52 , e.g., a handle, a shaft 55 , a gear box 57 and a screw lift assembly 58 . The lift pins 56 A comprise a threaded end 80 , a handle 81 , a stop nut 82 with tabs 85 , and a fixed nut 83 . The threaded end 80 of the lift pins 56 A extend through one or more of the structural members 53 of the frame 51 . An indicator pin 84 is coupled to a portion of the frame 51 . A measuring device or bracket 33 (see FIG. 5C ) is coupled directly or indirectly to the frame 12 or some other desired point of reference. Of course, the size, shape and configuration of the various components of the lift device 50 A may vary depending upon the particular application. Thus, the illustrative details depicted herein for the lift device 50 A should not be considered a limitation of the present invention. In one illustrative embodiment, the gear box 57 may be a miter gear box having a 1:1 gear ratio. Of course, gear boxes with different gear ratios may be employed. The lift pins 56 A may have any desired diameter, e.g., 0.5-1.5 inches.
[0033] The gear box 57 and shaft 55 may be operably coupled to the frame 12 as previously described for the embodiment shown in FIGS. 4A-4D . For example, the gear box 57 may be fastened to a support member 12 A of the frame 12 by a plurality of mechanical fasteners. One end of the shaft 55 may be coupled to the frame 12 via a bearing flange 59 , which allows the shaft 55 to rotate therein.
[0034] The center structural member 53 C of the lifting device 50 A may be operatively coupled to the screw lift assembly 58 , as previously described. The threaded block 72 is coupled to the center structural member 53 C by a plurality of mechanical fasteners 74 , e.g., screws, bolts, etc. As the screw lift assembly 58 is rotated, via the actuator device 52 and gear box 57 , the frame 51 travels up or down the screw lift assembly 58 via the engagement of the threaded block 72 . The movement of the frame 51 causes a corresponding movement of the lift pins 56 A. It should be understood that although an illustrative handle is depicted, the actuator device 52 may be a portion of a device or structure that is capable of causing movement of the lift pins 56 .
[0035] The embodiment depicted in FIGS. 5A-5C may be used as described previously with respect to the lift device 50 depicted in FIGS. 4A-4D . However, unlike the lift device 50 depicted in FIGS. 4A-4D , in the lift device 50 A depicted in FIGS. 5A-5C , the height or length of each of the lift pins 56 A is independently adjustable due to the addition of the threaded end 80 and its interaction with the other components described previously. With the individually adjustable lift pins 56 A, the tilt or level of a structure, e.g., the overflow structure 26 or the submerger 40 , relative to a reference horizontal plane may be adjusted. For example, by lowering or raising the front two lift pins 56 A, the overflow structure 26 or the submerger 40 may be made to tilt forward or rearward, respectively, relative to any reference horizontal surface. The length of the pins 56 A may be employed to cause the engaged structure to tilt from side to side as well, if desired. By controlling the length of the lift pins 56 A, the engaged structure, e.g., the overflow structure 26 or the submerger 40 , may be tilted from front to back, from side to side, or a combination thereof. In one particular example, the lift pins 56 A may be used to adjust the tilt of such a structure so that more or less batter is applied to the food as it passes through the machine. As with the previous embodiment depicted in FIGS. 4A-4D , the lift device 50 A depicted in FIGS. 5A-5C may also be uniformly raised by raising the frame 51 . In some applications, only a single adjustable length lift pin 56 A may be employed to control the tilt of the structure. For example, three pins may be employed to define a plane, e.g., such pins may be spaced in a triangular pattern, and only one of the pins may have an adjustable length like that described for the pins 56 A. Thus, various configurations are possible with the present invention.
[0036] The length of the pins 56 A may be readily adjusted. The fixed nut 83 may, in one embodiment, be welded to the structural member 53 . The stop nut 82 may be loosened by engaging the tabs 85 . Thereafter, the effective length of the lift pin 56 A, e.g., the distance between the end surface 70 and the top of the frame 51 , may be adjusted by rotating the lift pin 56 A, via the handle 81 , within the fixed nut 83 . The indicator pin 84 travels within the slot 86 within the measuring device or bracket 33 , i.e., a length or tilt indicator. In one embodiment, each of the lift pins 56 A may have an associated measuring device or bracket 33 positioned adjacent the lift pin 56 A. The position of the indicator pin 84 within the slot 86 may be indicative of the absolute or relative effective length of the lift pins 56 A and/or the relative or absolute position of the ends 70 . Once one or more of the lift pins 56 A are set at their desired height, the stop nut 82 may be tightened.
[0037] In operation, the lift device 50 A may be used to raise or lower a structure, e.g., the overflow structure 26 or the submerger 40 , relative to the main batter tank 19 of the batter applicator 10 . The lift device 50 A may also be employed to tilt or control the tilt of an engaged structure, e.g., the overflow structure 26 or the submerger 40 . In some embodiments, the end surfaces 70 of the lift pins 56 A may directly engage some portion of the structures to be moved or tilted relative to the main batter tank 19 , e.g., the end surfaces 70 may engage the underside of the flanges 43 of the submerger 40 . The end surfaces 70 of the lift pins 56 A may engage or be attached to the bottom surface 29 A of the support brackets 29 that, in turn, engage the brackets 27 of the overflow structure 26 . The lift pins 56 A may extend through openings 39 (see FIGS. 2A-2B ) formed in the frame 12 of the batter applicator 10 . Depending upon the particular application, the end surface 70 of the lift pins 56 A may only engage a portion of the structure to be lifted, or they may actually be coupled to another structure, such as the structure 29 depicted in FIG. 1 . Ultimately, the lift pins 56 A may directly engage the member to be lifted (as in the illustrative example employing the submerger 40 ) or they may indirectly engage the structure to be lifted via a variety of intermediate members, such as the bracket 29 that engages the underside of the flanges 27 on the overflow structure 26 as shown in FIG. 1 . In the embodiment where the submerger device 40 is employed, the end surface 70 of the lift pins 56 A is adapted to engage the underside of the flanges 43 of the frame 42 . Thus, when reference is made to the lift pins 56 A being operatively engaged or operatively coupled to another structure, it should be understood that such language is intended to cover direct coupling between the lift pins 56 A and such a structure or indirect coupling via one or more intermediate structures between the lift pin 56 and such a structure.
[0038] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. For example, the process steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below.
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A batter applicator with an adjustable coating mechanism is disclosed which includes a frame, a main batter tank, a structure comprising at least one of a submerger and an overflow structure that is adapted to be positioned proximate the main batter tank and actuatable means for tilting the structure relative to a reference horizontal surface.
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CROSS-REFERENCE TO THE RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/456,982, filed Jul. 12, 2006, which is a continuation of International Application No. PCT/CN2005/000051, filed Jan. 13, 2005, which claims the benefit of Chinese Patent Application Nos. 200410000964.2, filed Jan. 17, 2004, and 200410073713.7, filed Sep. 2, 2004, all four of which are hereby incorporated by reference in their entireties.
FIELD OF THE TECHNOLOGY
[0002] The present invention relates to handset technology, more particularly to a method for obtaining the direction of a target location through a handset.
BACKGROUND OF THE INVENTION
[0003] At present, handsets such as cell phone and Personal Digital Assistant (PDA) are more and more popular and have become people's indispensable tools to carry along. Accordingly, people are considering whether it is possible to configure more functions in the handset so that the handset can provide better services for users.
[0004] A scheme to equip the handset with a direction recognition function has been put forward, which is mainly to configure a digital compass module inside the handset to obtain geomagnetism direction data and configure a geomagnetism direction display module to convert the geomagnetism data into an image displaying data and display the image according to the image displaying data on a screen of the handset. According to this patent application, the handset is capable of distinguishing directions, in other words, a user can determine on a geomagnetism direction through this handset.
[0005] However, the user may not be satisfied with the geomagnetism direction determined by the handset. He may also want to further know the direction from his current location to a certain place. A typical example is: when exploring outside, the user needs to frequently acquire the direction from the current location to a target location. Islamic people need to frequently make pilgrimage in the direction of Mecca. It is very easy to distinguish the direction when it is clear or at a familiar place, but very difficult when it is cloudy or at an unfamiliar place. Although the compass can indicate the north direction for the user, it cannot tell the user the direction from the current location to Mecca.
[0006] So far, there is no scheme for determining the direction of a certain site through a handset for the user.
SUMMARY OF THE INVENTION
[0007] Therefore, the present invention provides a handset configured to implement a method for obtaining the direction of a target location, so that the user can acquire the direction of the location through the handset. The handset configured to implement the method includes the following steps: (1) the handset obtains geographical information of a current location and that of the target location, and figuring out a geographical meridian line of the current location; (2) the handset determines a direction from the current location to the target location according to the geographical information of the current location and that of the target location, and determines a first included angle between the direction from the current location to the target direction and the geographical meridian line of the current location, and then determines a second included angle of the geographical meridian line of the current location displayed on the screen of the handset; and (3) according to the first included angle and the second included angle, the handset figures out a display direction from the current location to the target location, and displays the display direction on the screen.
[0008] In the present invention, through the handset, the user can obtain geographical information of the current location and that of the target location, as well as obtain geographical meridian line of the current location, determine a first included angle between the direction from the current location and the target location and the geographical meridian line, determine a second included angle between geographical meridian line and the screen's vertical ordinate, determine a display angle between the direction of the current location to the target location and the screen's vertical ordinate according to the above-mentioned first and second included angles, and then display direction of the target location in terms of the current location according to the display angle, so that the user can conveniently confirm the direction of the target location in terms of current location through the handset at any time.
[0009] The scheme of the present invention can implement obtaining geographical information through GPS.
[0010] Furthermore, the scheme of the present invention can also preset relevant geographical information inside the handset or at the network side, for instance, presetting mapping relation between geographical identification and geographical information inside the handset and/or the network side, so that the handset can obtain corresponding geographical information according to geographical identification directly through the mapping relation stored in this handset or the network side, comparing with the process of adding a GPS module at the terminal, this process can satisfy low-side user's requirement as well as save equipment cost.
[0011] In the scheme of the present invention, the handset can determine the direction of a certain location from the current location by obtaining geographical information of the certain location, determining geographical meridian line corresponding to this location, direction of this geographical meridian line displayed on the screen and geographical information of the target location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a flowchart of an embodiment according to the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] According to an embodiment of the present invention, the method for obtaining the direction of the target location through a handset comprises the steps of determining a geographical meridian line of the current location, calculating a first included angle between the geographical meridian line and a circular art that takes the earth's core as the centre and goes through the current location and the target location, which can be also called the included angle between the geographical meridian line and the direction from the current location and the target location, and figuring out a second included angle between the geographical meridian line and a vertical ordinate of the handset screen, determining a display angle between the direction from the current location to a target location and the vertical ordinate of the handset screen according to the above-mentioned first and second included angles, and displaying the direction from the current location to the target location on the handset screen according to the display angle.
[0014] The present invention will be further illustrated in detail hereinafter with reference to accompanying drawings and specific embodiments.
[0015] With reference to FIG. 1 , a preferred embodiment of the present invention includes the following steps:
[0016] Step 101 : when the direction of a certain target location is needed, the user obtains geographical information of the current location and that of the target location through the handset.
[0017] The geographical information hereby should include geographical coordinate information (Gs), such as the longitude and the latitude of a location, so that the handset can perform a corresponding calculation accordingly.
[0018] The handset can obtain geographical information of the current location through GPS, for example, the handset can obtain geographical information of the current location through a GPS module configured inside the handset. As to mobile terminal equipment, the handset can obtain geographical information of the current location through a positioning function of the network side.
[0019] Since configuring a GPS module inside a handset will greatly increase the cost of the handset, an alternate choice is to establish a mapping relation table between geographical identifications and geographical coordinates inside the handset, so that the handset can find out a corresponding geographical coordinate to a geographical identification such as a structure's name or label, a street name, a park name and so on, according to the mapping relation table. The geographical identifications stored in the mapping relation table can also be relevant information of signal cells in a wireless communication system, for instance, the current location area or a cell label of the mobile terminal. In this way, while the handset is roaming, it can obtain the corresponding location area or cell label information and then obtain the corresponding geographical information from the mapping relation table according to the label information. Of course, if the handset can obtain an identifier of the access equipment in wireless communication system, such as the label of Access Point (AP) in Wireless Local Area Network (WLAN) or the information of Base Station (BTS) in wireless communication system, the label information can also be taken as the geographical identification information.
[0020] In practice, the mapping relation table of geographical information can be set for each city at the network side, wherein the table includes mapping relation between geographical identifications and geographical coordinates and can be called a mapping relation bank, so that the handset can obtain corresponding geographical coordinate information according to the geographical identification from the mapping relation bank at network side. Specifically, this procedure can include: the handset sends a short message including a geographical identification to network side equipment that stores the mapping relation bank, the network side equipment searches for the corresponding geographical coordinate in the stored mapping relation bank according to the geographical identification and sends the geographical coordinate information to the handset by a short message. The network side equipment can further add a command code to the short message to be sent to the handset, so that the handset can judge according to this command code whether the received short message carries the geographical coordinate information. Of course, the handset can also directly send a command to network side equipment that stores the mapping relation bank. The network side equipment determines the corresponding geographical identification information according to the current roaming information such as located area and cell, obtains the corresponding geographical information from the stored mapping relation bank according to the geographical identification information and takes this geographical information as that of the current location of the handset. The cost of the handset can be reduced through the above-illustrated process.
[0021] A special service command can also be set for the network side, so that the handset can obtain the corresponding geographical information from the network side by sending a service command that includes the geographical identification to the network side.
[0022] The user can also manually input a piece of geographical information to the handset. Of course, if the user knows the geographical information of the current location, the user can also input this geographical information in advance. This geographical information can also be transmitted by other users.
[0023] Geographical information of the target location obtained by the handset can be input by the user in advance or be transmitted by other users or be preset by the manufacturer of the handset. Similar to the procedure of obtaining the geographical information of the current location, mapping relations can be stored inside the handset or at the network side, so that the handset can obtain the corresponding geographical information by interacting with this mapping relation bank, for instance, by setting the mapping relation between Mecca and geographical location in the mapping relation bank at network side. The handset can obtain the corresponding geographical information according to the geographical name Mecca.
[0024] In addition, whether to obtain the geographical information of the current location or that of the target location, it is useful to store mapping relations between some frequently used geographical identifications and geographical information inside the handset. For instance, as to the current location, since the user's working place and living place are usually constant, the mapping relation between geographical information and relevant information of the handset such as resident cell and adjacent cells etc., can be set inside the handset. For example, the user's current living place and working place are usually in two different cells or in the same location area, the user can take these two different cells or this location as the resident cells. As to the target location, since the user usually needs to search for several target locations constantly, mapping relations between geographical information and these several target locations can be set inside the handset. Of course, mapping relations between geographical information and geographical identifications of all possible target locations can also be set at the network side. Based on such setting, while needing to acquire corresponding geographical information, the handset can judge if this geographical information is already stored inside this handset firstly, if this geographical information is not stored therein, the handset can then search for this geographical information at the network side. Through such setting, the handset is guaranteed to obtain relevant geographical information while maintaining less data information, so as to prevent accessing the network as much as possible and therefore save the accessing cost.
[0025] Step 102 : the handset finds out the geographical meridian line of the current location of the handset.
[0026] The geographical meridian line of the handset's current location can be determined according to the location and geographical coordinate of the earth's two poles: firstly determining the circle whose center is the core of earth and that goes through the earth's two poles as well as the current location, and then taking the semicircle determined by the current location and the earth's two poles as the geographical meridian line of the current location of Gs.
[0027] Step 103 : according to the handset's geographical information of the current location, geographical information of the target location and geographical meridian line of the current location, the handset determines the direction from the current location to the target location and figures out a first included angle, the first included angle is the included angle between the direction from the current location to the target location and the geographical meridian line.
[0028] While calculating the first included angle, it needs to determine the direction from the handset's current location to target location for the first place. Specifically speaking, according to geographical information of the handset's current location and that of the target location as well as according to coordinate information of the earth's core, a circular section on the earth is uniquely determined, therein the handset's current location and target location divide circumference of the circular section into two circular arcs, whose lengths can be calculated according to geographical coordinates of the handset's current location and that of target location, based on the shorter circular arc, the direction from the handset's current location to the target location along this shorter circular arc is taken as a positive direction of the target location in terms of the current location. Accordingly, the direction from the handset's current location to target location along the longer circular arc is taken as a negative direction of the target location in terms of the current location.
[0029] Of course, the positive direction and negative direction from the handset's current location to target location can also be obtained by other calculation methods.
[0030] Step 104 : the handset determines a second included angle of the geographical meridian line of the current location displayed on the handset's screen.
[0031] Since the direction of the geographical meridian line can be considered the same as that of geomagnetism direction, the second included angle can be determined by calculating the included angle between the geomagnetism direction and the screen's vertical ordinate. Thus, according to the second included angle as well as the first included angle, the handset can determine a display angle between the screen's vertical ordinate and the direction from the current located direction to the target location.
[0032] Hereby, the separation between the geomagnetism direction and the screen's vertical ordinate can be figured out by setting a digital compass in the handset.
[0033] Step 105 : according to the first included angle and the second included angle determined in step 103 and step 104 , the handset obtains the display angle and displays the direction from the current location to the target location displayed on the screen on the screen according to the display angle.
[0034] Specifically speaking, according to the included angle between the geographical meridian line and the direction from the current located direction to the target location, as well as the included angle between the geographical meridian line and the screen's vertical ordinate, the handset determines the display angle between the screen's vertical ordinate and the direction from the current located direction to the target location. After that, the handset displays the direction according to the display angle between the screen's vertical ordinate and the direction from the current located direction to the target location.
[0035] While the handset is used for displaying the direction, a direction-indicating pointer can be preset in the handset, and the direction-indicating pointer can display the direction of the target location in terms of the current location by taking the screen's vertical ordinate as reference frame. For display convenience, a circle can also be set in the handset, fixed end of the pointer is located at the circle's center and the movable end directs to the circle's circumference. Meanwhile, four direction identifiers, namely the east, west, south and north, can also be set in the handset, and the four direction identifiers can be correspondingly displayed on this circle's circumference according to the above-mentioned second included angle between the screen's vertical ordinate and the direction of the geomagnetism. And then the direction of the target location can be indicated by the direction-indicating pointer, direction identifiers and circle thereof.
[0036] Besides, the current scheme of the present invention can further figure out the distance from current location of the handset to the target location so that the user can acquire more information. The distance can be in just the positive direction, while the distance in the negative direction can also be provided.
[0037] The above illustration is just a preferable embodiment of the present invention and is not used for confining or limiting the protection scope of the present invention.
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The present invention discloses a method for obtaining the direction of a target location through a handset, which includes: the handset obtains geographical information of a current location and that of the target location, determines a geographical meridian line of the current location and a angle of this geographical meridian line displayed on the screen of the handset; the handset determines the direction from the current location to the target location according to geographical information of the current location and that of the target location, determines an included angle between this direction and the geographical meridian line. According to the included angle and that of the geographical meridian line displayed on its screen, the handset determines the direction displayed on the screen of the handset from the current location to the target location, and displays the direction of the target location on the screen according to the displayed direction. The present invention solves the problem that existing handsets cannot provide the direction of the target location for the user. The user can confirm the direction of the target location through the handset.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to building materials and systems and, in particular, to an acoustical panel for constructing monolithic ceilings and interior walls.
PRIOR ART
[0002] Sound absorption in buildings is commonly achieved with ceiling tiles carried on a suspended grid. Generally, the sound absorbing capacity of the tiles is achieved by material selection and/or characteristics of the room facing surface. Ceiling tile installations have the advantage of affording ready access to the space above the ceiling, but the divisions between the tiles, even when the grid is concealed, remain visible. Architects and interior designers have long sought a monolithic, texture free look in an acoustical ceiling particularly when there is no expected need for access to the space above the ceiling. Ordinary gypsum panel drywall ceiling construction does not achieve a sufficiently high noise reduction coefficient (NRC) that would qualify as acoustical. Perforated gypsum panels may achieve an acceptable NRC level but they are not monolithic in appearance.
SUMMARY OF THE INVENTION
[0003] The invention resides in the discovery that ordinary gypsum panels, such as drywall sheets, can be modified to construct an acoustical ceiling or wall with a monolithic plain face and surprising acoustical properties. Such panels can achieve an NRC of 0.70 or more.
[0004] In accordance with the invention, the gypsum core is made with a multitude of perforations or holes distributed throughout its planar area. The perforations or holes are restricted, preferably with a painted non-woven porous scrim fabric or veil at the front face and, optionally, a non-woven porous acoustical fabric at the back side.
[0005] The gypsum panel can be made, for example, by perforating standard sheets of drywall and thereafter covering the perforated sides of the sheet with additional laminated sheets or layers. These perforating and laminating steps can be performed by the original manufacturer of the drywall sheets or by a separate entity independent of the original drywall manufacturer.
[0006] Variations in the construction of the gypsum panel are contemplated. Common among these variations is a panel with a perforated gypsum core and with a face covered by a structure that is porous while appearing essentially imperforate to the unaided eye.
[0007] The disclosed gypsum-based panels can be installed in the same manner or a like manner as ordinary drywall. For ceiling applications, the acoustical panels of the invention can be screwed to a conventional drywall suspension system of grid tees or “hat channels” carried on black iron channels typically used in commercial applications or they can be attached to wood framing more often used in residential construction. Acoustical walls can be built by attaching the inventive acoustical panels to vertical studs, serving as spaced support elements. It will be seen that the inventive panels can be readily taped and painted like ordinary drywall, using the same or similar materials, equipment, tools and skills, to produce a smooth monolithic ceiling or wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a fragmentary, schematic, isometric view of a monolithic acoustical ceiling;
[0009] FIG. 2 is a fragmentary, cross-sectional view, on an enlarged scale, of the monolithic ceiling; and
[0010] FIG. 3 is a fragmentary, enlarged, cross-sectional view of a modified form of an acoustical panel of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] Referring now to FIG. 1 , there is shown a schematic partial view of an acoustical monolithic ceiling installation 10 . Portions of layers of the ceiling 10 are peeled away to reveal constructional details. The ceiling 10 is a suspended system including a drywall grid 11 , known in the art, comprising main tees 12 spaced on 4 ft. centers and intersecting cross tees 13 spaced on 16 in. or 2 ft. centers. Dimensions used herein are typically nominal dimensions and are intended to include industry recognized metric equivalents. The main tees 12 , to which the cross tees 13 are interlocked, are suspended by wires 14 attached to a superstructure (not shown). A perimeter of the grid 11 is conventionally formed by channel molding 15 secured to respective walls 16 .
[0012] Acoustical panels 20 are attached to the lower sides of the grid tees 12 , 13 with self-drilling screws 21 . The illustrated acoustical panels are 4 ft. by 8 ft. in their planar dimensions, but can be longer, shorter and/or of different width as desired or practical. The size of the panel 20 and spacing of the grid tees 12 and 13 , allows the edges of the panel to underlie and be directly attached to a grid tee, assuring that these edges are well supported.
[0013] Referring to FIG. 2 , the acoustical panel 20 of the invention is characterized with a perforated gypsum core 24 . One method of providing the core 24 is to modify a standard commercially available sheet of drywall by perforating it through a front paper face 23 , the gypsum core 24 , and a rear paper side or face 25 . Perforations 28 can be formed by drilling, punching, or with other known hole-making techniques. The perforations 28 are preferably uniformly spaced; by way of an example, the perforations can be round holes of 8 mm diameter on 16 mm centers. This arrangement produces a total area of the perforations substantially equal to 20% of the full planar area of a panel 20 . Other hole sizes, shapes, patterns and densities can be used. For example, tests have shown that a hole density of 9% of the total area can achieve good results. Marginal areas, as well as intermediate areas corresponding to centers of support grid, joists, or studs, of a sheet can be left unperforated to maintain strength at fastening points.
[0014] Sheets 29 , 30 are laminated to both full sides of the perforated drywall sheet thereby at least partially closing both ends of the perforations 28 . At a rear side of the drywall, the backer sheet or web 30 is preferably an acoustically absorbent non-woven fabric known in the acoustical ceiling panel art. By way of example, the backer fabric can be that marketed under the trademark SOUNDTEX® by Freudenberg Vliesstoffe KG. It has a nominal thickness of 0.2 to 0.3 mm and a nominal weight of 63 g/m 2 . Specifically, the main components of this non-woven fabric example are cellulose and E-glass with a synthetic resin binder such as polyacrylate, poly(ethylene-CO-vinylacetate). Alternatively, for example, the backer sheet 30 can be a porous paper layer. The sheet 30 can be provided with a suitable adhesive for binding it to the rear paper side 25 of the modified drywall sheet 22 .
[0015] At a front side of the drywall sheet 22 , a sheet or web in the form of a non-woven fabric scrim layer 29 is attached with a suitable adhesive. The facing layer or sheet 29 is porous; a suitable material for this application is that used commercially as a cover or face for conventional acoustical ceiling panels. An example of this type of veil material is that marketed by Owens Corning Veil Netherlands B.V. under the product code A125 EX-CH02. This scrim fabric comprises hydrated alumina fiberglass filament, polyvinyl alcohol, and acrylate copolymer. The unpainted scrim 29 has a nominal weight of 125 g/m 2 and an air porosity, at 100 Pa, of 1900 l/m 2 sec. To avoid blocking the face scrim 29 , the adhesive can be initially applied to the panel or sheet 22 . The facing sheet 29 should be sufficiently robust to withstand field finishing operations described below. It should also be compatible with drywall joint compound or similar material and commercially available paints, typically water-based paints such as that described below.
[0016] The panel 20 with other identical panels is hung on the grid 11 in the same manner as ordinary drywall is installed. Similarly, as shown in FIG. 1 , joints 33 are taped in the same way as regular drywall is taped. Drywall joint compound or similar material 34 is used to adhere a tape or similar material 35 to adjacent margins of two abutting panels 20 by applying it directly to the sheets 29 and over the tape 35 to conceal the tape. Typically, the long edges of the panels 20 are tapered to receive the joint tape 35 below the plane of the major part of the panel faces. The joint compound 34 can be conventional drywall joint compound and the tape 35 can be conventional drywall paper or mesh tape. The screws 21 securing the panels 20 to the spaced support elements 12 , 13 forming the grid 11 are countersunk, as is conventional in drywall construction, and are concealed with joint compound 34 applied with a taping knife or trowel in the same manner as if applied to ordinary drywall. The panels 20 can be adhesively attached to vertical stud supports when constructing a wall. When dry, the joint compound 34 can be sanded or wet sponged to blend it into the plane of the surface of the face sheet 29 .
[0017] After the joint compound 34 has been sanded or sponged smooth, the front sheets 29 and remaining joint compound are painted with a commercially available acoustical paint 31 used for painting acoustical tile. An example of a suitable water-based paint, sometimes referred to as a non-blocking paint, is available from ProCoat Products, Inc. of Holbrook, Me. USA, sold under the trademark ProCoustic. To improve the uniformity of the finished appearance of the ceiling, the taped joints can be covered with strips of the veil fabric 29 , wide enough to cover the joint compound, prior to painting. The paint application should leave as much porosity through the layer 29 as is desired but leave the appearance of an essentially imperforate surface to the unaided eye so that the perforations 28 are not seen. Alternatively, where high NRC is not necessary, satisfactory results can be obtained by using a conventional primer and a coat of interior latex paint 31 to complete the installation of the ceiling 10 . When the term monolithic is used herein, it is to denote that essentially the entire visible surface of a ceiling or wall appears to be a seamless expanse without joints.
[0018] A ½ or ⅝ in. drywall-based panel 20 , having the described perforation arrangement and front and rear sheets 29 , 30 and customary space behind the panel can exhibit NRC values up to and above 0.70, a rating equal to the performance of better-grade acoustical ceiling tile.
[0019] Presently, the preferred characteristics of the gypsum-based core 24 are:
Thicknesses: 0.5-0.625 in. Open area: 9.6-27.7% Hole diameters: 6-12 mm. Hole spacing: 15-25 mm.
[0024] Following are airflow characteristics of the backer layer 30 of the non-woven SOUNDTEX® material described above and the face layer 29 of the non-woven scrim material described above before and after painting with a proprietary acoustical coating and the acoustical ProCoustic coating.
[0000]
Airflow
Airflow
Resistance R
Specific
Resistivity
mks
Airflow
r o
Airflow
P
acoustic
Resistance r
mks
Resistivity
in.
U
in.
v
U
P
ohms,
mks rayls,
rayls/m,
r o
thick
l/min.
H 2 O
mm/s
m 3 /s
Pascal
(Pa · s/m 3 )
(Pa · s/m)
(Pa · s/m 2 )
MPa · s/m 2 )
Backer
0.009
2.00
0.0156
16.4
3.33E−05
3.9
116,574
236
1.09E+06
1.09
Unpainted
0.019
2.00
0.0027
16.4
3.33E−05
0.7
20,176
41
8.47E+04
0.08
Scrim
Painted
0.020
2.00
0.0143
16.4
3.33E−05
3.6
106,859
217
4.26E+05
0.43
Scrim w/
Proprietary
Coating
Painted
0.020
2.00
0.0144
16.4
3.33E−05
3.6
107,606
218
4.29E+05
0.43
Scrim w/
ProCoustic
[0025] The tables printed below show NRC values for the inventive board and boards of other constructions for comparison purposes. As in the preceding table, unless otherwise noted, the backer is the SOUNDTEX® material and the face is the scrim identified above.
[0000]
TEST I:
*Perforated Panel = ⅝ in. FC30 (drywall) with ⅜″ diameter
perforations, 16 mm o.c. spacing - 27.7% open area
NRC
Panel Configuration
Mounting
4FA
NRC
A Perforated panel only
E400
0.1967
0.20
B Panel + backer
E400
0.6572
0.65
BB Panel + backer used as
E400
0.6215
0.60
unpainted face
H Panel + backer + unpainted
E400
0.7442
0.75
scrim face
I Panel + backer + painted scrim
E400
0.7314
0.75
face
E Panel + backer + paper face
E400
0.1978
0.20
F Panel + backer + painted
E400
0.2963
0.30
paper face
G Panel + painted scrim face
E400
0.5772
0.60
K Panel + painted scrim face +
E400
0.6376
0.65
unpainted scrim backer
C Panel + unpainted scrim face
E400
0.4028
0.40
[0000]
TEST II:
*Perforated Panel = ½ in. Ultralight (drywall) with 6 mm
diameter perforations, 15 mm o.c. spacing, borders-hole
pattern = 12.6% open area, overall panel = 9.6% open area
NRC
Panel Configuration
Mounting
4FA
NRC
Perforated panel only
E400
0.1937
0.20
Panel + backer + unpainted scrim face
E400
0.5947
0.60
Panel + backer + painted scrim face
E400
0.4825
0.50
[0000]
TEST III:
Panel A (small holes) = ½ in. Knauf 8/18R with 8 mm. diameter
round perforations, 18 mm o.c. spacing & no borders-15.5% open area
Panel B (large holes) = ½ in. Knauf 12/25R with 12 mm.
diameter round perforations, 25 mm o.c. spacing & no borders-
18.1% open area
Panel Configuration
NRC Mounting
4FA
NRC
Panel A only (with backer)
E400
0.6480
0.65
Panel B only (with backer)
E400
0.7191
0.70
Panel A + backer + unpainted scrim
E400
0.6245
0.65
face
Panel B + backer + unpainted scrim
E400
0.6810
0.70
face
Panel A + backer + painted scrim
E400
0.5782
0.60
face
Panel B + backer + painted scrim
E400
0.5652
0.55
face
Panel A + backer + painted scrim
E400
0.6192
0.60
face over 1 in. fiberglass panel
Panel B + backer + painted scrim
E400
0.6031
0.60
face over 1 in. fiberglass panel
[0026] Panel E of Test I had a heavy manila paper face with a basis weight of 263.50 gm/m 2 , a caliper of 17.22 mils, a density of 0.60 c/m 3 and a porosity of 58.97 seconds. This test sample illustrates that a face, although porous, but with too high an air flow resistivity is unsuitable for use with the invention. Panel BB of Test I indicates that a face with a higher air flow resistivity (see above table) than a painted scrim face can achieve a satisfactory NRC.
[0027] The acoustical panel of the invention can be manufactured in additional ways and with different constructions, but maintaining the perforations effectively restricted on at least the face (room) side of a completed panel. For example, where high NRC values are not needed, the rear layer 30 may be omitted. Porous paper may be substituted for either of the non-woven layers 29 , 30 .
[0028] It has been further discovered that NRC can be measurably increased by orienting the perforations obliquely to the plane of the panel. Such a construction is illustrated in FIG. 3 . The perforations 28 can, for example, be oriented at 20 degrees off a line perpendicular to the plane of the panel. The reason or reasons for this improved acoustical performance is not presently completely understood, but could be the result of a greater perforation volume and/or internal reflection of sound waves due to the oblique angle, and/or a greater effective open area at the face.
[0029] The foregoing disclosures involve modification of a conventional drywall sheet to convert it to the acoustical panel of the invention. However, the inventive acoustical panel can be originally manufactured with perforations in the gypsum core while it is being originally formed or immediately after it is formed and prior to attachment of one or both cover sheets or layers to its front face and rear side. The perforations, for example, can be cast into the gypsum body. The cross-section of the perforation in the various disclosed embodiments can be accircular when not drilled.
[0030] It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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An acoustical panel for forming a monolithic ceiling or wall, the panel extending across a rectangular area, and having a core made primarily of gypsum, the core being essentially coextensive with the panel area such that it has two opposed sides, each of an area substantially equal to the area of the panel, the core having a multitude of perforations extending generally between its sides, the perforations being distributed substantially uniformly across the full area of the core and being open at both sides of the core, the face side of the core being covered by a porous layer, the perforations being optionally restricted at a rear side of the core, the porous layer at the face side of the core being suitable for adherence of drywall joint compound and a water-based non-blocking paint.
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FIELD OF THE INVENTION
[0001] This invention relates to an aluminium alloy suitable for use in aircraft, automobiles, and other applications and a method of producing such alloy. More specifically, it relates to an improved weldable aluminium product, particularly useful in aircraft applications, having high damage tolerant characteristics, including improved corrosion resistance, formability, fracture toughness and increased strength properties.
BACKGROUND OF THE INVENTION
[0002] It is known in the art to use heat treatable aluminium alloys in a number of applications involving relatively high strength such as aircraft fuselages, vehicular members and other applications. Aluminium alloys 6061 and 6063 are well known heat treatable aluminium alloys. These alloys have useful strength and toughness properties in both T4 and T6 tempers. As is known, the T4 condition refers to a solution heat treated and quenched condition naturally aged to a substantially stable property level, whereas T6 tempers refer to a stronger condition produced by artificially ageing. These known alloys lack, however, sufficient strength for most structural aerospace applications. Several other Aluminium Association (“AA”) 6000 series alloys are generally unsuitable for the design of commercial aircraft which require different sets of properties for different types of structures. Depending on the design criteria for a particular aircraft component, improvements in strength, fracture toughness and fatigue resistance result in weight savings, which translate to fuel economy over the lifetime of the aircraft, and/or a greater level of safety. To meet these demands several 6000 series alloys have been developed.
[0003] European patent no. EP-0173632 concerns extruded or forged products of an alloy consisting of the following alloying elements, in weight percent:
[0004] Si 0.9-1.3, preferably 1.0-1.15
[0005] Mg 0.7-1.1, preferably 0.8-1.0
[0006] Cu 0.3-1.1, preferably 0.8-1.0
[0007] Mn 0.5-0.7
[0008] Zr 0.07-0.2, preferably 0.08-0.12
[0009] Fe<0.30
[0010] Zn 0.1-0.7, preferably 0.3-0.6
[0011] balance aluminium and unavoidable impurities (each<0.05; total<0.15). The products have a non-recrystallised microstructure. This alloy has been registered under the AA designation 6056.
[0012] It has been reported that this known AA6056 alloy is sensitive to intercrystalline corrosion in the T6 temper condition. In order to overcome this problem U.S. Pat. No. 5,858,134 provides a process for the production of rolled or extruded products having the following composition, in weight percent:
[0013] Si 0.7-1.3
[0014] Mg 0.6-1.1
[0015] Cu 0.5-1.1
[0016] Mn 0.3-0.8
[0017] Zr<0.20
[0018] Fe<0.30
[0019] Zn<1
[0020] Ag<1
[0021] Cr<0.25
[0022] other elements<0.05, total<0.15
[0023] balance aluminium,
[0024] and whereby the products are brought in an over-aged temper condition. However, over-ageing requires time and money consuming processing times at the end of the manufacturer of aerospace components. In order to obtain the improved intercrystalline corrosion resistance it is essential for this process that in the aluminium alloy the Mg/Si ratio is less than 1.
[0025] U.S. Pat. No. 4,589,932 discloses an aluminium wrought alloy product for e.g. automotive and aerospace constructions, which alloy was subsequently registered under the AA designation 6013, having the following composition, in weight percent:
[0026] Si 0.4-1.2, preferably 0.6-1.0
[0027] Mg 0.5-1.3, preferably 0.7-1.2
[0028] Cu 0.6-1.1
[0029] Mn 0.1-1.0, preferably 0.2-0.8
[0030] Fe<0.6
[0031] Cr<0.10
[0032] Ti<0.10
[0033] the balance aluminium and unavoidable impurities.
[0034] The aluminium alloy has the mandatory proviso that [Si+0.1]<Mg<[Si+0.4], and has been solution heat treated at a temperature in a range of 549 to 582° C. and approaching the solidus temperature of the alloy. In the examples illustrating the patent the ratio of Mg/Si is always more than 1.
[0035] U.S. Pat. No. 5,888,320 discloses a method of producing an aluminium alloy product. The product has a composition of, in weight percent:
[0036] Si 0.6-1.4, preferably 0.7-1.0
[0037] Fe<0.5, preferably <0.3
[0038] Cu<0.6, preferably <0.5
[0039] Mg 0.6-1.4, preferably 0.8-1.1
[0040] Zn 0.4 to 1.4, preferably 0.5-0.8
[0041] at least one element selected from the group:
Mn 0.2-0.8, preferably 0.3-0.5 Cr 0.05-0.3, preferably 0.1-0.2
[0044] balance aluminium and unavoidable impurities.
[0045] The disclosed aluminium alloy provides an alternative for the known high-copper containing 6013 alloy, and whereby a low-copper level is present in the alloy and the zinc level has been increased to above 0.4 wt. % and which is preferably in a range of 0.5 to 0.8 wt. %. The higher zinc content is required to compensate for the loss of copper.
[0046] In spite of these references, there is still a great need for an improved aluminium base alloy product having improved balance of strength, fracture toughness and corrosion resistance.
SUMMARY OF THE INVENTION
[0047] It is an object of the invention to provide a weldable 6000-series aluminium alloy wrought product having an improved balance of yield strength and fracture toughness.
[0048] It is another object of the invention to provide a weldable 6000-series aluminium alloy wrought product having an improved balance of yield strength and fracture toughness, while having a corrosion resistance, in particular intergranular corrosion resistance, at least equal or better than standard AA6013 alloy product in the same form and temper.
[0049] It is another object of the invention to provide a weldable 6000-series aluminium alloy rolled product having an improved balance of yield strength and fracture toughness, while having a corrosion resistance, in particular intergranular corrosion resistance, at least equal or better than standard AA6013 alloy product in the same form and temper.
[0050] According to the invention there is provided a weldable, high-strength aluminium alloy wrought product, which may be in the form of a rolled, extruded or forged form, containing the elements, in weight percent, Si 0.8 to 1.3, Cu 0.2 to 1.0, Mn 0.5 to 1.1, Mg 0.45 to 1.0, Ce 0.01 to 0.25, and preferably added in the form of a Misch Metal, Fe 0.01 to 0.3, Zr<0.25, Cr<0.25, Zn<1.4, Ti<0.25, V<0.25, others each<0.05 and total<0.15, balance aluminium.
BRIEF DESCRIPTION OF THE DRAWING
[0051] FIG. 1 shows schematically a ratio of TS/Rp against yield strength
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] By the invention we can provide an improved and weldable AA6000-series aluminium alloy wrought product, preferably in the form of a rolled product, having an improved balance in strength, fracture toughness and corrosion resistance, and intergranular corrosion resistance in particular. With the alloy product according to the invention we can provide a wrought product, preferably in the form of a rolled product, having a yield strength of 340 MPa or more and an ultimate tensile strength of 355 MPa or more, in combination with an improved intergranular corrosion performance compared to standard AA6013 alloys and/or AA6056 alloys when tested in the same form and temper. The alloy product may be welded successfully using techniques like e.g. laser beam welding, friction-stir welding and TIG-welding.
[0053] The product can either be naturally aged to produce an improved alloy product having good formability in the T4 temper or artificially aged to a T6 temper to produce an improved alloy having high strength and fracture toughness, along with a good corrosion resistance properties. A good balance in strength, fracture toughness and corrosion performance it being obtained without a need for bringing the product to an over-aged temper, but by careful selection of narrow ranges for the Ce, Cu, Mg, Si, and Mn-contents.
[0054] The balance of high formability, improved fracture toughness, high strength, and good corrosion resistance properties of the weldable aluminium alloy of the present invention are dependent in particular upon the chemical composition that is closely controlled within specific limits in more detail as set forth below. All composition percentages are by weight percent.
[0055] A preferred range for the silicon content is from 1.0 to 1.15% to optimise the strength of the alloy in combination with magnesium. A too high Si content has a detrimental influence on the elongation in the T6 temper and on the corrosion performance of the alloy.
[0056] Magnesium in combination with the silicon provides strength to the alloy. The preferred range of magnesium is 0.6 to 0.85%, and more preferably 0.6 to 0.75%. At least 0.45% magnesium is needed to provide sufficient strength while amounts in excess of 1.0% make it difficult to dissolve enough solute to obtain sufficient age hardening precipitate to provide high T6 strength.
[0057] Copper is an important element for adding strength to the alloy. However, too is high copper levels in combination with Mg have a detrimental influence of the corrosion performance and on the weldability of the alloy. Depending on the application a preferred copper content is in the range of 0.25 to 0.5% as a compromise in strength, fracture toughness, formability and corrosion performance.
[0058] It has been found that in this range the alloy product has a good resistance against IGC. In another embodiment the preferred copper content is in the range of 0.5 to 1.0% resulting in higher strength levels and improved weldability of the alloy product.
[0059] The preferred range of manganese is 0.6 to 0.8%, and more preferably 0.65 to 0.78%. Mn contributes to or aids in grain size control during operations that can cause the alloy to recystallise, and contributes to increase strength and fracture toughness.
[0060] A very important alloying element according to the invention is the addition of Ce in the range of 0.01 to 0.25%, and preferably in the range of 0.01 to 0.15%. In accordance with the invention it has been found that the addition of cerium results in a remarkable improvement of the fracture toughness of the alloy product, in particular when measured via a Kahn-tear testing, and thereby improving in particular the relation between fracture toughness and proof strength and resulting in increased application possibilities of the alloy product, in particular as aircraft skin material. The cerium addition may be done preferably via addition in the form of a Misch Metal (“MM”) (rare earths with 50 to 60% cerium). The addition of cerium, mostly in the form of MM is known in the art to increase fluidity and the reduce die sticking in aluminium-silicon casting alloys. In aluminium casting alloys containing more than 0.7% of iron, it is reported to transform acicular FeAl 3 into a nonacicular compound.
[0061] The zinc content in the alloy according to the invention should be less than 1.4%. It has been reported in U.S. Pat. No. 5,888,320 that the addition of zinc may add to the strength of the aluminium alloy product, but it has been found also that too high zinc contents have a detrimental effect of the intergranular corrosion performance of the product. Furthermore, the addition of zinc tends to produce an alloy product having undesirable higher density, which is in particular disadvantageous when the alloy is being applied for aerospace applications. A preferred level of zinc in the alloy product according to the invention is less than 0.4%, and more preferably less than 0.25%.
[0062] Iron is an element having a strong influence on the formability and fracture toughness of the alloy product. The iron content should be in the range of 0.01 to 0.3%, and preferably 0.01 to 0.25%, and more preferably 0.01 to 0.2%.
[0063] Titanium is an important element as a grain refiner during solidification of the rolling ingots, and should preferably be less than 0.25%. In accordance with the invention it has been found that the corrosion performance, in particular against intergranular corrosion, can be remarkably be improved by having a Ti-content in the range of 0.06 to 0.20%, and preferably 0.07 to 0.16%. It has been found that the Ti may be replaced in part or in whole by vanadium.
[0064] Zirconium and chromium may be added to the alloy each in an amount of less than 0.25% to improve the recrystallisation behaviour of the alloy product. At too high levels the Cr present may form undesirable large particles with the Mg in the alloy product.
[0065] The balance is aluminium and inevitable impurities. Typically each impurity element is present at 0.05% maximum and the total of impurities is 0.15% maximum.
[0066] The best results are achieved when the alloy rolled products have a recrystallised microstructure, meaning that 80% or more, and preferably 90% or more of the grains in a T4 or T6 temper are recrystallised.
[0067] The product according to the invention is preferably therein characterised that the alloy having been aged to the T6 temper in an ageing cycle which comprises exposure to a temperature of between 150 and 210° C. for a period between 1 and 20 hours, thereby producing an aluminium alloy product having a yield strength of 340 MPa or more, and preferably of 350 MPa or more, and an ultimate tensile strength of 355 MPa or more, and preferably of 365 MPa or more.
[0068] Furthermore, the product according to the invention is preferably therein characterised that the alloy having been aged to the T6 temper-in an ageing cycle which comprises exposure to a temperature of between 150 and 210° C. for a period between 1 and 20 hours, thereby producing an aluminium alloy product having an intergranular corrosion after a test according to MIL-H-6088 present to a depth of less than 200 μm, and preferably to a depth of less than 180 μm.
[0069] In an embodiment the invention also consists in that the product of this invention may be provided with at least one cladding. Such clad products utilise a core of the aluminium base alloy product of the invention and a cladding of usually higher purity which in particular corrosion protects the core. The cladding includes, but is not limited to, essentially unalloyed aluminium or aluminium containing not more than 0.1 or 1% of all other elements. Aluminium alloys herein designated 1xxx-type series include all Aluminium Association (AA) alloys, including the sub-classes of the 1000-type, 1100-type, 1200-type and 1300-type. Thus, the cladding on the core may be selected from various Aluminium Association alloys such as 1060, 1045, 1100, 1200, 1230, 1135, 1235, 1435, 1145, 1345, 1250, 1350, 1170, 1175, 1180, 1185, 1285, 1188, or 1199. In addition, alloys of the AA7000-series alloys, such as 7072 containing zinc (0.8 to 1.3%), can serve as the cladding and alloys of the AA6000-series alloys, such as 6003 or 6253, which contain typically more than 1% of alloying additions, can serve as cladding. Other alloys could also be useful as cladding as long as they provide in particular sufficient overall corrosion protection to the core alloy. In addition a cladding of the AA4000-series alloys can serve as cladding. The AA4000-series alloys have as main alloying element silicon typically in the range of 6 to 14%. In this embodiment the clad layer provides the welding filler material in a welding operation, e.g. by means of laser beam welding, and thereby overcoming the need for the use of additional filler wire materials in a welding operation. In this embodiment the silicon content is preferably in a range of 10 to 12%.
[0070] The clad layer or layers are usually much thinner than the core, each constituting 2 to 15 or 20 or possibly 25% of the total composite thickness. A cladding layer more typically constitutes around 2 to 12% of the total composite thickness.
[0071] In a preferred embodiment the alloy product according to the invention is being provided with a cladding thereon on one side of the AA1000-series and on the other side thereon of the AA4000-series. In this embodiment corrosion protection and welding capability are being combined. In this embodiment the product may be used successfully for example for pre-curved panels. In case the rolling practice of an asymmetric sandwich product (1000-series alloy+core+4000-series alloy) causes some problems such as banaring, there is also the possibility of first rolling a symmetrical sandwich product having the following subsequent layers 1000-series alloy+4000-series alloy+core alloy+4000-series alloy+1000-series alloy, where after one or more of the outer layer(s) are being removed, for example by means of chemical milling.
[0072] The invention also consists in a method of manufacturing the aluminium alloy product according to the invention. The method of producing the alloy product comprises the sequential process steps of: (a) providing stock having a chemical composition as set out above, (b) preheating -or homogenising the stock, (c) hot working the stock, preferably by means of hot rolling (d) optionally cold working the stock, preferably by means of cold rolling (e) solution heat treating the stock, and (f) quenching the stock to minimise uncontrolled precipitation of secondary phases. Thereafter the alloy product can be provided in a T4 temper by allowing the product to naturally age to produce an improved alloy product having good formability, or can be provided in a T6 temper by artificial ageing. To artificial age, the product in subjected to an ageing cycle comprising exposure to a temperature of between 150 and 210° C. for a period between 0.5 and 30 hours.
[0073] The aluminium alloy as described herein can be provided in process step (a) as an ingot or slab for fabrication into a suitable wrought product by casting techniques currently employed in the art for cast products, e.g: DC-casting, EMC-casting, EMS-casting. Slabs resulting from continuous casting, e.g. belt casters or roll caster, may be used also.
[0074] Typically, prior to hot rolling the rolling faces of both the clad and the non-clad products are scalped in order to remove segregation zones near the cast surface of the ingot.
[0075] The cast ingot or slab may be homogenised prior to hot working, preferably by means of rolling and/or it-may be preheated followed directly by hot working. The homogenisation and/or preheating of the alloy prior to hot working should be carried out at a temperature in the range 490 to 580° C. in single or in multiple steps. In either case, the segregation of alloying elements in the material as cast is reduced and soluble elements are dissolved. If the treatment is carried out below 490° C., the resultant homogenisation effect is inadequate. If the temperature is above 580° C., eutectic melting might occur resulting in undesirable pore formation. The preferred time of the above heat treatment is between 2 and 30 hours. Longer times are not normally detrimental. Homogenisation is usually performed at a temperature above 540° C. A typical preheat temperature is in the range of 535 to 560° C. with a soaking time in a range of 4 to 16 hours.
[0076] After the alloy product is cold worked, preferably after being cold rolled, or if the product is not cold worked then after hot working, the alloy product is solution heat treated at a temperature in the range of 480 to 590° C., preferably 530 to 570° C., for a time sufficient for solution effects to approach equilibrium, with typical soaking times in the rang of 10 sec. to 120 minutes. With clad products, care should be taken against too long soaking times to prevent diffusion of alloying element from the core into the cladding detrimentally affecting the corrosion protection afforded by said cladding.
[0077] After solution heat treatment, it is important that the alloy product be cooled to a temperature of 175° C. or lower, preferably to room temperature, to prevent or minimise the uncontrolled precipitation of secondary phases, e.g. Mg 2 Si. On the other hand cooling rates should not be too high in order to allow for a sufficient flatness and low level of residual stresses in the alloy product. Suitable cooling rates can be achieved with the use of water, e.g. water immersion or water jets.
[0078] The product according to the invention has been found to be very suitable for application as a structural component of an aircraft, in particular as aircraft fuselage skin material.
EXAMPLE
[0079] Five different alloys have been DC-cast into ingots, then subsequently scalped, pre-heated for 6 hours at 550° C. (heating-up speed about 30° C./h), hot rolled to a gauge of 8 mm, cold rolled to a final gauge of 2.0 mm, solution heat treated for 15 min. at 550° C., water quenched, aged to a T6-temper by holding for 4 hours at 190° C. (heat-up speed about 35° C./h), followed by air cooling to room temperature. Table 1 gives the chemical composition of the alloys cast, balance inevitable impurities and aluminium, and whereby Alloy no. 3 is the alloy according to the invention and the other alloys are for comparison. The 0.03 wt. % cerium has been added to the melt via the addition of 0.06 wt. % of MM having 50% of cerium.
[0080] The tensile testing has been carried out on the bare sheet material in the T6-temper and having a fully recystallised microstructure. For the tensile testing in the L-direction small euro-norm specimens were used, average results of 3 specimens are given, and whereby “Rp” stands for yield strength, “Rm” for ultimate tensile strength, and A50 for elongation. The results of the tensile tests have been listed in Table 2. The “TS” stands for tear strength, and has been measured in the L-T direction in accordance with ASTM-B871-96. “UPE” stands for Unit Propagation Energy, and has been measured in accordance with ASTM-B871-96, and is a measure for toughness, in particular for the crack growth, and whereas TS is in particular a measure for crack initiation. Intergranular corrosion (“ICG”) was tested on two specimens of 50×60 mm in accordance with the procedure given in AIMS 03-04-000, which specifies MIL-H-6088 and some additional steps. The maximum depth in microns has been reported in Table 4.
[0081] FIG. 1 shows schematically the ratio of TS/Rp against the yield strength.
[0082] From the results of Table 2 it can be seen that adding cerium in accordance with the invention results in a significant increase in strength levels, in particular the yield strength of the alloy product (see Alloy 1 and 3). From the results of Table 3 it can be seen that adding cerium results in a significant increase of the fracture toughness of the alloy product when tested in the L-T direction (see Alloy 1 and 3). Only a very small increase in fracture toughness can be found when adding zirconium instead of cerium to the alloy. The shown strength increase was expected for the addition of 0.11% of zirconium. Alloys 1, 2 and 3 have a somewhat lower strength and fracture toughness than standard 6056 and 6013 alloy, which is to a large extent due to a significantly lower copper content in the aluminium alloys tested. When the TS/Rp-ratio is plotted against the yield strength, see FIG. 1 , it can be seen that the addition of even small amounts of cerium results in a significant increase in the balance between fracture toughness and yield strength, which increase is a desirable property for various applications, in particular in aerospace constructions.
[0083] From the results of Table 4 it can be seen that the addition of cerium in accordance with the invention has no significant influence on the performance against intergranular corrosion compared to aluminium alloy products having an almost similar chemical composition apart from the cerium addition while being in the same temper. However, the performance of Alloy no. 3 against intergranular corrosion is significantly better compared to standard 6056 and 6013 alloy products, whereas Alloy no. 3 has a yield strength and a TS/Rp-ratio close to the results of standard 6056 and 6013 alloy products in the same temper. It is believed that an increase of the Ti-content to for example 0.1 wt. % in the aluminium alloy product according to the invention would result in a reduction of the maximum intergranular corrosion depth. Furthermore, it is believed that optimising the T6 temper ageing treatment would also result in an improved resistance against intergranular corrosion.
[0084] Having now described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made without departing from the spirit or scope of the invention as herein described.
TABLE 1 Chemical composition of the alloys tested. Alloy Si Fe Cu Mn Mg Zn Ti Zr Ce 1 1.13 0.16 0.51 0.62 0.69 0.16 0.01 — — (comp) 2 1.20 0.18 0.52 0.72 0.69 0.15 0.04 0.11 — (comp) 3 1.17 0.16 0.48 0.67 0.69 0.15 0.01 — 0.03 (inv.) stan- 0.92 0.15 0.90 0.46 0.88 0.08 0.02 — — dard 6056 stan- 0.79 0.17 0.96 0.35 0.90 0.09 0.03 — — dard 6013
[0085]
TABLE 2
Tensile properties in the L-direction in T6-temper sheet material.
Alloy
Rp [MPa]
Rm [MPa]
A50 [%]
1
330
358
8.5
2
336
364
7.0
3
361
379
6.5
standard 6056
362
398
12
standard 6013
369
398
9
[0086]
TABLE 3
Fracture toughness results in the L-T direction.
Alloy
L-T TS [MPa]
UPE [kJ]
TS/Rp
1
552
207
1.67
2
564
208
1.68
3
595
211
1.65
standard 6056
590
215
1.66
standard 6013
593
184
1.66
[0087]
TABLE 4
ICG corrosion results in the T6-temper.
Alloy
Depth of max. [μm]
1
137
2
127
3 (inv.)
134
standard 6056
190
standard 6013
190
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The invention relates to a weldable, high-strength aluminium alloy wrought product, which may be in the form of a rolled, extruded or forged form, containing the elements, in weight percent, Si 0.8 to 1.3, Cu 0.2 to 1.0, Mn 0.5 to 1.1, Mg 0.45 to 1.0, Ce 0.01 to 0.25, and preferably added in the form of a Misch Metal, Fe 0.01 to 0.3, Zr<0.25, Cr<0.25, Zn<1.4, Ti<0.25, V<0.25, others each<0.05 and total<0.15, balance aluminium. The invention relates also to a method of manufacturing such an aluminium alloy product.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a method and system for improved emissions from a steam generation system having an integrated dry flue gas cleaning unit. More specifically, the present invention provides for a method and system for steam generation that employs the use of multi-combustion oxy-boiler chambers having advanced temperature control systems for helping to reduce NO x emissions.
BACKGROUND OF THE INVENTION
[0002] Steam generation through the combustion of fuels that contain nitrogen and sulfur lead to pollutants emissions such as nitrogen oxides (NO x ) and sulfur oxides (SO X ) to the atmosphere. NO x and SO x emissions to the atmosphere are known of having a negative impact on the environment. For example, NO x and SOx are responsible for acid rains and ozone depletion that affect the environment by reducing air quality and killing vegetation. They can also be responsible for serious troubles in human health in case of long exposure to these pollutants.
[0003] Due to their negative impacts as mentioned above, governments around the world monitor and control pollutant emissions, and impose restrictions for maximum levels of atmospheric emissions based on combustion plant size and type. Several processes are available for handling NO x and SO x removal from flue gases. These processes include precipitators to remove the dust and ash, catalytic or non-catalytic reactors to remove the NO x and dry or wet scrubbers to remove the SO x . This association of several technologies in order to remove the pollutants is usually very expensive in term of capital and operating costs since most of these technologies produce a by-product as a result of the flue gas cleaning. One way of reducing the cost of pollutant removal, is to integrate the flue gas cleaning into the boiler and reduce the amount of by-products produced by the flue gas treatment unit.
[0004] Climate change is another issue that is getting more attention, with particular focus on greenhouse gas emissions, since they are seen as the main culprit. Generally, the combustion of fossil fuels such as oil, coal or natural gas produces carbon dioxide (CO 2 ), thereby adding to the greenhouse gas effect. Several technologies are under development to mitigate CO 2 emissions. Among these technologies, CCS (CO 2 Capture and Sequestration) is foreseen as one of the most efficient solutions to reduce CO 2 emissions to the atmosphere. Oxy-combustion technology is part of CO 2 capture technologies and is considered as one of the most economical route to capture CO 2 for sequestration or Enhanced Oil Recovery (EOR).
[0005] Oxy-combustion technology uses oxygen (generally streams composed of more than 75% oxygen) instead of air to combust the fuel and produce a highly concentrated CO 2 stream that is easier to capture in comparison to the conventional amine scrubbing technology. This can be achieved by removing nitrogen from air and consequently producing flue gas flow rate that is four to five times lower than conventional air combustion flue gas. In oxy-combustion, since the flue gas flow rate is very low, the concentration of SO x is high allowing for improved removal due to the higher SO x gradient. This can simplify the flue gas desulfurization unit and drastically reduce its cost. In addition, the removal of nitrogen from air suppresses the thermal NO x that are formed by the oxidation of nitrogen in air-combustion systems.
[0006] The removal of nitrogen from air will also increase the temperature of the flue gas in the combustion chamber, which drastically impacts the heat transfer. For example; in a conventional air-boiler where about 35% of the energy released in the combustion chamber is used to vaporize the water circulating in the walls, the flue gas temperature is about 1300° C. whereas the flue gas temperature in an oxy-boiler with the same energy extraction is about 3650° C. Obviously this temperature is not compatible with conventional materials used for designing boilers. To avoid this high level temperature, it is usually suggested to recycle part of the flue gas exiting the boiler to the combustion chamber in order to reduce the flue gas temperature to acceptable temperatures. This solution is useful, but has the main drawback of reducing the thermal efficient of the oxy-boiler since the recycled flue gas act only as temperature moderator.
[0007] It would be desirable to have an improved process for generating steam from the combustion of a sulfur-containing fuel with oxygen, while minimizing equipment size and reducing SO x and NO x emissions. It would be advantageous to regenerate the adsorbent used to remove sulfur products in order to recycle the adsorbent back into the system.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a method and system that satisfies at least one of these needs. The present invention includes a method and system for generating steam while reducing emissions.
[0009] In one embodiment, the method for steam generation includes providing an oxidant enriched gas stream having an oxygen content of 21 to 100% by volume, preferably 75% to 100% by volume, combusting at least a portion of a fuel stream that can contain sulfur and/or nitrogen, which can be oil heavy residue and/or fuel gas, in the presence of the oxidant enriched gas stream in a combustion zone to produce a flue gas and heat, wherein the combustion zone is comprised of at least two combustion chambers, wherein each combustion chamber has an internal temperature gradient; and regulating said internal temperature gradients of each combustion chamber using one or several heat exchangers that are preferably positioned in the walls of the combustions chambers such that the flue gas temperature at the exit of the combustion chambers are within a predetermined temperature range of 800 to 1400° Celsius, wherein said heat exchangers employ the use of water (in the form of liquid water and/or steam), wherein the enthalpy of the water is increased through heat exchange with the flue gases from the combustion chambers. The flue gas can be introduced into a flue gas cleaning chamber to produce a third product stream comprised of spent adsorbent and desulfurized flue gas, wherein the desulfurized flue gas has reduced amounts of sulfur oxides (“SO X ”) as compared to the flue gas entering said flue gas cleaning chamber, the flue gas cleaning chamber having an amount of adsorbent contained therein that is operable to remove at least a portion of SO x from the flue gas entering said flue gas cleaning chamber. In one embodiment, the internal temperature gradients are regulated without recycling any portion of the flue gas or the desulfurized flue gas into the combustion zone.
[0010] In another embodiment, the combustion chambers can be configured in series or in parallel, with each combustion chamber being separated from another combustion chamber by at least one of the heat exchangers.
[0011] In another embodiment, the method for steam generation includes providing an oxidant enriched gas stream having an oxygen content of 21 to 100% by volume and combusting a portion of a fuel stream in the presence of the oxidant enriched gas stream in a first combustion chamber to generate a first product stream, the first product stream comprising flue gas and non-combusted fuel, the fuel stream comprising a fuel source having sulfur. One or several heat exchangers can be used to remove heat from the first product stream such that the temperature of the first product stream remains within a range of 800 to 1400° Celsius as it is being introduced to a second combustion chamber and further combusting the non-combusted fuel to produce a second product stream, the second product stream having a greater amount of flue gas as compared to the first product stream. Similarly, one or several heat exchangers can be used to remove heat from the second product stream such that the temperature of the second product stream remains within a range of 800 to 1400° Celsius as it is being introduced into a flue gas cleaning chamber to produce a third product stream comprised of spent adsorbent and desulfurized flue gas, wherein the desulfurized flue gas has reduced amounts of SO x as compared to the flue gas within the second product stream, the flue gas cleaning chamber having an amount of adsorbent contained therein that is operable to remove at least a portion of SO x from the second product stream. The third product stream is then introduced into a first precipitator and the third product stream can be separated into a spent adsorbent stream and a cleaned flue gas stream, with the cleaned flue gas stream being preferably sent to a CO 2 recovery unit. In another embodiment, the cleaned flue gas stream can be released to the atmosphere. Concurrently, water is heated to increase the enthalpy of the water. Preferably, the water absorbs the heat produced from the combustion chambers as the water turns into steam or superheated steam, depending upon the initial conditions of the water (e.g. liquid or gaseous).
[0012] In one embodiment of the present invention, the adsorbent is a solid having particle sizes in the range of 50 to 500 microns. Preferred solid adsorbents include calcium oxide (“CaO”) and/or magnesium oxide (“MgO”). In one embodiment, the first and second combustion chambers have water circulating within walls of each chamber for regulating the temperature within each combustion chamber. Preferably, the walls include membrane tubes and welded fins connecting the membrane tubes. In one embodiment, the temperature within each chamber is within a range of about 800° C. to about 2500° C.; preferably 1000° C. to about 1400° C. In one embodiment, a reducing agent can be introduced into the flue gas cleaning chamber in order to reduce the NO x concentration of the third product stream as compared to the second product stream. Preferred reducing agents include ammonia, urea, and combinations thereof. Additionally, it is preferred that the reducing agent be dispersed homogeneously throughout the flue gas cleaning chamber.
[0013] In another embodiment, the cleaned flue gas stream can be introduced into a second precipitator to remove additional amounts of adsorbent prior to sending the cleaned flue gas stream to the CO 2 recovery unit or to the atmosphere. In a preferred embodiment, the first precipitator can be a cyclone, and the second precipitator can be selected from the group consisting of an electrostatic precipitator type, a fabric filter bag type, and combinations thereof. In another embodiment, the method can include comprising introducing the cleaned flue gas stream into a heat exchanger to transfer heat energy from the flue gas stream to a target fluid prior to sending the cleaned flue gas stream to the CO 2 recovery unit or to the atmosphere, wherein the target fluid is selected from the group consisting of saturated steam and water.
[0014] In yet another embodiment of the present invention, the method can further include introducing the spent adsorbent stream into a regeneration unit; contacting the spent adsorbent stream with a reducing gas to produce regenerated adsorbent and spent reducing gas; introducing the spent reducing gas to a sulfur recovery unit; and recycling the regenerated adsorbent to the flue gas cleaning chamber.
[0015] The system for generating steam include an oxidant delivery system, a first and second combustion chamber, a first and second heat exchanger, a flue gas cleaning chamber, a precipitating unit, an adsorbent storage tank, a discharge line, a reducing gas feed line, a regeneration unit, and a sulfur discharge line. The oxidant delivery system can be for providing an oxidant enriched gas stream having an oxygen content of 21 to 100% by volume. Preferred oxidant delivery systems include air separation processes having cryogenic separation of air, pressure swing air separation and temperature swing air separation units. The first combustion chamber is preferably in fluid communication with the oxidant delivery system, such that the first combustion chamber is operable to combust a portion of a fuel stream in the presence of the oxidant enriched gas stream to generate a first product stream comprised of flue gas and non-combusted fuel. The first heat exchanger is preferably in fluid communication with the first combustion chamber, such that the first heat exchanger is operable to remove heat from the first product stream such that the temperature of the first product stream is maintained within a desired range.
[0016] The second combustion chamber is preferably in fluid communication with the first heat exchanger, such that the second combustion chamber is operable to combust a portion of the non-combusted fuel of the first product stream to produce a second product stream, wherein the second product stream has a greater amount of flue gas as compared to the first product stream. The second heat exchanger is preferably in fluid communication with the second combustion chamber, such that the second heat exchanger is operable to remove heat from the second product stream such that the temperature of the second product stream is maintained within a desired range. The flue gas cleaning chamber is preferably in fluid communication with the second heat exchanger, the flue gas cleaning chamber having an amount of adsorbent contained therein that is operable to remove at least a portion of SO x from the second product stream to produce a third product stream, the third product stream comprising a desulfurized flue gas and spent adsorbent, the desulfurized flue gas having reduced amounts of SO x as compared to the flue gas within the second product stream. The precipitating unit is preferably in fluid communication with the flue gas cleaning chamber for removing the spent adsorbent from the desulfurized flue gas to produce a spent adsorbent stream and a cleaned flue gas stream.
[0017] The adsorbent storage tank is preferably in fluid communication with the precipitating unit for receiving the spent adsorbent stream. The discharge line is preferably in fluid communication with the precipitating unit for sending the cleaned flue gas stream to a CO 2 recovery unit or to the atmosphere. The reducing gas feed line is preferably in fluid communication with the flue gas cleaning chamber for introducing reducing gas to the flue gas cleaning chamber. The regeneration unit is preferably in fluid communication with the adsorbent storage tank, the reducing gas feed line, and the flue gas cleaning chamber. The regeneration unit being operable to regenerate the spent adsorbent stream by contacting the spent adsorbent stream with a reducing gas to produce regenerated adsorbent and spent reducing gas, wherein the regenerated adsorbent is then recycled back to the flue gas cleaning chamber. The sulfur discharge line is preferably in fluid communication with the regeneration unit, wherein the sulfur discharge line can be operable to introduce the spent reducing gas to a sulfur recovery unit.
[0018] In one embodiment of the present invention, the adsorbent is a solid having particle sizes in the range of 50 to 500 microns. Preferred solid adsorbents include CaO and/or MgO. In one embodiment, the first and second combustion chambers have water circulating within walls of each chamber for regulating the temperature within each combustion chamber. Preferably, the walls include membrane tubes and welded fins connecting the membrane tubes. In one embodiment, the temperature within each chamber is within a range of about 800° C. to about 2500° C.; preferably 800° C. to about 1400° C. In one embodiment, a reducing agent can be introduced into the flue gas cleaning chamber in order to reduce the NO x concentration of the third product stream as compared to the second product stream. Preferred reducing agents include ammonia, urea, and combinations thereof. Additionally, it is preferred that the reducing agent be dispersed homogeneously throughout the flue gas cleaning chamber.
[0019] In another embodiment of the present invention, the precipitating unit includes a first precipitator that is operable to remove substantially all of the spent adsorbent from the desulfurized flue gas. In another embodiment, the system can further include a third heat exchanger in fluid communication with the precipitating unit and the discharge line, the third heat exchanger operable to transfer heat energy from the flue gas stream to a target fluid prior to sending the cleaned flue gas stream to the CO 2 recovery unit, wherein the target fluid is selected from the group consisting of saturated steam and liquid water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it can admit to other equally effective embodiments.
[0021] FIG. 1 is an embodiment of the present invention.
DETAILED DESCRIPTION
[0022] While the invention will be described in connection with several embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all the alternatives, modifications and equivalence as may be included within the spirit and scope of the invention defined by the appended claims.
[0023] In FIG. 1 , fuel 2 and oxidant enriched gas stream 4 enter combustion zone CZ and are fed into first combustion chamber 10 , wherein fuel 2 combusts to produce flue gas and heat. In one embodiment, oxidant enriched gas stream 4 has an oxygen content between 75% to 100% oxygen by volume. This increased level of oxygen content provides an increased level of desulfurization over lower levels of oxygen content. In a preferred embodiment, the heat is partially transferred to a mixture of liquid water and steam circulating within the walls of the first combustion chamber 10 . Preferably, the walls of first combustion chamber 10 are of membrane type tubes having tubes connected by welded fins. The temperature within first combustion chamber 10 can be adjusted by controlling the flow rate of fuel 2 and oxidant enriched gas stream 4 entering first combustion chamber 10 . In one embodiment, the temperature is maintained within a range from 800 to 2500 degrees Celsius. In another embodiment, the temperature is maintained within a range from 1000 to 1400 degrees Celsius, in order to help prevent NO x formation. The flue gas, which in some embodiments can include unreacted fuel and oxygen, exit first combustion chamber 10 via line 12 and passes through first heat exchanger HX 1 at a predetermined flow rate such that the temperature of the exiting flue gas is maintained between 200 and 1600 degrees Celsius. The flue gas then enters second combustion chamber 20 via line 14 , wherein additional fuel is combusted to produce additional flue gas and heat. If there is not enough unreacted fuel or oxygen in line 14 , then a fresh makeup stream of fuel 6 and/or oxidant 8 can be added to second combustion chamber 20 . Similar to the behavior of first combustion chamber 10 , the flue gas exits second combustion chamber 20 via line 22 and passes through second heat exchanger HX 2 at a predetermined flow rate such that the temperature of the flue gas in line 24 is maintained between 200 and 1600 degrees Celsius.
[0024] The cooled flue gas then enters dry flue gas cleaning chamber 30 and is contacted with adsorbent 26 in order to remove the sulfur oxides from the flue gas. Adsorbent 26 is a solid and could be of any type that allows for removal of sulfur oxides from flue gases. Preferably, adsorbent 26 will be recoverable in order to reduce the production of by-products. In one embodiment, the particle size of adsorbent 26 can be between 50 and 500 microns. Exemplary adsorbents include MgO and CaO.
[0025] In one embodiment, dry flue gas cleaning chamber 30 is equipped with one or more injectors that allow for homogenous dispersion of the adsorbent within dry flue gas cleaning chamber 30 . Recycled flue gas can be used to improve the dispersion of the adsorbent within dry flue gas cleaning chamber 30 . Depending upon the temperature of the flue gas in line 24 , the walls of dry flue gas cleaning chamber 30 may or may not be of the membrane type like first combustion chamber 10 and second combustion chamber 20 . In embodiments in which the temperature of the flue gas in line 24 is between 800 and 1100 degrees Celsius, a reducing agent such as urea or ammonia can be injected into dry flue gas cleaning chamber 30 along with adsorbent 26 in order to remove the nitrogen oxide.
[0026] Flue gas and spent adsorbent travel to first precipitator 40 via line 32 . In one embodiment, first precipitator 40 is a cyclone. First precipitator 40 separates the flue gases from the spent adsorbent. The cleaned flue gases can sometimes contain fine-adsorbent particles. In these situations, the cleaned flue gases are sent to second precipitator 50 via line 42 in order to remove the remaining adsorbent particles. Examples of second precipitator 50 can include an electrostatic precipitator type or fabric filter bag type. The removed adsorbent particles are evacuated through line 51 and sent with the adsorbent removed from first precipitator 40 via line 44 to adsorbent storage tank 60 . The cleaned flue gases exit second precipitator 50 through line 52 and pass through one or several heat exchangers (HX 3 , HX 4 ). Preferably, third heat exchanger HX 3 is fed with saturated steam to produce super-heated steam that can be fed to first heat exchanger HX 1 or second heat exchanger HX 2 . Fourth heat exchanger HX 4 is preferably fed with liquid water in order to increase its temperature before being used in the walls of first combustion chamber 10 and/or second combustion chamber 20 .
[0027] After passing through third heat exchanger HX 3 and fourth heat exchanger HX 4 , the cleaned flue gas is split into two streams, with recycle stream 56 being used to help recycle regenerated adsorbent back to dry flue gas cleaning chamber 30 . CO 2 recovery stream 58 can be sent to a carbon dioxide recovery unit for additional process, or alternatively released to the atmosphere.
[0028] The spent adsorbent travels from first precipitator 40 to adsorbent storage tank 60 via line 44 . In a preferred embodiment, gases produced from other parts of the system, such as nitrogen or cleaned flue gas, may be used to transport the spent adsorbent throughout the system. From adsorbent storage tank 60 , the spent adsorbent travels to adsorbent regenerator 70 via line 62 , where the spent adsorbent is contacted with a regeneration gas 64 . Adsorbent regenerator 70 can be any reactor that allows efficient contact of the spent adsorbent and the regeneration gas, such as fluidized bed, fixed bed, or moving bed reactor. Preferred regeneration gases include hydrogen, methane, ethane, propane, and combinations thereof. Any other light hydrocarbon that is operable to react with the adsorbent can also be used as a regeneration gas. Spent regeneration gas exits adsorbent regenerator 70 via line 74 and can be sent to a sulfur recovery unit (not shown). Regenerated adsorbent leaves adsorbent regenerator 70 and can be combined with recycle stream 56 en route to dry flue gas cleaning chamber 30 .
[0029] In an alternate embodiment, a portion of the spent adsorbent can be recycled back to dry flue gas cleaning chamber 30 via line 61 before being sent to adsorbent regenerator 70 . This allows the adsorbent to be used multiple times, which advantageously improves the desulfurization efficiency of the system.
[0030] In an alternate embodiment, third heat exchanger HX 3 is not required since the adsorption of the sulfur oxides within dry flue gas cleaning chamber 30 occurs at a temperature that is not compatible with superheating steam after dry flue gas cleaning chamber 30 . For example, in an embodiment in which the temperature within line 32 is at or less than the boiling point of water, third heat exchanger HX 3 is not required.
Example 1
[0031] In this example, magnesium oxide (M g O) is used as the dry adsorbent to remove the sulfur oxide from the produced flue gases. The system combusts an oil heavy residue having a composition (in mass basis) according to Table I.
[0000]
TABLE I
Fuel Composition in ppm
Carbon
Hydrogen
Sulphur
Nitrogen
Metals
84
9
6
1
290e−6
[0032] The Low Heating Value (LHV), which represents the amount of energy contained in the fuel, is estimated at 38 MJ/kg. The system is designed to produce about 100 MW of superheated steam at 480° C. and 80 bar. The oxidizer composition is given in Table IT in mass basis.
[0000]
TABLE II
Oxidizer Composition
Oxygen
Nitrogen
Argon
95
3
2
[0033] Based on fuel composition and oxidizer composition, the flue gas composition exiting the combustion zone and prior to the dry flue gas cleaning chamber is given in Table III in mass basis.
[0000]
TABLE III
Flue Gas Composition
CO 2
H 2 O
N 2
O 2
SO 2
A r
68.41
23.16
1.92
2.02
2.67
1.83
[0034] The temperature at the entry of the dry flue gas cleaning chamber was adjusted to 1000° C. in order to optimize the adsorption of sulphur oxides. The basic reaction for adsorption and regeneration of the adsorbent are:
[0035] Oxidation of SO 2 :
[0000] SO 2 +1/2O 2 SO 3
[0036] Adsorption of SO 3 :
[0037] M g O+SO 3 M g SO 4
[0038] Regeneration of the used adsorbent:
[0000] H 2 +M g SO 4 SO 2 +H 2 O+M g O
[0000] H 2 S+M g SO 4 SO 2 +H 2 O+M g O+S
[0039] A catalyst can be used in order to increase the conversion of SO 2 in the oxidation reaction. This catalyst can be any materials that have the property of improving the oxidation of SO 2 to SO 3 for example a cerium oxide CeO. The regeneration gas is a mixture of hydrogen H 2 and hydrogen sulphur H 2 S.
[0040] The molar ratio between magnesium and fuel sulphur (M g /S) was adjusted according to the adsorbent residence time in the dry flue gas cleaning chamber. With an M g /S ratio at nine and a residence time in the dry flue gas cleaning chamber of two seconds, a desulphurization ratio of 94% can be achieved. Table IV displays the composition of the resulting cleaned flue gas in mass basis.
[0000]
TABLE IV
Desulfurized Flue Gas Composition
CO 2
H 2 O
N 2
O 2
SO 2
A r
70.17
23.76
1.97
2.07
0.16
1.87
Example 2
[0041] The same procedure was run for Example 2, with the exception that the oxygen levels of oxidant stream were increased to 100%. Table V and Table VI below provide a summary of the temperature, flow rates, and resulting composition data of various streams throughout the system.
[0000]
TABLE V
Temperature, Flow Rate, and Composition
Data of Various Streams
Stream
4
2
12
22
Temperature (° C.)
25
230
1344
1344
Flow rate (kg/s)
4.2
1.3
5.8
12
Stream composition (wt %)
CO 2
71.22
72.57
H 2 O
23.90
22.46
SO 2
2.77
2.83
O 2
100
0.12
2.14
N 2
Ar
H 2 S
M g O
M g SO 4
CeO 2
Fuel
100
[0000]
TABLE VI
Temperature, Flow Rate, and Composition Data for Additional Streams
Stream
26
32
58
61
64
74
72
Temperature (° C.)
20
695
180
695
1128
700
700
Flow rate (kg/s)
0.004
17.34
12
5.34
1.36
1.52
1.2
Stream composition (wt %)
CO 2
38.3
74.55
74.55
76.9
40.86
36.36
H 2 O
23.07
23.07
13.3
14.31
SO 2
0.17
0.17
1.18
9.85
O 2
11.7
2.2
2.2
N 2
Ar
H 2 S
15.12
10.03
H 2
0.38
0.27
M g O
45
0.004
48.5
69.84
M g SO 4
0.004
44.47
21.61
CeO 2
5
0.001
7.04
8.56
S
29.16
29.18
Fuel
[0042] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed.
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A method for producing steam while concurrently reducing emissions. The method includes combusting fuel and an oxidant stream having a high concentration of oxygen in a combustion zone having multiple combustion chambers and heat exchangers to produce a flue gas. The flue gas is subsequently cleaned in a dry flue gas cleaning chamber by contacting it with a dry adsorbent. In one embodiment, the method advantageously regenerates the dry adsorbent so that the dry adsorbent can be subsequently recycled back into the dry gas flue chamber.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to the following United States provisional patent applications which are incorporated herein by reference in their entirety:
Ser. No. 60/989,957 entitled “Point-to-Point Communication within a Mesh Network”, filed Nov. 25, 2007; Ser. No. 60/989,967 entitled “Efficient And Compact Transport Layer And Model For An Advanced Metering Infrastructure (AMI) Network,” filed Nov. 25, 2007; Ser. No. 60/989,958 entitled “Creating And Managing A Mesh Network Including Network Association,” filed Nov. 25, 2007; Ser. No. 60/989,964 entitled “Route Optimization Within A Mesh Network,” filed Nov. 25, 2007; Ser. No. 60/989,950 entitled “Application Layer Device Agnostic Collector Utilizing ANSI C12.22,” filed Nov. 25, 2007; Ser. No. 60/989,953 entitled “System And Method For Real Time Event Report Generation Between Nodes And Head End Server In A Meter Reading Network Including From Smart And Dumb Meters,” filed Nov. 25, 2007; Ser. No. 60/989,956 entitled “System and Method for False Alert Filtering of Event Messages Within a Network”, filed Nov. 25, 2007; Ser. No. 60/989,975 entitled “System and Method for Network (Mesh) Layer And Application Layer Architecture And Processes,” filed Nov. 25, 2007; Ser. No. 60/989,959 entitled “Tree Routing Within a Mesh Network,” filed Nov. 25, 2007; Ser. No. 60/989,961 entitled “Source Routing Within a Mesh Network,” filed Nov. 25, 2007; Ser. No. 60/989,962 entitled “Creating and Managing a Mesh Network,” filed Nov. 25, 2007; Ser. No. 60/989,951 entitled “Network Node And Collector Architecture For Communicating Data And Method Of Communications,” filed Nov. 25, 2007; Ser. No. 60/989,955 entitled “System And Method For Recovering From Head End Data Loss And Data Collector Failure In An Automated Meter Reading Infrastructure,” filed Nov. 25, 2007; Ser. No. 60/989,952 entitled “System And Method For Assigning Checkpoints To A Plurality Of Network Nodes In Communication With A Device Agnostic Data Collector,” filed Nov. 25, 2007; Ser. No. 60/989,954 entitled “System And Method For Synchronizing Data In An Automated Meter Reading Infrastructure,” filed Nov. 25, 2007; Ser. No. 61/025,285 entitled “Outage and Restoration Notification within a Mesh Network”, filed Jan. 31, 2008; Ser. No. 60/992,312 entitled “Mesh Network Broadcast,” filed Dec. 4, 2007; Ser. No. 60/992,313 entitled “Multi Tree Mesh Networks”, filed Dec. 4, 2007; Ser. No. 60/992,315 entitled “Mesh Routing Within a Mesh Network,” filed Dec. 4, 2007; Ser. No. 61/025,279 entitled “Point-to-Point Communication within a Mesh Network”, filed Jan. 31, 2008, and which are incorporated by reference. Ser. No. 61/025,270 entitled “Application Layer Device Agnostic Collector Utilizing Standardized Utility Metering Protocol Such As ANSI C12.22,” filed Jan. 31, 2008; Ser. No. 61/025,276 entitled “System And Method For Real-Time Event Report Generation Between Nodes And Head End Server In A Meter Reading Network Including Form Smart And Dumb Meters,” filed Jan. 31, 2008; Ser. No. 61/025,282 entitled “Method And System for Creating And Managing Association And Balancing Of A Mesh Device In A Mesh Network,” filed Jan. 31, 2008; Ser. No. 61/025,271 entitled “Method And System for Creating And Managing Association And Balancing Of A Mesh Device In A Mesh Network,” filed Jan. 31, 2008; Ser. No. 61/025,287 entitled “System And Method For Operating Mesh Devices In Multi-Tree Overlapping Mesh Networks”, filed Jan. 31, 2008; Ser. No. 61/025,278 entitled “System And Method For Recovering From Head End Data Loss And Data Collector Failure In An Automated Meter Reading Infrastructure,” filed Jan. 31, 2008; Ser. No. 61/025,273 entitled “System And Method For Assigning Checkpoints to A Plurality Of Network Nodes In Communication With A Device-Agnostic Data Collector,” filed Jan. 31, 2008; Ser. No. 61/025,277 entitled “System And Method For Synchronizing Data In An Automated Meter Reading Infrastructure,” filed Jan. 31, 2008; Ser. No. 61/025,285 entitled “System and Method for Power Outage and Restoration Notification in An Automated Meter Reading Infrastructure,” filed Jan. 31, 2008; and Ser. No. 61/094,116 entitled “Message Formats and Processes for Communication Across a Mesh Network,” filed Sep. 4, 2008.
This application hereby references and incorporates by reference each of the following United States nonprovisional patent applications filed contemporaneously herewith:
Ser. No. 12/275,236 entitled “Point-to-Point Communication within a Mesh Network”, filed Nov. 21, 2008; Ser. No. 12/275,305 entitled “Efficient And Compact Transport Layer And Model For An Advanced Metering Infrastructure (AMI) Network,” filed Nov. 21, 2008; Ser. No. 12/275,238 entitled “Communication and Message Route Optimization and Messaging in a Mesh Network,” filed Nov. 21, 2008; Ser. No. 12/275,242 entitled “Collector Device and System Utilizing Standardized Utility Metering Protocol,” filed Nov. 21, 2008; Ser. No. 12/275,245 entitled “System and Method for False Alert Filtering of Event Messages Within a Network,” filed Nov. 21, 2008; Ser. No. 12/275,252 entitled “Method and System for Creating and Managing Association and Balancing of a Mesh Device in a Mesh Network,” filed Nov. 21, 2008; and Ser. No. 12/275,257 entitled “System And Method For Operating Mesh Devices In Multi-Tree Overlapping Mesh Networks”, filed Nov. 21, 2008.
FIELD OF THE INVENTION
This invention pertains generally to methods and systems for providing power outage and restoration notifications within an Advanced Metering Infrastructure (AMI) network.
BACKGROUND
A mesh network is a wireless network configured to route data between nodes within a network. It allows for continuous connections and reconfigurations around broken or blocked paths by retransmitting messages from node to node until a destination is reached. Mesh networks differ from other networks in that the component parts can all connect to each other via multiple hops. Thus, mesh networks are self-healing: the network remains operational when a node or a connection fails.
Advanced Metering Infrastructure (AMI) or Advanced Metering Management (AMM) are systems that measure, collect and analyze utility usage, from advanced devices such as electricity meters, gas meters, and water meters, through a network on request or a pre-defined schedule. This infrastructure includes hardware, software, communications, customer associated systems and meter data management software. The infrastructure allows collection and distribution of information to customers, suppliers, utility companies and service providers. This enables these businesses to either participate in, or provide, demand response solutions, products and services. Customers may alter energy usage patterns from normal consumption patterns in response to demand pricing. This improves system load and reliability.
A meter may be installed on a power line, gas line, or water line and wired into a power grid for power. During an outage, the meter may cease to function. When power is restored, meter functionality may be restored.
SUMMARY
A method and system provide power outage and restoration notifications within an AMI network. Mesh networks are used to connect meters of an AMI in a geographical area. Each meter may communicate with its neighbors via the mesh network. A mesh gate links the mesh network to a server over a wide area network (WAN). When a power outage occurs among the meters of a mesh network, leaf meters transmit outage messages first. Parent meters add a parent identifier before forwarding the outage messages. This reduces the number of transmitted outage messages within the mesh network. Similarly, restoration messages are transmitted from the leaf nodes first, while parent nodes piggy-back parent identifiers when forwarding the restoration messages from the leaf meters.
In one aspect, there is provided a system and method for power outage and restoration notification in an advanced metering infrastructure network.
In another aspect, there is provided a method of transmitting a meter power status, including: recognizing a power status change at a meter; if the meter is scheduled to transmit first, transmitting a notification message to at least one neighboring meter towards a mesh gate, wherein the notification message includes a power status indicator and a meter identifier; if the meter is not scheduled to transmit first, waiting a predetermined time period to receive a notification message from at least one neighboring meter; responsive to receiving a notification message, adding a meter identifier to the received notification message before retransmitting the modified notification message to at least one neighboring meter; and retransmitting the notification message.
In another aspect, there is provided a method of transmitting a network power status, including: receiving at least one notification message from a meter, wherein the notification message includes a power status indicator and at least one meter identifier; aggregating the received meter identifiers into a composite notification message, the composite notification message including a power status indicator and at least one meter identifier; transmitting the composite notification message to a server over a wide area network; and retransmitting the composite notification message.
In another aspect, there is provided a system for transmitting a network power status, including: (A) a mesh network; (B) a wide area network separate from the mesh network; (C) at least one meter in communication with the mesh network, the meter configured to: recognize a power status change at a meter, if the meter is scheduled to transmit first, transmit a notification message to at least one neighboring meter towards a mesh gate, wherein the notification message includes a power status indicator and a meter identifier, if the meter is not scheduled to transmit first, wait a predetermined time period to receive a notification message from at least one neighboring meter, responsive to receiving a notification message, adding a meter identifier to the received notification message before retransmitting the modified notification message to at least one neighboring meter, and retransmitting the notification message; (D) a mesh gate in communication with the meter over the mesh network and in communication with the wide area network, the mesh gate configured to: receive at least one notification message from a meter, wherein the notification messages include a power status indicator and at least one meter identifier, aggregate the received meter identifiers into a composite notification message, the composite notification message includes a power status indicator and at least one meter identifier, transmit the composite notification message to a server over a wide area network, and retransmitting the composite notification message; and (E) a server in communication with the mesh gate over the wide area network, the server configured to receive the composite notification message.
In another aspect, there is provided a system for transmitting a network power status, including: a mesh network; a wide area network separate from the mesh network; at least one meter in communication with the mesh network; a mesh gate in communication with the meter over the mesh network and in communication with the wide area network; and a server in communication with the mesh gate over the wide area network, the server configured to receive the composite notification message.
In another aspect, there is provided a computer program stored in a computer readable form for execution in a processor and a processor coupled memory to implement a method of transmitting a meter power status, the method including: recognizing a power status change at a meter; if the meter is scheduled to transmit first, transmitting a notification message to at least one neighboring meter towards a mesh gate, wherein the notification message includes a power status indicator and a meter identifier; if the meter is not scheduled to transmit first, waiting a predetermined time period to receive a notification message from at least one neighboring meter; responsive to receiving a notification message, adding a meter identifier to the received notification message before retransmitting the modified notification message to at least one neighboring meter; and retransmitting the notification message.
In another aspect, there is provided a computer program stored in a computer readable form for execution in a processor and a processor coupled memory to implement a method of transmitting a network power status, including: receiving at least one notification message from a meter, wherein the notification message includes a power status indicator and at least one meter identifier; aggregating the received meter identifiers into a composite notification message, the composite notification message including a power status indicator and at least one meter identifier; transmitting the composite notification message to a server over a wide area network; and retransmitting the composite notification message.
In another aspect, there is provided a method of transmitting a meter power status, including: recognizing a power status change at a meter; if the meter is scheduled to transmit first, transmitting a notification message from the meter to at least one neighboring meter towards a mesh gate, wherein the notification message includes a power status indicator and a meter identifier; if the meter is not scheduled to transmit first, waiting a predetermined time period to receive a notification message from at least one neighboring meter; responsive to receiving a notification message, adding a meter identifier to the received notification message before retransmitting the modified notification message to at least one neighboring meter, wherein the notification message includes a power status indicator and at least one meter identifier; aggregating the received meter identifiers into a composite notification message, the composite notification message including a power status indicator and at least one meter identifier; transmitting the composite notification message to a server over a wide area network; and retransmitting the composite notification message.
In another aspect, there is provided a computer program stored in a computer readable form for execution in a processor and a processor coupled memory to implement a method of transmitting a meter power status, the method including: recognizing a power status change at a meter; if the meter is scheduled to transmit first, transmitting a notification message from the meter to at least one neighboring meter towards a mesh gate, wherein the notification message includes a power status indicator and a meter identifier; if the meter is not scheduled to transmit first, waiting a predetermined time period to receive a notification message from at least one neighboring meter; responsive to receiving a notification message, adding a meter identifier to the received notification message before retransmitting the modified notification message to at least one neighboring meter, wherein the notification message includes a power status indicator and at least one meter identifier; aggregating the received meter identifiers into a composite notification message, the composite notification message including a power status indicator and at least one meter identifier; transmitting the composite notification message to a server over a wide area network; and retransmitting the composite notification message.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an example system for providing AMI communications over a mesh network.
FIG. 2A illustrates an example meter for use within a mesh network.
FIG. 2B illustrates an example mesh gate for use within a mesh network.
FIG. 3 illustrates an example network stack for use within a mesh radio.
FIG. 4A illustrates an example procedure for transmitting outage and restoration notifications from a meter within a mesh network.
FIG. 4B illustrates an example procedure for transmitting outage and restoration notifications from a mesh gate within a wide area network.
FIG. 5A illustrates a first timing of transmitting outage notifications from a meter within a mesh network.
FIG. 5B illustrates a second timing of transmitting outage notifications from a meter within a mesh network.
FIG. 5C illustrates a third timing of transmitting outage notifications from a meter within a mesh network.
FIG. 6 illustrates a timing of transmitting restoration notifications from a meter within a mesh network.
DETAILED DESCRIPTION
FIG. 1 illustrates an example system for providing AMI communications over a mesh network. A mesh network A 100 may include a mesh gate A 102 and a plurality of meters: meters A 104 , B 106 , C 108 , D 110 , E 112 , and F 114 . A mesh gate may also be referred to as a NAN-WAN gate or an access point. The mesh gate A 102 may communicate to a server 118 over a wide area network 116 . Optionally, a mesh gate B 120 and a mesh network B 122 may also communicate with the server 118 over the wide area network (WAN) 116 . Optionally, a mesh gate C 124 and a mesh network C 126 may also communicate with the server 118 over the wide area network 116 .
In one example embodiment, the server 118 is known as a “head end.” The mesh gate may also be known as a collector, a concentrator, or an access point.
It will be appreciated that a mesh device association can include a registration for application service at the mesh gate A 102 or the server 118 . The mesh gate A 102 and the server 118 can maintain a table of available applications and services and requesting mesh devices.
The mesh network A 100 may include a plurality of mesh gates and meters which cover a geographical area. The meters may be part of an AMI system and communicate with the mesh gates over the mesh network. For example, the AMI system may monitor utilities usage, such as gas, water, or electricity usage and usage patterns.
The mesh gate A 102 may provide a gateway between the mesh network A 100 and a server, discussed below. The mesh gate A 102 may include a mesh radio to communicate with the mesh network A 100 and a WAN communication interface to communicate with a WAN.
The mesh gate A 102 may aggregate information from meters within the mesh network A 100 and transmit the information to the server. The mesh gate A 102 may be as depicted below. It will be appreciated that while only one mesh gate is depicted in the mesh network A 100 , any number of mesh gates may be deployed within the mesh network A 100 , for example, to improve transmission bandwidth to the server and provide redundancy. A typical system will include a plurality of mesh gates within the mesh network. In a non-limiting embodiment for an urban or metropolitan geographical area, there may be between 1 and 100 mesh gates, though this is not a limitation of the invention. In one embodiment, each mesh gate supports approximately 400 meters, depending on system requirements, wireless reception conditions, available bandwidth, and other considerations. It will be appreciated that it is preferable to limit meter usage of bandwidth to allow for future upgrades.
The meters A 104 , B 106 , C 108 , D 110 , E 112 , and F 114 may each be a mesh device, such as a meter depicted below. The meters may be associated with the mesh network A 100 through direct or indirect communications with the mesh gate A 102 . Each meter may forward or relay transmissions from other meters within the mesh network A 100 towards the mesh gate A. It will be appreciated that while only six meters are depicted in the mesh network A 100 , any number of meters may be deployed to cover any number of utility lines or locations.
As depicted, only meters A 104 and D 110 are in direct communications with mesh gate A 102 . However, meters B 106 , E 112 and F 114 can all reach mesh gate A 102 through meter D 110 . Similarly, meter C 108 can reach mesh gate A 102 through meter E 112 and meter D 110 .
The wide area network (WAN) 116 may be any communication medium capable of transmitting digital information. For example, the WAN 116 may be the Internet, a cellular network, a private network, a phone line configured to carry a dial-up connection, or any other network.
The server 118 may be a computing device configured to receive information from a plurality of mesh networks and meters. The server 118 may also be configured to transmit instructions to the mesh networks, mesh gates, and meters.
It will be appreciated that while only one server is depicted, any number of servers may be used in the AMI system. For example, servers may be distributed by geographical location. Redundant servers may provide backup and failover capabilities in the AMI system.
The optional mesh gates B 120 and C 124 may be similar to mesh gate A 102 , discussed above. Each mesh gate may be associated with a mesh network. For example, mesh gate B 120 may be associated with mesh network B 122 and mesh gate C 124 may be associated with mesh network C 126 .
The mesh network B 122 and the mesh network C 126 may be similar to the mesh network A 102 . Each mesh network may include a plurality of meters (not depicted).
Each mesh network may cover a geographical area, such as a premise, a residential building, an apartment building, or a residential block. Alternatively, the mesh network may include a utilities network and be configured to measure utilities flow at each sensor. Each mesh gate communicates with the server over the WAN, and thus the server may receive information from and control a large number of meters or mesh devices. Mesh devices may be located wherever they are needed, without the necessity of providing wired communications with the server.
FIG. 2A illustrates an example meter for use within a mesh network. A meter 200 may include a radio 202 , a communication card 204 , a metering sensor 206 , and a battery or other power or energy storage device or source 208 . The radio 202 may include a memory 210 , a processor 212 , a transceiver 214 , and a microcontroller unit (MCU) 216 or other processor or processing logic.
A mesh device can be any device configured to participate as a node within a mesh network. An example mesh device is a mesh repeater, which can be a wired device configured to retransmit received mesh transmissions. This extends a range of a mesh network and provides mesh network functionality to mesh devices that enter sleep cycles.
The meter 200 may be a mesh device communicating with a mesh gate and other mesh devices over a mesh network. For example, the meter 200 may be a gas, water or electricity meter installed in a residential building or other location to monitor utilities usage. The meter 200 may also control access to utilities on server instructions, for example, by reducing the flow of gas, water or electricity.
The radio 202 may be a mesh radio configured to communicate with a mesh network. The radio 202 may transmit, receive, and forward messages to the mesh network. Any meter within the mesh network may thus communicate with any other meter or mesh gate by communicating with its neighbor and requesting a message be forwarded.
The communication card 204 may interface between the radio 202 and the sensor 206 . Sensor readings may be converted to radio signals for transmission over the radio 202 . The communication card 204 may include encryption/decryption or other security functions to protect the transmission. In addition, the communication card 204 may decode instructions received from the server.
The metering sensor 206 may be a gas, water, or electricity meter sensor, or another sensor. For example, digital flow sensors may be used to measure a quantity of utilities consumed within a residence or building. Alternatively, the sensor 206 may be an electricity meter configured to measure a quantity of electricity flowing over a power line.
The battery 208 may be configured to independently power the meter 200 during a power outage. For example, the battery 208 may be a large capacitor storing electricity to power the meter 200 for at least five minutes after a power outage. Small compact but high capacity capacitors known as super capacitors are known in the art and may advantageously be used. One exemplary super capacitor is the SESSCAP 50 f 2.7 v 18×30 mm capacitor. Alternative battery technologies may be used, for example, galvanic cells, electrolytic cells, fuel cells, flow cells, and voltaic cells.
It will be appreciated that the radio 202 , communication card 204 , metering sensor 206 and battery 208 may be modular and configured for easy removal and replacement. This facilitates component upgrading over a lifetime of the meter 200 .
The memory 210 of the radio 202 may store instructions and run-time variables of the radio 202 . For example, the memory 210 may include both volatile and non-volatile memory.
The memory 210 may also store a history of sensor readings from the metering sensor 206 and an incoming queue of server instructions.
The processor 212 of the radio 202 may execute instructions, for example, stored in memory 210 . Instructions stored in memory 210 may be ordinary instructions, for example, provided at time of meter installation, or special instructions received from the server during run time.
The transceiver 214 of the radio 202 may transmit and receive wireless signals to a mesh network. The transceiver 214 may be configured to transmit sensor readings and status updates under control of the processor 212 . The transceiver 214 may receive server instructions from a server, which are communicated to the memory 210 and the processor 212 .
In the example of FIG. 2A , the MCU 216 can execute firmware or software required by the meter 200 . The firmware or software can be installed at manufacture or via a mesh network over the radio 202 .
In one embodiment, any number of MCUs can exist in the meter 200 . For example, two MCUs can be installed, a first MCU for executing firmware handling communication protocols, and a second MCU for handling applications.
It will be appreciated that a mesh device and a mesh gate can share the architecture of meter 200 . The radio 202 and the MCU 216 provide the necessary hardware, and the MCU 216 executes any necessary firmware or software.
Meters may be located in geographically dispersed locations within an AMI system. For example, a meter may be located near a gas line, an electric line, or a water line entering a building or premise to monitor a quantity of gas, electricity, or water. The meter may communicate with other meters and mesh gates through a mesh network. The meter may transmit meter readings and receive instructions via the mesh network.
FIG. 2B illustrates an example mesh gate for use within a mesh network. The mesh gate 230 may include a mesh radio 232 , a wide area network interface 234 , a battery 236 , and a processor 238 . The mesh radio 232 may include a memory 242 , a processor 244 , and a transceiver 246 .
The mesh gate 230 may interface between mesh devices (for example, meters) in a mesh network and a server. For example, meters may be as discussed above. The mesh gate 230 may be installed in a central location relative to the meters and also communicate with a server over a WAN.
The mesh radio 232 may be a mesh radio configured to communicate with meters over a mesh network. The radio 232 may transmit, receive, and forward messages to the mesh network.
The WAN interface 234 may communicate with a server over a WAN. For example, the WAN may be a cellular network, a private network, a dial up connection, or any other network. The WAN interface 234 may include encryption/decryption or other security functions to protect data being transmitted to and from the server.
The battery 236 may be configured to independently power the mesh gate 230 during a power outage. For example, the battery 236 may be a large capacitor storing electricity to power the mesh gate 230 for at least five minutes after a power outage. A power outage notification process may be activated during a power outage.
The processor 238 may control the mesh radio 232 and the WAN interface 234 . Meter information received from the meters over the mesh radio 232 may be compiled into composite messages for forwarding to the server. Server instructions may be received from the WAN interface 234 and forwarded to meters in the mesh network.
It will be appreciated that the mesh radio 232 , WAN interface 234 , battery 236 , and processor 238 may be modular and configured for easy removal and replacement. This facilitates component upgrading over a lifetime of the mesh gate 230 .
The memory 242 of the mesh radio 232 may store instructions and run-time variables of the mesh radio 232 . For example, the memory 242 may include both volatile and non-volatile memory. The memory 242 may also store a history of meter communications and a queue of incoming server instructions. For example, meter communications may include past sensor readings and status updates.
The processor 244 of the mesh radio 232 may execute instructions, for example, stored in memory 242 . Instructions stored in memory 242 may be ordinary instructions, for example, provided at time of mesh gate installation, or special instructions received from the server during run-time.
The transceiver 246 of the mesh radio 232 may transmit and receive wireless signals to a mesh network. The transceiver 246 may be configured to receive sensor readings and status updates from a plurality of meters in the mesh network. The transceiver 246 may also receive server instructions, which are communicated to the memory 242 and the processor 244 .
A mesh gate may interface between a mesh network and a server. The mesh gate may communicate with meters in the mesh network and communicate with the server over a WAN network. By acting as a gateway, the mesh gate forwards information and instructions between the meters in its mesh network and the server.
FIG. 3 illustrates an example network stack for use within a mesh radio. A radio 300 may interface with an application process 302 . The application process 302 may communicate with an application layer 304 , which communicates with a transport layer 306 , a network layer 308 , a data link layer 310 and a physical layer 312 .
The radio 300 may be a mesh radio as discussed above. For example, the radio 300 may be a component in a meter, a mesh gate, or any other mesh device configured to participate in a mesh network. The radio 300 may be configured to transmit wireless signals over a predetermined frequency to other radios.
The application process 302 may be an executing application that requires information to be communicated over the network stack. For example, the application process 302 may be software supporting an AMI system.
The application layer 304 interfaces directly with and performs common application services for application processes. Functionality includes semantic conversion between associated application processes. For example, the application layer 304 may be implemented as ANSI C12.12/22.
The transport layer 306 responds to service requests from the application layer 304 and issues service requests to the network layer 308 . It delivers data to the appropriate application on the host computers. For example, the layer 306 may be implemented as TCP (Transmission Control Protocol), and UDP (User Datagram Protocol).
The network layer 308 is responsible for end to end (source to destination) packet delivery. The functionality of the layer 308 includes transferring variable length data sequences from a source to a destination via one or more networks while maintaining the quality of service, and error control functions. Data will be transmitted from its source to its destination, even if the transmission path involves multiple hops.
The data link layer 310 transfers data between adjacent network nodes in a network, wherein the data is in the form of packets. The layer 310 provides functionality including transferring data between network entities and error correction/detection. For example, the layer 310 may be implemented as IEEE 802.15.4.
The physical layer 312 may be the most basic network layer, transmitting bits over a data link connecting network nodes. No packet headers or trailers are included. The bit stream may be grouped into code words or symbols and converted to a physical signal, which is transmitted over a transmission medium, such as radio waves. The physical layer 312 provides an electrical, mechanical, and procedural interface to the transmission medium. For example, the layer 312 may be implemented as IEEE 802.15.4.
The network stack provides different levels of abstraction for programmers within an AMI system. Abstraction reduces a concept to only information which is relevant for a particular purpose. Thus, each level of the network stack may assume the functionality below it on the stack is implemented. This facilitates programming features and functionality for the AMI system.
FIG. 4A illustrates an example procedure for transmitting outage and restoration notifications from a meter within a mesh network. A mesh device, such as a meter, may include a sensor for measuring utilities and receive power from a power grid. At times, the power grid may fail during a power outage. The power grid may also be restored after an outage. The meter may include a battery configured to power the meter for a period of time, during which the meter executes a power outage notification procedure to inform a mesh gate and a server of the power outage. Similarly, the meter may execute a power restoration notification when functionality is restored after power is restored to the power grid.
In 400 , the meter may detect a power status change. For example, the meter may include an electric sensor sensing a power, current, or voltage of an electric line powering the meter from a power grid. When the sensor senses a cut-off in electricity, the meter may wait a predetermined recognition period before determining that a power outage has occurred.
When a meter's power is restored after an outage, the meter may also wait a predetermined recognition period before determining that the power outage has ended and power has been restored. Using a recognition period before an outage or a restoration has occurred prevents the meter from trigging the notification procedure for brief outages and restorations.
In 402 , the meter tests whether it is the first to transmit. For example, the meter may look up a neighborhood table to determine whether it is a leaf meter. A leaf meter may have no children meters, and is thus the last meter on its associated branch. For example, FIG. 1 depicts meters A 104 , B 106 , C 108 , and F 114 as leaf meters. Meter F 114 is a leaf meter because no child meter would transmit through it to reach mesh gate A 102 , even though meter F 114 has two alternate paths to the mesh gate A 102 (F 114 to E 112 to D 110 to mesh gate or F 114 to D 110 to mesh gate).
A one-hop device, which can be a device in direct communications with the mesh gate, may transmit immediately.
Alternatively, the meter may look up the neighborhood table to determine a number of hops to the mesh gate. If it is farthest from the mesh gate on its branch, it will transmit first. If the meter determines yes, the meter proceeds to 404 . If no, the meter proceeds to 410 . The neighborhood table can be built during association requests and subsequent neighbor exchanges.
In 404 , the meter may transmit a notification message. The notification message may include a nature of the notification (whether a power outage or restoration has occurred, as determined in 400 ) and a meter identifier. The meter identifier may be a globally unique identifier assigned to the meter at manufacture or installation that identifies the meter to the mesh gate and the server.
If the notification message has previously been transmitted, the meter may attempt a retry transmission. Retries may be attempted until an acknowledgement is received or a predetermined number of retry attempts has been exceeded.
Information transmitted in the transmission may include a device identifier, a time of outage, and any other necessary information. In one embodiment, a number of transmitted neighbor information may be restricted. For example, only a predetermined maximum number of parents, siblings, and children node information can be transmitted to limit message size. Neighbors can be selected based on a preferred route ratio. Neighbors that are on a preferred route of a meter's path to the mesh gate may be prioritized. The preferred route ratio can be used to select routes with a minimum of hops over a best minimum signal quality link to the mesh gate.
In 406 , the meter may test whether it has exceeded a predetermined retry attempts. The meter may increment a counter for a number of retries after every attempt to transmit a notification message in 404 . The predetermined retry attempts may be set to limit network congestion, both within the mesh network and over a WAN from a mesh gate to the server during a power outage and restoration.
Alternatively, the meter may continually attempt to transmit until its battery is drained during a power outage notification procedure. This may be used in an AMI system where it is important to receive as many accurate outage notifications as possible, or where network bandwidth is of lesser concern. If the predetermined retry attempts have been exceed, the procedure ends. If no, the meter procedures to 408 .
In 408 , the meter optionally delays a random time period. For example, the delay may allow other meters in the mesh network to transmit and reduce collisions. Further, the delay may improve battery life after a power outage.
The random time period may be associated with a predetermined floor value, below which it cannot be set. This may be an exclusion period during which no retransmission may be attempted by the meter.
In 410 , the meter tests whether a child message has been received. For example, a non-leaf meter will not transmit during a first attempt, and may receive notification messages from child meters. If yes, the meter proceeds to 412 . If no, the meter proceeds to 404 . In one embodiment, if the meter determines it has missed the child messages, it may immediately transmit its message.
In 412 , the meter may insert a meter identifier in the notification message. The notification message received from the child meter in 410 may include a status (whether the notification is for a power outage or restoration) and at least one meter identifier associated with children meters. The meter may insert its own identifier into the message before forwarding the message in 404 .
By executing the procedure above, leaf meters transmit notification messages first. Each meter waits to receive a notification message from children meters before adding its identifier and forwarding the notification to its parent meter. This reduces message congestion in the mesh network during a notification procedure.
In an alternative example, each parent meter may determine how many children meters it has, and wait for notification messages from all children meters before compiling the messages into one message to be forwarded. Alternatively, the parent meter may wait for a predetermined period of time, because only some children meters may be affected by a power outage.
It will be appreciated that if a meter has not suffered a power outage, it would simply forward any received notification messages to its parent without adding its identifier into the message. Similarly, if a parent meter has not had a power restoration; it will remain off and be unable to forward notification messages. In this example, children meters may attempt alternative routes to transmit notification messages, as discussed below.
FIG. 4B illustrates an example procedure for transmitting outage and restoration notifications from a mesh gate within a wide area network. A mesh gate and its associated mesh devices, such as meters, may receive power from a power grid. At times, the power grid may fail during a power outage. The power grid may also be restored after an outage. The mesh gate may include a battery configured to power the mesh gate for a period of time, during which the mesh gate executes a power outage notification procedure to inform a server of the outage and affected meters. Similarly, the mesh gate may execute a power restoration notification when power is restored to the power grid.
In 450 , the mesh gate may receive a notification message from a meter within its mesh network. For example, the notification message may include a status indicating whether it is an outage or restoration notification and at least one meter identifier. The notification message may be as discussed above.
In 452 , the mesh gate may test whether it has finished receiving notification messages from the mesh network. For example, the mesh gate may continually receive notification messages until its battery drops to a critical level during an outage. The critical level may be set to where enough power remains in the battery to allow the mesh gate to transmit its composite notification message to the server, as discussed below, along with a predetermined number of retries.
Alternatively, the mesh gate may wait for a predetermined time period after receiving a first notification message. For example, the predetermined time period may be determined, in part, based on the size of the mesh network, the maximum number of hops to reach a leaf meter, the link quality of the mesh network, etc.
Alternatively, the mesh gate may proceed as soon as message notifications from all children meters within the mesh network have been received. If all children meters are accounted for, the mesh gate does not need to wait for further notification messages.
If the mesh gate has finished receiving notification messages, it may proceed to 454 . If no, it may proceed to 450 to await more notification messages.
In 454 , the mesh gate may select a power reporting configuration. For example, two power reporting configurations may be available: one used for minor outage, such as one affecting only a few meters, and one used for major outages, such as one affecting many meters. The power reporting configuration may affect the retry attempts and delay periods discussed below.
For example, it may be very important to inform the server of a major outage. Thus, a high number of retry attempts may be set. It may be likely that a major outage has affected other mesh networks. Thus, a longer delay period may be used to reduce transmission collisions over the WAN. In addition, a longer window may be set to wait for notification messages from meters.
In 456 , the mesh gate may aggregate all the notification messages into a composite notification message. For example, the mesh gate may create the composite notification message containing a status indicating whether an outage or restoration has occurred in the mesh network and a list of meter identifiers associated with the notification. For example, the list of meter identifiers may be received in 452 from one or more meters.
In one example, the mesh gate may receive both an outage and a restoration notification message. The mesh gate may aggregate a first notification message, for example, all received outage notification messages, for transmission. Then, the mesh gate may aggregate a second notification message, for example, the restoration notification message for transmission.
In 458 , the mesh gate may transmit the composite notification message to the server over a WAN. For example, the WAN may be a cellular network, a wired network, or another network configured to carry information. In one example, the WAN used to transmit the composite notification message may be a secondary communications medium. A primary wired network may fail during a power outage, and therefore a backup network may be used. For example, the backup network may be a battery-powered network, cellular network, a battery-powered wired network, or another network configured to operate during an outage.
If the composite notification message has previously been transmitted, the mesh gate may attempt a retry transmission. Retries may be attempted until an acknowledgement is received or a predetermined number of retry attempts has been exceeded.
In 460 , the mesh gate may test whether a predetermined number of retry attempts has been exceeded. The mesh gate may increment a counter for a number of retries after every attempt to transmit a notification message in 458 . The predetermined retry attempts may be set to limit network congestion over the WAN to the server during a power outage and restoration.
Alternatively, the mesh gate may continually attempt to transmit until its battery is drained during a power outage notification procedure. This may be used in an AMI system where it is important to receive as many accurate outage notifications as possible, or where network bandwidth is of lesser concern.
For example, the predetermined number of retry attempts may be set in part based on the power reporting configuration selected in 454 . If the predetermined number of retry attempts has been exceeded, the mesh gate may end the procedure. If no, the mesh gate may proceed to 462 .
In 462 , the mesh gate may optionally delay a random time period. For example, the delay may allow other mesh gates in the WAN to transmit and reduce collisions. Further, the delay may improve battery life after a power outage.
For example, the delay period may be set in part based on the power reporting configuration selected in 454 . The random time period may be associated with a floor value, below which it cannot be set. This may be an exclusion period during which no retransmission may be attempted.
The mesh gate may aggregate all notification messages sent to it by meters over the mesh network. The composite notification message consists of a power status and a list of meter identifiers identifying the meters affected by the power status. The composite notification message may be transmitted over an outage-resistant communications link to a server.
FIG. 5A illustrates a first timing of transmitting outage notifications from a meter within a mesh network. A power outage notification process allows orderly transmission of power outage notification from one or more mesh devices (such as a meter) in a mesh network to a mesh gate. The mesh gate aggregates the notifications and transmits a composite message to a server. Because the mesh network may include a large number of meters, transmitting individual notifications from each meter may cause network congestion, especially because other meters within the mesh network are also likely affected by the same outage and will also be sending outage notifications.
A recognition period (e.g., RECOGNITION_PERIOD) may elapse between an occurrence of a power outage and time T 1 , when the power outage is recognized by the meter. The recognition period may prevent minor power fluctuations or outages from triggering the outage notification procedure.
FIG. 5B illustrates a second timing of transmitting outage notifications from a meter within a mesh network. The meter may wait for a first random period before a first attempt to send a power outage notification at time T 2 . A first attempt wait period (e.g., PO_RND_PERIOD) may represent a maximum random delay in seconds used before the first attempt. This random delay starts after recognition period (RECOGNITION_PERIOD) elapses at time T 1 . The first attempt is reserved for leaf meters. A meter which is not a leaf meter will not transmit during the first attempt.
The meter may wait for a retry random period before a retry attempt at time T 3 . A retry wait period (e.g., PO_RETRY_RND_PERIOD) may represent a maximum random delay in seconds used for each retry. This random delay starts after time T 2 , when a first transmission attempt occurs.
Using a random delay before the first and retry attempts prevents colliding transmission from multiple meters and reduces network congestion. If a meter attempts to transmit but a transmission is already in progress, the meter may wait for the transmission in progress to end before attempting to transmit.
If a meter receives a notification from a child meter, its transmission includes the child's notification plus the meter's identifier. By piggy-backing the meter's identifier in a child's notification and forwarding the notification, the number of individual notifications and messages are reduced in the mesh network.
The meter may continually retry to transmit an outage notification until the meter's battery is drained. In addition, there may be a predetermined maximum number retries. In addition, there may be a minimum period for the first delay and the subsequent retry delays. The minimum delay periods may eliminate the possibility of immediate retransmissions and guarantee a minimum delay between attempts.
The mesh gate may receive all the power outage notification messages and compile the information into a message for transmission to a server over a WAN. The mesh gate may also retransmit the compiled notification as necessary, until its battery is drained.
Child meters in a mesh network transmit outage notifications first, and parent meters piggy-back meter identifiers into the child notifications before forwarding the child notifications. A number of messages and notifications transmitted in the mesh network during an outage are thereby reduced.
FIG. 6 illustrates a timing of transmitting restoration notifications from a meter within a mesh network. A power restoration notification process allows orderly transmission of power restoration notification messages from one or more mesh devices (such as a meter) in a mesh network to a mesh gate. The mesh gate aggregates the notifications and transmits a composite message to a server. Because the mesh network may include a large number of meters, transmitting individual notifications from each meter may cause network congestion, especially because other meters within the mesh network are also likely affected by the restoration and will also be sending restoration notifications.
When power is restored at a meter, the meter may first wait for a recognition period before deciding the power has been restored. The recognition period may prevent triggering restoration notifications when power returns for a brief moment before the outage continues.
A first random period, PR_RND_PERIOD, may represent a maximum random delay used before a first attempt is made to send a power restoration notification. This first random period may begin after the power restored recognition period, PR_RECOGNITION_PERIOD. A first notification may be transmitted. Only leaf meters transmit during the first attempt.
A retry random period, PR_RETRY_RND_PERIOD, may represent a maximum random delay before a retry to send a power restoration notification. The retry random period begins after the first random period.
Using a random delay before the first and retry attempts reduces colliding transmission from multiple meters. If a meter attempts to transmit but a transmission is already in progress, the meter may wait for the transmission to end before attempting to transmit.
Referring to FIG. 5C , after the first attempt to transmit has been made, the mesh gate may wait a minimum delay (e.g., MIN_DELAY) to time T 4 and an additional random period (e.g., RAND_PERIOD) to time T 5 before retrying transmission. Each retry attempt may be preceded by a retry random period (e.g., RETRY_RND_PERIOD) to time T 6 , and a maximum number of retry attempts may be set at maximum retries (e.g., MAX_RETRIES). The procedure may stop at time T 7 , after all retry attempts have been made.
If a meter receives a notification from a child meter, its transmission includes the child's notification plus the meter's identifier. By piggy-backing the meter's identifier in a child's notification and forwarding the notification, the number of individual notifications and messages are reduced in the mesh network.
The mesh gate may receive all power restoration notification messages and compile the information into a composite message for transmission to a server over a WAN. Similarly, the mesh gate may also repeatedly attempt to transmit the composite restoration message until a maximum number of retries have been made or the server acknowledges the transmission.
Child meters in a mesh network transmit restoration notifications first, and parent meters piggy-back meter identifiers into the child notifications before forwarding the child notifications. A number of messages and notifications transmitted in the mesh network during a restoration are thereby reduced.
If a child meter attempts to forward a message to a parent meter that is not functional (for example, the parent meter's power has not been restored); the child meter may wait a predetermined period of time. If the parent meter remains non-functional, the child meter may attempt to send its notification via an alternative path through the mesh network stored in its memory. If that fails, the child meter may attempt to discover a new route through the mesh network to the mesh gate. If that fails, the child meter may attempt to associate with a new mesh network in order to transmit its restoration notification message.
Although the above embodiments have been discussed with reference to specific example embodiments, it will be evident that the various modification, combinations and changes can be made to these embodiments. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than in a restrictive sense. The foregoing specification provides a description with reference to specific exemplary embodiments. It will be evident that various modifications may be made thereto without departing from the broader spirit and scope as set forth in the following claims. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense.
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A method and system are provided to transmit a meter power status. The method includes recognizing a power status change at a meter. The method includes, if the meter is scheduled to transmit first, transmitting a notification message to at least one neighboring meter towards a mesh gate, wherein the notification message includes a power status indicator and a meter identifier. The method includes, if the meter is not scheduled to transmit first, waiting a predetermined time period to receive a notification message from at least one neighboring meter. The method includes, responsive to receiving a notification message, adding a meter identifier to the received notification message before retransmitting the modified notification message to at least one neighboring meter. The method includes retransmitting the notification message.
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The present invention is a method and apparatus for detecting bearing overheating in oil-lubricated vertical turbine pumps, and for giving warning and shuting down water well vertical pumps.
BACKGROUND
A problem associated with well vertical pumps and their rotating parts is the overheating of bearings in which the parts rotate. Bearing overheating may be the result of (1) the breaking down of the chemical integrity of a lubricant with a consequent loss of lubricating qualities or (2) the interruption of the flow of lubricant through narrow passages through the bearings and packings.
In the latter case, for instance in a typical well pump system, the needle valve that regulates the flow of oil in the oil-lubricated, vertical turbine pump becomes clogged easily. The oil is gravity fed from an oil container drum and regulated through a sight gauge by an adjustable needle valve to provide a flow of approximately 6 to 8 drops per minute. It is delivered to the top bearing of the well through a 1/4" copper tube and then through grooves cut in the top bearing and the rest of the well bearings, which are spaced at five foot intervals, all the way down to the bottom of the well where the pump bowls are located. The needle valve regulator is sensitive to moisture, dust and various foreign particles that are present in farm environments, all of which cause clogging in the needle valve. The consequent loss of oil flow causes increased friction which, in turn, permits the pump shaft and bearings to overheat. Sixty-five minutes after the lubricant flow interruption, temperatures in a lineshaft may exceed 400 F. (the flash point of common motor oils), causing residual oil in the shaft to vaporize. If the pump continues operation thereafter without lubrication the bearing temperature will exceed 1100 F. in less than one hour, causing a typical bronze bearing to experience massive wear very quickly and to flake off into the oil chamber and onto the bearing below, resulting in pump shaft failure.
Pump shaft failure involves expensive repairs and loss of service while the well is down. For example, in agriculture, crucial periods in crop growth require a constant supply of irrigation water; consequently, any significant loss of water supply at such times results in partial or complete crop failure
Prior art patents offer some suggestions for dealing with the problem of bearing failure resulting from excessive temperature. Heckert (U.S. Pat. No. 2,089,369) described an overheated bearing and journal detection and identification system associated with wheel axles of railway cars. Heckert's heat detection system relied on the melting point of a fusible closure disk intimately associated with a journal box and a bearing.
Others have resorted to the use of various temperature sensing means imbedded in the bearing itself or, alternatively, in the bearing housing support to detect and monitor bearing temperatures (Waseleski et al, 3,824,579; Bergman et al 4,074,574; Gustafson 3,052,123; Reumund 2,964,875). However, because bearings associated with well pumps are located within oil tube lineshaft encasements surrounded by flowing water, temperature sensors embedded in such bearings may be inaccurate and their temperature readings unreliable. Even the flow of water below the bearing affects the temperature perceived by a sensor embedded in the bearing. Sometimes a packing heats up instead of a bearing, but a sensor imbedded in the bearing is not sensitive to the packing temperature, and it is not practical to embed a sensor in the packing.
FEATURES OF THE INVENTION
It is an object of this invention to overcome the problems of the prior art and provide an inexpensive, accurate method of early detection and system shutdown in the presence of abnormal temperatures before bearing damage or pump failure occurs, saving costly repair bills and preventing loss due to water supply interruption. The various features and advantages of this invention are:
A means and method for detecting bearing and packing temperature changes indirectly is provided;
The device of this invention may be retrofitted to an existing pump or incorporated into original equipment manufacture;
The device of this invention may be adapted to remote temperature monitoring and remote audio or visual warning;
The invention uses existing energy sources;
The invention may be incorporated in a customized temperature warning device adaptable to any bearing composition with readjustable temperature warning set points.
Other objects and features of this invention will appear to persons skilled in the art as the description unfolds.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides a method of use and a device having temperature sensing or detecting means, such as a temperature probe, disposed in the air space above the first line shaft pump bearing at a point where it is not materially affected by water flowing through the pump. Alternatively, the probe may be disposed in the oil inlet chamber or in the air space between the shaft and the oil tube wall, just above the top bearing.
The temperature sensing means is operatively connected to a temperature monitoring means with a selected alarm point that signals an abnormal rise in the air space temperature to alert pump operators that a bearing is overheating. Corrective actions may then be taken before the pump fails.
Alternatively, a limiting temperature set point is used as a failsafe mechanism to signal a switch that automatically shuts down the pump when the detection means signals a temperature in the air space exceeding a predetermined value, thus preventing bearing damage and consequent pump failure.
A signal, responsive to a predetermined temperature valve, is generated by a temperature sensing means and sent from the well to a switch having a limiting temperature set point. The set point is responsive to a pre-set maximum emergency temperature. The signal energizes a red warning light and a switch to shut down the pump motor before any damage can occur to the pump shaft and bearings. The switch acts as a fail safe mechanism to protect the well shaft and bearings from damage.
In one embodiment, the signal means is a warning light visible from a distance. In another embodiment the signal operates a remote switch that shuts down the pump motor, and may also operate a remote warning device to alert the pump operators to the overheating bearig.
The method involves the step of measuring the temperature of the air space above the top bearing and giving an alarm and/or shutting down the pump system at a predetermined value when an abnormal temperature is detected.
BRIEF DESCRIPTION OF THE DRAWINGS
Turning now to the drawings, wherein a presently preferred embodiment of the invention is shown:
FIG. 1 is an elevation view of a pump and well apparatus, partially broken away to show interior details, that is retrofitted with the detection device herein disclosed.
FIG. 2 is a section of the view of FIG. 1, taken along the lines 2--2.
FIG. 3 is a section of the view of FIG. 1, taken along the lines 3--3.
FIG. 4 is an enlarged portion of the view of FIG. 1;
FIG. 5 is a schematic drawing of the electrical circuit used in a presently preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is based on the discovery that the top bearing in a vertical well pump system fails first, producing an increase in heat in and around the pumpshaft immediately above the top bearing in the stuffing box, and upon the further discovery that one may reliably detect an overheated bearing by taking the temperature of the air space above the top bearing. A temperature sensing means disposed in the air space above the top bearing can be used to monitor the shaft temperature, which has a significant relationship to bearing temperature, thus providing indirectly an inexpensive, reliable warning of an overheating bearing.
Although persons skilled in the art will recognize that the invention of this disclosure may be incorporated in original pump equipment systems for many different uses, it is also ideally suited to the retrofit modification of existing pump systems, and the description that follows is couched in terms of a retrofit application to an existing vertical pump installation.
Referring now to figures 1 and 2, in a typical vertical pump well system wherein a lubricant is gravity fed from an oil delivery reservoir 22 serving the production well vertical pump system 10, and regulated through a sight gage 24 by an adjustable needle valve oil regulator 23 providing an oil flow measured in drops per minute, oil is delivered through a copper tube 13 passing through the oil tube packing nut 21 to the top bearing 12 of the pump line shaft 11. As seen in FIG. 2, the oil then seeps through grooves 29 cut in the bearings 12 and through the remaining line shaft bearings 20, (not shown, but spaced at five foot intervals along the pump line shaft 11, to the bottom of the well where the pump bowl is located).
Referring additionally to FIGS. 3 and 4, a temperature probe 17, provided according to this invention, is mounted in a bore 25 in the oil tube packing nut 21 and opening to an air space 18 communicating between the oil inlet chamber 26 below the dust seal packing 15 and the oil tube space 18a. The bore opening 25, tapped in the wall of the oil inlet chamber 26, is fitted with a brass collar 27. The probe 17 is inserted in the collar 27 and secured in place by a collet 31. A type "E" thermocouple probe 17 encased in a protective stainless steel tube is set 1/8 inch from the pump shaft 11 by first touching the shaft and then backing it off the required distance
FIG. 5 shows a simple relay circuit responsive to temperatures sensed by the type "E" thermocouple probe 17. A power source (not shown) supplies standard 110-120 volt power which is stepped down to 12-24 volts by a step-down transformer 38 to supply a type."E" thermocouple probe 17.
As the resistance of the type "E" thermocouple probe 17 decreases responsive to an increase in oil inlet chamber 26 temperature, more voltage is applied across the variable resistor 39 to a point where there is current flow through the gate-cathode junction of the silicon controlled rectifier 40 during positive half cycles applied to the anode thereof, thereby causing a full alternating current signal to be applied across the relay coil 41 which energizes the relay.
When the type "E" thermocouple probe 17 senses a sufficiently high temperature and the silicon controlled rectifier 40 is conductive to the point of energizing the relay coil 41, a pair of normally open contacts 42 are closed and a warning light 43 is then energized through the closed contacts, indicating the limiting temperature has been reached, and simultaneously shutting down the pump motor.
Adjustments of the variable resistor may be accomplished with a set point potentiometer serving to adjust the level at which the silicon controlled rectifier 40 becomes conductive. The potentiometer can be located at a point remote from the bearing which makes it possible for the type "E" thermocouple probe 17 to be operated over a wide range of temperatures.
In an optional embodiment, the temperature probe 17, which is connected to a temperature monitoring instrument as in the first embodiment, may be extended downward into the air space 18a between the shaft 11 and the oil tube 30 to a point above the top bearing, preferably 1/2 inch above it. Located in either position the limiting temperature set point may be computed and set by persons skilled in art, without undue experimentation, with reference to the composition of the bearings used in the pump shaft system.
In some circumstances an optional embodiment may be desired to include a pre-shutdown warning light. A first signal, responsive to a predetermined increase in temperature, may be generated by the type "E" thermocouple probe 17 and sent from the well to a switch having two limiting temperature set points. The first set point may be responsive to a slight increase in temperature operating ranges above normal, turning on an amber light so that a caretaker may take early corrective action before the pump shuts down and interrupts the flow of water. If the temperature continues to rise, a second set point, responsive to a pre-set maximum (emergency) temperature shuts down the pump a described above.
Various alternative equivalent means and structures will suggest themselves to persons skilled in the art from a study of this specification which sets forth the presently preferred embodiments. The invention, however, is limited only by the attached claims and equivalents thereof.
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A deep well water pump system has a temperature probe (17) in the air space above the top bearing (12), preferably in the oil inlet chamber (26), and provides means for signalling abnormal temperatures to warning and system shutdown means. A method of detecting bearing overheating indirectly by sensing the shaft temperature and/or the temperature in the enclosed air space above the bearing is disclosed.
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FIELD OF THE INVENTION
This invention relates to hard disk drives. More particularly, it relates to suspension designs with a bi-layer flexure base.
BACKGROUND
Hard disk drives are common information storage devices essentially consisting of a series of rotatable disks that are accessed by magnetic reading and writing elements. These data transferring elements, commonly known as transducers, are typically carried by and embedded in a slider body that is held in a close relative position over discrete data tracks formed on a disk to permit a read or write operation to be carried out. In order to properly position the transducer with respect to the disk surface, an air bearing surface (ABS) formed on the slider body experiences a fluid air flow that provides sufficient lift force to “fly” the slider and transducer above the disk data tracks. The high speed rotation of a magnetic disk generates a stream of air flow or wind along its surface in a direction substantially parallel to the tangential velocity of the disk. The air flow cooperates with the ABS of the slider body which enables the slider to fly above the spinning disk. In effect, the suspended slider is physically separated from the disk surface through this self-actuating air bearing. The ABS of a slider is generally configured on the slider surface facing the rotating disk, and greatly influences its ability to fly over the disk under various conditions.
Some of the major objectives in ABS designs are to fly the slider and its accompanying transducer as close as possible to the surface of the rotating disk, and to uniformly maintain that constant close distance regardless of variable flying conditions. The height or separation gap between the air bearing slider and the spinning magnetic disk is commonly defined as the flying height. In general, the mounted transducer or read/write element flies only approximately a few nanometers above the surface of the rotating disk. The flying height of the slider is viewed as one of the most critical parameters affecting the reading and recording capabilities of a mounted read/write element. For example, there are many advantages for reducing or having a relatively small flying height. A relatively small flying height allows the transducer to achieve greater resolution between different data bit locations and magnetic fields emanating from closely defined regions on the disk surface. Also, a low flying slider is known to provide improved high density recording or storage capacity of magnetic disks which is usually limited by the distance between the transducer and the magnetic media. Narrow separation gaps permit shorter wavelength signals to be recorded or read as a result. At the same time, with the increasing popularity of lightweight and compact notebook type computers that utilize relatively small yet powerful disk drives, the need for a progressively smaller slider body with a lower flying height has continually grown.
It has also been observed that a constant flying height provides desirable benefits which may be more readily achieved through particular ABS designs. Fluctuations in flying height are known to adversely affect the resolution and the data transfer capabilities of the accompanying transducer or read/write element. The amplitude of the signal being recorded or read does not vary as much when the flying height is relatively constant. Additionally, changes in flying height may result in unintended contact between the slider assembly and the magnetic rotating disk. Sliders are generally considered to be either direct contacting, pseudo-contacting or living sliders which is descriptive of their intended contact with a rotating disk. Regardless of the type of slider, it is often desirable to avoid unnecessary contact with the surface of the spinning magnetic disk so as to reduce the wear on both the slider body and the disk. The deterioration or wear of the recording media may lead to the loss of recorded data, while slider wear may also result in the ultimate failure of the transducer or magnetic element.
In order to make the ABS fly stably and reliably under variable conditions, many parameters of the suspension supporting the ABS must be accounted for. For example, a suspension system will have a vertical stiffness (Kz), a gimbal pitch (Kp), a roll stiffness (Kr), and a gimbal static attitude (pitch/roll static attitude, PSA/RSA), all of which will affect the flying behavior of the ABS. Existing art for suspension designs focuses on minimizing the effects of environmental conditions such as temperature and humidity on these parameters. There is a need for an improved approach to achieving a stable flying height.
SUMMARY OF THE INVENTION
Rather than trying to minimize the effects of different environmental conditions, one embodiment of the present invention calls for designing a suspension system where the change experienced by one element of the suspension will counteract the changes experienced by a different element, thus resulting in no net change to the flying height.
Flexures as known in the art are made of a single materials typically stainless steel. In one embodiment of the present invention, a bi-layered flexure, made with two different materials, is used to improve a slider's flying height sensitivity to temperature. Pairing materials with mismatched coefficients of thermal expansion may cause the flexure to exert either an upward or downward force on the slider and read/write element as temperature changes. A suspension design may use this upward or downward force to counteract any protrusion or retraction of the read/write element that may result from varying temperatures, thus achieving a substantially constant flying height across a wide range of temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a three-dimensional representation of a suspension design with a bi-layer flexure base.
FIG. 2 is a three-dimensional representation of a suspension design with a slider floating above a rotating disk.
FIGS. 3 a - c are two-dimensional representations of a suspension design with a bi-layer flexure base.
FIGS. 4 a - b are alternative two-dimensional representations of a suspension design with a bi-layer flexure base.
DETAILED DESCRIPTION
FIG. 1 is a three-dimensional illustration of a portion of a suspension with a loadbeam 110 , a flexure 120 and a slider 130 with electrical terminations 140 to the flexure. The slider 130 has a read/write element embedded in its trailing edge 150 . FIG. 2 shows an alternative view of a head slider 230 flying over the surface of a magnetic disk 204 . The slider 230 is floating over the surface of the disk 204 on a cushion of air that is generated from the disk's 204 rotation. The slider 230 is connected to a load beam 210 via a flexure 220 , and the slider contains a read/write element 201 at its trailing edge.
The slider body 230 may be made of a ceramic material wile the read/write element 201 will typically be made of a metallic material. Metallic materials typically have larger coefficients of thermal expansion compared to ceramic materials, meaning changes in temperature may cause the read/write element 201 to contract or protrude relative to the slider body 230 . As illustrated by FIG. 2 , the flexure 220 prevents the slider from being rigidly attached to the load beam 210 . Flexures 220 are typically made of stainless steel, meaning they will also thermally expand or contract at changing temperatures. An embodiment of the present invention utilizes a flexure 220 that, when undergoing thermal expansion or contraction, will lower or elevate the slider body 230 by an amount that offsets the contraction or protrusion of the read/write element 201 , therefore achieving a substantially constant flying height.
An embodiment of the present invention uses a bi-layer flexure base made with two different materials with different coefficients of thermal expansion (CTE). The table below gives a sample of some of the materials that can be used in layers of a flexure and their associated properties:
SST Au Pt Ti alloy Invar Al E (GPa) 178.5 77.2 171 110 148 70 ν 0.32 0.42 0.39 0.33 0.23 0.33 ρ (g/cc) 8.072 19.32 21.45 4.7 8.05 2.7 CTE (ppm/° C.) 17.2 14.4 9.1 8.7 1.3 24 PSA change −0.09 −0.38 −1.36 −1.13 −2.28 0.58 (min/° C.)
When choosing materials for the layers of the flexure base, factors such as a material's Young's Modulus (E), Poissson's ratio (υ), density (ρ), and pitch static attitude (PSA) must all be considered in addition to the materials' CTE. For example, when choosing materials, it is common to choose polymers that are non-absorbent and will, therefore, not expand with increased humidity.
FIGS. 3 a - c are two-dimensional illustrations of a suspension design with a bi-layer flexure. The drawings are not to scale, and changes in the relative positions of elements are exaggerated to more clearly show aspects of the present invention. A flexure 320 made of two different materials 320 a and 320 b supports a slider 302 with a read/write element 310 at the trailing edge. The airflow 330 created from the spinning disk 304 lifts the slider 302 above the disk 304 to a nominal flying height 306 .
FIG. 3 b shows the change the read/write element 310 might experience at a higher temperature as the result of the thermal expansion effect. The increase in temperature causes the pole tip of the read/write element 310 to protrude toward the disk by an additional amount 312 . The net spacing 314 between the pole tip and the disk is then equal to the nominal flying height 306 less the additional amount 312 .
FIG. 3 c shows an implementation of the present invention. By using a bi-layered flexure with two different materials with different CTEs, the protrusion of the pole tip can be offset by a lilting force created by the bi-layered flexure 320 .
FIGS. 4 a - b show alternate, two-dimensional views of a slider 402 connected to a flexure 420 . As with FIGS. 3 a - c , the drawings are not to scale, and changes in the relative positions of elements are exaggerated to more clearly show aspects of the present invention. The flexure is bi-layer, with a first layer 420 b made of one material and a second layer 420 a made of a different material. The first layer 420 b is the side adjacent to the slider 402 . The second layer 420 a has a smaller CTE than the first layer 420 b . FIG. 4 a shows the flexure and slider at a high temperature. At increasing temperatures, the first layer 420 b will expand more than the second layer 420 a , creating a torque in the direction shown at arrow 430 a . The torque will result in a lifting force elevating the slider body 402 relative to the disk 404
FIG. 4 b , shows the flexure 420 and slider 402 at a low temperature. At decreasing temperatures, the first layer 420 b will contract more than the second layer 420 a , creating a torque in the direction shown at arrow 430 b . The torque will result in the slider 402 being lowered relative to the disk 404 .
Based on the type and pattern of the second material 420 a , a flexure may be designed where the torque will elevate the slider 402 in an amount approximately equal to any protrusion caused by thermal expansion and lower the slider approximately equal to any retraction caused by thermal contraction, thus providing a virtually constant flying height at varying temperatures. Several variations in this general method are possible to achieve the desired thermal sensitivity of PSA, together with other parameters that need to be optimized.
In the simplest structure, the second layer can be made conformal to the first layer; i.e. one side of the flexure base is completely covered by and an identical second layer of uniform thickness. In a more complicated structure, the second layer can be made to cover selected areas on one side of the flexure base. A patterned design for the second layer provides an additional method to achieve the desired thermal sensitivity. Additionally, the thickness of the two layers may vary from one location to the next, adding another level of control to achieve the optimum thermal sensitivity, as well as other parameters.
As to how such a bi-layer based flexure can be produced, there are numerous available methods. One method is to use a bi-layer blank sheet to replace the single layered sheets currently used in the art. Another method is to deposit the second layer onto one side of a single layered sheet. Deposition of the second layer may be done by plating or various vacuum deposition methods. In either method, patterning of the second layer can be done by selective etching or deposition.
The previous description of embodiments is provided to enable a person skilled in the art to make and use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles and specific examples defined herein may be applied to other embodiments without the use of inventive faculty. For example, some or all of the features of the different embodiments discussed above may be deleted from the embodiment. Therefore, the present invention is not intended to be limited to the embodiments described herein but is to be accorded the widest scope defined only by the claims below and equivalents thereof.
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A flexure with improved temperature sensitivity is disclosed. An embodiment of the present invention includes a bi-layered flexure that raises or lowers a read/write element a distance that is approximately equal to the distance of protrusion and retraction at varying temperatures.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of controlling reactive sputtering deposition of transparent metal oxide films on substrates, and further, to the formation of reproducible uniform films of indium oxide or titanium oxide.
2. Discussion of the Technical Problem
Methods are known in the art of thin films for producing a titanium oxide-based transparent electroconductive coating. For example, U.S. Pat. No. 3,698,946 to Kaspaul et al. discloses coatings comprising a first layer of titanium monoxide, a second layer of copper, silver, gold, platinum, or tin, and a third layer of titanium monoxide. The coated articles are useful as photodetectors, light emitting devices, image converters and image amplifiers. While the coated articles are described as transparent and electrically conductive, the transmittances of 38 to 76 percent and resistances of 1600 to 200,000 ohms per square are unsuitable for certain applications such as motor vehicle windows which require a high transmittance, preferably 80 percent or higher, and very low resistance, preferably less than 10 ohms per square, to develop useful amounts of heat with available generator voltages. In addition, the titanium monoxide imparts a distinct color to transmitted light.
U.S. Pat. No. 3,962,488 to Gillery teaches a method for making a colorless, highly transparent coating which also has excellent conductivity, the resistance being less than 10 ohms per square. Gillery discloses that the substitution of titanium dioxide for the monoxide of Kaspaul eliminates the color and transparency problems. However, direct deposition of titanium dioxide is incompatible with the intermediate conductive layer. An intermediate silver film, for example, which is initially continuous and highly conductive becomes discontinuous, resulting in a marked increase in resistance and decrease in transmittance in less than 24 hours. Gillery's invention involves depositing the titanium oxide layers as TiO x wherein x is greater than 1.3 but less than 1.7. While the coating may initially be somewhat colored, it becomes colorless as the titanium suboxide is oxidized upon exposure to a normal atmosphere of air or when subjected to the conditions of lamination.
U.S. Pat. No. 4,194,022 to Gillery teaches a method of controlling the rate of oxidation of a film of titanium suboxide in the above-described coating by treating the coating with a vapor of an oil, wax, heavy organic alcohol, or amine prior to exposure to an oxidizing atmosphere. Such a method was preferred because uncontrolled oxidation of the titanium suboxide film may jeopardize the continuity of the adjacent electroconductive film.
While useful in producing desirable electroconductive coatings by evaporation techniques, the previously discussed techniques have limitations associated therewith which would preferably be avoided. For example, the techniques required both a deposition step and a subsequent oxidation step. Further, the treatment of the coating with an oxidation-retarding medium may prove to be inconvenient. Thus, previously utilized techniques for making a titanium oxide-based transparent electroconductive coating resulted in either undesirable optical and electrical properties, or involved inconvenient procedures. It would be desirable to eliminate such difficulties.
Methods are also known for producing a transparent, electroconductive indium oxide film. However, indium oxide films having low resistance and high luminous transmittance were previously obtainable only by deposition onto hot substrates or by deposition with subsequent heat treatment. It would be desirable to have a method of depositing a transparent electroconductive indium oxide film which could be used with both ambient temperature substrates and elevated temperature substrates.
Further, considerable difficulty has been encountered in the reactive sputtering deposition art in controlling the stoichiometry, optical characteristics, and electrical properties of deposited oxide-containing films. One source of such difficulty is the varying amounts of outgassing which occur during the sputtering process, leading to uncertainty in the composition of the sputtering atmosphere. As a result, coating uniformity and reproducibility has been less than ideal.
U.S. Pat. No. 4,113,599 to Gillery teaches a sputtering technique for the reactive deposition of indium oxide in which the flow rate of oxygen is adjusted to maintain a constant discharge current while the flow rate of argon is adjusted to maintain a constant pressure in the sputtering environment. While successful in controlling reactive deposition by conventional D.C. or R.F. processes where the substrate temperature, gas partial pressures, and gas flow rates are relatively high with respect to outgassing contributions, such as technique does not provide the preferred degree of control when utilized in reactive magnetically enhanced sputtering, where the gas partial pressures and gas flow rates are preferably relatively low. In such an environment outgassing contributions may be proportionally more significant, thus requiring more precise control over chamber conditions. It would be desirable to have a method of controlling reactive sputtering deposition which is sufficiently precise to be utilizable in magnetically enhanced sputtering techniques as well as in conventional D.C. and R.F. sputtering techniques.
SUMMARY OF THE INVENTION
The present invention provides a method of and apparatus for controlling the deposition of an oxide-containing film formed by reactive sputtering. An evacuated atmosphere of partial pressures of oxygen and a chemically inert gas is established in a coating chamber having a preselected total pressure less than about 10 -1 torr. A predetermined level of electrical power is applied to a cathode within the coating chamber to initiate sputtering of a selected material from the cathode surface toward a substrate. While sputtering proceeds, the deposition rate of the oxide-containing film being formed on the substrate is monitored to indicate oxygen partial pressure in the chamber, while the gas pressure within the coating chamber is also monitored. In response to the monitored deposition rate and gas pressure, the input rates of the oxygen and chemically inert gas are adjusted to maintain a constant deposition rate and gas pressure in the coating chamber.
The oxygen partial pressure in the chamber determines the stoichiometry, optical and electrical properties of the reactively deposited film. Therefore, production of desirable oxide-containing films requires precise control of oxygen partial pressure, which has heretofore been largely unattainable. According to the present invention, oxygen partial pressure can be controlled during the deposition process by monitoring the deposition rate, which is a sensitive function of oxygen partial pressure. Constant oxygen partial pressure can be maintained during deposition by monitoring the deposition rate and adjusting the oxygen input rate to maintain the deposition rate constant. Therefore, desirable oxide-containing coatings which are substantially uniform throughout their thickness may be produced by maintaining a constant predetermined cathode power, chamber pressure, and deposition rate during the deposition process.
The present invention also provides a method of making a transparent electroconductive coating, which method includes the steps of magnetically enhanced sputtering a first substantially transparent film of titanium oxide onto a substrate; depositing a substantially transparent electroconductive film of a selected metallic material onto the first titanium oxide film; and magnetically sputtering a second substantially transparent film of titanium oxide onto the electroconductive film. The magnetically enhanced sputtering is conducted in an evacuated atmosphere having a controlled partial pressure of oxygen to provide the first titanium oxide film with an optical extinction coefficient between about 0.03 and 0.3 when deposited and the second titanium oxide film with an optical extinction coefficient less than about 0.3. Unlike the previously discussed techniques, the method of the present invention provides for the deposition of ideally oxidized titanium oxide films which are substantially transparent upon deposit, require no subsequent oxidation or oxidation retarding treatment, and which promote stability of the electroconductive film conductivity. The term "titanium oxide" is used generically herein to mean a composition of titanium and oxygen, irrespective of relative proportions thereof.
The present invention further relates to a method of depositing a transparent, electroconductive indium oxide film on substrates at ambient temperature as well as at elevated temperatures. The present invention includes the steps of establishing an evacuated atmosphere of about 50% to 90% argon and about 50% to 10% oxygen at a total pressure between about 2×10 -4 torr and 20×10 -4 torr; magnetically enhanced sputtering of indium or an indium-tin alloy from a cathode at a predetermined cathode power; monitoring the deposition rate of the indium oxide film being formed on a substrate and the total gas pressure; and inputting oxygen and/or argon into the chamber in response to the monitored deposition rate and total pressure to maintain a constant deposition rate and total pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view in partially schematic form of the interior of a coating chamber incorporating features of the invention having portions removed for purposes of clarity.
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1, additionally schematically illustrating a deposition control system according to the present invention.
FIG. 3 is a view similar to FIG. 2 illustrating an alternate embodiment of a deposition control system according to the present invention, having portions removed for purposes of clarity.
FIG. 4 is a sectional side view of a transparent electroconductive article according to the present invention.
FIG. 5 is a sectional side view similar to FIG. 4 of an alternate transparent electroconductive article according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, a substrate 10 is supported within a coating chamber 12 in any convenient manner, e.g., by support rails 14 and sheet 16 (shown only in FIGS. 2 and 3), in face-to-face relation with a cathode 18 having a target surface 19. During operation, the surface of the substrate 10 and the target surface 19 of cathode 18 are preferably spaced about 31/2 inches (8.8 cm) apart. As indicated by the arrows, although not limiting to the invention, the cathode 18 is preferably a scanning cathode which is controllably traversed by motor 20 and drive shaft assembly 21 along a reciprocating path upon support tracks 22 so as to completely cover and extend beyond the surface area of the substrate 10, as shown in phantom in FIG. 1.
The coating chamber 12 may be of the type disclosed in U.S. Pat. No. 4,094,763, which teachings are herein incorporated by reference, or it may be of the type available from the High Vacuum Engineering Equipment Corp. of Hingham, Mass. or from the Stokes Division of Pennwalt Corporation of Philadelphia, Pa. A vacuum pump 24 communicates with the interior of chamber 12 to controllably draw a vacuum therein.
The substrate 10 which may be used in the practice of this invention includes glass, ceramics, rigid plastics, and certain flexible plastics. Organic materials which may be used include polyesters, cast and stretched acrylics, polycarbonates, chlorinated plastics, epoxies, and other convenient materials which are compatible with expected temperatures within the chamber 12 during deposition.
The cathode 18 may be of the type generally known in the vacuum sputtering art, and in preferred embodiments of the invention includes a magnetic element 26 (shown only in FIGS. 2 and 3) adjacent its target surface 19 to promote magnetically enhanced sputtering. The cathode target surface should be faced with an appropriate oxide-forming material, the choice depending upon the desired final product. Preferred materials in the practice of the present invention include indium, indium-tin alloys, titanium, zirconium, chromium, and vanadium.
With continued reference to FIGS. 1 and 2, a deposition rate monitor 28 may be mounted within the chamber 12 within the area swept out by the cathode 18 adjacent to but spaced from the peripheral edge of the substrate 10, preferably in the same plane as substrate 10. The deposition rate monitor 28 is mounted in a housing 30 which provides both fluid cooling and magnetic shielding from excess electron bombardment to protect it from undesirable heating which could cause premature failure. In this configuration the stationary deposition rate monitor 28 is used for cyclic measurement of the deposition rate and is preferably activated each time the cathode 18 is centrally positioned thereover during its reciprocating movement.
With reference to FIG. 3, there is shown an embodiment of the apparatus of the present invention wherein the deposition rate monitor 28 and housing 30 are mounted to the cahode 18 by bracket 32 for continuous movement therewith. In this embodiment of the invention the deposition rate monitor 28 may be continuously activated to continuously measure the deposition rate as the cathode 18 scans over the substrate 10.
The deposition rate monitor 28 utilized in the practice of the present invention is preferably a quartz crystal monitor such as those commercially available from Inficon Leybold Heraeus, Corp. of East Syracuse, N.Y., Model XMS-3. When electrically activated, such a crystal vibrates at a certain frequency which is dependent upon the mass of material which is deposited thereon. A measurement of the change in frequency of vibration in an increment of time yields a reliable value representing the deposition rate upon the crystal. Routing of electrical cables to the deposition rate monitor 28 should be carefully arranged so as to avoid spurious signals.
The deposition rate monitor 28 is electrically connected to an electrical control panel 34 (shown only in FIG. 2) which amplifies the signal therefrom, displays a numerical value corresponding to the deposition rate, and preferably acts on an oxygen input valve 36 in response thereto, as will be described more fully hereinafter. Oxygen input valves 36 which may be used in the present invention include piezoelectric gas leak valves such as those commercially available from Veeco Instruments, Inc. as Model PV-10.
An ionization gauge 38 is also mounted adjacent to and communicates with the interior of chamber 12 for monitoring the total gaseous pressure therein. The ionization gauge 38 provides a signal to the control panel 34, which displays a numerical value for the pressure in chamber 12 and acts on an argon input valve 40 in response thereto. The ionization gauge 38 and argon input valve 40 may be of the type sold by the Granville Phillips Company of Boulder, Colo. as Series 216.
With reference to FIG. 2, a source of light 42, e.g., a modulated beam photometer 42, is mounted outside the chamber 12 to project a monochromatic beam of light (e.g. 550 nm) through a transparent port 43 toward the substrate 10. A photoelectric cell 44 (also shown in FIG. 1) is conveniently positioned adjacent a transparent port 45 beneath the substrate 10 in a position to determine the intensity of the beam of light and thereby measure the luminous transmittance of the substrate 10 as deposition progresses. Alternatively, and for particular use with a nontransparent substrate 10, luminous transmittance of the deposited film may be measured by positioning the photoelectric cell 44 to receive light from the light source 42 which is reflected by the film. Preferred transmittance measuring equipment was obtained from Edwards of London, England.
With continued reference to FIG. 2, a power source 46 is provided for electrical connection with the cathode 18. The power source 46 may be a D.C. power source such as those commercially available from Vactec Systems, Inc. of Boulder, Colo., or it may be an R.F. power source such as those commercially available from Varian Corp. of Palo Alto, Calif.
In operation, reactive sputtering is conducted according to the present invention by positioning a substrate 10 within the chamber 12 upon sheet 16 and thereafter evacuating the chamber 12 with vacuum pump 24 to a preselected pressure less than about 10 -1 torr, preferably less than about 10 -4 torr, and most preferably less than about 3×10 -5 torr. A predetermined evacuated atmosphere of partial pressures of oxygen and a chemically inert gas, preferably argon, is then established within the chamber 12, the composition and total pressure of which is dependent upon the type of sputtering to be conducted and the final product sought. Generally, magnetically enhanced sputtering may be conducted at lower total pressures than D.C. or R.F. sputtering.
With reference to the stationary deposition rate monitor 28 of FIGS. 1 and 2, the cathode 18 is initially centrally positioned over the deposition rate monitor 28, afterwhich the cathode 18 is energized with a predetermined electrical power and the deposition rate monitor 28 is electrically activated to measure the initial deposition rate at the position below the cathode center. Any variance between the initial deposition rate and a predetermined preferred deposition rate is eliminated by a signal from the control panel 34 which causes an adjustment of the oxygen input rate at the oxygen input valve 36. Generally, an increase in oxygen input rate decreases the deposition rate and a decrease of oxygen input rate increases the deposition rate. Total chamber pressure is maintained constant by signals from the control panel 34 to the argon input valve 40, in response to signals received from the ionization gauge 38. The predetermined cathode power, preferred deposition rate, and total chamber pressure are each selected to achieve the desired degree of oxidation in the oxide-containing film to be deposited upon the substrate 10.
After the gaseous input rates have been adjusted to attain the desired operating conditions, the cathode 18 is scanned over the surface of the substrate 10 to deposit a thin film thereon, afterwhich it returns to its initial position over the deposition rate monitor 28. Necessary adjustments are made in oxygen and argon input rates to maintain the desired operating conditions, and scanning is recommenced. This procedure is continued until an oxide-containing film having the desired thickness, electrical properties, and optical properties is attained.
With reference to FIG. 3, the movably mounted deposition rate monitor 28 may be used to transmit continuous signals to the control panel 34 (shown only in FIG. 2), which in turn responds to the continuously received signals from the ionization gauge 38 and deposition rate monitor 28 with appropriate adjustments of the oxygen and argon input rates at oxygen input valve 36 and argon input valve 40, thereby continuously maintaining the desired deposition conditions.
Of course it will be appreciated that the present invention is not limited to the above-described preferred apparatus and control techniques, as successful deposition can also be achieved by manual adjustment of the oxygen and argon input rates in response to the signals received from the deposition rate monitor 28 and ionization gauge 38, respectively. Further, it will be appreciated that continuous and automatic deposition control can be achieved by holding the cathode 18 and the deposition rate monitor 28 stationary while conveying the substrate 10 with respect thereto.
Referring to FIG. 4, a transparent electroconductive article 50 produced in accordance with the present invention is shown, consisting of a substrate 52, an inner layer 54 of titanium oxide, an intermediate electroconductive layer 56, and an outer layer 58 of titanium oxide.
The substrate 52 may be selected from a variety of materials, the choice being governed by the end use desired and the compatability of the substrate 52 and the inner layer 54. Preferred substrates are nonstretchable under normal use to avoid damaging the layers 54, 56, and 58, and also do not contain excessive amounts of volatile materials such as plasticizers, water vapor, or absorbed gases. Suitable candidates include glass, ceramics, rigid plastics, and certain flexible plastics such as polyesters, cast acrylics, polycarbonates, chlorinated plastics, and epoxies.
The inner layer 54 of titanium oxide, deposited in a manner to be discussed below, has a particular combination of properties which are desirable in an article produced in accordance with the practice of the present invention. First, the inner layer 54 adheres extremely well to glass and relatively well to plastics, thus contributing to a durable end product. Second, the inner layer 54 deposited according to the teachings of the present invention promotes the stable formation of a continuous thin film of the selected metallic material, e.g., silver or gold, used in the intermediate electroconductive layer 56. More normally, thin silver or gold films are found in discontinuous, globular form. Third, the inner layer 54 has a high refractive index which enables it to reflect sufficient energy out of phase with the intermediate layer 56 to produce an antireflective effect, and therefore, a highly transmitting combination.
The degree of oxidation of the titanium oxide of the inner layer 54 has been found to be closely related to the electroconductive and luminous transmittance characteristics of the final product, i.e., article 50. If the titanium oxide of inner layer 54 is too highly oxidized, the electroconductivity of the intermediate layer 56 may be made unstable, resulting in immediate high resistances, or in marked increases in resistance with time. If the titanium oxide of inner layer 54 is not sufficiently oxidized, the luminous transmittance of the layer 54 is adversely affected.
Prior to the present invention, it was customary to attain a desired degree of oxidation in titanium oxide films by an evaporation technique carried out in two distinct stages; first, by depositing titanium oxide in an under-oxidized state and thereafter, by introducing an oxidizing atmosphere thereto to attain the desired degree of oxidation.
It has been found according to the present invention that the titanium oxide of inner layer 54 can be successfully magnetically enhanced sputtered onto the substrate 52 with the degree of oxidation desired, thus eliminating the need for further oxidation. Further, and contrary to previous understanding in the art, such ideally oxidized titanium oxide films are fully compatible with subsequently deposited metallic thin films. Deposition of ideally oxidized titanium oxide films is also more easily controlled in the practice of the present invention than heretofore, yielding a more consistent final product.
It is believed that the preferred titanium oxide films deposited according to the present invention comprise a combination of titanium dioxide intermixed with atoms and/or small agglomerations of titanium metal, i.e., films of titanium oxide having greater than 1.7 but less than 2.0 parts oxygen to parts titanium, and preferably between 1.9 and 2.0. Such films may be characterized as having an optical extinction coefficient between about 0.03 and 0.3, preferably between 0.03 and 0.09, and most preferably between 0.06 and 0.08. Inner layer 54 is preferably deposited with a thickness within the range of about 200 to 500 Angstroms to obtain the desired optical properties and film continuity. The inner layer 54 should be of a specific thickness so as to cooperate interferometrically with the intermediate layer 56 to give high luminous transmittance.
The inner layer 54 is preferably deposited according to the present invention by magnetically sputtering a titanium metal cathode in an evacuated atmosphere having partial pressures of oxygen and argon. Initially, the coating chamber 12 is evacuated to less than 3×10 -5 torr, after which an atmosphere of about 75% argon and 25% oxygen at a total pressure of about 6×10 -4 torr is established. The cathode 18 is activated at a preselected constant electrical power, and the deposition rate and total chamber pressure are established at preselected values as hereinbefore described.
Upon reaching the desired coating conditions, the cathode 18 is scanned across the surface of the substrate 52 at a preselected rate to deposit a thin layer of an ideally oxided film thereon. The luminous transmittance of the substrate 52 is monitored during deposition by the photometer 42 and photoelectric cell 44 and decreases as the thickness of the film increases, from an initial value of about 90% for a glass substrate 52. Deposition rate, and therefore the degree of oxidation of the deposited titanium oxide film, is maintained constant either cyclically, utilizing the apparatus of FIGS. 1 and 2, or continuously, utilizing the embodiment of the invention illustrated in FIG. 3. Deposition of the inner layer 54 is preferably terminated when the luminous transmittance decreases to a value between about 72% and 76%, (about 80% to 85% of the transmittance of the uncoated substrate) a condition which is usually reached with a film thickness between about 300 A and 350 A, entailing about 5 to 7 passes of the cathode 18 over the substrate 52. Generally during the above-described procedure, the oxygen input rate is gradually increased to compensate for decreasing amounts of outgassing from the coating chamber 12. The inner layer 54 preferably has an optical extinction coefficient between about 0.06 and 0.08 upon deposit, according to the present invention.
The intermediate layer 56 of the article 50 comprises a substantially transparent, electroconductive layer of a metallic material. Metallic materials suitable for use in intermediate layer 56 includes those which form thin films having surface resistances of less than about 30 ohms per square while maintaining a transmittance, when ideally antireflected by surrounding dielectric layers, of greater than about 60%. Preferred metallic materials form films having surface resistances of less than about 10 ohms per square, and exhibit transmittance greater than about 95% when ideally antireflected. Known materials exhibiting such properties include silver, gold, copper, tin, aluminum, magnesium or platinum. Silver or gold are preferred materials for the formation of high conductivity films having thicknesses sufficiently small to retain high luminous transmittance. Such high conductivity films should be continuous, even slight discontinuities producing drastic decreases in electrical conductivity and luminous transmittance. Preferably, the intermediate layer 56 has a thickness between about 60 Angstroms and 250 Angstroms for gold, and between about 100 Angstroms and 250 Angstroms for silver. Thicknesses significantly greater than 250 Angstroms may adversely affect the luminous transmittance of intermediate layer 56. The intermediate layer 56 may be deposited upon the inner layer 54 in any convenient manner, e.g., by D.C. sputtering, by R.F. sputtering, by vacuum evaporation, or by magnetically enhanced sputtering. Preferably, the intermediate layer 56 is deposited by magnetically enhanced sputtering in the same chamber in which the inner layer 54 and outer layer 58 are deposited.
Such deposition is preferably accomplished at a high rate and at a low substrate temperature, e.g., 94 A/sec at 25° C., in order to promote the desired thin continuous film. Luminous transmittance of the substrate 52 is monitored during such deposition and the deposition is preferably terminated when luminous transmittance has decreased to between about 66% and 62%, (an additional decrease of between about 10% and 12% of the original luminous transmittance of the uncoated substrate 52) preferably resulting in films having electrical resistivity of less than about 10 ohms per square.
The outer layer 58 of titanium oxide is preferably deposited upon the intermediate layer 56 under the same operating parameters utilized in depositing the inner layer 54. The outer layer 58 again preferably exhibits a high index of refraction to contribute to a high luminous transmittance of the final product. In addition, the outer layer 58 provides a relatively hard coating for the intermediate layer 56, thus protecting it from abrasion and attack which could adversely affect its electrical conductivity. As previously discussed in relation to the inner layer 54, the degree of oxidation of the titanium oxide of outer layer 58 may be ideally established in a single deposition step without the need for a subsequent oxidation step. The oxidation of outer layer 58 is controlled by monitoring deposition rate to produce a film having an optical extinction coefficient less than about 0.3. The outer layer 58 preferably has a thickness between about 200 Angstroms and 500 Angstroms, the specific thickness selected so as to cooperate interferometrically with the intermediate layer 56 to give high luminous transmittance. In this regard, luminous transmittance of the substrate 52 is monitored during the deposition of the outer layer 58, deposition being preferably terminated as the luminous transmittance of the article 50 increases to a peak at around 80%, due to the antireflective characteristics of the layers 54, 56, and 58. As the luminous transmittance will vary sinusoidally with continued deposition of the outer layer 58, it is preferred to terminate deposition at the first peak attained, but the present invention is not limited thereto.
The deposition of the inner layer 54, intermediate layer 56, and outer layer 58 should be accomplished at temperatures which are fully compatible with the thermal stability of the substrate 52, and which minimize the tendency of the silver or gold to agglomerate. Accordingly, temperatures in excess of about 200° C. are preferably avoided, and a usable temperature range between about 25° C. and 200° C. is preferred.
While the article 50 described above was produced with the use of a titanium metal cathode, a titanium oxide cathode which is only partially oxidized may also be utilized in the practice of the present invention. In such a case, smaller oxygen partial pressures are required to maintain the oxidation levels of the layers 54 and 58 within the desired ranges.
It will be understood from the preceding discussion that in a reactive deposition procedure in which the cathode power, deposition rate and total pressure are maintained constant, the preferred transparent electroconductive article 50 of the present invention may be produced by monitoring the luminous transmittance of the substrate 52 during each deposition step. Therefore, while it is preferred that deposition rate and total pressure be maintained constant according to the teachings hereinbefore disclosed, the present method of producing a transparent electroconductive article is not limited thereto.
For example, a coating chamber may be subjected to evacuated conditions for an extended time such that outgassing therefrom has fully stabilized or ceased. In such a system, constant argon and oxygen input rates could produce a constant deposition rate and pressure, thus resulting in a constant degree of oxidation in the titanium oxide films produced thereby. By a trial and error technique, appropriate cathode power, total pressure, and gaseous flow rates could be determined for producing the desired degree of oxidation in the titanium oxide films. After such appropriate parameters were determined and established, deposition of the inner titanium oxide layer 54 could be effected until the monitored luminous transmittance of the article 50 is between about 75% and 80% of the luminous transmittance of the uncoated substrate 52. Thereafter, the intermediate electroconductive layer 56 could be deposited until the luminous transmittance of the article 50 decreased an additional amount between 10% and 12% of the luminous transmittance of the uncoated substrate 52. The outer layer 58 would thereafter be deposited until the luminous transmittance peaked, preferably for the first time, at a value greater than 75% of the luminous transmittance of the uncoated substrate 52.
Such a control method is suited for use in a sealed production line system for the production of the transparent electroconductive article 50. Such a production line system would ideally incorporate both of the control methods herein disclosed, the former for use during start-up and quality control checks, and the latter for use during steady state operation.
Referring now to FIG. 5, a second transparent, highly conductive article 60 is formed of a film 64 of indium oxide deposited upon a substrate 62 utilizing the apparatus and deposition control method of the present invention. Heretofore, indium oxide films of low resistance and high electrical stability were obtainable only by deposition onto hot substrates, or by subsequent heat treatments of the deposited film. Practice of the present invention permits the production of such indium oxide films on ambient or elevated temperature substrates without subsequent heat treatments.
A magnetron cathode 18 is faced with an indium-tin alloy containing between 10% and 20% tin. The concentration of tin in the cathode affects the final film stability and minimum resistances obtainable, 10% tin concentrations generally yielding lower resistances and less stability when used with an ambient temperature substrate 62.
A coating chamber 12 is evacuated to less than 3×10 -5 torr, and thereafter an evacuated atmosphere of argon and oxygen at a predetermined total pressure established therein. The magnetron cathode 18 is activated with a preselected constant power to begin sputtering overtop the activated deposition rate monitor 28. Deposition rate is then set at a predetermined value by adjustment of the oxygen input valve 36 and the total pressure is maintained constant by adjustment of the argon input valve 40.
The resistance of the indium oxide film 64 is conveniently monitored during deposition through the use of a pair of electrical connectors 66 disposed on opposite marginal edges of the surface of the substrate 62 to be coated. An ohmmeter 68 electrically connected between the electrical connectors 66 monitors the resistance therebetween, thereby measuring the resistivity of the film 64 as it is deposited. The luminous transmittance of the substrate 62 is also monitored during the deposition procedure, preferably starting at an initial value of about 90% for an uncoated clear plastic substrate.
After reaching the desired deposition conditions, the cathode 18 is scanned over the surface of the substrate 62, at a predetermined rate. A thin layer of indium oxide is deposited, the electrical resistance and luminous transmittance of which is monitored while the deposition rate is maintained constant. The electrical resistance of the film decreases with increased film thickness, while the luminous transmittance of the film decreases and increases sinusoidally due to the interferometric interaction of the film 64 and substrate 62. Deposition is preferably terminated at a point where the electrical resistance is as required and the luminous transmittance is maximized, a condition generally occurring when the film has a thickness which is a multiple of about 1350 A.
Using a cathode 18 faced with 10% tin-indium on a cold substrate, an article 60 having an electrical resistivity of about 15 ohms per square and an optical transmittance of about 80% may be produced according to the present invention. 20% tin-indium cathodes may be utilized to produce an article 60 having an electrical resistivity of about 25 ohms per square and an optical transmittance of about 80%. Lower film resistances may be attained by further increasing thickness but increased deposition time is of course required. Additionally, a resistance gradient may be established on the article 60 by scanning the cathode 18 over the surface of the substrate 62 at a controlled, non-uniform rate.
EXAMPLE I
With reference to FIGS. 1, 2, and 4, a transparent electroconductive article 50, produced according to the practice of the present invention, included a substrate 52 of glass, an inner layer 54 of titanium oxide, an intermediate layer 56 of silver, and an outer layer 58 of titanium oxide.
The chamber 12 was evacuated to less than 3×10 -5 torr, after which an atmosphere of about 75% argon and 25% oxygen at a total pressure of about 6×10 -4 torr was established. The cathode 18 was activated at a power of 25 watts/in 2 (3.9 watts/cm 2 ) to begin sputtering from a titanium metal target surface overtop the activated deposition rate monitor 28. The initial deposition rate was read by the deposition rate monitor 28 and thereafter adjusted to a valve of about 10.6 A/sec by adjustment of the oxygen input rate at the oxygen input valve 36. Total pressure was maintained constant by adjustment of the argon control valve 40.
The inner layer 54 of titanium oxide was deposited upon the substrate 52 by scanning the cathode 18 thereover at a rate of 2 inches/sec (5 cm/sec.), while deposition rate, total pressure, and cathode power were maintained constant. Deposition was terminated when the luminous transmittance decreased to between 80% and 85% of the transmittance of the uncoated substrate 52, as measured by the photometer 42 and photoelectric cell 44. The inner layer 54 had an optical extinction coefficient between 0.06 and 0.08 as deposited.
The intermediate layer 56 of silver was thereafter magnetically sputtered onto the inner layer 54 from a silver target surface at a rate of 94 A/sec at 25° C., at the same atmospheric conditions as were utilized previously. Deposition of the intermediate layer 56 was terminated when the luminous transmittance decreased an additional amount of between 10% and 12% of the transmittance of the uncoated substrate 52.
The outer layer 58 was magnetically sputtered onto the intermediate layer 56 under the same conditions used to sputter inner layer 54. Deposition was terminated when the luminous transmittance of the article 50 increased to about a peak value, preferably about 90% of the transmittance of the uncoated substrate 52. The final article 50 had an electrical resistivity of less than about 10 ohms per square.
EXAMPLE II
With reference to FIGS. 1, 2 and 5, a transparent, electroconductive article 60 was produced according to the present invention, consisting of a substrate 62 of an ambient temperature transparent substrate, having a film 64 of indium oxide deposited thereon.
A coating chamber 12 was evacuated to less than 3×10 -5 torr, and an evacuated atmosphere of about 75% argon and 25% oxygen at a total pressure of 6×10 -4 torr thereafter established. The cathode 18 was activated with a power of 6.25 watts/in 2 (0.97 watts/cm 2 ) to begin sputtering from a 10% tin-indium target surface overtop the activated deposition rate monitor 28. Deposition rate was set at 30 A/sec by adjustment of the oxygen input valve 36 while total pressure was maintained constant by adjustment of the argon input valve 40.
Deposition proceeded as the cathode 18 was scanned over the substrate 62 at a rate of 2 in/sec (5 cm/sec), and was terminated when the monitored electrical resistivity decreased to 15 ohms per square and the monitored optical transmittance peaked at about 80%.
EXAMPLE III
An article 60 was produced as in Example II, except that an initial atmosphere of about 55% argon, 45% oxygen was established, cathode power was set at 14 watts/in 2 (2.2 watts/cm 2 ), and deposition rate was maintained at a 60 A/sec. An article 60 having an electrical resistivity of 15 ohms per square and 80% luminous transmittance resulted.
A comparison of Examples II and III illustrates that the present invention may be practiced over a wide range of cathode power settings and deposition rates. Accordingly, the foregoing examples are offered to illustrate the present invention, but are not intended to be limiting thereto, the scope of the present invention being defined by the claims which follow.
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A method and apparatus for the control of reactive sputtering deposition of oxide-containing films, including the monitoring of and maintaining the constancy of the deposition rate and total pressure of the system by adjustment of the oxygen and argon input flow rates. Deposition rate is monitored by an activated quartz crystal, and behaves as a sensitive function of actual oxygen partial pressure. Stoichiometry, optical and electrical properties of the oxide-containing films are therefore controllable by maintaining constant oxygen partial pressure.
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FIELD OF THE INVENTION
This invention relates to shutter assemblies, for example, for doors or windows. The invention also relates to laths which comprise component parts of shutter assemblies.
1. Background of the Invention
It is now common for shop doors to be closed at night by shutters comprising a plurality of laths or louvers joined together. These shutters can usually be lifted or rolled up during the day to open the doorway in order to allow access, for example, to a shop. A growing problem with shops is a crime which has been colloquially termed "ram-raiding" in which criminals drive a vehicle into a door or a shutter closing a doorway to force entry into premises. It is difficult to stop ram-raiding. At present, a structurally effective and aesthetically sound means of preventing ram raiding has not been found.
2. Description of the Prior Art
It is known from European Patent No. 0 248 837 to provide the laths of a roller shutter with a rigid flat steel strip, or rod, passing through a hollow center of the lath, the ends of the steel strip carrying guide pins which are received in and cooperate with guideways provided at the side of a doorway.
It is an aim of the invention to provide a new shutter suitable for preventing or hindering ram raiding.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, I provide a lath for a shutter assembly comprising a lath body and an extensible member associated with the body, the extensible member having a location lug at each end adapted to be received in a channel at the side of an aperture, the arrangement of the lath being such that if the lath is hit by a vehicle the body and extensible member will extend, the extensible member absorbing energy as it extends so as to slow the vehicle.
Thus, the extensible member extends, rather than breaks, and in so doing absorbs energy and maintains the integrity of a barrier between one channel to one side of an aperture and another to the other side of the aperture.
EP 0 248 837 is not suitable to prevent ram raiding. It is too brittle and cannot absorb enough energy while maintaining its structural integrity. The shutter of EP 0 248 837 is designed to prevent entry by burglars using hand tools. This is a very different problem.
Preferably, the extensible member is also resilient. The extensible member is preferably a rope, such as a steel or wire rope. The extensible member is preferably received in a hollow cavity defined by the body of the lath.
According to a second aspect of the invention, I provide a shutter assembly comprising a plurality of laths extending between a pair of side channels disposed to either side of a doorway, window, or the like, at least one of the laths having a main body and an extensible member retained at each end to respective side channels by retention members associated with the extensible member, the extensible member being sufficiently strong to withstand a heavy blow to the shutter assembly in the vicinity of the extensible member, extending with the blow and thereby absorbing energy rather than breaking.
Preferably, the extensible member is resilient, and is most preferably a rope, such as a metal or wire cable. The rope is preferably sufficiently flexible as to bend through 90° within a length of 10 cm or so. The extensible member is preferably not stressed significantly in its normal state.
Preferably, there are a plurality of laths having extensible members and associated retention members. Preferably, at least one lath having an extensible member is interposed between two laths having no extensible member, and/or vice versa. Preferably, a set of laths having extensible members is alternatively interlaced with a set of laths having no such members.
A lath or laths, preferably one not having an extensible member, preferably has a guide lug at one, or both, of its ends received in a, or each respective, guide or side channel. The guide lug may be adapted to deform or break under the force of a vehicle hitting the closed shutter assembly, thus absorbing energy. The guide lug may be of plastic material.
The guide channels preferably define a sliding space for the retention members which may have guide faces adapted to co-operate with complementary faces on the guide channels to guide the members for longitudinal and/or transverse movement, at least when the shutter laths are deformed following a blow.
The retention members preferably have a first portion extending transversely to the extensible member and a second portion extending away from the first portion. The second portion may extend towards the aperture of the doorway or the like. There may be a pair of second portions, one or each of which is spaced from and faces a complementary recess in the guide channel.
The guide channels are, of course, fixed very firmly to the walls or other suitable structure adjacent the aperture capable of withstanding the impact generated by the vehicle.
According to a third aspect, the invention consists in a method of strengthening shutters comprising putting extensible members through or beside laths of a shutter and retaining the ends of the extensible members in side members adjacent to the ends of the laths.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, of which:
FIG. 1 shows a schematic cut-away perspective view of a part of a door shutter installation;
FIG. 2a shows a schematic side view of the installation of FIG. 1;
FIG. 2b shows a schematic view of a part of the installation from above;
FIGS. 3a and 3b show details of a plastics guide lug provided at the end of a lath of the shutter of the installation of FIG. 1;
FIG. 4 shows detail of a lath of the installation of FIG. 1 having the lath body roughly represented schematically in chain dotted lines;
FIG. 5 shows an end view along line V--V of FIG. 4 in which the lath body is represented fully;
FIG. 6 is a cross-section of the guide channel and associated cable used in the installation of FIG. 1;
FIGS. 7 and 8 show details of an alternative retention member, and guide channel;
FIG. 9 shows detail of an alternative guide channel and windlock arrangement;
FIG. 10 shows a cross section of an alternative lath; and
FIG. 11 shows a side view of the alternative retention member of FIGS. 7 and 8.
Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show a roller shutter assembly 1 comprising a shutter 2, a mounting, or door, frame 3, and a motor 4.
The frame 3 comprises two opposed aluminum side channels 5 and 6, one to either side of a doorway 7 connected at their upper ends by a shutter retracting and rolling mechanism 8 having the motor 4 which moves the shutter up and down. The side channels 5 and 6 are recessed into appropriate receiving recesses 9 in walls 10 surrounding the doorway 7. The base of each channel 5 and 6 is set into a concrete floor 11. The shutter retracting and rolling mechanism 8 has anchor plates 12 which extend in a concrete ceiling 13 of the room which the shutter assembly closes. The anchor plates 12 have angle sections 14 to key them to the concrete ceiling against forces developed in a ram raid.
Each side channel 5 and 6 comprises a back wall 15, two side walls 16, and a pair of oppositely directed retention flanges 17 provided at the front edge of the side walls 16. The flanges 17 are spaced from each other and define a gap 18. The side walls 16 also have a second pair of oppositely directed partition flanges 19 at an intermediate point in their transverse extent. The partition flanges are spaced from each other and define a longitudinal gap which is filled by a removable plastics insert strip 20. Alternatively, the strip 20 may be omitted. When the insert strip 20 is in place, the flanges 19 and the strip 20 effectively form a continuous smooth wall. The back wall 15 has an array of mounting holes through which fixing means, such as bolts 21, extend to hold the channels to the walls 10. The side walls 16, retention flanges 17, partition flanges 19, and strip 20 define a vertically extending guideway 5' or 6'.
The shutter 2 comprises individual interlinked laths, or slats, 22. Each lath has a hollow body 23 of extruded aluminum having a male hook formation 24 at its upper edge and a female socket formation 25 at its lower edge (best seen in FIG. 3b and FIG. 5). The male and female formations of adjacent laths are interlinked and allow a degree of pivoting about their junction. The shutter 2 is made of two kinds of laths, a first set of laths 26 having plastics material windlocks 27 at each end, and a second set of laths 28 having reinforced cables 29 passing through them. The two sets of laths are alternatively interlaced so that a lath of the first kind is interposed between adjacent laths of the second kind, and vice versa.
FIGS. 3a and 3b illustrate a lath 26. The windlock 27 at each end of the lath has a plug 30 inserted into the hollow end of the lath, a fixing plate 31 riveted to the lath, and a guide lug 32 received in use in the guideway 5' or 6' of whichever of the channels 5 or 6 it is retained in. The lugs 32 have a projecting portion 33 which extends through the gap 18, and a guide and retention portion 34 which locates behind a retention flange 17 and serves to guide the lath for vertical sliding movement.
FIGS. 4 and 5 show a lath 28 of the other kind. A pair of the wire ropes 29, in this case a 7×19 rope (seven twisted strands each of nineteen wires) of about 6 mm in diameter, each with a breaking load of about 2000 kilograms. Such a rope can be bent by hand through 90° over a length of about 5 to 10 cm of the rope--it is quite flexible. Such a rope is also stretchable to a significant degree. The ends of the ropes 29 are swaged or otherwise connected to shafts 35 having abutment shoulders 36 and projecting screw threads 37. At each end of the lath 28 a metal retention formation, or plate, 38 is held clamped against the shoulders 36 by nuts 39. The retention formation 38 has a pair of vertical edges 40, each of which carries a projecting flange 41 extending towards the lath 28. The shafts 35 extend in use through the gap 18 and the retention formations 38 are held and retained in the guideways 5' and 6', without touching the guideways. The relative positions in the guideway of the retention formations 38 and the windlocks 27 are shown in FIG. 6.
The removable and replaceable strips are snapped into place after the channels 5 and 6 have been bolted to the walls. Alternatively, they could be omitted if there is no danger of fouling on the bolts which hold the channel in place. A force-spreading plate may be provided between a channel-mounting bolt and tile channel wall 15.
When the shutter is in normal use, the windlocks 27 contact the channels 5 and 6 and are guided for vertical sliding movement. The retention formations 38 do not touch anything and are simply carried from their laths 28. The motor lifts the shutter up and down. The cables 29 are not tensioned to any significant extent--they are just taut enough to eliminate slack.
When the shutter 2 is hit by a vehicle, such as a car, during a ram-raid, the hollow bodies of the two kinds of laths buckle under impact. The plastics windlocks may be strong enough to stop the car, but if the car is travelling fast enough, they will break off or be so deformed that they pull out of the channels 5 and 6. As the laths buckle more and more, the cable 29 will draw the retention formations 38 towards the retention flanges 17. When the retention formations 38 hit the flanges 17, further forward movement of the car results in the cables 29 stretching and absorbing energy. The retention formations 38 anchor the cables to the channels 5 and 6 as they stretch. The interlinked laths have sufficient inherent strength, and the joints between adjacent laths are strong enough, to distribute the impact load through the connecting joints to other laths containing other cables. Thus, the impact energy of a vehicle is absorbed by several cables, not just those of a particular lath. The impact energy of the car is absorbed by the stretching of the cables, and the car is slowed and should eventually be stopped with the doorway still being blocked by the deformed but structurally substantially whole shutter. In some extreme cases the car may break the shutter.
It will be appreciated that the bending of the bodies of the laths, the deformation and/or breaking of the windlocks, and the bending and stretching of the cables all absorb energy and serve to slow the car progressively, rather than trying to present a rigid barrier which needs to be very strong or it will break. By absorbing the energy progressively, one can provide a shutter which is effective against ram raiding.
The edges 40 and flanges 41 of the formations 38 ensure that the formation does not twist too much as it is drawn towards the retention flanges 17.
It will also be noted that the flanges 17 of FIG. 6 are slightly different from those shown in FIG. 1 in that they have rearwardly projecting lips 45. The flanges 41 of the retention formation 38 hook into the recess (referenced 46) between the lips 45 and the side walls 16. FIG. 6 also shows the provision of plastics slide strips 47 to reduce friction and noise during opening and closing of the shutter and to seal against the ingress of dirt.
It will also be appreciated that strip 20 may enable a smooth continuous wall surface to be presented near the nuts 39 which helps to avoid them fouling, should the laths experience side-to-side forces during sliding of the shutter.
FIGS. 7 and 8 illustrate an alternative retention member 70 held by a pair of bolts 71 against a hollow lath body 72. The bolts 71 are screwed onto screw-threaded ends of a pair of couplings 73 swayed to respective ones of a pair of cables 74 housed in the hollow cavity of the lath body 72. The member 70 is made of extruded aluminum. The retention member 70 is received in a space defined by a guide, or side, channel 103.
The co-operation between the member 70 and the channel 75 is similar to that shown in FIG. 6.
FIG. 9 shows an arrangement of a side channel 90 and a windlock 91 in which the channel 90 has a pair of partition flanges 92, but no insert strip similar to strip 20 is provided. The arrangement of the windlock 91 is such that it cannot foul on any mounting bolts 95 provided to mount the channel 90 to a wall. The head of the windlock engages the flanges 92 if it is pushed towards them, and this restrains inward movement of the windlock which might otherwise cause fouling.
FIG. 9 also shows the provision of a force spreading bar 93 interposed between the channel 90 and a plurality of mounting bolts. The channel 90 defines a pair of recesses 94 which may receive dust brushes, either in addition to the seal strips shown or instead of them.
An alternative lath 96 is shown in FIG. 10. Unlike the laths 26 and 28, this lath 96 is not a hollow box section. The lath is in the form of a sheet 97 which is provided with a male hook formation 24' and a female socket formation 25' at its upper and lower portions. The lath 96 may also be provided with windlocks at each end of its ends in order to provide additional energy absorbing components in the event of an impact to the shutter.
FIG. 11 shows the retention member 70 in greater detail. The member is basically in the form of a T-shape with two arms 98 and 99 branching off from a body portion 100. Inner surfaces of the arms are linked to the body portion 100 and define sloping surfaces 101,102. FIG. 7 shows this retention member located in a guide channel 103. If the shutter is hit by a vehicle and the laths buckle, the retention member 70 is by pulled in a horizontal direction and the inner surfaces 101,102 engage with retention flanges 17' thereby providing resistance against the movement of the retention member 70 out of the guide channel 103, and usually retaining it within the channel.
The body portion of the retention member is provided with ridges 104 and 105 which each encircle the body portion 100. The ridges anchor the retention member securely into a hollow lath body 72.
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A shutter assembly has a plurality of laths which extend between a pair of vertically extending side channels disposed to either side of a doorway, window or the like. A number of the laths are strengthened and are hollow box sections through which a pair of wire cables extend. The wire cables are anchored to retention members which can move vertically in the side channels. The remaining laths have windlocks at their ends which are located in and are moveable in the side channels. The wire strengthened laths are alternately interlaced with the remaining laths. The wire cables give additional strength to the strengthened laths and are sufficiently strong to withstand a heavy blow to the shutter assembly in the vicinity of the strengthened laths, extending with the blow and thereby absorbing energy rather than breaking.
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Work on this invention was supported by funding from National Science foundation contract CHE 8800675.
This application is a continuation of application Ser. No. 07/365,171, filed Jun. 12, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved process for the fractionation of particles. More particularly, the invention relates to a new field-flow fractionation (FFF) process which uses a modified channel structure to improved the speed and effectiveness of operation.
Specifically, the invention provides a modified continuous flow FFF process for the separation of samples of particles and macromolecules which uses a modified channel structure to reduce the relaxation effect, reduce sample adhesion to the wall, and where possible eliminate the stop-flow procedure and thus greatly increase the speed and stability of operation. The new process of the invention comprises an improvement in the FFF process wherein a carrier fluid containing the particles to be separated is forced through a thin flow channel having an inlet and outlet end and a field or gradient is used to induce a driving force acting across the thin dimension perpendicular to the flow axis and the particles entering the channel at the inlet end undergo a relaxation process and approach a steady state distribution within the channel, the improvement comprising using as the thin channel a thin channel whose thickness is reduced at the inlet end for a substantial distance beyond the inlet means, such as the conventional triangular or near triangular piece, and then broadened out at the outlet end.
The invention further provides an apparatus for conducing the above-described process.
2. Prior Art
There is a growing need in industry and health sciences for the separation and characterization of micron sized particles including biological cells, latices, environmental particles, industrial powders, crystallization products, and related particulate matter. There is also a growing need for the separation of submicron sized particles, macromolecules and synthetic polymers.
Various methods have been proposed, but in general, they have been too slow, complex in operation, inefficient and expensive or have failed to effect the separation with the desired degree of resolution needed for commercial operations.
Some of the highest resolutions techniques disclosed have been those based on field-flow fractionation (FFF) as disclosed in the following U.S. patents and copending patent applications: U.S. Pat. No. 3,449,938, U.S. Pat. No. 4,147,621, U.S. Pat. No. 4,214,981, U.S. Pat. No. 4,250,026, U.S. Pat. No. 4,737,268, and copending patent applications--Giddings--"Lif-Induced Hyperlayer Field-Flow Fractionation Process for Particle Separation" Ser. No. 153,774, filed Feb. 8, 1988, U.S. patent application--Giddings--"Process for Continuous Particle and Polymer Separation in Split-Flow thin Cells using Flow-Dependent Lift Forces", Ser. No. 194,851, filed May 17, 1988, U.S. patent application--Giddings--"High Speed Separation of Ultra-High Molecular Weight Polymers by Hyperlayer Field-Flow Fractionation" Ser. No. 217,707, filed Jul. 11, 1988, and U.S. patent application--Williams--"Process of Programming of Field-Flow Fractionation"--Ser. No. 237,188, filed Aug. 29, 1988.
Attempts have been made to improve the FFF process, such as disclosed in Giddings et al--Anal. Chem. 56 2099) 1984, which discloses a method for reducing disturbances at the triangular end piece by reducing volume and thickness at the end piece.
The field-flow fractionation technique, however, has been limited for certain operations because of the problem as to speed of operation and the loss of sample material by adhesion to the wall for the following reasons.
When a particle sample first enters a field-flow fractionation channel, it is generally distributed broadly over the channel cross-section. Before normal sample migration can occur, the components of the sample must undergo a relaxation process in which they approach a steady-state distribution within the channel, usually by accumulating near one channel wall. This process requires a finite time (typically from 10 seconds to 30 minutes) described by the relaxation time ν. Because a good deal of band broadening can occur during the relaxation process, a stop-flow procedure is commonly used in which the flow through the channel is halted for a period of time ν in order to allow relaxation to occur under static conditions. The stop-flow procedure, generally required to avoid losses in resolution, is particularly essential for high flow rate runs. However, under any circumstances, stop-flow is an inconvenience and it consumes additional time for separation and often introduces baseline instabilities in sample detection. Sample losses due to adsorption or adhesion at the accumulation wall are also greatest during the stopflow period. Attempts to reduce the stopflow time by increasing the field strength only magnify the sample loss problem. Clearly, the development of a method to reduce relaxation effects and, where possible, eliminate the stop-flow procedure would represent an important advance in FFF techniques, particularly for high speed operations.
It is an object of the invention, therefore, to provide an improved FFF process which solves the above-noted problem as to relaxation time. It is a further object to provide a new FFF process which effects a reduction in the relaxation effect and where possible eliminates the stop-flow procedure. It is a further object to provide a modified FFF process which is capable of effecting separation at a very high rate of speed. It is a further object to provide a modified FFF process which can be adapted to any of the above-noted FFF techniques. These and other objects of the invention will be apparent from the following detailed description thereof.
SUMMARY OF THE INVENTION
It has now been discovered that these and other objects can be accomplished by the new process of the invention which presents for the first time an efficient process for reducing the relaxation effect and in many cases eliminates the stop-flow procedure which has limited the prior known FFF techniques.
The new process comprises an improvement in the FFF technique wherein a carrier fluid containing the particles to be separated is forced through a thin flow channel having an inlet and outlet end and a field or gradient is used to induce a driving force acting across the thin dimension perpendicular to the flow axis and the particles entering the channel at the inlet end undergo a relaxation process and approach a steady state distribution within the channel, the improvement comprising using as the thin channel one whose thickness is reduced at the inlet end relative to the thickness at the outlet end. Preferably the thin channel has a blocking element at the inlet end of the channel which reduces the thickness for a sufficient distance in the channel to largely complete the relaxation effect within that distance, after which the thickness increases to its normal value for the remaining length of the channel.
It has been surprisingly found that by the technique of reducing the channel thickness at the inlet end of the channel one can greatly hasten the relaxation process and in many cases eliminate the stop-flow procedure without a significant loss of resolution and thus greatly increase the speed of operation. In addition, as shown below the new technique is applicable to any and all of the above-noted FFF processes as indicated below.
The reduction in relaxation times can be put to use in three principal ways. First, if ν is short enough, a stop-flow procedure is not necessary; injection without stopping or reducing flow rate is termed here stopless-flow injection. Second, injection and relaxation can proceed at a reduced (but not zero) flowrate to reduce sample losses to the wall. This is termed slow-flow injection. Third, even when stopflow is needed, the time delay before the initiation of FFF separation is reduced and the separation time is accordingly diminished.
It is important to note that a thin channel is generally desirable for the achievement of separation in FFF, as it is for the achievement of relaxation However, separation and relaxation are two relatively independent processes and the optimum channel thickness for one does not necessarily correspond to the optimum thickness for another. The present method allows the independent adjustment of channel thickness in two portions or segments of the channel, one optimized for separation and the other optimized for relaxation.
DESCRIPTION OF THE DRAWINGS
The various objects and features of the present invention can be more fully understood by reference to the accompanying drawings.
FIG. 1 shows a graphic, perspective view of a FFF flow channel depicting the flow and the field gradient applied.
FIG. 2 depicts an FFF flow channel with enclosed structure around the channel.
FIG. 3 is a graphic illustration of a side view of the channel showing the relaxation trajectories of particles and the resultant bimodal distribution of particles near the inlet of an FFF channel with stopless flow injections.
FIG. 4 is a graphic illustration of the structure of a pinched inlet channel for FFF. The relaxation process for one component is shown.
FIGS. 5A, 5B, 5C and 5D are graphic illustrations of various places where the blocking element or elements can be placed in the channel.
FIG. 6 shows how a blocking element can be put in place in an FFF channel using two differently cut spacer layers sandwiched between plates.
FIGS. 7A-7C show three different elution profiles for the polymer latex spheres used in the Example at the end of the specification.
Referring to FIG. 1, the basic concept of FFF is represented by the flowrate vectors V, associated flow vectors and the driving force vector F. These vectors are drawn in relation to two closely spaced parallel plate means, 10 and 12. The region between these plates is identified as a flow channel 14, through which the fluid is conducted. This fluid flow is represented by the flowrate vector V and by a velocity profile 16 which shows relative fluid movement by means of channel flow velocity vectors 18. The b is the breadth, L the length and w the thickness of the channel.
A primary driving force is imposed normal to the channel flow axis for the purpose of controlling the transverse positions of the particles. This driving force is illustrated as F oriented perpendicular to the channel flowrate vector V and the respective plate means. The plate means 12 is the channel wall toward which the particles are normally driven by the primary driving force and is termed the accumulation wall. The opposite channel wall defined by plate means 10 is termed the depletion wall.
The structure can be implemented by means of variations of basic elements. One example is shown in FIG. 2. The flow channel 32 is substantially defined by a first and second plate means 33 and 34. Side wall structures 30 and 35 provide the respective plate means to fully enclose the chamber region 32. A general configuration might comprise a spacer plate 35 having the desired thickness w interposed between respective nonpermeable or semi-permeable plates, the combination being tightly clamped together.
Inlet means 36 and outlet means 38 are provided at opposite ends of the chamber to enable channel flow there through. Flow control means associated therewith are desirable to facilitate adjustment of V. Typically, the outlet end will feed effluent to detection means for obtaining separation results.
The inlet means consists of a narrower fluid inlet and a short tapered end piece usually roughly triangular in shape that serves to distribute the incoming flow smoothly out across the breadth of the channel.
FIG. 3 is a sketch of the inlet end of an FFF channel showing how a narrow particle particle band is broadened in the course of relaxation. The parameter z is the distance along the axial coordinate, with the other components as described in the Figure.
FIG. 4 is a graphic illustration of the pinched inlet concept with the blocking element being at the top or depletion wall of the channel at the inlet end.
FIG. 5 is a graphic illustration showing some of the various positions in which the blocking element may be placed, such as in FIG. 5A at the top of the inlet end, FIG. 5B at the bottom of the inlet end of the channel, FIG. 5C at both the top and at the bottom of the inlet end of the channel, and FIG. 5D as a sloping blocking element at both the top and bottom walls.
FIG. 6 is an illustration showing how a blocking element can be put in place in an FFF channel using two differently cut spacer layers A and B sandwiched between plates C and D. The resulting length of the relaxation segment or pinched inlet segment is shown as L r and the length of the separation segment or broadened section of the channel is shown as L s . The inlet flow means is shown as E and the outlet flow means as F.
As noted FIG. 7 shows three different elution profiles for the polymer spheres used in the Example at the end of the specification.
DETAILED DESCRIPTION OF THE INVENTION
The implementation of the pinched inlet concept should be relatively simple as illustrated in FIG. 4. For channels having a sandwich construction in which the channel volume consists of a section cut out and removed from a spacer layer sandwiched between two wall layers, an appropriately segmented channel can be constructed by using two or more spacer layers from which volume elements of different lengths are removed. Thus, a channel like that in FIG. 4 can be made by sandwiching together two spacer elements between the primary walls of the system. A section of one spacer (termed blocking element) can be left intact while the corresponding region of &he companion spacer can be removed to form the pinched segment of the channel volume as shown in FIG. 6. Alternatively, part or all of the segmentation might be produced by machining. The length L r of the relaxation segment is chosen in general such that most of the major components will undergo a major part, if not all, of their relaxation within this segment with continuous flow; L r >h o . This relaxation is shown for one component in FIG. 4. Clearly, L r and flow velocity are interrelated. For high speed stopless-flow operation with correspondingly large V and h o values, it is anticipated that the relaxation segment will occupy a substantial fraction of the total length of the channel system. Alternately, with slow-flow injection L r can be greatly reduced.
Flow in thin FFF channels is almost universally laminar. It is important that the flow in the transition region between segments maintains these laminar characteristics despite the rather abrupt change in cross section. Mixing currents at this point would have the potential to redistribute the component particles over the cross-section of the separation segment, in which case a second and less favorable relaxation process would be required. However, with smooth channel surfaces, a blocking element free of sharp edges and rough protrusions, and thin channel segments, effective flow laminarity should be achieved.
If the flow passing through the transition region were completely laminar, the transverse position of the blocking element would be immaterial. It could lie against the depletion wall, as shown in FIGS. 4 and 5A, or it could with equal effectiveness be layered against the accumulation wall as in FIG. 5B, or even divided into two layers, one adjacent to each wall as in FIG. 5C. However, the arrangement shown in FIG. 4 is preferred because the sample components, once concentrated at the accumulation wall, will be likely to proceed through the transition region without substantial perturbation even if flow disturbances are generated toward the interior of the channel.
It should be noted that the two-segment channel system shown in FIG. 4 has an initial portion preferably having a substantially uniform thickness, but could be replaced by a tapered channel that is relatively thin toward the inlet and thicker toward the outlet as shown in FIG. 5D. No distinct segments need exist. The general advantages of the method proposed here are expected from any such system no matter how the transition from the thin inlet region to the thicker outlet region is realized.
It should also be noted that an abbreviated relaxation step will generally occur after the component particles pass through the transition region. The expansion of the flow channel will lead to a comparable fractional expansion of the particle-containing lamina upon passage through the transition region; the steady-state concentration profile of particles may also change at the transition point. Thus, concentration re-equilibrium will be necessary after the transition region is passed. However, providing the particles are rather tightly confined in a thin laminae, most often adjacent to the accumulation wall, through the transition region, the readjustment necessary to the new steady-state conditions should be relatively brief and nondisruptive to the separation.
While in FIG. 4 a channel is shown with well-defined accumulation and depletion walls, under some circumstances different particles in the sample can go to opposing walls. This happens, for example, in sedimentation FFF when the carrier density is intermediate between that of two different particle populations. The pinched inlet concept will be equally applicable to this case providing proper attention is paid to the streamlining of the channel system in the transition region.
In general, wherever the channel is made thinner than at the outlet end, the additional wall material responsible for reducing the thickness, whether produced by machinery or by inserting thin films of material, is considered to be part of the blocking element or elements responsible for the pinched inlet configuration.
The pinched inlet method should constitute a useful modification to any field-flow fractionation system irrespective of field type, operating mode or channel geometry. However, special consideration will apply for each individual system. Some of these special considerations will be examined below for several subtechniques of FFF carried out in thin rectangular channels.
Sedimentation FFF
The application of the pinched inlet concept to sedimentation FFF should be straight forward. For a channel having a sandwich construction, the single spacer element normally used would only have to be replaced by two spacers, one of which would provide the blocking element as suggested in FIG. 4 and 6. However, in view of the strong centrifugal forces, it is important that the blocking element be sufficiently rigid or supported that it does not substantially sag into the channel space of the relaxation segment.
Alternately, if the density of a blocking element held at the inside wall is less than that of the carrier liquid, little channel distortion should be encountered because of buoyancy forces on the blocking element. Denser blocking elements might best be placed adjacent to the outside wall providing smooth laminar flow can be maintained through the transition region. In some cases it might be preferable to machine part or all of the channel volume out of one of the channel walls so that mechanical stability would be assured.
Thermal FFF
The primary challenge of thermal FFF is the thinness of the channel space; state-of-the-art channels are now typically 75 μm thick. To implement the pinched inlet concept without, sacrificing the thinness of the separation segment, it would be necessary to utilize a blocking segment of extraordinary thinness, 25-50 μm. The thin spacer layer containing this blocking element could be made from a variety of materials. Both the uniformity of this layer and its thermal conductivity are important considerations. A highly conductive layer (e.g. made up of a film of metal) would lead to the highest temperature gradient in the relaxation segment of the channel and would thus give the fastest relaxation. Also the relaxation segment could be shortened in proportion to the reduction of h o resulting from the increase in U.
However, since a high conductivity blocking element would tend to give a high heat flux through the relaxation segment and possibly distort the temperature distribution elsewhere in the channel system, there would be some advantages to constructing the blocking element from a low conductivity layer of material. for example, one made of Mylar. The material should not have a heat conductivity appreciably lower than that of the carrier liquid; a value too low would not provide an adequate temperature gradient to drive the relaxation process.
Flow FFF
The following consideration should be give to applying the pinched inlet concept to flow FFF systems. The most uniform spacer materials for forming the blocking element are impermeable to flow, thus making normal crossflow difficult to realize in the relaxation segment. Without crossflow, relaxation would fail to occur. One solution is to use a thin membrane for the spacer forming the blocking element despite its greater nonuniformity. A second approach would involve using a tapered channel, perhaps formed around a spacer of continuously variable thickness. Alternately, a tapered channel or a channel with a blocking element like that shown in FIG. 4 might be partially or entirely machined out of the frit material forming the depletion wall, allowing a normal crossflow flux into the channel along its entire length. More specifically, the thickness of the relaxation segment might be provided by a spacer while the additional thickness of the separation segment could be machined from the depletion wall.
Another solution would entail using an asymmetric relaxation segment resembling asymmetric flow FFF channels previously developed (Wahlund, Giddings--J. C. Anal. Chem. 1987 59 1332).
Steric FFF
The pinched inlet strategy proposed here should be directly applicable to steric FFF applications. Here, too, the sample must be forced to one wall before normal migration can occur. Hydrodynamic lift forces will have some influence on relaxation but the net effect should not change substantially because under steady-state conditions the sample particles still occupy thin laminae usually near the wall.
By using stopless flow injection in steric FFF, continuous lift forces will be exerted on the sample particles. For the larger particles used in steric systems, the flow velocity can be adjusted to a value high enough to prevent the particles from adhering at the wall. Thus, a major problem of stop-flow injection, namely, particle adhesion to the accumulation wall, should be possible to circunvent. In flow/steric or flow/hyperlayer FFF, for example, it should be possible not only to avoid particle adhesion but to dispense with the membrane normally used at the accumulation wall and use only the rigid frit material supporting the membrane. Such a system would be simpler, more uniform in channel dimensions, and less prone to clogging.
Programmed Field FFF
The magnitude of relaxation effects in stopless flow FFF can be reduced by using programmed field FFF. These advantages are complemented and amplified by a pinched inlet system. It is noted that relaxation tends to occur faster in the case of programming because generally a higher initial field strength is used than in the nonprogrammed (isocratic)case. The disadvantage of this high initial field strength is that it can increase the adhesion of particles to the accumulation wall. On the basis of these favorable characteristics of programmed field operation, it should be possible to use stopless flow or slow flow injection to advantage in a majority of programmed runs.
The cases cited above where the use of a pinched inlet system would be advantageous are simply examples of its general utility in FFF operation. The same general advantages could be stated for electrical FFF, magnetic FFF, cyclical-field FFF, and other subtechniques and operating modes.
While the pinched inlet geometry will often reduce relaxationl zone broadening in stopless flow operation to acceptable levels, there are cases in which such zone broadening will still be excessive. Rather than using stop-flow injection in these cases, a slow-flow injection process (where relaxation occurs at reduced flow rates) could be used to bring relaxational broadening within acceptable limits.
The blocking element utilized in the thin channel can be of any suitable construction and any means of attachment to the channel walls. It may be incorporated directly in the wall or may be attached thereto by adhesives, etc. or incorporated as described herein above. The element can be prepared from any suitable material, such as plastic, metal, etc. and is often of the same type as used in the construction of the channel itself.
The thickness of the element will be as needed to effect the needed reduction in the relaxation effect. In general, with channels of a thickness varying from 50 to 500 μm, the thickness of the blocking element can preferably vary from about 25 to 75 percent of the channel thickness.
The length of the blocking element again should be sufficient to effect the above-noted purpose as to the reduction in the relaxation effect under stopless or slow flow conditions. In general, this will be from about 10% to 50% of the total length of the channel.
The conditions to be employed in the FFF systems are well known and fully illustrated in the prior art. For example, the type of particles, macromolecules and polymer molecules (all referred to herein as "particles") to be separated, the carrier fluids, the concentration of particles, the type of fields or gradients to be used, strength of field, temperature of separation, rate of flow, recovery techniques and general construction of the thin channels are all illustrated in Giddings--U.S. Pat. No. 4,737,268 and so much of that disclosure pertinent to the present invention is incorporated herein by reference.
To illustrate the operation of the presently claimed process and to compare the results obtained by that process over the conventional channel without the pinched inlet configuration, the following example is given.
COMPARATIVE EXAMPLE
The process employed was a steric FFF process using one conventional channel and two pinched inlet channels.
The channel volumes were cut out of thin plastic spacers and sandwiched between glass plates, then clamped together between polymethyl methacrylate bars. This general structure is useful for steric FFF using gravity as the driving force.
A Teflon spacer of 254 μm thickness was used for the uniform channel (lacking a pinched inlet). The channel, cut from the spacer, has a tip-to-tip length L of 38.4 cm and a breadth b of 2 cm. The void volume, measured as the elution volume of an unretained sodium benzoate peak, is 1.84 mL.
Two pinched inlet channels were constructed. Both utilized two sheets of Mylar in their construction, one with the full channel length removed and the other cut in such a way that a "blocking element" was left in place. The blocking element is a strip of material that occupies the inlet end of the channel in order to reduce its thickness and thus realize the pinched inlet geometry. The construction of the systems is illustrated in FIG. 6. The combined thickness of the two films is 254 μm in both cases, the same as the thickness of the uniform channel. For pinched inlet channel I, the two thicknesses are both 127 μm. For channel II, the film with the blocking element is 178 μm thick and the film from which the pinched inlet is cut is 76 μm thick. The length (38.4 cm) and breadth (2 cm) of the pinched inlet channel systems are identical to those used for the uniform channel The length L r of the blocking element, measured from the channel tip to the blocking edge is 15.4 cm in both cases, 40% of the total channel length. The void volumes, also measured with a nonretained peak, are 1.52 mL for channel I and 1.41 mL for channel II.
The samples used in this study were polystyrene latex beads with mean diameters of 15 and 20 μm. The carried liquid was doubly distilled water with 0.01% FL-70 detergent and 0.02% sodium azide used as a bacteriocide. All runs were carried out at room temperature, 293±1 K. From 15 to 20 μL of the sample suspension (containing 2-3×10 4 particles) were injected into the channel through a septum by means of a microsyringe.
For the stopflow method the sample was slowly carried to the head of the channel with a Gilson Minipuls 2 pump. The flow was then completely stopped for a period adequate to allow the particles to relax to the accumulation wall. The relaxation time was calculated from the Stokes-Einstein equation. Following relaxation, flow was resumed.
In the case of stopless flow injection, the sample was introduced by syringe directly into the carrier stream. The flow of the latter was held constant, without change or interruption.
The eluted sample was monitored by a UV detector model UV-106, at a wavelength of 229 nm. A strip chart recorder was used to record the emerging peaks.
RESULTS
FIGS. 7A-7C show three different elution profiles for the 15 μm polystyrene latex spheres run at the same flow rates, 0.73 mL/min, equivalent to a linear flow velocity of 0.24 cm/s in the separation segment of the channel where the channel thickness (254 μm ) is greatest. FIG. 7a shows the concentration profile of the particles emerging from the reference (nonpinched) channel after application of the stopflow procedure. For this case, the stopflow time was 42 s, equal to the calculated relaxation time of the particles across the full channel thickness (254 μm). FIG. 7b shows the results of a run identical in all respects to that of FIG. 7a except that the stopflow procedure was used to bypass the flow interruption of stopflow. The emerging peak in this case shows a substantial loss of sharpness as expected for stopflow operation. (For smaller particles with longer relaxation times than that of the 15 μm particle, the stopflow profile would be much broader and would have a bimodal shape.) We also observe that the trailing edge of the peaks in FIGS. 7a and 7b nearly coincide in their positions, the leading edge of the FIG. 7b profile, however, appears considerably earlier than that for the FIG. 8a peak as a consequence of the accelerated elution of those particles starting the run near the top wall of the channel where relaxation effects are maximal.
FIG. 7c shows the profile of the 15 um beads emerging from pinched inlet channel System I after stopless flow injection. We observe that the excessive band broadening illustrated by FIG. 7b has been eliminated through the use of the pinched inlet channel. The band width is comparable to that in FIG. 8a for normal stopflow operation. More specifically, the standard deviation δ t in times units for the three profiles are 0.86, 2.35 and 0.77 s for FIGS. 7a, 7b and 7c, respectively. The corresponding plate heights are 0.43, 3.7 and 0.52 mm, respectively.
It is noted that to fully utilize the capabilities of the pinched inlet channel system, the flowrate must be matched to the dimensions of the pinched inlet segment in order to assure complete relaxation of all components before they enter the second stage, the separation segment. The flowrate used in conjunction with FIGS. 7A-7C accordingly yields an h o /L value of 0.26, well below the maximum allowable value of 0.4, equal to the ratio of the length of the pinched segment to the total channel length.
Related results are found for the 20 μm polymer particles.
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A continuous flow FFF process for the separation of samples of particles which uses a modified channel structure to reduce the relaxation effect, reduce sample adhesion to the wall, and where possible eliminate the stop-flow procedure and thus greatly increase the speed and stability of operation, said modified channel comprises a thin channel whose thickness is reduced at the inlet end for a substantial distance beyond the inlet, such as the conventional triangular or near triangular piece, and then broadened out at the outlet end of the channel.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a net structure formed by the knitting of metal ropes, a net for protection against the fall of one or more heavy bodies, such as stone blocks, which is formed from said structure, and a device for protection against the falls of such heavy bodies.
DESCRIPTION OF THE PRIOR ART
[0002] It is well known to use anti-submarine netting to form the net of a device for protection against the falls of stones or other bodies liable to fall onto a zone to be protected. The stock of this type of netting tends, however, to become exhausted, and the cost of producing new nets of this type is too great to be acceptable. Moreover, some of these nets are of uncertain or even unknown origin, which does not provide all the required assurances as regards their strength in this specific application.
[0003] There are also nets formed by the weaving or knitting of metal ropes. The disadvantage of existing nets of this type is that they have only a greatly reduced capacity for dissipating the energy transmitted by a stone block or other similar bodies. This results in an enormous force being transmitted to the anchoring points of the nets which may be induced to break.
SUMMARY OF THE INVENTION
[0004] The present invention is aimed at overcoming the abovementioned disadvantages by providing a net structure formed by the knitting of metal ropes, which has a high capacity for dissipating the energy transmitted by the fall of a body, while at the same time remaining relatively cost-effective to manufacture.
[0005] According to the invention, each mesh which this net structure comprises is connected to the laterally adjacent mesh by means of a breakable junction piece, this junction piece having a breaking threshold markedly lower than that of the ropes forming the structure of the net.
[0006] The breaking threshold of the junction piece may, in particular, be of the order of a quarter of the breaking threshold of these ropes.
[0007] The junction pieces make it possible to keep the meshes normally in a position close to one another, so that, for a given number of meshes, the area of the net according to the invention is smaller than the area of a net having the same knitting structure, for the same number of meshes without junction pieces.
[0008] When a body, in particular a stone block, falls, the junction pieces break in succession, starting from the point of impact and radiating from the latter, thus freeing the assembly of meshes. These successive breaks make it possible to absorb part of the energy transmitted by the body and also make it possible to trigger the possibility of an additional deformation of the net. This additional deformation, when it occurs, generates frictions and torsions of the ropes, thus contributing to the absorption of the energy transmitted by the fall of the body.
[0009] The breaking of the junction pieces is interrupted when the energy transmitted by the fall of the body becomes insufficient to cause these breaks.
[0010] Thus, by virtue of the combination of a knitting of metal ropes and of these junction pieces, the net structure according to the invention makes it possible to absorb more energy, without a breaking of the ropes, hence without a break in the intactness of the structure of the net.
[0011] Preferably, the knitting of the ropes is of the Jersey type.
[0012] The junction pieces may comprise open metal sleeves crimped on the ropes or pieces of the type consisting of make-up links for a chain.
[0013] According to a first embodiment of the invention, each rope or rope portion constituting a row of meshes forms successive “S”s defining inverted loops of circular shape, and the junction pieces gather together the strands of adjacent ropes of the adjacent meshes; each rope or rope portion constituting the row of meshes which is directly adjacent to that mentioned above has a structure identical to that of this first row of meshes, and the rope portion forming a mesh of this second row of meshes reenters a corresponding mesh of said first row of meshes, passes behind the strands of the two adjacent meshes of this first row of meshes and reemerges from the adjacent mesh.
[0014] In a variant, alternately from one row of meshes to the other,
a rope portion forming a mesh of a row of meshes in question reenters a corresponding mesh of one of the adjacent rows of meshes, passes behind the strands of the two adjacent meshes of this row of meshes and reemerges from the adjacent mesh, and a rope portion forming a mesh of this same row of meshes in question emerges from a corresponding mesh of the other of the adjacent rows of meshes, passes in front of the strands of the two adjacent meshes of this row of meshes and reenters the adjacent mesh.
[0017] According to another embodiment of the invention, each rope or rope portion constituting a row of meshes forms successive pear-shaped loops in the form of an e, and the junction pieces gather together the strands of adjacent ropes of the adjacent meshes; each rope or rope portion constituting the row of meshes which is directly adjacent to that mentioned above has a structure identical to that of this first row of meshes, the rope portion which forms a mesh of this second row of meshes reentering a corresponding mesh of said first row of meshes, passing behind the two strands of the two adjacent meshes of this first row of meshes and reemerging from the adjacent mesh.
[0018] The net according to the invention is formed from the structure described above.
[0019] Where it has a length and a width, in particular when it has a rectangular shape, the length of the meshes may be oriented parallel or perpendicularly to the length of the net.
[0020] In a particular embodiment of a net according to the invention:
the net has a length of 10 m and width of 6 m; the diameter of the circular part which each mesh forms is 350 mm; the diameter of the ropes used is 12 mm; the elasticity of the ropes is at most 1.15% before break; the breaking threshold of the ropes is 84 kN; the breaking threshold of the junction pieces is of the order of 20 kN.
[0027] The protective device according to the invention comprises a net, as defined above.
BRIEF DESCRIPTION OF THE DRAWING
[0028] To understand it clearly, the invention is described above once again, with reference to the accompanying diagrammatic drawing illustrating by way of nonlimiting examples two possible embodiments of the net structure to which it relates.
[0029] FIG. 1 is a plan view of a rope portion which it comprises, according to a first embodiment, constituting a series of successive loops intended to form meshes;
[0030] FIG. 2 is a plan view of the net structure, including a series of rope portions of the same configuration as that shown in FIG. 1 and knitted to one another;
[0031] FIG. 3 is a plan view of a similar structure, with an alternative embodiment in terms of the knitting;
[0032] FIG. 4 is a plan view of a rope portion which the net structure comprises, according to a second embodiment, constituting a series of successive loops intended for forming meshes;
[0033] FIG. 5 is a plan view of the net structure, including a series of rope portions of the same configuration as that shown in FIG. 4 and knitted to one another;
[0034] FIG. 6 is a plan view of a net formed from the structure shown in FIG. 2 , and
[0035] FIG. 7 is a plan view of another net formed from the structure shown in FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] FIG. 1 illustrates a rope portion 1 forming successive “S”s which define inverted loops 2 of circular shape. The strands of adjacent ropes 2 a of two adjacent loops 2 are gathered together by means of junction pieces 3 formed by metal sleeves crimped on these strands 2 a.
[0037] The junction pieces 3 are breakable and have a breaking threshold markedly lower than that of the rope 1 , in particular of the order of a quarter of the breaking threshold of this rope 1 .
[0038] For the production of a net having a length of 10 m and a width of 6 m, designed to equip a device for protection against the falls of heavy bodies, such as stone blocks, the diameter of the circular part which each loop 2 forms is 350 mm, the diameter of the rope 1 used is 12 mm, the elasticity of this rope 1 is at most 1.15% before break, the breaking threshold of the rope 1 is 84 kN, and the breaking threshold of the junction pieces 3 is of the order of 20 kN.
[0039] FIG. 2 illustrates a net structure 5 including a series of six rope portions 1 a to 1 f of the same configuration as that shown in FIG. 1 and knitted to one another, each loop 2 forming a mesh of this knit. As is apparent, each mesh of a rope portion in question reenters a corresponding mesh of the directly adjacent rope portion, passes behind the strands 2 a of the two adjacent meshes of this rope portion and reemerges from the adjacent mesh.
[0040] FIG. 3 illustrates a similar structure 5 , in which, however, the knitting of the portion 1 b to the portion 1 a , of the portion 1 d to the portion 1 c and of the portion 1 f to the portion 1 e differs: each mesh of a portion 1 b , 1 d or 1 f emerges from a corresponding mesh of the portion 1 a , 1 c or 1 e respectively, passes in front of the strands 2 a of the two adjacent meshes of this rope portion 1 a , 1 c or 1 e and reenters the adjacent mesh.
[0041] The knitting of the portion 1 b to the portion 1 c and of the portion 1 d to the portion 1 e is identical to that described above.
[0042] FIG. 4 illustrates a rope portion 10 forming successive pear-shaped loops 12 in the form of an e. The strands of adjacent ropes 12 a of two adjacent loops 12 are gathered together by means of junction pieces 3 identical to those described above.
[0043] FIG. 5 illustrates a net structure 50 including a series of six rope portions 10 a to 10 f of the same configuration as that shown in FIG. 4 and knitted to one another, each loop 12 forming a mesh of this knit. As is apparent, each mesh of a rope portion in question reenters a corresponding mesh of the directly adjacent rope portion, passes behind the strands 12 a of the two adjacent meshes of this rope portion and reemerges from the adjacent mesh.
[0044] FIGS. 6 and 7 show rectangular nets 100 , 101 formed from the structure 5 . As regards the net 100 illustrated in FIG. 6 , the length of the meshes 2 is oriented parallel to the length of the net, whereas, as regards the net 101 illustrated in FIG. 7 , the length of the meshes 2 is oriented perpendicularly to the length of the net.
[0045] As described above, the invention affords a decisive improvement to the prior art by providing a net structure 5 , 50 having a high capacity for dissipating the energy transmitted by the fall of a body.
[0046] To be precise, the junction pieces make it possible to keep the meshes normally in a position close to one another, so that, for a given number of meshes, the area of the net according to the invention is smaller than the area of a net having the same knitting structure, for the same number of meshes.
[0047] When a body, in particular a stone block, falls when the net equips a device for protection against the falls of stones, the junction pieces 3 break in succession, starting from the point of impact and radiating from the latter, thus freeing the assembly of meshes. These successive breaks make it possible to absorb part of the energy transmitted by the body and also make it possible to trigger the possibility of an additional deformation of the net. This additional deformation, when it occurs, generates frictions between the ropes which contribute to absorbing the energy transmitted by the fall of the body.
[0048] The breaking of the junction pieces 3 is interrupted when the energy transmitted by the fall of the body becomes insufficient to cause these breaks.
[0049] Thus, by virtue of the combination of a knitting of metal ropes and of these junction pieces, the net structure according to the invention makes it possible to absorb the energy transmitted by said body, without a break of the ropes, hence without a break in the intactness of the structure of the net.
[0050] It goes without saying that the invention is not limited to the embodiment described above by way of example, but that, on the contrary, it embraces all its alternative embodiments coming within the scope of protection defined by the accompanying claims.
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The invention concerns a net structure ( 5, 50 ) wherein each mesh comprised therein is linked to the laterally adjacent mesh by a breakable junction piece ( 3 ), said junction piece ( 3 ) having a rupture threshold markedly lower than that of the wires constituting the net structure.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a piezoceramic device and a method for manufacturing it wherein the device includes a stack of at least two ceramic layers and an electrode layer arranged between the two ceramic layers.
[0003] Such devices may comprise a plurality of layers and uses. For example, they may be used in: actuators for effecting a low-inertia mechanical vibration of comparably high force via application of a select control voltage; bending elements to effect a high mechanical vibration of less force via application of select control voltage; or production of high electrical voltages. Piezoceramic devices may serve to detect mechanical acoustic vibrations and/or serve in their production via implementation in relevant devicse.
[0004] In the manufacture of piezoceramic devices, technical solutions have up until now been predominantly based on ceramic masses of the Perovskite structure type with the general formula ABO 3 . Herein, the piezoelectrical characteristics are brought to bear in a ferroelectrical condition. Lead zirconate titanate ceramics Pb(Zr 1−x Ti x )O 3 =PZT, modified with select additives, have been shown to demonstrate particular advantages. The combination of ceramics and additives is tailored to the so-called morphotropic phase interface of two co-existing ferroelectrical phases: a tetragonal and a rhombodic phase. Between the ceramic layers, produced according to known methods of ceramic foil technology, precious metal internal electrodes are applied by screen printing. The electrodes may comprise Ag/Pd in the molar ratio 70/30. At up to several hundred electrode layers, the piezoceramic devices are burdened with substantial costs. The precious metal electrodes permit the elimination of thermal dispergers and binders as well as other organic additives used in the process of ceramic foil production. Likewise organic components of screen printing-metal paste of the multilayer stacks are eliminated via air depolymerisation and oxydation such that a later sinter condensation at approximately 1100° C. to 1150° C. is made possible without damaging effects. Such effects may for example be effected by residual carbon which negatively influences the characteristics of the ceramics due to reduction reactions.
[0005] 2. Description of the Related Art
[0006] Examples of La 2 O 3 or Nd 2 O 3 doped Pb(Zr,Ti)O 3 ceramics are documentated in the literature, including by G. H. Haertling in the American Ceramic Society Bulletin (43(12), 113-118 (1964) and Journal of the American Ceramic Society 54, 1-11 (1971) as well as in Piezoelectric Ceramics , Academic Press, London and New York (1971) of B. jaffe, W. R. Cook and H. Jaffe. Additional discussion may be found in Y. Xu in Ferroelectric Materials and their Applications , Elsevier Science Publishers, Amsterdam (1991).
[0007] La 2 O 3 —in particular Nd 2 O 3 —additives induce the production of cation vacancies in the Pb positions of the crystal structure and at the same time increase the tendency to act as donors, particularly at insufficient oxygen partial pressure, which can lead to a depression of the insulating resistance and a rise in the dielectrcial losses, i.e. the sensitivity of the ceramic towards reduction is increased. At the same time, the additives stabilize the tetragonal phase and the kinetics of the orientation of the domains in the field direction at the polarity, i.e. the electromechanical behavior of the “soft piezoceramic” is influenced positively by such additives. For an advancement of the sinter condensation and prevention of evaporation losses of PbO in the ceramic, a low PbO surplus at the originally weighed-in composition is generally considered. The relationship between doping level by La 2 O 3 , in a Pb(Zr 0,47 Ti 0,53 )O 3 -ceramic (supplied with 3 molar-% PbO surplus) is discussed in the Journal of Electroceramics 2(2), 75-84 (1998) by M. Hammer and M. Hoffmann. In the journal, the sinter behavior and structure formation associated therewith and electro magnetic characteristics (such as coupling factor) and dielectricity constant (such as curie temperature, maximum temperature for ferroelectrical) as well as associated piezoelectrical behavior are all examined.
[0008] Ceramic masses with bismuth oxide in place of lead oxide (for example (Bi 0.5 Na 0.5 )TiO 3 —KNbO 3 —BiScO 3 ) were also taken into consideration by T. Takenaka and H. Nagata in The Proceedings of the 11 th Interational Symposium of Applied Ferroelectrics , Montreux 1998, IEEE 98CH36245, 559-562 (1998). Herein, Pb(Ti x Zr 1−x )O 3 was combined with BiScO 3 and/or BiInO 3 . All of these ceramics are based on Perovskite mixed crystal phases which, in combination with Ag/Pd internal electrodes, produce a relatively positive behavior for the purpose of a piezostack when the debindering (the removal of the binder or binders) and the sinter condensation is performed.
[0009] Piezoelectrical ceramic masses of the general composition (Pb 1−x−∝−y Sr x Na ∝ M y ) a [(Nb b Y c Cr d Co e Sb β ) f Ti g Zr 1−f−g ]O 3 are set out in U.S. Pat. No. 5,648,012 and are distinguished by high electromechanical coupling factors, whereby M is at least a rare earth metal of La, Gd, Nd, Sm and Pr and the parameter areas 0.005≦x≦0.08, 0.002≦y≦0.05, 0.95≦a≦1.105, 0.47≦b≦0.70, 0.02≦c≦0.31, 0.11≦d≦0.42, 0.01≦e≦0.12, 0.02≦f≦0.15, 0.46≦g≦0.52,0≦∝≦0.005,0≦β≦0.13 such that b+c+d+e+β=1.00 are effected.
[0010] The publication DE 9700463 discloses the production of green foils for piezoceramic multilayer devices. The green foils are based on a piezoceramic powder of the type PZT, to which a stochiometric surplus of a heterovalent rare earth metal (up to a content from 1 to 5 molar-%) and a stochiometric surplus of an additional 1-5 molar-% lead oxyde is added. In addition, it is disclosed in above publication that Ag + -ions from the area of Ag/Pd internal electrodes diffuse into the ceramic layers of the multilayer devices such that the heterovalent doping produced cation vacancies are occupied and accordingly result in a filled up Perovskite structure. This structure may be: Pb 0,99 Ag 0,01 La 0,01 [Zr 0,30 Ti 0,36 (Ni ⅓ Nb ⅔ ) 0,34 ]O 3 or Pb 0,96 Ag 0,02 Nd 0,02 (Zr 0,54 , Ti 0,46 )O 3 . Herein, a piezoceramic is produced with a comparatively high Curie temperature for applications of up to 150° C. Furthermore, solidity between the Ag/Pd internal electrode (70/30) and the ceramic, as well as growth during the sintering, are positively influenced by building silver into the ceramic.
[0011] U.S. Pat. No. 5,233,260 discusses piezoactuators which are not produced in the tradiational monolithic manner. Rather, the ceramic layers are separately sintered and only then stacked and agglutinated. This production method is costly. Furthermore, these piezoactuators have the disadvantage that the glue used has a negative effect the electrical characteristics.
[0012] Cao et al. in the journal American Ceramic Society 76(12) 3019 (1993) discuss a donor doped ceramic and in particular, a Cu foil laid between pre-made ceramic segments Pb 0,988 (Nb 0,024 Zr 0,528 Ti 0,473 )O 3 . The sandwich arrangement is subject to sintering at 1050° C. under vacuum. The composite between the ceramic and Cu internal electrode and the absence of the migrational effects (such as those observed at Ag electrodes on air) are emphasized in the article. However, the disclosed method does not lend itself to the requirements of an efficient production, including foil multilayer technology, and is therefore not appropriate for a mass production.
[0013] Kato et al. teach, in Ceramic Transactions Vol. 8, pages 54-68 (1990), of the production of multilayer condensators with Z5U based on ceramics having the general formula (Pb a —Ca b ) (Mg ⅓ Nb ⅔ ) x Ti y (Ni ½ W ½ ) z O 2+a+b (a+b>1, x+y+z=1) with Cu internal electrodes, wherein a copper oxide screen-printing paste is used. Air-debindering is thereby made possible. The carbon formation, which would inevitably come into effect under nitrogen at a well tolerated metallic copper (with oxygen) partial pressure, and afterwards at the sinter condensation, leads to a reductive degradation of the ceramic with Cu/Pb alloying production the eutectic melting point lying at TS=954° C. is thereby avoided. After the debindering, the sinter condensation is then carried out at 1000° C. by additional dosage of hydrogen at an oxygen partial pressure of 10 −3 Pa and the copper oxide is accordingly reduced to copper. The process is interference-prone, because of the shrinkage during the reduction from copper oxide to copper and resulting delamination and has up to now not been technologically converted into products.
[0014] DE 19749858 C1 sets out the production of COG with internal electrodes formed of a ceramic mass with the general composition (Ba II 1−y Pb y ) 6−x Nd 8+2x/3 Ti 18 O 54 +z m-% TiO 2 +pm-% Glas at lower PbO content(0.6<x<2.1; 0<y<0.6, 0<z<5.5 and 3<p<10). A sufficient elimination of the organic components by feeding steam into the nitrogen flux with <10 −2 Pa oxygen partial pressure at temperatures up to 680° C. and the sinter condensation at 1000° C. is reached by apt glass frit addititives.
BRIEF SUMMARY OF THE INVENTION
[0015] An advantage of the present invention provides an alternative to the expensive Ag/Pd internal electrodes used in the related art. It is a further advantage to provide a substitution which does not oxidize and remains relatively stable during production. It is still a further advantage to provide a method which can be implemented to enable mass production at reasonable engineering effort and expense and with maximally replicable component characteristics. These and other advantages are realized by the present invention wherein, copper is substituted for Ag/Pd for use in a PZT-type piezoceramic multilayer element. Copper has been shown not to reduce or oxidize and otherwise remain stable under conditions, including temperatures around 1000° C. under low oxygen partial pressure of <10 −2 .
[0016] The present invention encompasses all piezoceramic devices available in a monolithic multilayer formation, and in particular Perovskit ceramic. Modifications by mixed crystal formation via building in cations on the-A positions and/or substitution of the B-cations with suitable replacement cations or combinations thereof can be effected. Ceramic foil production techniques may be employed along with sintering techniques in the formation of the present invention. For example, screen printing can be used for making the copper or copper mixted internal electrodes.
[0017] Such piezoceramic multilayer devices can be realized for example as actuators by an apt process guide, by which the debindering of the green foil stacks is carried out by steam thereby avoiding the oxidation of the copper containing internal electrodes. The following sinter condensation to a monolithic multilayer device can be carried out in an advantageous ways at about 1000° C., i.e. below the melting temperture of the copper. A further advantage of the present invention may be found in that for a PZT ceramic mass, copper-containing internal electrodes are applied in place of the normally used Ag/Pd internal electrodes (70/30) on the basis of the multilayer foil technique, whereby the practically complete debindering can be successfully done before effecting the sinter condensation, and under inert conditions, in such a way that a lot of steam is supplied to the inert atmosphere during the debindering thereby permitting only a set oxygen partial pressure, and hence leaving the copper containing internal electrodes relatively intact. Accordingly, by the present method, piezoactuators are created which have the same if not superior quality to those currently available. Likewise, the presence of the copper electrodes do not have any deliterious effects on the piezoactuators.
[0018] A preferred step in the present method includes a step wherein cations are built in on A-positions of the ceramic and at which cations on B-positions are replaced by apt other cations or combinations of cations. For example, on A-positions of the ceramic bivalent metal cations M II may be built. These can be selected for example from a group of elements, which contain barium, strontium, calcium, copper and bismuth. Bivalent metal cations M II from a group of elements including scandium, yttrium, lantanum or from group of lanthanides can be considered for the A-positions of the ceramic.
[0019] Further, monovalent cations can be built in on the A-positions of the ceramic, which are selected advantegously and from a group of elements which contains silver, copper, sodium and potassium. In addition it is also possible, to build in combinations of bivalent metal cations M II and monovalent cations on A-positions.
[0020] Furthermore, a preferred embodiment includes the partial substitution of the quadrivalent cations Zr and Ti on the B-positions of the ferroelectrical Perovskite ceramic. In fact, combinations of mono- and quintvalent metal cations M I ¼ M V ¾ with M I =Na, K and M V =Nb, Ta or two- and quintvalent metal cations M II ⅓ M V ⅔ with M II =Mg, Zn, Ni, Co and M V =Nb, Ta or three- and quintvalent metal cations M III ½ M V ⅔ with M III =Fe, In, Sc, heavier lanthanide-elements and M V =Nb, Ta or combinations M III ⅔ M V I ⅓ with M III =Fe, In, Sc, heavier lanthanide-elements and M VI =W resp. M II ½ M Vi ½ with M II =Mg, Co, Ni and M VI =W may be employed.
[0021] Still a further advantage includes the composition of the ceramic with the general formula
[0022] [0022] Pb 1−x−y SE x Cu y V ′″x/2( Zr 0,54−z Ti 0,46+z) O 3 wherein 0,01<x<0,05,−0,15<z<+0,15 and 0<y<0,06, whereby SE is a rare earth metal, V is a vacancy and a PbO-surplus is set from 1 up to maximally 5 molar-%.
[0023] Yet further, atop the ceramic an additive of CuO may be included.
[0024] The invention includes the realization that the by donors, e.g. a rare earth metal doped piezo ceramic on the basis of PZT, because of the formation of cation vacancies on the A-positions of the Perovskit structure, e.g. according to the composition Pb II 0,97 Nd III 0,02 V″Pb,0,01( Zr 0,54 Ti 0,46) O 3 (V″ meaning an empty space), develops a certain affinity to absorb copper from the internal electrodes without destroying them by elimination of equivalent PbO-shares, whereby the latter combination acts as a sinter aid and up to some percentage of PbO is separately added to the ceramic anyway.
[0025] The sinter condensation is supported by the known mobility of the copper ions and leads, by the copper migration, to a solid adhesion between the electrode layer and ceramic such that delaminations can be effectively avoided.
[0026] It is still further an advantage to already add some CuO within the limits 0<y<0,15 to the original mixture of the used recipe for piezostacks, e.g. on the basis of PZT with Cu-internal electrodes corresponding to the general formula Pb II 1−x−y SE III x Cu y V″ x/2 (Zr 0,54−z Ti 0,46+z )O 3 with 0,005<x<0,05 and −0,15<z<+0,15 (SE=Rare Earth Metal). The piezoelectrical characteristics, like the high value for the electromechanical coupling factor can be maintained at corresponding adjustment of the parameter z to the morphotropic phase interface.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0027] Some of the features, advantages, and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings wherein:
[0028] [0028]FIG. 1 depicts temperature control during debindering and sintering;
[0029] [0029]FIGS. 2 a and 2 b depict a partial cross section of a multilayer stack with alternating sequence of PZT ceramic foils and Cu-internal electrodes;
[0030] [0030]FIGS. 3 a and 3 b depict a measuring curve of copper content of piezoceramic layer and a section view of the piezoceramic layer;
[0031] [0031]FIG. 4 depicts a diagram of an excursion curve for a polarized PZT-piezoactuator with Cu-internal electrodes; and
[0032] [0032]FIG. 5 depicts a calculation of thermodynamic data as curves for different H 2 /H 2 O concentrations.
DETAILED DESCRIPTION OF THE INVENTION
[0033] A piezoceramic Perovskite-mixed crystal phase is built according to the following steps: TiO 2 , ZrO 2 (each may be from a mixed precipitation produced precursor (Zr, Ti)O 2 ) and PbCo 3 (e.g. Pb 3 O 4 and dopants like La 2 O 3 or from another oxyde of the rare earth metals) and if necessary an additive of CuO based raw material mixture is set in its composition on the morphotropic phase interface with a PbO-surplus of maximally 5% to support the sinter condensation; for even distribution, the component undergoes a grinding step in diluted suspension and is calcinated after the filtering; and drying occurs at 900 to 950° C. To obtain sinter condensation in 2 to 4 hours at about 1000° below the melting temperature of copper, a pulverization to a medium grain size <0,4 μm is necessary. The sinter activity of the powder is normally sufficient to guarantee a condensation of >96% of the theoretical density at both sufficient grain growth and adequate mechanical solidity in the ceramic structure.
[0034] The finely ground powder is suspended in a diluted slip with approx. 70 m-% solid substance content by use of a disperger, thus corresponding to approximately 24 vol.-%. For this, the optimal dispersing dispergator portion is separately determined in a series of tests, which can be recognized by obtaining a certain viscosity minium. For the formation of the piezoceramic-green foils, approximately 6 m-% of a commercial binder is added to the dispersed suspended solids, which is thermohydrolytically degradable. Accordingly, a diluted polyurethane dispersion has been shown to have advantage effects. It is mixed in a disperse mill and accordingly provided for the process of “foil-pulling” (in particular for the production of a spraying granular apt slip).
[0035] Compact green discoids (produced from the granular) or small square multilayer printed boards (“MLP” produced by stacking and laminating 40 to 50 μm thick green foils without print and with Cu-electrode paste) can be debindered up to a residue carbon content of 300 ppm in a H 2 O-steam containg inert atmosphere at a defined oxygen partial pressure, which fulfills the condition of the coexistency of PbO and in particular Bi 2 O 3 -containing piezoceramic and copper.
[0036] The hydrolytical separation of the binder takes place primarily at a low temperature of 200±50° C. and at a steam partial pressure larger than 200 mbar. The oxygen partial pressure is set to a value which is well-tolerated by the copper containing electrodes. This is done by gettering the oxygen from the flow of gas at surfaces of Cu or by adding H 2 . During the debindering by oxidation, the flow of gas avoids damage to the ceramic. Although the electrode layers support the debindering, because preferred paths for a binder transportation is created by them, there is still a considerable debindering time necessary, particularly for the actuators with 160 electrodes (measurements 9,8*9,8* 12,7 mm 3 ).
[0037] The invention enables herewith the production of actuators with more than 100 internal electrodes, which has the advantage of a highly obtainable actuator-excursion. Examples for a debindering control are found in table 1 by indicating the residue carbon content of the obtained devices. The dew point for steam of both debindering programs lies at 75° C., the partial pressure of the steam corresponds to 405 mbar.
TABLE 1 Debindering of ceramic samples MLP and actuators Profile Conditions (R: ramp, H: holding time) Samples C EK 1 R: 30 K/h H: 220° C./10 h R: 30 K/h Ceramic 240 H: 500° C./20 h, at 100 l/h N 2 , 30 g/h samples H 2 O, with Cu-gettering MLP EK 2 R: 30 K/h H: 220° C./40 h R: 30 K/h Actuator 160 300 ± H: 500° C./20 h, at 100 l/h N 2 , 30 g/h electrodes 30 H 2 O, with Cu-gettering
[0038] The soaking time at 220° C. is prolonged to 40 h for actuators with 160 layers (EK 2). Afterwards a condensation of the ceramic at 1000° C. without detrimental reductive degradation is effected with the residue carbon of 300±30 ppm in the indicated sinter profile.
[0039] [0039]FIG. 1 shows the temperature control during the debindering and sintering. The steam partial pressure supplied with the nitrogen flux corresponding to a dew point of 75° C. is indicated as well. At such debindered PZT-ceramic samples, the sinter condensation is effected at 1000° C. without creating a reductive degradation of the ceramic. The dielectrical and especially the piezoelectrical characteristics of the obtained samples with the measurements of approximately 10.10 mm 2 and 0,7 (in particular 2 mm consistency) are measured after contacting by sputtering of Au-electrodes and compared with the air-debindered (sintered at 1130° C.) samples of the same geometry.
[0040] For air-sinterings of ceramic samples MLP without internal electrodes with the composition Pb II 0,97 Nd III 0,02 V′″ 0,01 (Zr 0,54 Ti 0,46 )O 3 and under inert conditions, whereby the latter correspond to the requirements of a common sintering with copper, the results of the electrical measurings are compiled in table 2. Measurements of the polarized samples are set out in tables 3 to 5. In addition, the codes of a CuO-doped ceramic mass during sintering under inert conditions are also set out.
[0041] Table 2 includes characteristics of square ceramic samples MLP (edge length 1 , consistency h): Samples (a), (b) and (c) with composition Pb 0,97 Nd 0,02 (Zr 0,54 Ti 0,46 )O 3 . Sample (d) with the composition Pb 0,96 Cu 0,02 Nd 0,02 (Zr 0,54 Ti 0,46 )O 3 (a) powder pre-ground to a medium grain size d50%=0,53 μm, air-sintering at 1120 °C.; (b), (c) and (d) powder finely ground to a medium grain size d50%=0,33 μm, air-sintered (b) at 1000 °C. resp. (c) and (d) at 1000 °C. under N 2 /H 2 O-steam are also set out.
Sample MLP h/mm 1/mm C/nF ε Tan δ R IS /Ω ρ/Ωcm (a) 0.59 ± 0.02 10.8 ± 0.1 2.20 ± 0.05 1268 ± 30 2.1 ± 0.1% 1 * 2 * 10 11 10 12 (b) 0.70 ± 0.01 10.6 ± 0.1 1.60 ± 0.03 1137 ± 58 2.8 ± 0.2% 2 * 3 * 10 11 10 12 (c) 0.71 ± 0.02 11.0 ± 0.8 1.62 ± 0.07 1132 ± 81 2.8 ± 0.6% 5 * 9 * 10 9 10 10 (d) 0.70 ± 0.01 11.3 ± 0.1 1.92 ± 0.01 1196 ± 8 1.9 ± 0.3% 7 * 1 * 10 10 12 12
[0042] [0042] TABLE 3 Characteristics of square ceramic samples MLP (edge length 1, consistency h) with the composition according to table 2 after the polarity with 1200 V (a) and 1400 V ((b) and (c) and (d)). Sample MLP h/mm 1/mm C/nF ε Tan δ□ R IS /Ω ρ/Ωcm (a) 0.59 ± 0.02 10.8 ± 0.1 2.54 ± 0.13 1460 ± 134 1.9 ± 0.1% 1 * 2 * 10 11 10 12 (b) 0.70 ± 0.01 10.6 ± 0.1 1.70 ± 0.03 1207 ± 58 2.1 ± 0.1% * 2 * 10 11 10 12 (c) 0.71 ± 0.02 11.0 ± 0.8 1.75 ± 0.05 1238 ± 69 2.3 ± 0.1% 2 * 5 10 11 10 12 (d) 0.70 ± 0.01 11.3 ± 0.1 2.11 ± 0.01 1317 ± 69 10.2 ± 0.8% 8 * 1 * 10 10 10 12
[0043] The characteristic values prove that PZT ceramic samples, which were not air-bindered and were sintered, show comparable dielectrical characteristics.
[0044] The results of table 4 are based on electromechanical vibration measurements with the aid of an impedance measuring bridge, whose evaluation from the parallel and serial resonance frequency fp, f s of the resonant circuit is effected according to the following:
f s = 1 2 π · 1 C 1 L 1 f p = 1 2 π · C 0 + C 1 C 0 · C 1 L 1
[0045] thereby permitting calculation for each vibration mode of the MLP sample of the effective coupling factor according to:
k eff 2 = f p 2 - f s 2 f p 2 = C 0 + C 1 C 0 C 1 L 1 - C 0 C 0 + C 1 L 1 C 0 + C 1 C 0 C 1 L 1 = C 1 C 0 + C 1 .
[0046] As such, the proportion of the mechanical energy for the entire energy is indicated by C 1 /(C 0 +C 1 ).
[0047] Table 4 depicts effective piezoelectrical coupling factors of the MLP samples from table 3 for two fundamental vibrations, determined from the measurement of each 3 MLP samples, sintered under the indicated conditions (a), (b), (c) and (d) in table 2,
Planar vibration Consistency mode of vibration MLP f S/kHz f p/KHz k eff f S/kHz f p/KHz k eff (a) 158 ± 1 191 ± 2 0.56 ± 0.01 3292 ± 15 3848 ± 79 0.52 ± 0.03 (b) 166 ± 2 198 ± 4 0.54 ± 0.01 2900 ± 78 3197 ± 25 0.42 ± 0.05 (c) 163 ± 1 189 ± 5 0.51 ± 0.04 2830 ± 111 3100 ± 108 0.40 ± 0.02 (d) 154 ± 2 186 ± 2 0.56 ± 0.03 2668 ± 36 3048 ± 47 0.48 ± 0.03
[0048] The measurement of the Curie temperature at samples (c) show a value of 339±2° C.
[0049] Electromechanical coupling factors which are in the area of the air-sintered samples are accrued from the produced samples sintered commonly under these conditions with copper. The results of an excursion measurement on ceramic samples MLP are listed in table 5. The excursion Δh was determined parallely to the polarized direction 3, in which the measuring voltage was set. The excursion measurement was carried out by inductive path measuring by setting up an electrical field E with a field strength of 2000 V/mm. Prior to this measurement, the samples were impinged by a field strength of 2000 V/mm in the polarized direction to rule out after-polarity effects and increased hysteresis because of the bedding after the polarity.
[0050] The relative density S of the ceramic samples MLP is calculated from the measured excursion Δh divided by the sample consistency h. From this, the piezoelectrical coefficient d 33 results for the equation:
S
3
=d
33
*E
3
[0051] wherein d 33 is a geometrically independent value for the piezoelectrical large signal characteristics of the examined ceramic.
[0052] Table 5 sets out an excursion measurement of square ceramic samples ML: (edge length 1, consistency h) with the composition according table 2 by setting a voltage of 2kV/mm. Electrical measurement voltage U, excursion Δh, and the piezoelectrical constant d 33 are indicated.
Sample MLP h/mm U/V Δh/μm d 33 · 10 −12 m/V (a) 0.59 ± 0.02 1180 ± 4 0.88 ± 0.01 747 ± 10 (b) 0.70 ± 0.01 1400 ± 4 0.99 ± 0.01 712 ± 10 (c) 0.71 ± 0.02 1420 ± 4 1.03 ± 0.06 723 ± 40 (d) 0.70 ± 0.01 1400 ± 4 1.03 ± 0.01 739 ± 4
[0053] In case of printing on Cu-internal electrodes, a Cu-screen print paste is preferable which has a metal content as high as possible of approx. 75 m-% and is processed with a special high-polymer and is thereby a very viscous binder (which produces at already <2 m-%, related to the solid susbstance content, a viscosity as thixotrope as possible, preferably >2000 mPa*s). First, multilayer samples “VS” with up to 20 internal electrodes are produced for sampling purposes. Thereafter, piezostacks with 100 to 300 Cu-internal electrodes are built up in a second step and are debindered and sintered under the above mentioned conditions of a defined oxygen partial pressure in the presence of steam.
[0054] The piezoceramic green foils are produced in a consistency, which produces, by considering the linear shrinkage during the sintering of typically 15%, a piezoceramic consistency from 20 to 200 μmm. The Cu-electrodes have a layer consistency from 1 to 3 μm after the sintering.
[0055] [0055]FIG. 2 a and 2 b depict a schematic cross section of a multilayer stack with an alternating sequence of PZT ceramic foils and Cu-internal electrodes in 500 times (FIG. 2 a ) and in 1000 times (FIG. 2 b ) enlargement.
[0056] [0056]FIG. 3 b shows a measuring curve for the Cu-content of the piezoceramic layer, shown in FIG. 3 a , about the layer consistency after the sintering of a piezostack on the basis of the used original composition Pb II 0,97−y Nd 0,02 Cu y V″ 0,01 (Zr 0,54−z Ti 0,46+z )O 3 . It can be seen that the copper content in the ceramic layer dissolves starting from the border. The calibration produces in the middle of the ceramic layer the minimal amount of y=0.001. At the borders there is a value which is 20 times higher. Some lead oxide is displaced from the combination as a result of the influence of diffused Cu-ions. The good connection of the Cu-internal electrodes to the ceramic is thereby set out.
[0057] The electrical characteristics of the multilayer ceramic components VS of the original composition Pb 0,97 Nd 0,02 V 0,01 (Zr 0,54 Ti 0,46 )O 3 after the sintering at 1000° C. with 16 Cu-internal electrodes—and for comparison with 20 Ag/Pd-internal electrodes (70/30) after the air-sintering at 1120° C.—are indicated in table 6. Table 6 sets out electrical characteristics of PZT multilayer ceramic samples VS on the basis of the original composition
[0058] Pb II 0,97 Nd III 0,02 V″ 0,01 (Zr 0,54 Ti 0,46 )O 3 : (a) powder pre-ground, medium grain size d50%=0,53 μm, 20 internal electrodes Ag/Pd (70/30), air-sintering at 1120° C., (c) powder finely ground, medium particle size d50%=0,33 μm, 16 Cu-internal electrodes, sintering at 1000° C. under inert conditions by N 2 /H 2 O steam.
ε ε tan δ ρ IS / Ωcm Sample before after after after VS Comments C/nF polarization polarization polarization polarization (a) Ag/Pd (70/30): 125 ± 5 1104 ± 54 1561 ± 92 0.015 7.9 10 11 Debindering/air-sintering 1120° C., Cu-finished. (c1) Cu-internal electrodes: 110 ± 4 908 ± 35 953 ± 37 0.027 2.7 10 10 Debindering/sintering under N 2 /H 2 O steam, Cu-finished. (c2) Cu-internal electrodes: 114 ± 4 946 1013 0.026 1.6 10 10 Debindering/sintering under N 2 , H 2 O steam, Cu-finished.
[0059] Production of a piezo actuator from a ceramic of PZT type with Cu-internal electrodes.
[0060] For the production of piezo actuators with 160 Cu-internal electrodes, the green foils produced according to the method of the consistency from 40 to 50 μm are further processed according to the multilayer ceramic condensators method. The printing of the square cut PZT ceramic foils is done mechanically by screen printing technique (400 mesh) with the piezo actuators common electrode design by usage of a commercial Cu-electrode paste. The stacking is done such that on every two non-printed foils a printed one follows. 100 piezo actuators in a green condition are received from the block, after laminating, and pressing or sawing.
[0061] The debindering is carried out according to the FIG. 1 shown temperature time diagram in nitrogen stream by adding steam and hydrogen so that there is a target value from 5*10 −2 to 2*10 −1 Pa for the O 2 partial pressure produced in the area of 500° C. Essentially, lower oxygen partial pressures occur locally during the debindering. The ceramic is not subject to the reductive degradation in the temperature area of the debindering, because the equilibrated oxygen partial pressure is lowered as well, conditioned thermodynamically, and the reduction processes are kinetically sufficiently obstructed. The green parts of the multilayer piezo actuators still show a residue content of carbon of 300 ppm after the debindering and are afterwards ready to be sintered in the same set atmosphere without causing a reductive degradation which lead to cracking, delamination and eventually to drifting of the internal electrodes because of the production of a low melting Cu/Pb-alloy.
[0062] Steam and forming gas are added to the nitrogen flux (N 2 +5% H 2 ). The dissociation of the steam according to
H 2 O ⇔ H 2 - 1 2 O 2
[0063] is used for setting a certain oxygen partial pressure. Corresponding to the law of mass action
K D = p ( O 2 ) 1 2 · p ( H 2 ) p ( H 2 O )
[0064] a certain oxygen partial pressure is thereby determined at a given temperature for a defined partial pressure ratio of steam and hydrogen. The calculation of the thermodynamic data produces the data depicted in FIG. 5, namely the curves for different H 2 /H 2 O ratios of concentration.
[0065] Normally the gas composition is selected in such a way, that the requested oxygen partial pressure is produced at sinter temperature T Sinter . This condition is for example depicted in FIG. 5. Starting from this value the p(O 2 ) runs parallel to the other curves with decreasing temperature. However, the p(O 2 ) value is low for T<T Sinter , which is still tolerable if needed. The gas control curve Cu1 according to table 7 corresponds to this process. The equilibrium of Pb/PbO falls short starting at approx. 900° C., conditioned by the narrow thermodynamic window through which metallic lead is produced if there is sufficient kinetic activity.
[0066] Alternatively, p(O 2 ) was set with different forming gas dosage corresponding to the gas control Cu 2 —the actual course of the oxygen partial pressure at upto 400° C. lay in the thermodynamic window. This way of process is good for the little reductive solid PZT mixture. The used adjustments Cu1 and Cu2 for the gas control are indicated in table 7. FIG. 5 shows the calculated course of the partial pressure for the different ratios of concentration of the gases.
TABLE 7 Gas control Cu1 and Cu2 Cu1 Dosage Cu2 Dosage N 2 Entire sintering 900 l/h Entire sintering 1200 l/h H 2 /H 2 O Entire sintering 40 g/h Entire sintering 100 g/h N 2 + 5% H 2 Entrie sintering 256 ml/h 25-650° C. 25 ml/h 650-900° C. 85 ml/h 900-1000° C. 200 ml/h Dewing point Dewing point 36° C. 48° C.
[0067] The sinter profile is as follows: the holding time at maximal temperature lies between 2 and 12 hours. The heating up ramp and the cooling down ramp are effected at 5 K/min; and the actuators are slowly heated up at 1 K/min. The in steps adjusted set-up of the oxygen partial pressure (FIG. 5) runs in conformity with the temperature curve, which is obtained by an alteration of the forming gas flow meter. Thereby, the steam partial pressure (100 g/h) is constant.
[0068] The obtained ceramic is tightly sintered to >96% and shows mostly homogenous low porosity. The sinter grains grow according to the piezoelectrical characteristics with an advantageous medium grain size of 0.8-5 μm. Intact and crack-free actuators are obtained. The sequence of the internal electrodes and PZT ceramic layers is shown in a section in FIGS. 2 a and 2 b . The medium grain size in the ceramic structure is d 50 =1,6±0,3 μm.
[0069] The piezo actuators are ground and polished for the finishing and contacted in the area of the exiting internal electrodes according to applications common to Cu-paste and burned-in at 935° C. according to a preset temperature time curve. The piezo actuators respond to the electrical measuring after the application of wires by known Bond technology.
[0070] The diagram of a vibration curve for a polarized PZT-piezoactuator with 160 Cu-internal electrodes is depicted in FIG. 4. A density of 0,123% is produced by a voltage setting of 140,6 Volt at a consistency of 70 μm of the PZT ceramic layers. The piezoelectrical coefficient in direction to the applied field d 33 is 614,6 10 −12 m/V.
[0071] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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The present invention relates to a piezoelectrical device whose electrode layers contain copper. The usage of copper in electrode layers is enabled by a debindering process, which is carried out by steam.
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BACKGROUND OF THE INVENTION
This invention relates generally to a device in which an electrical shock is delivered to the animal that comes into contact with it. Such devices find primary utility as pest deterrent devices. In particular, this invention pertains to such a device that is particularly well adapted for use as a bird deterrent device, but could be utilized with other animals as well.
Ever since electricity was first put to commercial and residential use in the United States in the late 1800's to solve the age-old problem of darkness, the ability of electrical current to deliver an electric shock to a person or animal has been recognized, and electricity utilized as a result for things other than powering lights and motors. Non-lethal applications of electricity for use in encouraging animals to do something or not do something soon followed the use of electricity for lights and motors. The electric cattle prod is perhaps the best known of those devices. Today, however, electricity is used in many ways with animals, such as electric fences to keep farm animals in and predators out, and even dog trainers sometime use an electrical stimulus in a dog collar to assist in their training.
Another age-old problem that has been perplexing mankind since long before the discovery and harnessing of electricity is the propensity of pests in general, but particularly birds, to land in areas where their human neighbors would prefer they didn't. Since the very first bird deterrent device used by man—undoubtedly a thrown rock—an incredible array of devices have been used to dissuade birds from landing or roosting in areas desired by the birds but undesirable to humans. Metallic spike-like, coil or rotating devices, sound-emitting devices, imitation predators, and even real predators, are just a few examples of bird deterrent devices that have been used. Therefore, it is not at all surprising that devices using lethal and non-lethal electrical shock would also be employed along the way.
A typical device of this type is shown in U.S. Pat. No. 4,299,048, in one embodiment of which a pair of copper wires connected to a power source are embedded in opposites sides of a cable of appropriate diameter such that when the birds of choice (in this case, starlings) land on the cable, their feet touch both wires, closing the circuit and thereby delivering a lethal shock to the birds.
The much more recently-issued U.S. Pat. No. 6,283,064 discloses another version of a bird and pest deterrent device in which a pair of crimped copper wires are appropriately spaced apart so that the bird's or other pest's feet will touch both wires, resulting in a short circuit and delivering a shock to the bird or other pest.
Other devices for carrying electric charges for discouraging birds and other pests are described in U.S. Pat. Nos. 3,294,893; 3,336,854; 3,717,802; 4,299,048; and 5,850,808, for example. Each of these necessarily include the broad concept of appropriately spaced-apart wires which will both be contacted by the bird (or other pest's) feet (or other part of their anatomy) so as to deliver the appropriate electric shock.
While all of these devices work, at least initially, to an acceptable degree in some installations, the problem that prior art devices of this type have long encountered has been in providing such a device that can be used in something other than relatively straight-line, flat applications and that have a sufficiently long expected useful life in that application. These problems arise from the fact that these devices inherently need two things—1) the conductive elements, typically metal wires, that carry the electrical current; and 2) a non-conductive base element, to which the wires are attached. Most typically, the metal wires are held by friction and/or glue within an appropriately sized channel in the base. See, for example, the devices disclosed in U.S. Pat. Nos. 5,850,808; 4,299,048 and 3,366,854. Because the metal wires and the non-metallic bases have different coefficients of expansion and contraction, and different degrees of flexibility, however, there is a tendency for the wires in these devices to become detached from the base over time since these devices are typically used in locations that are directly exposed to the weather. This problem is exacerbated if the location to which the device is applied is other than a straight, flat surface, as any twisting or bending of the device places unequal stresses on the base and the wires causing them to become loose or even pop out of their holding channels.
These two problems have been addressed in different ways, and continue to cause problems in the industry, as those skilled in the art continue to seek to find ways to solve the problems. For one recent example, in U.S. Pat. No. 6,283,064, the base “has spaced notches along each edge to provide flexibility to the base, whereby the base may be bent both out of the plane and within the plane” (id., Col. 1, lines 64-66) and the “wires are crimped in undulating fashion along their length, to provide them with give so that they will not disassociate from the base when it is bent or when the wires and base expand and contract at different rates.” (Id., Col. 2, lines 7-11).
While the prior art devices are useful to a degree, they still suffer from certain drawbacks, including limitations on the degree to which they can be bent without inducing potentially disabling stresses, and relatively higher cost. Therefore, there exists a need in the art for an improved electrical shock deterrent device that solves these problems, and does so in an efficient, reliable, low cost way.
SUMMARY OF THE INVENTION
This invention provides such an improved device by replacing the typically-used wire with a braided element that can be sewn to the base, entirely eliminating the need for an appropriately-sized channel into which the metallic wire is inserted. The braided element can be composed of individual strands of any sufficiently conductive material, such as metal wire. The strands could also include some conductive and some non-conductive strands. The individual strands can be of any appropriate cross-sectional design, such as round, square, oblong or flat. The base can be of any non-conductive material, and is preferably PVC or other elastomeric material that is, in addition to being an insulator, UV resistant and extremely flexible. The size and spacing of the braided element and the size and configuration of the base can be designed for whatever animal, pest or bird is to be deterred.
Because the braided element is not a single, solid piece of metal, but comprised of individual strands woven together to form the braided element, such that each strand can move relative to one another, the braided element can be easily sewn directly onto the base, creating a very strong mechanical bond. If an embodiment is used in which the braided element is substantially flat, it can also be glued to the base, although sewing has proven sufficient and preferable. Other attachment means could also be employed.
Because the preferred base is constructed of a very flexible material, because of the very secure mechanical attachment between the braided elements and the base accomplished by sewing, and because the braided element is extremely flexible, the base and braided element combination of this invention can literally be bent into a 180-degree angle, inwardly or outwardly, within a curvature radius of less than one inch without experiencing any detachment. In the area of curvature, the braided element simply expands or contracts in width (depending on which way the device is bent) as the added stresses are distributed over all of the individual strands in the braided element, rather than having to be handled by one, single, large wire. Also, because the individual strands are braided, there is significant leeway for them to flex so as to accommodate the severe bending action.
DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of the preferred embodiment of this invention.
FIG. 2 is an end view of the preferred embodiment of this invention, showing the braided element in the preferred position on the elevated pedestal portion of the base.
FIG. 3 is a side view of the preferred base of this invention, showing that it is preferably constructed of a single extruded piece of material in the desired length.
FIG. 4 is a top view of the preferred embodiment of this invention. The dotted line extending down the middle of each of the braided element represents the stitching of the sewn attachment means and can also represent spaced apart staples if staples are used as the attachment means. The spaced-apart holes in the center of the base that can be used for attaching the base to the desired surface area are also shown.
FIG. 5 is an isolated, enlarged view taken from circle- 5 in FIG. 4 . It shows in greater detail the braided nature of the conductive element and the preferred sewing attachment means. As also depicted here, in the preferred embodiment, the individual strands of the braided element are not braided tightly together at rest, but have some free space. Although the individual strands of the braided element shown here and in the other Figures are depicted as being in a fairly linear cross-hatched arrangement, in one of the preferred embodiments the strands are in a much more curvilinear configuration forming the braided element.
FIG. 6 shows the preferred embodiment (absent the sewn stitching as it would appear if spot gluing or heat welding were used to adhere the the braid to the base) in which the top side of the device is being bent in a concave fashion. Although this Figure shows a very significant curvature, the device of this invention is actually capable of being bent much more severely without adversely affecting the attachment between the conductive braided elements and the non-conductive base.
FIG. 7 is an isolated, enlarged view taken from circle- 7 in FIG. 6 , and shows that in concave flex, the elongation stress placed on the braided element is absorbed by the individual strands within the braided element pulling tightly together.
FIG. 8 shows the preferred embodiment (absent the sewn stitching) in which the top side of the device is being bent in a convex fashion. Although this Figure shows a very significant curvature, the device of this invention is actually capable of being bent much more severely without adversely affecting the attachment between the conductive braided elements and the non-conductive base.
FIG. 9 is an isolated, enlarged view taken from circle 9 in FIG. 8 , and shows that in convex flex, the compression stress placed on the braided elements is absorbed by the individual strands expanding apart from one another, and the overall width of the braided elements becoming larger.
FIG. 10 is an end view of one embodiment of the braided element.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking at FIG. 1 , it is seen that the preferred embodiment of this invention is of essentially three-piece construction, having a base 10 and a pair of braided elements 12 a and 12 b attached thereto.
The base 10 has a flat lower surface 20 that is presented for attachment to the surface of the location from which the pests or birds are to be deterred. In this embodiment, as best seen in FIG. 2 , the cross-sectional shape of the base 10 is essentially co-joined pedestals 22 a and 22 b that each present an elevated section 24 a and 24 b , respectively, and each having and upper flat surface 26 a and 26 b to which the braided elements 12 a and 12 b are attached. A central gap 28 exists between the two elevated section 24 a and 24 b , and is useful to provide for water run-off to prevent accidental short circuiting of the device in the presence of water which may accumulate due to rain or irrigation.
In this embodiment, the base 10 is approximately 1.5 inches wide, and approximately 0.25 inches high (from the lower surface 20 to the upper surfaces 26 a and 26 b . The height of the elevated sections 24 a and 24 b is approximately 0.06 inches. The width of each of the upper surfaces 26 a and 26 b is approximately 0.25 inches, and the distance between the longitudinal centerlines of the upper surfaces 26 a and 26 b is approximately 0.625 inches, leaving a gap area 28 between them of approximately 0.375 inches. These dimensions are, of course, by way of illustration only. The dimensions can be varied in any fashion as appropriate to the application. Also, the length of the device segment shown is relatively short. The base 10 can be constructed of any length, and is preferably constructed in as long a length as feasible so as to avoid inter-connecting segments of the device. Because the device of this invention can be curved without harming its performance or life-expectancy, it can be rolled for shipment and storage, thus allowing for much longer single-formed pieces than with other prior art devices.
As best seen in FIGS. 1 and 4 , holes 30 are placed through the base 10 in the gap area 28 at regular intervals along the entire length of the base to facilitate attachment of the device to the perch location (not shown), for example. Plainly, the holes 30 are only one of innumerable ways in which the attachment can be facilitated. Attachment can be by any mechanical means such as screw, bolts, staples or nails, or any other attachment means such as adhesives, or a combination of them.
The base 10 can of course be of any shape and size as dictated by the specific size and type of animal, bird or pest to be deterred, and the area to which the device is to be installed, so long as the two braided elements are kept a sufficient distance apart so as to prevent short circuiting, and are not so far apart at to not be short-circuited when the intended-to-be-deterred animal, pest or bird contacts the device.
The base 10 can also be constructed of any material so long as there is sufficient non-conductive material immediately adjacent the braided elements 12 a and 12 b so as to prevent short circuiting. In the preferred embodiment, the entire base 10 is of a single material, in this case extruded polyvinyl chloride (“PVC”), that is extremely flexible, durable and UV resistant, and is sufficiently soft so as to allow for the sewing operation whereby the braided elements 12 a and 12 b can be sewn directly to the base. The base 10 can also be constructed of any color so as to blend with the structure to which it will ultimately be attached. As noted, it is not necessary that the base be of unitary material and construction. The PVC used in the base can be either cellular, flex or rigid. Other possible material for construction of the base include but are not limited to neoprene, fluoroelastomer (available commercially under trademarks Vitron® and Flourel®), silicone, natural rubber, buna N (nitrile), buna S (SBR), thermoplastic rubber, synthetic polyisoprene, EPDM and polyurethane.
In the preferred embodiment, the braided elements 12 a and 12 b are comprised of elongate individual strands 32 that are braided in a length-wise substantially curvilinear fashion rather than a mesh comprised of separate warp and weft strands that are arranged in a substantially perpendicular relationship to one another. The braided elements 12 a and 12 b comprise individual strands 32 which can be of any suitable conductive material. In some not (for example, if a few strands of a very strong, albeit non-conductive material might be desired to add even more strength and durability). While flat braids are preferred, non-flat braided material could also be used. Also, while stainless steel is preferred, copper or zinc plated copper are just two examples of many other conductive materials that could be substituted. A suitable commercially available braid is that provided by Hamilton Products, Sherburne N.Y. (www.hamprods.com). The size of the braid, the number of strands, the size of the individual strands and other specifications for the braided is elements are matters of choice depending on the application for the device. However, a ⅜ inch wide braid having 48 strands, and capable of handling up to 40 nominal amperes of current has proven effective for a wide range of applications. Also, although the preferred braided elements 12 a and 12 b have a substantially flat cross-section configuration, braided elements having a substantially oblong, round, rectilinear or even triangular (or any other shape) cross-sectional configuration could also be used.
The preferred means for attaching the braided elements 12 a and 12 b to the base 10 is by sewing. Because the braided elements 12 a and 12 b are composed of multiple strands 32 somewhat loosely woven together rather than the single copper wire used in most prior art devices, there is sufficient free space 34 between the adjacent strands 32 such that the sewing operation never has to pierce, and preferably does not pierce, any of the strands 34 . Rather, the sewing operation creates a secure mechanical lock as the thread used to sew bridges across the individual strands. While any suitably durable and string thread can be used in the sewing operation, 100% polyester Star Ultra® Monocord from Coats, North American (www.coatscna.com) has proven suitable. A single line of stitching 36 down the longitudinal center of each braided element 12 a and 12 b (best seen in FIG. 5 ) has proven sufficient, although many other sewing stitches, styles and placement would word as well. As shown in FIG. 4 , the spaced apart lines 36 could also represent staples, if that is the preferred attachment means.
Of course, other attachment means for attaching the braided elements 12 a and 12 b to the base 10 could be used instead of or in addition to sewing. For example, the braided elements 12 a and 12 b could also be glued or heat-melted to the base, or stapled, or bolted, or screwed into place on the base. However, it is believed that for ease of construction, for durability, and for attractiveness, sewing is preferred.
The ends of braided elements 12 a and 12 b are attached to the terminals of a conventional power source (not shown). A charge of approximately 800 volts alternating current, at low ampere (10 mA) or 7.5 KV, 3 amp direct current, has proven effective to deter birds. Larger voltages and amperes may be necessary for larger animals. Of course, if the desire was to execute the pest rather than simply deter, then the voltages and amperes would have to be increased accordingly, and the current bearing characteristics of the braided elements 12 a and 12 b would have to be adjusted accordingly as well.
The device of this invention can be attached to just about any surface where deterrence is desired—from hat horizontal surfaces (such as window ledges, building edges and billboard tops where some birds like to perch and roost), to vertical or skewed surfaces (such as fence rails, posts or other surfaces where the device might be used to deter farm animals, vermin or varmints), to radically curved surfaces (such as on outdoor artwork and statues to deter birds from perching and defacing the structure with their droppings). The device can also easily accommodate planar and non-planar angles. Because the device can be radically bent in a non-planar way, most non-planar surface transitions can be accommodated simply by bending the device. For planar surface transitions, the base 10 and braided elements 12 a and 12 b can be easily cut through at any angle using conventional means so that adjacent ends of the cut pieces can be brought together to follow the application topography. The adjacent cut ends of the braided elements 12 a and 12 b can be reattached to recreate the circuit by any conventional means such as flexible, crimpable connector pieces or soldering, as only two of many examples.
Although preferred embodiments have been shown and described, the disclosed invention and the protection afforded by this patent are not limited thereto, but are of the full scope of the following claims, and equivalents thereto.
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A deterrent device for delivering an electric shock to an animal, pest or bird to be deterred, having the typical components of a non-conductive base to which the electrically conductive elements are attached. Instead of the typically-used copper wire, however, the braided elements comprise smaller strands of a conductive material, such as copper, aluminum or stainless steel wire, is used and is mechanically attached to the non-conductive base. The braided elements can be mechanically attached using a simple sewing operation in which the braid is sewn to the base. Because of the mechanical attachment and the ability of the braided elements to flex in both contraction and extension, the device of this invention can be used in tight corners and other contorted locations without having the wires of the typical prior art device pull free of the base.
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RELATED APPLICATIONS
[0001] This application claims the benefit of priority to the U.S. Provisional Patent Application for “Wireless Mobile Device Charging Mat Charm with clip and battery and with or without retractable cord to re-charge the charging mat,” Ser. No. 62/211,130 filed on Aug. 28, 2015, and currently co-pending.
FIELD OF THE INVENTION
[0002] The present invention pertains generally to chargers for mobile electronic devices. More particularly, the present invention pertains to a mobile device charger using inductive coupling with a mechanism for convenient storage of the cable and increased portability of the charger, and attachment of the charger to a purse or backpack. The present invention is particularly, but not exclusively, useful as a personal electronic device charger for persons temporarily in places away from home.
BACKGROUND OF THE INVENTION
[0003] Electricity is not always available to use to charge phones and mobile devices. Mobile device charger cords and metal tips are exposed to damage because they are not protected. In addition, people leave mobile device chargers at home and in hotel rooms, resulting in loss of the charger and depletion of the battery within the device.
[0004] Existing Wireless Charging Mats are not Bag Charms and cannot be attached to other objects such as purses, pant loops, computer bags, necklaces. Therefore, they are easy to leave behind and hard to carry. Existing electric mobile device chargers do not have batteries built into them. They are disorganized, easily forgotten and easily broken.
[0005] The present invention allows the user to charge their mobile device either from the battery or using an external power source while it is still attached to their bag so that they do not forget it in the outlet.
[0006] This invention eliminates the problem of leaving phone charging mats behind when traveling or on the go. This invention eliminates the problem of not being able to charge a phone when electricity is not available.
[0007] Mobile device chargers provide a means for charging the batteries of personal electronic devices by connecting them to a power source. The power source to which a mobile device charger connects is generally either a standard power outlet in a building or a vehicle's power source through a cigarette lighter outlet or dedicated charging port.
[0008] Mobile device chargers currently offered for sale are easily damaged. The cords and connectors are not protected by the charger itself, and so they often sustain damage through exposure to people, pets, or other objects. Additionally, currently available mobile device chargers are often accidentally left at home or away from home in places where the owner was using them, such as offices or hotel rooms. Thus, special care must be taken to avoid damage or loss of currently available mobile device chargers.
[0009] In light of the above, it would be advantageous to provide a device for inductive charging of portable electronic devices that is durable, easy to use, and comparatively cost effective.
SUMMARY OF THE INVENTION
[0010] One object of the present invention is convenient portability and storage of a mobile device charger. Another object of the present invention is the avoidance of damage to a mobile device charger or loss of the charger.
[0011] As stated above, electricity is not always available to use to charge phones and mobile devices. In addition, users of phones often leave their phone charger behind when traveling or on the go. The invention claimed here solves this problem. The present invention allows the user to carry a wireless mobile device charging mat attached to a purse, backpack or computer back so that it is not left behind when travelling or on the go.
[0012] The claimed invention differs from what currently exists. We are not aware of any wireless mobile device charging mat enclosed in a bag charm that exists today. Existing wireless charging mats are not bag charms and cannot be attached to other objects such as purses, pant loops, computer bags, necklaces.
[0013] This invention eliminates the problem of leaving phone charging mats behind when traveling or on the go. This invention eliminates the problem of not being able to charge a phone when electricity is not available.
[0014] Existing mobile device chargers do not have a clip on them to allow them to be attached to anything else, so they are easily forgotten. Existing mobile device charger cords and metal tips are often damaged because they are exposed.
[0015] The present invention includes a wireless charging mat to charge mobile devices and display advertisements, logos, etc., a housing under the mat to hold a battery and a built in electrical plug, a charm clip to attach the mat to other objects such as purses or belt loops, a battery to charge a mobile device when an electrical outlet is not available, and an electrical plug built into the housing.
[0016] The present invention consists of a protective enclosure containing an inductive coupling charging circuit. A mobile device sitting on top of the present invention is charged through inductive coupling. An alternative embodiment includes a retractable cable with a connector at the end. The connector plugs into a power source such as a USB port in order to pass current from the power source to the inductive coupling charging circuit to charge the internal battery. When the invention is not in use, the enclosure protects the retracted cable and its connector, thus avoiding damage to the cable or connector. In an alternative embodiment, the cable and connector also provide current from the inductive mobile device charger to a mobile device, providing the additional ability of charging a mobile device that doesn't support inductive charging.
[0017] An alternative embodiment includes a retractable cable with a connecter at the end, such as a USB connector, a “Lightning” connector, or another type of charging connector, in conjunction with a mobile device charging circuit. The connector and corresponding charging circuit allows for charging a mobile device lacking support for inductive charging.
[0018] The enclosure on the present invention includes a connector for a chain. In one embodiment, this is a recessed part of the enclosure in which one side of the enclosure connects to the opposite side over the recess via a bridge or rod extending across the recess. A chain may be attached to the bridge or rod, In an alternative embodiment, the enclosure is extended on one end and the connector consists of an opening in the extension through which a chain may be connected. A clip or keychain may thus be attached to the enclosure through a cord or chain. By attaching the invention to another object via the clip, loss of the mobile device charger can be avoided,
[0019] A preferred embodiment of the present invention uses a transformer to charge an internal battery, with a flyback controller on the primary side of the transformer and a synchronous rectifier circuit on the secondary side. The flyback controller switches the rectified main current through the primary side of the transformer at approximately 80 kHz. The switching speed is dithered to lessen harmonic content and ease EMI compliance. The resulting current is monitored by the flyback controller on an auxiliary winding on the primary side of the transformer, allowing the controller to protect against over-voltage and over-current conditions and the current to be monitored entirely on the primary side of the transformer. The secondary side of the transformer contains a synchronous rectifier circuit in place of the traditional diode, greatly improving the efficiency during use by removing the voltage/power loss across the diode. Further, when the load is removed entirely, a monitor circuit issues a special set of pulses through the transformer indicating to the primary-side flyback controller that there is no load, causing it to enter a low-power standby mode. This feature results in virtually zero standby power when the adapter is not connected to a device.
[0020] A preferred embodiment of the present invention includes a foldable plug that sits flush with the enclosure when folded in, but may be extended in order to connect to a power source. In one variation of said embodiment, a recess around the folded plug allows easy access to the plug in order to extend it. In another variation, the ends of the plug's prongs, when folded in, sit against the edge of the enclosure, allowing extension by grasping the end of said prongs and pulling outward via a motion of the hand against the edge of the enclosure. By folding in the plug so that it sits flush with the enclosure, the mobile device charger may be easily transported in a pocket or a purse without damaging other objects stored with it.
[0021] Also, a preferred embodiment of the present invention uses a cylindrical enclosure with rounded or beveled edges which allow it to easily be carried in a pocket or a purse without damaging other objects stored with it.
[0022] A battery is included inside the enclosure in an embodiment of the present invention, thus allowing the mobile device charger to provide current to a mobile device when no outside power source is available. Some embodiments may further include a receiving coil and related charging circuit to charge the internal battery via inductive charging from another mobile device charger, thus allowing the mobile device chargers of the present invention to charge each other. In this way, various mobile device chargers of the present invention can be stacked on top of each other and their internal batteries charged through inductive charging via a single original power source. The original power source may be a single household power outlet, which would suffice to simultaneously charge multiple mobile device chargers of the present invention.
[0023] A stand in an embodiment of the present invention is formed by a lever attached to the bottom of the wireless charging mat which sits flush in a first configuration and pivots outward and locks into various angles in other configurations. By locking the lever at an angle from the rest of the charging mat, the charging mat may be seated on a desk or table at an angle from the horizontal, allowing convenient use of the mobile device while the device is being charged.
[0024] A preferred embodiment of the present invention is made up of stackable modules. One module is the charging mat itself and includes the inductive charging circuitry. Another module provides the battery and a third module provides the power cord. The user can stack all three modules on top of each other, or use only the modules needed. For example, if the user is on the road and will not be able to use a power outlet, the power cord module may be left behind for the sake of convenience and portability. At home, the battery module may not be wanted. A stand may be formed with a lever attached to a base module or the bottom of any module. The lever sits flush with the base or module in a first configuration and pivot outward and lock into place at various angles in alternate configurations. Finally, battery charging circuitry allows the battery module to charge its internal battery when the invention is placed on another inductive mobile device charger.
[0025] A preferred embodiment of the present invention has a diameter of roughly 4 inches, or about 10 centimeters, which would be appropriate for charging most inductive-charging ready mobile phones. A rectangular embodiment would have a length of roughly 4 inches for the same reasons. Other embodiments have larger diameters or lengths for greater convenience in charging tablet computers. Embodiments of the present invention include other sizes as appropriate for charging various types of electronic devices, such as watches, jewelry, and step counters.
[0026] The Components are related as follows: The wireless charging mat is used to charge phones. The charm housing is attached to the mat and is used to hold the battery and the folding electrical plug. The charm clip is attached to the wireless charging mat and the housing to other objects. The battery is used to charge mobile devices. The folding electrical plug is used to charge the battery and provide power to the wireless charging mat charm.
[0027] The Invention Works as follows: The wireless charging mat charm is used to charge phones. The charm housing is attached to the mat charm and is used to hold the battery and the folding electrical plug. The charm clip is used to attach the wireless charging mat charm and the charm housing to other objects. The battery is used to charge mobile devices. The folding electrical plug is used to charge the battery and provide power to the wireless charging mat charm.
[0028] In order to make the invention, a person would make a wireless mobile charging mat and attach it to the housing. Then, insert a battery inside the housing and add a folding electrical plug. Then, a person would add a chain, rope, elastic or another type of cord and a clip. The battery, the wireless charging mat charm, the housing and a power source are all necessary. A USB port could be added to charge the battery. A retractable charging cord could be added to coil into the housing. A car charging plug could be added to charge the battery. If a USB port or a car charging plug was added, the folding electrical plug could be removed.
[0029] To use the invention, a person would attach the wireless mobile device charging mat charm to their purse, bag or backpack, belt loop or necklace, etc. and carry it with them so that they do not leave it behind when traveling or on the go. The person would charge their mobile device using the invention when they do not have access to electricity. A person would re-charge the mat charm when it runs out of power.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
[0031] FIG. 1 is a top view of an inductive mobile device charger with a chain for convenient attachment of the charger to another object;
[0032] FIG. 2 is a side view of an alternative embodiment of the present invention showing a retractable USB cable;
[0033] FIG. 3 is bottom view of an inductive mobile device charger;
[0034] FIG. 4 is a diagram showing the major components of the inductive charging system of a preferred embodiment of the present invention;
[0035] FIG. 5 is a schematic diagram showing the layout of electrical components in an AC/DC converter circuit used in charging the internal battery in a preferred embodiment of the present invention;
[0036] FIG. 6 is a perspective view of an embodiment of the present invention showing various modules comprising the elements of a mobile device charger which are stacked on top of each other; and
[0037] FIG. 7 is a side view of an embodiment of the present invention showing a lever which allows the mobile device charger to sit at an angle for convenient use of a mobile device during charging.
DETAILED DESCRIPTION
[0038] FIG. 1 illustrates a top view of a preferred embodiment of an inductive mobile device charger 100 comprising an inductive charging circuit inside a housing 102 . Housing 102 has a front face 104 on which a logo or advertisement may be displayed. A chain 106 is attached at one end to the housing 102 by a connector 108 . A loop 110 is attached to the other end of chain 106 , allowing the inductive mobile device charger 100 to be attached to a purse or other object. Loop 110 may be replaced by a clip, keychain, or other attachment in various embodiments of the present invention. The inductive mobile device charger 100 charges a mobile device sitting on its front face 104 through inductive coupling.
[0039] FIG. 2 illustrates a side view of an alternative embodiment of a inductive mobile device charger 100 which includes a charging connector 112 attached to the inductive mobile device charger 100 via a retractable cable 114 . The charging connector 112 and retractable cable 114 allow charging the internal battery of the inductive mobile device charger 100 via an alternative power source. In a preferred embodiment, the charging connector 112 is a USB connector, allowing the mobile device charger 100 to use power from a USB port to charge the internal battery. A USB charging port 115 allows a user to connect and charge a personal electronic device that does not support inductive charging from either the internal battery of the mobile device charger 100 or its external power source.
[0040] FIG. 3 illustrates back view of an inductive mobile device charger 100 , showing back face 116 on which sits an electrical plug 118 . The electrical plug 118 provides power to the inductive mobile device charger 100 in order to charge a mobile device. Alternatively, electrical power is provided to the inductive mobile device charger 100 through electrical plug 118 in order to charge an internal battery. The inductive mobile device charger 100 then uses internal battery power to charge a mobile device, allowing charging to take place when an electrical socket is unavailable.
[0041] FIG. 4 illustrates the primary components and functionality of an inductive mobile device charging system 200 comprising an inductive mobile device charger 100 and a mobile device 204 . A power source 206 , such as an internal battery or rectified current from a power outlet, provides power to an inverter 208 . The inverter 208 provides an AC waveform to a primary coil 210 . In a preferred embodiment, the frequency of the waveform is between 100 and 200 kHz. In a preferred embodiment, the inverter 208 transfers power to the primary coil 210 by a full-bridge switching arrangement at a 50% duty cycle and a 130 kHz switching frequency. It is to be understood, however, that different frequencies may be used according to the needs of any individual project. A voltage sensor 212 monitors the primary coil 210 and provides data to a controller circuit 214 . The controller circuit 214 in turn adjusts the output of the inverter 208 in order to provide an amount of power appropriate to the load provided by the mobile device 204 . The voltage sensor 212 and the controller circuit 214 may also detect communications from the mobile device 204 and respond by increasing, decreasing, or shutting off the provided power.
[0042] The alternating current through the primary coil 210 creates a magnetic flux, which in turn creates an alternating current in a secondary coil 216 inside the mobile device. The current is rectified by a rectifying circuit 218 and passed on to the load 220 . A controller circuit 222 in communication with both the rectifying circuit 218 and the load 220 causes signals to be sent to the inductive mobile device charger 100 requesting the amount of power needed by the load 220 . In most instances, the load 220 will comprise a battery, and the power necessary will vary depending on the amount of charge already present in the battery. The controller circuit 222 of the mobile device 204 may communicate with the controller circuit 214 of the inductive mobile device charger 100 through backscatter modulation by brief alterations of the load placed on the secondary coil 216 , which in turn are detected by the voltage sensor 212 in the inductive mobile device charger 100 . Additionally, in some embodiments, communication across the primary coil 210 and secondary coil 216 may be accomplished through frequency-shift keying.
[0043] In a preferred embodiment of the invention, power source 206 comprises a battery as well as its own secondary coil, rectifier, and controller, which act as load 220 , secondary coil 216 , rectifying circuit 218 , and controller circuit 214 , respectively. Such a configuration allows multiple mobile device chargers 100 to be stacked onto each other, thus allowing for the simultaneous charging of the internal batteries of each mobile device charger 100 . Such a configuration is particularly useful when multiple mobile device chargers 100 need to be charged, but only a single power outlet is available.
[0044] FIG. 5 is a schematic of an AC/DC converter circuit 300 as used in charging the internal battery in a preferred embodiment of the invention. The AC input is passed through initial rectifier 302 to a primary side flyback controller 304 . A low-profile transformer 306 then steps down the voltage. A wake-up monitor and synchronous rectifier 308 on the secondary side of the transformer detects the presence or absence of a load, and signals the flyback controller 304 accordingly. The wake-up monitor and synchronous rectifier also acts as a near-ideal diode to rectify the current. An active charge indicator 310 detects when a personal electronic device is being charged and turns on light-emitting diode 332 .
[0045] In the initial rectifier 302 , a neutral AC line feeds one side of a diode bridge 312 , while a hot AC line feeds the other side through a protective fuse 314 . The rectified current is provided to the flyback controller 304 , which is based on a UCC28730 integrated circuit 316 . The flyback controller switches the current through primary winding 318 of transformer 306 , and monitors the current through auxiliary winding 320 of the transformer. The winding ratios of transformer 306 may differ in different embodiments of the invention intended for sale in different regions of the world, as appropriate to the standard household outlet voltage of the region.
[0046] When there is no load, wake-up monitor and synchronous rectifier 308 , based on a UCC24650 integrated circuit 322 , sends a series of pulses through the transformer signaling the flyback controller 304 to shut down, saving power when there is no device connected to the charger. A UCC24610 integrated circuit 324 provides the synchronous rectifier function, acting as a near-ideal diode providing high efficiency and low voltage or power loss.
[0047] Finally, active charge indicator 310 uses a comparator 326 provide a voltage difference across light-emitting diode 332 when a voltage drop across filter inductor 328 indicates an active device is connected. Light-emitting diode 332 thus indicates when a connected personal electronic device is being charged.
[0048] After the AC input is transformed and rectified, the internal battery is charged with current provided through 5-volt output 330 .
[0049] As shown in FIG. 6 , an embodiment of the present invention may consist of separable modules, allowing the user to save space by attaching only the modules needed at any given time. This embodiment of mobile device charger 100 includes a wireless charging mat 404 , in which is circuitry which receives DC power input and uses an inverter to transfer power to a primary coil, providing power via induction to a secondary or receiving coil in a mobile device. The mat 404 stacks on top of another module which provides the DC power input. Such a power source can be a battery module 406 which includes an internal battery, or a cord module 408 . The cord module 408 acquires power from an external power source to provide to either a battery module 406 for charging its internal battery, or directly to the charging mat 404 . The cord module 408 includes either a retractable USB cord configured to acquire power through a USB port, a retractable electrical plug configured to acquire power through a household power outlet, or both. Appropriate circuitry converts the power to the necessary DC output for the mat 404 or the battery module 406 .
[0050] The mat 404 is shown stacked on top of the battery module 406 , which in turn is stacked on the cord module 408 , allowing the internal battery of the battery module 406 to be charged while power is provided to the mat 404 for charging a mobile device. If no power outlet is available, a user may stack the mat 404 on the battery module 406 alone and omit the cord module 408 . If a power outlet is available and the user wishes to save space, the mat 404 may be stacked directly onto the cord module 408 , omitting entirely the battery module 406 .
[0051] FIG. 7 shows an embodiment of the present invention configured for positioning a mobile device charger 100 at an angle for convenient use of a mobile device during charging. A charging mat 440 comprises a power source 206 , an inverter 208 , a primary coil 210 , a voltage sensor 212 , and a controller circuit 214 as shown in FIG. 4 . Attached to the bottom of the charging mat 440 is a lever 442 which, in a first configuration, sits flush with the charging mat 440 . The lever 442 is attached to the charging mat 440 via a hinge, which allows the lever 442 to pivot outward into alternate configurations. The lever 442 is configured to lock into alternate configurations at desired angles. One way in which this may be accomplished is via a base 444 attached to one end of the charging mat 440 via a hinge. The base 444 would normally sit in a first configuration flush with the charging mat 440 , and covering the lever 442 sitting in its first configuration. When folded outward, the lever 442 would be held in each of its configurations via stoppers 446 on the base 444 . Stoppers 446 are preferably grooves in the base 444 or ridges on the base 444 which allow the lever 442 to be held in place.
[0052] While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. Thus the scope of the invention should not be limited according to these factors, but according to the following claims.
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Wireless Mobile Device Charging Mat Charm with clip and battery and with or without retractable cord to re-charge the charging mat is disclosed. This invention eliminates the problem of leaving phone charging mats behind when traveling or on the go. This invention eliminates the problem of not being able to charge a phone when electricity is not available.
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FIELD OF THE INVENTION
[0001] This invention relates generally to internal combustion engines. More specifically it relates to a control strategy for selectively utilizing homogeneous-charge compression-ignition (HCCI) in a way that takes advantage of HCCI's attributes in different ways during different modes of engine operation.
BACKGROUND OF THE INVENTION
[0002] HCCI is a known process for fueling a diesel engine in a manner that creates a substantially homogeneous air-fuel charge inside an engine cylinder during a compression upstroke of an engine cycle. After a desired quantity of fuel for the charge has been injected into the cylinder to create a substantially homogeneous air-fuel mixture, the increasing compression of the charge by the upstroking piston creates sufficiently large pressure to cause auto-ignition of the charge. In other words, the HCCI mode of operation of a diesel engine may be said to comprise 1) injecting a desired amount of fuel into a cylinder at an appropriate time during the compression upstroke so that the injected fuel mixes with charge air that has entered the cylinder during the preceding intake downstroke and early portion of the compression upstroke in a manner that forms a substantially homogeneous mixture within the cylinder, and then 2) increasingly compressing the mixture to the point of auto-ignition near or at top dead center (TDC). Auto-ignition may occur as the substantially simultaneous spontaneous combustion of vaporized fuel at various locations within the mixture. No additional fuel is injected after auto-ignition.
[0003] One of the attributes of HCCI is that relatively lean, or dilute, mixtures can be combusted, keeping the combustion temperatures relatively low. By avoiding the creation of relatively higher combustion temperatures, HCCI can yield significant reductions in the generation of NO X , an undesired constituent of engine exhaust gas.
[0004] Another attribute of HCCI is that auto-ignition of a substantially homogeneous air-fuel charge generates more complete combustion and consequently relatively less soot in engine exhaust.
[0005] The potential benefit of HCCI on reducing tailpipe emissions is therefore rather significant, and consequently HCCI is a subject of active investigation and development by scientists and engineers.
[0006] One aspect of HCCI seems to impose a limit on the extent to which it can provide drastically reduced tailpipe emissions of soot and NO X . At higher engine speeds and larger engine loads, the rate of combustion is difficult to control. Consequently, known engine control strategies may utilize HCCI only at relatively lower speeds and smaller engine loads. At higher speeds and/or larger loads, the engine is fueled so that the fuel combusts by conventional diesel (CD) combustion.
[0007] The nature of a diesel engine and the commercial availability of fuel injection systems that can control fuel injection with great precision allow fuel to be injected as a series of individual injections during an engine cycle. Hence known fueling systems in diesel engines can serve to control injection of fuel for both CD combustion and HCCI combustion.
[0008] CD fuel injection during an engine cycle is sometimes described by its particular fueling pulses, such as pilot injection pulses, main injection pulses, and post-injection pulses. Any particular fuel injection process typically always comprises at least one main fuel injection pulse, with one or more pilot and/or post-injection pulses being optional possibilities.
[0009] Contemporary fuel injection systems allow injection pressure, injection rate, and injection timing to be controlled with high degrees of precision so that fuel can be injected into a cylinder in precise quantities at precise times during an engine cycle. That is why known fuel injection and associated processing systems can handle both CD and HCCI combustion.
[0010] As will be explained by later description, the present invention takes advantage of the capabilities of those fuel injection and processing systems to control fuel injections in different ways depending on certain aspects of engine operation. Exactly how any particular fuel injection system will be controlled by an associated processing system in any given engine will depend on specifics of the engine, the fuel injection system, and the processing system.
[0011] Because a diesel engine that powers a motor vehicle runs at different speeds and loads depending on various inputs to the vehicle and engine that influence engine operation, fueling requirements change as speed and load change. An associated processing system processes data indicative of parameters such as engine speed and engine load to develop control data for setting desired engine fueling for particular operating conditions that will assure proper control of the fuel injection system for various combinations of engine speed and engine load.
SUMMARY OF THE INVENTION
[0012] The present invention relates to an engine, system, and method for enhancing the use of HCCI combustion in a diesel engine toward objectives that include reducing the generation of undesired constituents in engine exhaust, especially soot and NO X , and improving thermal efficiency. The invention is embodied in the fuel injection control strategy, a strategy that is programmed in an associated processing system.
[0013] One generic aspect of the present invention relates to a method of operating a compression ignition engine by processing certain data to select one of plural fueling modes for operating the engine. When a result of the processing selects a first fueling mode, the engine is fueled during an engine cycle to create a substantially homogeneous air-fuel charge within one or more combustion chambers. That charge is compressed to combust by auto-ignition, with no more fuel being introduced after auto-ignition. When a result of the processing selects a second fueling mode, the engine is fueled during an engine cycle to create a substantially homogeneous air-fuel charge within the one or more combustion chambers. That charge is compressed to combust by auto-ignition, after which more fuel is introduced into the one or more combustion chambers to provide additional combustion.
[0014] Another generic aspect of the invention relates to a compression ignition engine that has a control system for processing data, one or more combustion chambers, and a fueling system for introducing fuel into the one or more combustion chambers. The control system controls the fueling system using a result of the processing of certain data by the control system to select one of plural fueling modes for operating the engine. When the result of the processing selects a first fueling mode, the engine is fueled during an engine cycle to create a substantially homogeneous air-fuel charge within the one or more combustion chambers. That charge is compressed to combust by auto-ignition, with no more fuel being introduced after auto-ignition. When the result of the processing selects a second fueling mode, the engine is fueled during an engine cycle to create a substantially homogeneous air-fuel charge within the one or more combustion chambers. That charge is compressed to combust by auto-ignition, after which more fuel is introduced to provide additional combustion.
[0015] Still another generic aspect relates to a method of operating a compression ignition engine by performing a succession of steps during an engine cycle. The steps include: a) injecting diesel fuel into a combustion chamber during a compression phase of the cycle to create a substantially homogeneous combustible charge; b) compressing the charge to a pressure at which the charge will auto-ignite; and c) injecting more diesel fuel into the combustion chamber after auto-ignition of the charge to provide additional combustion.
[0016] A further generic aspect relates to a compression ignition engine comprising a control system for processing data, a combustion chamber, and a fueling system for injecting diesel fuel into the combustion chamber. The control system controls the fueling system's injection of diesel fuel into the combustion chamber during a compression phase of each of successive engine cycles a) to cause creation of a substantially homogeneous combustible charge and compression of the charge to a pressure at which the charge will auto-ignite, and b) then to cause the injection of more diesel fuel into the combustion chamber to provide additional combustion.
[0017] In one disclosed embodiment of the invention, the certain data that is processed comprises engine speed data and engine load data. In another embodiment, the processing of the engine speed data is unnecessary.
[0018] The foregoing, along with further features and advantages of the invention, will be seen in the following disclosure of a presently preferred embodiment of the invention depicting the best mode contemplated at this time for carrying out the invention. This specification includes drawings, now briefly described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A is a representative graphic portrayal of known fueling strategy comprising HCCI combustion for some speed-load conditions and CD combustion for other speed-load conditions.
[0020] FIG. 1B is a representative graphic portrayal of fueling strategy in accordance with principles of the present invention comprising an HCCI combustion mode for some speed-load conditions and an HCCI-CD combustion mode for other speed-load conditions.
[0021] FIG. 2 is a general schematic diagram of portions of an exemplary diesel engine relevant to principles of the present invention.
[0022] FIG. 3 is a flow diagram illustrating an embodiment of the inventive strategy.
[0023] FIG. 4 is a representative graphic portrayal illustrating the HCCI-CD fueling aspect of the inventive strategy.
[0024] FIG. 5 is another representative graphic portrayal of fueling strategy in accordance with principles of the present invention comprising HCCI combustion for some speed-load conditions and HCCI-CD combustion for other speed-load conditions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] FIG. 1A is a graph whose vertical axis represents engine load and whose horizontal axis represents engine speed. At the origin of the graph, engine load is zero, and engine speed is zero. Respective solid lines 10 and 12 demarcate two zones labeled I. HCCI and II. CD.
[0026] Zone I covers an area that encompasses various combinations of relatively smaller engine loads and relatively lower engine speeds. Zone II covers an area that encompasses various combinations of relatively larger engine loads and relatively higher engine speeds. When a compression ignition engine is operating at a speed and load that falls within Zone I, fuel is injected into the engine cylinders in a manner that creates HCCI combustion. When the engine is operating at a speed and load that falls within Zone II, fuel is injected into the engine cylinders in a manner that creates CD combustion.
[0027] FIG. 1B is a second graph similar to that of FIG. 1A in that the vertical axis represents engine load and the horizontal axis represents engine speed. At the origin of the graph, engine load is zero, and engine speed is zero. Respective solid lines 14 and 16 demarcate two zones labeled I. HCCI and II. HCCI-CD.
[0028] Zone I of FIG. 1B is divided into two-subzones by a broken line 18 . One sub-zone to the left of line 18 covers an area that is essentially the same as Zone I of FIG. 1A , encompassing substantially the same combinations of relatively smaller engine loads and relatively lower engine speeds as in FIG. 1A . The other sub-zone to the right of line 18 extends HCCI combustion to combinations of even higher engine speeds but smaller engine loads. Zone I of FIG. 1B is an inner zone that bounds the origin of the graph while zone II is an outer zone that bounds zone I.
[0029] When the engine is operating at a speed and load that falls within either sub-zone of Zone I of FIG. 1B , fuel is injected into the engine cylinders in a manner that creates HCCI combustion (HCCI mode). When the engine is operating at a speed and load that falls within Zone II however, fuel is injected into the engine cylinders a manner that creates HCCI-CD combustion (HCCI-CD mode).
[0030] FIG. 2 shows schematically a portion of an exemplary diesel engine 20 operating in accordance with the inventive strategy for powering a motor vehicle. Engine 20 comprises cylinders 22 within which pistons reciprocate. Each piston is coupled to a respective throw of a crankshaft by a corresponding connecting rod. Intake air is delivered to each cylinder through an intake system when a respective intake valve is open.
[0031] The engine has a fueling system that comprises fuel injectors 24 for the cylinders 22 . The engine also has a processor-based engine control unit (ECU) 26 that processes data from various sources to develop various control data for controlling various aspects of engine operation. The data processed by control system 22 may originate at external sources, such as various sensors 28 , and/or be generated internally. Examples of data processed may include engine speed, intake manifold pressure, exhaust manifold pressure, fuel injection pressure, fueling quantity and timing, mass airflow, and accelerator pedal position.
[0032] ECU 26 controls the injection of fuel into cylinders 22 by controlling the operation of the fueling system, including controlling the operation of fuel injectors 24 . The processing system embodied in ECU 26 can process data sufficiently fast to calculate, in real time, the timing and duration of device actuation to set both the timing and the amount of each injection of fuel into a cylinder. Such control capability is used to implement the inventive strategy.
[0033] Regardless of how data values for engine speed and engine load are developed, one embodiment of the invention uses instantaneous engine speed and instantaneous engine load to select the particular fueling mode for the engine, either the HCCI mode for creating HCCI combustion (Zone I of FIG. 1B ) or the HCCI-CD mode for creating HCCI-CD combustion (Zone II of FIG. 1B ), and to then operate the fueling system to fuel the engine according to the strategy of the selected fueling mode. Another embodiment uses only engine load.
[0034] FIG. 3 shows a flow diagram 30 for the inventive strategy as executed by the processing system of ECU 26 . The flow diagram represents one iteration of the strategy during one engine cycle for one cylinder. The reference numeral 32 represents the start of the iteration. A step 34 determines if engine speed is higher than a selected maximum speed limit above which HCCI combustion is not allowed. That maximum limit corresponds to the point MSL in FIG. 1B .
[0035] If step 34 determines that engine speed is higher than speed MSL, diagram 30 discloses that fuel will be injected to create HCCI-CD combustion, reference numeral 36 . FIG. 4 illustrates an example of fueling for HCCI-CD combustion. It may be considered to have two phases: an HCCI phase and a CD phase.
[0036] The HCCI phase may have one or more discrete injections. Regardless of the number of discrete injections, the HCCI phase introduces fuel into a cylinder during a compression upstroke of the piston that reciprocates in the cylinder. The fuel mixes with charge air that entered the cylinder during the immediately preceding intake downstroke and early portion of the compression upstroke, and the resulting air-fuel mixture is a substantially homogeneous one. The HCCI phase fueling concludes before any combustion occurs. When the charge has been compressed sufficiently to auto-ignite, the HCCI combustion commences.
[0037] The CD phase may also have one or more discrete injections, but regardless of the particular number, the CD phase causes more fuel to be introduced into the cylinder after the HCCI combustion commences. The introduction of that additional fuel is like conventional diesel injection and provides more combustion, and hence release of more energy for operating the engine at the higher speeds and loads that zone II of FIG. 1B encompasses.
[0038] In FIG. 3 , flow diagram 30 shows a first step 38 of the HCCI-CD mode to comprise commencement of the HCCI phase. A step 40 determines when the HCCI phase is complete. The next step 42 is commencement of the CD-phase. A step 44 determines when the CD phase is complete, after which the iteration ends as indicated by the reference numeral 46 .
[0039] When step 34 determines that engine speed is not larger than MSL, a step 48 determines if, for the particular instantaneous engine speed, engine load is larger than the load defined by line 14 . If it is, then fueling is performed according to the HCCI-CD mode. If it is not, then fueling is performed according to the HCCI mode, reference numeral 50 .
[0040] A first step 52 represents commencement of the HCCI mode. A step 54 determines when the HCCI mode is complete, after which the iteration ends as indicated by the reference numeral 46 .
[0041] In the example shown by FIG. 5 , the HCCI mode is possible at all engine speeds, but only at certain engine loads. Hence, engine load by itself is determinative of whether the HCCI mode or the HCCI-CD mode is selected. In that case step 34 of flow diagram 30 would be unnecessary. After the start (reference numeral 32 ), the flow diagram goes directly to the step 48 to determine the engine load.
[0042] Another manner of selecting the mode is by using one or more maps in the processing system to define the zones I and II and comparing data values for instantaneous engine speed and engine load against the maps.
[0043] FIG. 4 shows that a distinct dwell is present between the HCCI phase and the CD phase. The duration of the CD phase can be shorter than, equal to, or longer than that of the HCCI phase, depending on the engine load, as measured in crankshaft degrees. Dwell between the two phases can also vary, depending on the engine load. The quantity of fuel injected during the HCCI phase may be smaller than, equal to, or greater than that injected during the CD phase. Likewise, the fuel injection pressure during the HCCI phase may be smaller than, equal to, or greater than that during the CD phase.
[0044] The invention has the following advantages:
1) It can concurrently reduce NO X and soot. 2) It has high thermal efficiency. 3) It can cover the whole operating range of an engine. 4) It can be used in heavy-duty, medium-duty, and light-duty diesel engines. 5) The invention can be implemented in the processor alone, provided that the processor has sufficient capacity, and this makes the invention quite cost-effective.
[0050] While a presently preferred embodiment of the invention has been illustrated and described, it should be appreciated that principles of the invention apply to all embodiments falling within the scope of the following claims.
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A compression ignition engine ( 20 ) has a control system ( 26 ) for processing data, one or more combustion chambers ( 22 ), and fuel injectors ( 24 ) for injecting fuel into the combustion chambers. The control system controls fueling using a result of the processing of certain data, such as engine speed and engine load, to select one of two fueling modes (HCCI, HCCI-CD) for operating the engine. When the result of the processing selects the HCCI mode, the engine is fueled to cause homogeneous-charge compression-ignition (HCCI) combustion within the combustion chambers. When the result of the processing selects the HCCI-CD mode, the engine is fueled to create a substantially homogeneous combustible charge within each combustion chamber that is compressed to auto-ignition, and after auto-ignition, more fuel is injected to provide additional combustion in the manner of the conventional diesel combustion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority benefit under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/615,307, filed Mar. 25, 2012, titled Physiological Monitor User Controls; U.S. Provisional Patent Application Ser. No. 61/615,316, filed Mar. 25, 2012, titled Physiological Monitor User Interface; and U.S. Provisional Patent Application Ser. No. 61/615,876, filed Mar. 26, 2012, titled Physiological Monitor Touchscreen; all of the above referenced applications are hereby incorporated in their entireties by reference herein.
BACKGROUND OF THE INVENTION
Pulse oximetry is a widely accepted noninvasive procedure for measuring the oxygen saturation level of arterial blood, an indicator of a person's oxygen supply. A typical pulse oximetry system utilizes an optical sensor attached to a fingertip to measure the relative volume of oxygenated hemoglobin in pulsatile arterial blood flowing within the fingertip. Oxygen saturation (SpO 2 ), pulse rate and a plethysmograph waveform, which is a visualization of pulsatile blood flow over time, are displayed on a monitor accordingly.
Conventional pulse oximetry assumes that arterial blood is the only pulsatile blood flow in the measurement site. During patient motion, venous blood also moves, which causes errors in conventional pulse oximetry. Advanced pulse oximetry processes the venous blood signal so as to report true arterial oxygen saturation and pulse rate under conditions of patient movement. Advanced pulse oximetry also functions under conditions of low perfusion (small signal amplitude), intense ambient light (artificial or sunlight) and electrosurgical instrument interference, which are scenarios where conventional pulse oximetry tends to fail.
Advanced pulse oximetry is described in at least U.S. Pat. Nos. 6,770,028; 6,658,276; 6,157,850; 6,002,952; 5,769,785 and 5,758,644, which are assigned to Masimo Corporation (“Masimo”) of Irvine, Calif. and are incorporated in their entirety by reference herein. Corresponding low noise optical sensors are disclosed in at least U.S. Pat. Nos. 6,985,764; 6,813,511; 6,792,300; 6,256,523; 6,088,607; 5,782,757 and 5,638,818, which are also assigned to Masimo and are also incorporated in their entirety by reference herein. Advanced pulse oximetry systems including Masimo SET® low noise optical sensors and read through motion pulse oximetry monitors for measuring SpO 2 , pulse rate (PR) and perfusion index (PI) are available from Masimo. Optical sensors include any of Masimo LNOP®, LNCS®, SofTouch™ and Blue™ adhesive or reusable sensors. Pulse oximetry monitors include any of Masimo Rad-8®, Rad-5®, Rad®-5v or SatShare® monitors.
Advanced blood parameter measurement systems are described in at least U.S. Pat. No. 7,647,083, filed Mar. 1, 2006, titled Multiple Wavelength Sensor Equalization; U.S. Pat. No. 7,729,733, filed Mar. 1, 2006, titled Configurable Physiological Measurement System; U.S. Pat. Pub. No. 2006/0211925, filed Mar. 1, 2006, titled Physiological Parameter Confidence Measure and U.S. Pat. Pub. No. 2006/0238358, filed Mar. 1, 2006, titled Noninvasive Multi-Parameter Patient Monitor, all assigned to Cercacor Laboratories, Inc., Irvine, Calif. (Cercacor) and all incorporated in their entirety by reference herein. Advanced blood parameter measurement systems include Masimo Rainbow® SET, which provides measurements in addition to SpO 2 , such as total hemoglobin (SpHb™), oxygen content (SpOC™), methemoglobin (SpMet®), carboxyhemoglobin (SpCO®) and PVI®. Advanced blood parameter sensors include Masimo Rainbow® adhesive, ReSposable™ and reusable sensors. Advanced blood parameter monitors include Masimo Radical-7™, Rad87™ and Rad57™ monitors, all available from Masimo. Such advanced pulse oximeters, low noise sensors and advanced blood parameter systems have gained rapid acceptance in a wide variety of medical applications, including surgical wards, intensive care and neonatal units, general wards, home care, physical training, and virtually all types of monitoring scenarios.
SUMMARY OF THE INVENTION
A physiological monitor touchscreen interface presents interface constructs on a touchscreen display that are particularly adapted to finger gestures so to change at least one of a physiological monitor operating characteristic and a physiological touchscreen display characteristic. The physiological monitor touchscreen interface has a first interface construct operable to select a menu item from a touchscreen display and a second interface construct operable to define values for the selected menu item.
In various embodiments, the first interface construct has a first scroller that presents a rotating set of the menu items in a touchscreen display area and a second scroller that presents a rotating set of thumbnails in a display well. The thumbnails reference the menu items and the thumbnails rotate with the menu items. The first scroller presents a rotating set of second level menu items upon selection of the menu item. The second interface construct is a slider for selecting limits for one of the second level menu items. A spinner is used in conjunction with the slider for making a first gross limit selection with the slider followed by a finer limit selection with the spinner. A parameter area displays parameter values in a full presentation format and a parameter well area displays parameter values in a abbreviated presentation format. The full presentation format is a larger font that the abbreviated presentation format. A dynamic space allocation for the parameters values is presented in the parameter area such that the more parameters there are in the parameter area and, accordingly, the fewer parameters there are in the parameter well area, then the larger the display font for the parameters in the parameter area.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a hierarchical chart of a physiological monitor touchscreen interface including interface constructs and finger controls;
FIGS. 2-7 are illustrations of various touchscreen interface constructs for controlling a physiological monitor;
FIGS. 2A-D are illustrations of a scroller;
FIGS. 3A-C are illustrations of a physiological monitor main menu and sub-menus implemented with a scroller;
FIGS. 4A-C are illustrations of a spinner;
FIGS. 5A-B are illustrations of a slider;
FIG. 6 is an illustration of a slider-spinner; and
FIGS. 7A-D are illustrations of a parameter monitor touchscreen providing dynamic allocation of the parameter display area utilizing a parameter well.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a touchscreen interface 100 for a physiological monitor 10 and, in particular, for a touchscreen display 20 integral to the monitor 10 . In general, the touch screen interface 100 provides an intuitive, gesture-oriented control for the physiological monitor 10 . In particular, the touchscreen display 20 presents a user with interface constructs 110 responsive to finger controls 120 so as to change displays and settings, such as monitor operating characteristics, display contents and display formats using a finger touch, a finger touch and move, or a fingertip flick.
As shown in FIG. 1 , interface constructs 110 include a scroller 111 , a spinner 112 , a slider 113 , a slider-spinner 114 and a scalable parameter well 115 . A scroller 111 is described below with respect to FIGS. 2-3 . A spinner 112 is described below with respect to FIGS. 4A-C . A slider 213 is described below with respect to FIGS. 2-3 . A slider-spinner 214 is described below with respect to FIGS. 5A-B . A scalable parameter well 216 is described below with respect to FIGS. 7A-D .
Also shown in FIG. 1 , finger controls 120 include a touch 121 , a touch and move 121 and a flick 121 . A touch 121 is finger contact with an active display area. A touch and move 121 is finger contact in conjunction with finger movement in a particular direction. A flick 121 is finger contact in conjunction with a quick finger movement in a particular direction.
FIGS. 2-7 illustrate various touchscreen interface constructs 110 ( FIG. 1 ) for controlling a physiological monitor 10 ( FIG. 1 ), as described above. FIGS. 2A-D illustrate a scroller 200 construct configured for a touchscreen display. The scroller 200 is organized as a menu 210 disposed on a virtual, horizontally-rotatable loop. Only a viewable section 201 - 204 of the menu 210 is visible on the display at any given time. The scroller 200 is responsive to finger controls so as to bring into view any menu section, as described below.
Also shown in FIGS. 2A-D , a scroller 200 embodiment has thumbnails 250 disposed on a second, virtual, horizontally-rotatable loop located in a display well 211 . The menu 210 has menu icons 230 and corresponding menu titles 240 . The thumbnails 250 have a one-to-one correspondence to the menu icons 230 , as indicated by thumbnail icons corresponding to the menu icons or thumbnail initials corresponding to the menu titles 240 .
Further shown in FIGS. 2A-D , the scroller 200 advantageously allows for an unrestricted number of menu items. A user can rotate the scroll left or right using touch and move 122 ( FIG. 1 ). A user can scroll left or right with velocity using flick 123 ( FIG. 1 ). Further, a user can navigate to a menu item using touch 121 ( FIG. 1 ) on menu item icon or title. In addition, a user can quick scroll to menu item using touch 121 ( FIG. 1 ) on a thumbnail in the display well 211 .
As shown in FIGS. 2A-D , when the user applies touch and move 207 ( FIG. 2A ) to the menu icons the user can freely and smoothly slide the menu 201 ( FIG. 2A ) to the left 202 ( FIG. 2B ) or the right. On release the menu icons snap and lock 203 ( FIG. 2C ) to their closest grid location employing an ease-in animation so the transition is smooth and natural and not abrupt. Then, on touch 208 ( FIG. 2C ) the user can navigate to any visible menu option 210 . The navigate executes on release.
Further shown in FIGS. 2C-D , when the user wants to jump to a menu item not on the screen they can use a quick scroll. The user applies touch 209 ( FIG. 2C ) on a particular thumbnail indicator (K) 233 and the icon menus scroll into position giving center focus to the menu item (Icon K) 214 FIG. 2D represented by the touched thumbnail indicator 233 . As shown in FIG. 2D , once the icon menu scroll animation is complete, the thumbnail indicators rapidly slide to their new orientation.
When the user applies flick (not shown) to the menu icons 210 , the menu icons move with velocity along the horizontal vector the gesture implied and the icon menus slide into place. In particular, when the menu icons momentum decreases and they begin to come to a stop, the menu icons will snap to their closest grid location as described above.
FIGS. 3A-C illustrate a physiological monitor main menu 301 ( FIG. 3A ) and sub-menus 302 , 303 ( FIGS. 3B-C ) implemented with a scroller construct, as described above with respect to FIGS. 2A-D . For example, a user may touch “parameter settings” 310 in the main menu scroller 301 and be presented with a parameter menu stroller 302 . The user may then touch “alarm limits” 320 in the parameter settings stroller 302 and be presented with the alarm limits scroller 303 .
FIGS. 4A-C illustrate a spinner having one or more tiers, which open one at a time. Shown is a two-tiered spinner 400 . Each spinner tier 410 , 420 can display any specified number. The user applies touch to open one tier of the spinner at a time. The spinner elements include a label 430 , buttons 440 and corresponding button text. A tier open state 401 ( FIG. 4B ), 402 ( FIG. 4C ) has two preceding and two trailing values on a spinner element, and a spinner closed state 403 ( FIG. 4B ) displaying the selected value. In the spinner open state, the user can use a vertical touch and move or flick to adjust the value. When open, a spinner tier overlays other user controls on the screen. To close the spinner the user can touch the center, highlighted value or another control on the screen.
FIGS. 5A-B illustrate a slider 500 that allows one touch value settings, such as for parameter limits as one example. FIG. 6 illustrates a slider-spinner 600 embodiment, which is a combination of a slider and spinner, each described separately above. A slider-spinner 600 advantageously allows both a quick and an accurate capability to set a value. In particular, the slider 601 allows a user to quickly get to a specific range and the spinner allows a fine adjustment of that range.
FIGS. 7A-D illustrate a scalable parameter display 700 and corresponding parameter well 710 advantageously providing a parameter monitor touchscreen with dynamic allocation of the parameter display area 700 so as to maximize screen capability and a caregiver's ability to automatically emphasize and distinguish parameters of greater importance from parameters of lesser importance. In particular, different monitor users care about different parameters. For example, a hemotologist might focus on blood-related parameters, such as SpHb, a noninvasive and continuous reading of total hemoglobin. Accordingly, the user has the ability to remove parameters of little or no interest from a main display area 700 and to place them in the parameter well 710 . This is accomplished by a touch and hold gesture over a parameter to select the parameter, followed by a drag and drop gesture to remove the selected parameter from the main display area 700 into the well 710 . The parameters remaining in the main display area 700 become bigger in size according to the number of remaining parameters. The removed parameters become smaller in size according to the number of parameters in the well 710 . That is, the monitor dynamically adjusts parameter size according the available main display and well display areas. For example, FIG. 7A illustrates eight parameters in the main display 700 and one parameter (SpOC) in the well 710 . FIG. 7B illustrates the relative size of six parameters in the main display 700 , with three parameters in the well 710 . FIG. 7C illustrates three parameters in the main display 700 dynamically increasing in size and six parameters in the well 710 . FIG. 7D illustrates a single, very large SpO2 parameter advantageously solely displayed 700 so as to provide particular emphasis to that parameter and in a manner that can be seen across a room and readily noticed and monitored for change even by caregivers passing by at a distance. Sensors trigger parameters that are displayed so as not to hold space for non-active parameters.
A physiological monitor touchscreen interface has been disclosed in detail in connection with various embodiments. These embodiments are disclosed by way of examples only and are not to limit the scope of the claims herein. One of ordinary skill in art will appreciate many variations and modifications.
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A physiological monitor touchscreen interface which presents interface constructs on a touchscreen display that are particularly adapted to finger gestures. The finger gestures operate to change at least one of a physiological monitor operating characteristic and a physiological touchscreen display characteristic. The physiological monitor touchscreen interface includes a first interface construct operable to select a menu item from a touchscreen display and a second interface construct operable to define values for the selected menu item. The first interface construct can include a first scroller that presents a rotating set of menu items in a touchscreen display area and a second scroller that presents a rotating set of thumbnails in a display well. The second interface construct can operate to define values for a selected menu item.
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BACKGROUND OF THE INVENTION
Lower alkyl esters of L-phenylalanine are preferred starting materials in the manufacture of certain sweetening agents as disclosed in U.S. Pat. No. 3,492,131. However, heretofore those starting materials have been difficult and expensive to obtain. Due to the absence of suitable asymmetric syntheses, prior art efforts have been directed most often to the resolution of the DL-compounds.
Prior art methods have employed resolving agents derived from amino acids different than those being resolved, see for example, Kato and Tsuchiya, Agr. Bio. Chem., Vol. 26, No. 8, 467 and 473 (1962). As an exception, the resolution of the t-butyl ester of DL-phenylalanine employing N-carbobenzoxy-L-phenylalanine as the resolving agent has been reported in Roczniki. Chem., 40 (11/12), 1895 (1966). However, the urethane type carbobenzoxy group employed therein is not desirable because of its potentially dangerous preparation from phosgene and benzyl alcohol. Additonally, from an economic standpoint, it is undesirable to utilize a derivative of L-phenylalanine as resolving agent since its use as starting material for the production of sweetening agents makes it very valuable. Even small losses of resolving agent would result in substantial additional costs.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an economical and facile process for the preparation of the alkyl esters of L-phenylalanine from the alkyl esters of DL-phenylalanine; it is another object of this invention to utilize a derivative of D-phenylalanine, the undesired isomer in the preparation of sweetening agents, as a resolving agent; it is furthermore an object of this invention to utilize appropriate derivatives which may be recycled within the process to minimize overall costs; it is also an object of this invention to utilize materials which will form insoluble salts with the alkyl esters of L-phenylalanine, thus assuring purity of the L-isomer product. The successful achievement of these and other objects of this invention will be apparent from the following description of the invention.
DESCRIPTION OF THE INVENTION
The invention is concerned generally with the resolution of amino acids. More particularly, it is concerned with a new and unobvious process for the resolution of alkyl esters of DL-phenylalanine. Also, it is concerned with the production of certain novel salts of the alkyl esters of L-phenylalanine and N-acyl-D-phenylalanines. Those salts are conveniently represented by the following formula ##EQU1## wherein R 1 is a lower alkyl radical containing 1-4 carbon atoms inclusive and R 2 is hydrogen or a lower alkyl radical containing 1-7 carbon atoms inclusive. The salts are useful intermediates in the preparation of the lower alkyl esters of L-phenylalanine. Illustrative of those alkyl radicals intended are methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl and tert-butyl.
Other art equivalent acyl blocking groups, both aliphatic and aryl, may be utilized for R 2 , but the lower alkyl radicals described above are preferred.
The instant process is practiced preferably by contacting an alkyl ester of DL-phenylalanine in a suitable solvent, preferably a polar solvent, with an N-acyl-D-phenylalanine; isolating the salt of the corresponding alkyl ester of L-phenylalanine and N-acyl-D-phenylalanine; decomposing the salt into its respective components; and isolating the desired alkyl exter of L-phenylalanine.
The formation of the crystalline D-L salt of N-acyl-D-phenylalanine with the alkyl esters of L-phenylalanine is surprising and unobvious particularly in view of the disclosure in Roczniki. Chem., 40 (11/12), 1895 (1966), of the L-L salt formation of N-carbobenzoxy-L-phenylalanine with the t-butyl ester of L-phenylalanine. The instant salt formation is most advantageous since it permits the N-acyl derivatives of D-phenylalanine to be utilized as the resolving agents, effecting substantial cost savings over the use of the L-isomer. Thus, the desired L-isomer of phenylalanine need not be tied up in the process. Furthermore, the crystallization of the D-L salts affords, upon decomposition and separation, pure product consisting of the appropriate alkyl ester of L-phenylalanine.
The particular combination of an alkyl ester of a DL-amino acid and an acyl blocked optically active D-amino acid resolving agent, which is derived from the same amino acid from which the alkyl ester is derived, results in the selective precipitation of the corresponding salt of the N-acyl-D-amino acid and the L-amino acid alkyl ester. Thus, when the N-acyl derivative of a D-amino acid is contacted with the idential DL-amino acid alkyl ester, the salt of the N-acyl-D-amino acid and the L-amino acid alkyl ester preferentially crystallizes from solution. The naturally occuring amino acids, e.g. aspartic acid, asparagine, glutamine, glutamic acid, alanine, valine, leucine, isoleucine, serine, threonine, methionine, cysteine, cystine, tyrosine, proline, lysine, aginine and ornithine may be resolved in this manner. Also, similar synthetic amino acids may be resolved in the manner described. It is noted that when an N-acyl-L-amino acid resolving agent is employed, there is obtained, preferentially, the salt comprised of the N-acyl-L-amino acid and the alkyl ester of the D-amino acid.
Typically, N-acetyl-D-phenylalanine is allowed to contact DL-phenylalanine methyl ester in a suitable solvent, e.g. methanol or water, to produce a crystalline salt of N-acetyl-D-phenylalanine and L-phenylalanine methyl ester. That salt is separated from the filtrate and decomposed with aqueous hydrochloric acid to afford N-acetyl-D-phenylalanine as a precipitate and L-phenylalanine methyl ester hydrochloride in solution. After filtering, the solvent in the filtrate is removed to afford the hydrochloride salt of L-phenylalanine methyl ester. Alternatively, the salt of N-acetyl-D-phenylalanine and L-phenylalanine methyl ester is dissolved in aqueous potassium carbonate and extracted with ether. The D-amide remains in the aqueous phase and the L-ester remains in the organic phase. After phase separation, the ethereal solution is acidified with hydrochloric acid-isopropanol to precipitate the hydrochloride salt of L-phenylalanine methyl ester.
It is apparent that the starting materials useful in the instant process may be employed as their equivalent salts without affecting the operability of the process. For example, the hydrochloride salt of DL-phenylalanine methyl ester may be utilized along with the sodium salt of N-acyl-D-phenylalanine.
It is understood that once the D-L salt is obtained, standard chemical techniques can be employed to separate the individual components. Decomposition of the salt with aqueous hydrochloric acid is satisfactory. Alternatively, an aqueous solution of the salt may be contacted with a base such as sodium carbonate, then separated and acidified to yield the desired components. Also, the desired L-phenylalanine alkyl esters may conveniently be separated as salts, e.g. hydrochloride salts, when they are oils in their free state, for ease of handling and storage.
In another embodiment of this invention, the particular by-products of the resolution process are recycled, thereby making the process additionally advantageous. The alkyl ester of D-phenylalanine remaining in solution after the separation of the D-amide-L-ester salt can be racemized to afford the DL-ester starting material. This racemization preferably is accomplished with an alkali metal alkoxide in the corresponding lower alkanol solvent. Illustrative of the alkali metals are lithium, sodium and potassium. The lower alkanols intended contain 1-6 carbon atoms and are illustrated by methanol, ethanol and t-butanol. Typical alkoxide groups contain 1-4 carbon atoms and are illustrated by methoxide, ethoxide, t-butoxide and the like. Thus, for example D-phenylalanine methyl ester is refluxed with sodium methoxide in methanol to afford DL-phenylalanine methyl ester. It is not necessary that the reaction be run at the reflux temperature. However, at lower temperatures the racemization takes place at a slower rate. For example, complete racemization of D-phenylalanine methyl ester takes approximately 2 days at room temperature, whereas it is completed in about 2 1/2 hours at the reflux temperature. Generally, it is desirable to choose an alkoxide group and a lower alkanol corresponding to the alkyl ester being racemized. It is noted that any L-phenylalanine alkyl ester present will be racemized as well as may be recycled to provide starting DL-ester.
It is apparent also that the N-acyl-D-phenylalanine, recovered from the decomposition of the salt of N-acyl-D-phenylalanine and L-phenylalanine alkyl ester, can be recycled to provide starting resolving agent.
Alternatively, but less preferably, the D-phenylalanine alkyl esters can be hydrolyzed and acylated to provide the N-acyl-D-phenylalanine resolving agent. Since large quantities of the N-acyl derivatives are not lost in the process, only a portion of the N-acyl derivatives produced by this alternate process would likely be utilized. Thus, the N-acyl-D-phenylalanines can also be racemized to the DL-derivatives corresponding, they hydrolyzed and esterified to provide additional amounts of DL-phenylalanine alkyl ester.
A further and particularly unobvious advantage of the process is manifested by the unexpected purity of the salt of the D-amide-L-ester obtained when water is utilized as the solvent medium during salt formation. Initial salt obtained from the reaction mixture is of such purity that it need not be recrystallized further and can be decomposed immediately to obtain the desired L-phenylalanine alkyl ester.
Reaction conditions for the practice of the instant invention will be apparent to those skilled in the art of chemical manufacturing procedures. Temperatures, solvents and reaction times are not critical to the instant process and may be chosen according to standard chemical manufacturing techniques. However, polar solvents, e.g. water, lower alkanols such as methanol, ethanol and t-butanol, and equivalent solvents, have been found preferable for D-L salt formation. Generally, salt formation occurs at room temperatures, but is not limited thereto.
It is noted that the general method described herein for the formation of the salts of N-acyl-D-phenylalanines and alkyl esters of L-phenylalanine may be employed to afford the salts of the mirror images. Thus, contacting of an alkyl ester of DL-phenylalanine with an N-acyl-L-phenylalanine affords the salt comprised of N-acyl-L-phenylalanine and the alkyl ester of D-phenylalanine. The salt can be decomposed by usual methods to obtain pure alkyl ester of D-phenylalanine. That material may be hydrolyzed and acylated to provide resolving agent for use in the instant process. Typically, DL-phenylalanine methyl ester is contacted with N-acetyl-L-phenylalanine to afford the salt of D-phenylalanine methyl ester and N-acetyl-L-phenylalanine.
Depending on the availability of starting materials, various other methods of their preparation may be utilized. For example, DL-phenylalanine may be converted into the N-acyl-DL-phenylalanine with an appropriate acylating agent. Then that acylated derivative is contacted with an alkyl ester of L-phenylalanine to afford the salt of the N-acyl-D-phenylalanine and the alkyl ester of L-phenylalanine. Subsequent decomposition of the salt yields pure N-acyl-D-phenylalanine, useful as resolving agent. Alternatively, the alkyl ester of D-phenylalanine may be employed in a similar manner to yield N-acyl-L-phenylalanine, which, as noted hereinbefore, is useful to obtain the alkyl esters of D-phenylalanine from the corresponding DL-compounds. As mentioned previously the D-phenylalanine alkyl esters may be hydrolyzed and acylated to provide N-acyl-D-phenylalanine.
Particular examples further illustrating the present invention follow. They are, however, not intended to limit the invention either in spirit or in scope from that previously described and subsequently claimed. In the examples temperatures are presented in degrees Centigrade (° C) and quantities of materials in parts by weight unless parts by volume is specified.
EXAMPLE 1
N-Acetyl-D-phenylalanine
To a stirred solution of 20.0 parts of D-phenylalanine in 121 parts of water, cooled to about 1°-2°, is added, portionwise, an aqueous 50% sodium hydroxide solution until pH 12 is reached. Then 37 parts of acetic anhydride is added, while continuously adding aqueous 50% sodium hydroxide to keep the pH at about 12 and cooling the solution to keep the temperature at between about 10° to 30°. After about 20 minutes the mixture is acidified to pH 1 with concentrated hydrochloric acid and filtered. The recovered solid is recrystallized from water to afford N-acetyl-D-phenylalanine, melting at about 170°-172°.
EXAMPLE 2
N-Propionyl-D-phenylalanine
By substituting an equivalent quantity of propionic anhydride in the procedure of Example 1, there is produced N-propionyl-D-phenylalanine.
EXAMPLE 3
N-n-Butyryl-D-phenylalanine
Substitution of an equivalent quantity of butyric anhydride in the procedure of Example 1 affords N-n-butyryl-D-phenylalanine.
EXAMPLE 4
N-Acetyl-D-phenylalanine.L-phenylalanine Methyl Ester
10.35 Parts of N-acetyl-D-phenylalanine is dissolved in 40 parts of methanol, then treated with 17.9 parts of DL-phenylalanine methyl ester. A precipitate forms immediately and a additional 60 parts of methanol is added. The mixture then is filtered and the solid remaining is washed with additional methanol and dried. Recrystallization from methanol affords the crystalline salt of N-acetyl-D-phenylalanine and L-phenylalanine methyl ester, melting at about 170°-172° and displaying an [α] D in 0.5% water of about -33.3°.
EXAMPLE 5
N-Acety-D-phenylalanine.L-Phenylalanine Methyl Ester
A solution consisting of 1.8 parts of L-phenylalanine methyl ester dissolved in 12 parts of methanol is treated, at room temperature, with 1.0 part of N-acetyl-D-phenylalanine. The precipitate which forms immediately is recovered by filtration and recrystallized from methanol to afford the crystalline salt of N-acetyl-D-phenylalanine and L-phenylalanine methyl ester, identical to the product obtained in Example 4, melting at about 170°-172°.
EXAMPLE 6
N-Acetyl-D-phenylalanine.L-Phenylalanine Ethyl Ester
Substitution of an equivalent quantity of DL-phenylalanine ethyl ester in the procedure of Example 4 and utilization of ethanol as solvent in place of the methanol described therein affords the salt of N-acetyl-D-phenylalanine and L-phenylalanine ethyl ester.
EXAMPLE 7
N-Propionyl-D-phenylalanine.L-Phenylalanine Methyl Ester
When an equivalent quantity of N-propionyl-D-phenylalanine is substituted in the procedure of Example 4, there is obtained the salt of N-propionyl-D-phenylalanine and L-phenylalanine methyl ester.
EXAMPLE 8
N-Acetyl-D-phenylalanine.L-Phenylalanine Methyl Ester
Utilization of water in place of methanol as the solvent in Example 4 affords the salt of N-acetyl-D-phenylalanine and L-phenylalanine methyl ester.
EXAMPLE 9
Hydrochloride Salt of L-Phenylalanine Methyl Ester
0.5 Part of the salt of N-acetyl-D-phenylalanine and L-phenylalanine methyl ester is dissolved in 5 parts of hot water. Then 0.2 part by volume of concentrated hydrochloric acid is added and the mixture is filtered, thereby collecting the N-acetyl-D-phenylalanine solid and leaving crude L-phenylalanine methyl ester hydrochloride in the filtrate. The filtrate is evaporated to dryness, and the hydrochloride salt of L-phenylalanine methyl ester then is dissolved in water. Sodium carbonate is added, then ether. The ethereal extract is separated and acidified to yield the hydrochloride salt of L-phenylalanine methyl ester, which, upon recrystallization from methanol, exhibits an [α] D in 2% ethanol of about +35.7°.
EXAMPLE 10
Hydrochloride Salt of L-Phenylalanine Methyl Ester
A stirred solution of 2.0 parts of the salt of N-acetyl-D-phenylalanine and L-phenylalanine methyl ester in 20 parts of water is treated with 3.5 parts of potassium carbonate. An aqueous layer and an oily layer form and the mixture is extracted with ether. The aqueous layer, containing N-acetyl-D-phenylalanine, is separated and acidified with hydrochloric acid to yield, after cooling and filtering, N-acetyl-D-phenylalanine. The ethereal layer is dried over anhydrous sodium sulfate, then acidified with a hydrochloric acid-isopropanol mixture. The solid which forms is collected by filtration, then redissolved in methanol. Addition of ether affords crystals of the hydrochloride salt of L-phenylalanine methyl ester, displaying an [α] D in 2% ethanol of about +35°. That product is the same as that obtained in Example 9.
EXAMPLE 11
By substituting equivalent quantities of the products of Examples 6 and 7 in the procedure of Example 10, there is afforded the hydrochloride salt of L-phenylalanine ethyl ester and the hydrochloride salt of L-phenylalanine methyl ester, respectively.
EXAMPLE 12
5.0 Parts of D-phenylalanine methyl ester, dissolved in 80 parts of methanol, is treated, at room temperature, with 0.90 part of sodium methoxide. The mixture is heated rapidly to reflux and maintained at reflux for about 21/21/2 hours. Then the reaction mixture is cooled, acidified to pH 2 with concentrated hydrochloric acid and evaporated to dryness. The remaining crystalline residue is taken up in water, and sodium carbonate is added. 1,2-Dichloroethane is added to form two phases and the mixture is shaken and filtered. The organic layer is separated, washed with saturated sodium chloride solution, dried over anhydrous magnesium sulfate and filtered. The filtrate is acidified with hydrochloric acid, cooled and stripped of solvent. Trituration with ether of the material which remains after solvent removal and subsequent filtration yields DL-phenylalanine methyl ester hydrochloride, melting at about 162°.
EXAMPLE 13
Substitution of an equivalent quantity of D-phenylalanine ethyl ester in the procedure of Example 12 and utilization of sodium ethoxide and ethanol in place of sodium methoxide and methanol therein, affords DL-phenylalanine ethyl ester hydrochloride.
EXAMPLE 14
To 310 parts by volume of an aqueous 0.5N sodium hydroxide solution, heated to about 70°, is added, successively, 17.7 parts of N-acetyl-L-phenylalanine and 33.3 parts of DL-phenylalanine methyl ester hydrochloride. A precipitate forms and upon cooling and filtering, the salt of N-acetyl-L-phenylalanine and D-phenylalanine methyl ester is obtained. Recrystallization from hot water affords the pure salt exhibiting an [α] D in 0.5% water of about +32.2°.
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Treatment of DL-phenylalanine alkyl esters with N-acyl-D-phenylalanines results in the formation of insoluble salts of the L-phenylalanine alkyl esters and N-acyl-D-phenylalanines. The salts are isolated and decomposed to afford the desired L-phenylalanine alkyl esters, which are important starting materials in the preparation of artificial sweetening agents.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/980,826, filed Oct. 18, 2007 and U.S. Provisional Application No. 61/012,605, filed Dec. 10, 2007, which are incorporated by reference as if fully set forth.
FIELD OF INVENTION
This application is related to wireless communications.
BACKGROUND
With advances in wireless technology, 3G networks are enabling network operators to offer users a wider range of more advanced services while achieving greater network capacity through improved spectral efficiency. These services include not only improved voice calls, but multimedia messaging, and broadband wireless data, all in a mobile environment. The Third Generation Partnership Project (3GPP) Long Term Evolution (LTE), for example, may offer downlink peak rates of at least 100 Mbit/s, 50 Mbit/s in the uplink and RAN (Radio Access Network).
As wireless mobile equipment becomes more data centric, increases in required data rates are outpacing improvements in central processing unit (CPU) clock speeds (and power efficiency at the speeds). The 3GPP standards body continues to develop additional features and capabilities to provide these higher data rates. At the same time, users are demanding smaller and more power efficient designs. The modem footprint and power consumption must not grow in proportion with data rates. Accordingly, an extensible architecture is desired for supporting the 3GPP evolution while meeting the user requirements for efficient design.
SUMMARY
A method and apparatus for optimization of a wireless modem are disclosed. A plurality of hardware accelerators are configured to perform data processing functions, wherein the hardware accelerators are parameterized. A processor is configured to selectively activate the plurality of hardware accelerators according to the desired function, and a shared memory is selectively configured for communication between the plurality of hardware accelerators.
BRIEF DESCRIPTION OF THE DRAWINGS
A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings wherein:
FIG. 1 shows a wireless communication system 100 including a plurality of WTRUs 110 , a base station 120 , and an RNC 130 ;
FIG. 1A is a functional block diagram 200 of a WTRU 110 and the base station 120 of the wireless communication system 100 of FIG. 1 ;
FIG. 2 is a block diagram of a modem;
FIG. 3 shows an embodiment of the modem of FIG. 2 ;
FIG. 4 shows the Shared Memory Arbiter (SMA) of FIG. 1 ;
FIG. 5 shows a flow diagram of method of HW acceleration of downlink data;
FIG. 6 shows a flow diagram of a method of HW acceleration in the uplink; and
FIGS. 7A and 7B show a modem partitioned into different power domains to achieve more effective power management and power conservation.
DETAILED DESCRIPTION
When referred to hereafter, the terminology “wireless transmit/receive unit (WTRU)” includes but is not limited to a user equipment (UE), a mobile station, a fixed or mobile subscriber unit, a pager, a cellular telephone, a personal digital assistant (PDA), a computer, or any other type of user device capable of operating in a wireless environment. When referred to hereafter, the terminology “base station” includes but is not limited to a Node-B, a site controller, an access point (AP), or any other type of interfacing device capable of operating in a wireless environment.
FIG. 1 shows a wireless communication system 200 including a plurality of WTRUs 110 , a base station 120 , and an RNC 130 . As shown in FIG. 1 , the WTRUs 110 are in communication with the base station 120 , which is in communication with the RNC 130 . Although three WTRUs 110 , one base station 120 , and one RNC 130 are shown in FIG. 1 , it should be noted that any combination of wireless and wired devices may be included in the wireless communication system 100 . For example, although the RNC 130 is shown in the wireless communication system 100 , the RNC 130 may not be included in an LTE system.
FIG. 1A is a functional block diagram of a WTRU 110 and the base station 120 of the wireless communication system 100 of FIG. 1 . As shown in FIG. 1A , the WTRU 110 is in communication with the base station 120 and both are configured to perform a method for optimizing a modem for high data rate applications.
In addition to the components that may be found in a typical WTRU, the WTRU 110 includes a processor 115 , a receiver 116 , a transmitter 117 , an antenna 118 , a hardware acceleration module 119 , a memory module 121 , and a modem 122 . The processor 115 is configured to perform a method for optimizing a modem for high data rate applications. The receiver 116 and the transmitter 117 are in communication with the processor 115 . The antenna 118 is in communication with both the receiver 116 and the transmitter 117 to facilitate the transmission and reception of wireless data.
In addition to the components that may be found in a typical base station, the base station 120 includes a processor 125 , a receiver 126 , a transmitter 127 , and an antenna 128 . The processor 125 is configured to perform a method for optimizing a modem for high data rate applications. The receiver 126 and the transmitter 127 are in communication with the processor 125 . The antenna 128 is in communication with both the receiver 126 and the transmitter 127 to facilitate the transmission and reception of wireless data.
When referred to hereinafter, the term hardware accelerator 119 may be used to refer to any modules within the hardware accelerator 119 .
When referred to hereinafter, processor 115 may be used to refer to any of the modules within the processor 115 .
FIG. 2 shows a block diagram of a modem 200 including a processor 115 , a shared memory arbiter (SMA) 320 , shared memory (SM) 350 , and a plurality of HW accelerators 119 . The processor 115 may be configured to perform Layer 1 (L1), Layer 2 (L2), and Layer 3 (L3) processing. The HW accelerators 119 may be configured and activated by the processor 115 . The hardware accelerators 119 may be configured to handle modem data (i.e. voice and data traffic), while the processor 115 may be configured to provide control using parameters that control how the modem data passes through the hardware accelerators 119 and not through the processor 115 . Accordingly, as shown in FIG. 2 , modem data primarily passes through the hardware accelerators 119 . The hardware accelerators 119 may further be configured to pass data to other hardware accelerators 119 through the SM 350 . The SMA 320 controls the hardware accelerators' 119 access to the SM 350 . Accordingly modem data may be processed through the hardware accelerators 119 without requiring the modem data to pass through the processor 115 .
Each hardware accelerator 119 or sub-system (multiple hardware accelerators 119 ) may be semi-autonomous, meaning that a start signal may power-up the appropriate hardware accelerators 119 and initiate processing. As a result, processor 115 loading may grow only minimally with increasing data rate. Signal processing functions may also be implemented in the hardware accelerators 119 . Upon completion of a task, clocks and power domains may be turned off. Each of the hardware accelerators 119 may be programmed to signal an indication to other hardware accelerators 119 when they complete a particular task. By allowing each of the hardware accelerators 119 to start other hardware accelerators 119 , the processor 115 may be more autonomous from the hardware accelerators 119 .
FIG. 3 shows one example of the modem of FIG. 2 . The functionality of the processor 115 shown in FIG. 2 may be split up into multiple modules. The processor 115 may comprise an L23 protocol stack module 301 , an L1 manager and scheduler 302 , a Transmission (Tx) Frame software (SW) module 303 , a Tx Chip SW module 304 , a radio interface processor (RIP) and Digital Front End (DFE) SW module 305 , an L1 Debug Agent Module 306 , a Receive (Rx) Frame SW module 307 , an Rx Chip/Rake Manager 308 an Automatic Frequency Control (AFC) SW module 309 , a cell search (CS) module 310 , and an Automatic Gain Control (AGC) SW module 311 . The functionality of the hardware accelerators 119 as shown in FIG. 2 may be further divided among a plurality of hardware accelerators shown in FIG. 3 , the hardware accelerators 119 include a Protocol Engine (PE) 321 , a DRAM Shared Memory Arbiter (DSMA) 322 , a Memory Controller 323 , a Tx Frame HW module 324 , a Tx Chip HW module 325 , a DFE HW module 326 , a timing manager 327 , a sleep timer 328 , an AGC HW module 329 , an indicator channel (ICH) module 330 , a Path Search module 331 , an HS-SCCH/AGCH module 332 , an L1 Feedback Module 333 , a channel estimation enhanced normalized least mean squares (CE-NLMS) module 334 , a Rake module 335 , an Rx Frame HW and MAC-hs module 336 , an AFC HW module 337 , a cell search HW module 338 , and a universal serial interface (USIF) module 339 . The HW accelerators 119 may be configured and activated by the modules of the processor 115 .
The SM 350 may be configured to provide data connectivity between hardware accelerators 119 , to provide configuration of the hardware accelerators 119 via a processor 115 , and as an interface to a host processor. The SM 350 and the SMA 320 may allow efficient extensibility by allowing memory to be shared in support of functions that operate in mutually exclusive states. Buffer space is allocated in the SM 350 . Buffers may provide memory storage for component input and outputs. The SM 350 may be partitioned to provide reuse of buffers for processes that do not run at the same time.
In order to reduce or eliminate traffic data from entering the processor 115 , the HW accelerators 119 may be programmed and scheduled to autonomously process data. The timing manager 327 may be configured to issue start pulses when fine-grained timing is needed. A linked list of control blocks may be configured to de-couple setup and execution of the hardware accelerators 119 . Control of the components may be configured a frame ahead of time, wherein the hardware accelerators 119 may be configured to interrupt the processor 115 upon completion of a function, or at an end of the linked list of control blocks. Upon completion of a task, a hardware accelerator 119 may be configured to trigger operation of another hardware accelerator 119 .
FIG. 4 shows the SMA 320 . As shown in FIG. 4 , the SMA 320 may be configured to communicate with a plurality of other modules including the Tx Frame HW module 324 , the Tx Chip SW module 304 , the CS module 338 , the timing manager 327 , a Layer 2 & 3 CPU 405 , a Layer 1 CPU 406 , a host interface 407 , an Rx AGC module 408 , an Rx Transceiver 2 module 409 , an Rx Comp 2 module 410 , an Rx Transceiver 1 module 411 , an Rx Comp 1 module 412 , an Rx Chip 413 , a CAP/DAP memory 404 , a WAP memory 403 , an internal memory 402 , and an external memory 401 . The SMA 320 may be configured to control access to memory shared by any hardware accelerator 119 , the processor 115 , and a host interface. The SMA 320 may comprise address registers and sequencing logic. The SMA 320 may be configured to allow the hardware accelerators 119 and the processor 115 to efficiently share access to available memory 350 . The external memory 401 may be added to extend the amount of available SDRAM.
The SM 350 may comprise the WAP memory 403 and the CAP/DAP memory 404 . The SM 350 may be configured to store pointers that are written to the SMA 320 . The CAP/DAP memory 404 may be configured to store pointers for SMA channels that are used to read control information. The CAP/DAP memory 404 may further be configured to store pointers for SMA channels that are used to read/write data.
The timing manager 327 may be configured to maintain system time and to create pulses based on specific frame/slot/chip times. The pulses may be used to start modules and/or create interrupts. The timing manager 327 may also include controller, (e.g. ARM interrupt controllers). The signal output by the timing manager 327 may be used by the Layer 1 manager and scheduler 203 to synchronize the operation of all other modules.
The sleep timer 328 may be configured to provide the countdown and mechanism to power the modules of the modem 122 (e.g. when the L1 CPU 406 enters a sleep state). The sleep timer 328 may be configured to utilize a low-power, low-accuracy 32.768 kHz real-time clock (RTC) to count during sleep. Higher precision may be obtained by calibrating the RTC against a more accurate microcontroller when the 3G L1 CPU 406 is awake in-between sleep cycles.
Referring to FIG. 4 , the L1 CPU 406 may be configured to enter sleep states if a cell search fails after initialization, in frequency division duplexing (FDD) discontinuous reception (DRX) mode, or in GSM mode.
Referring back to FIG. 3 , the Tx Frame HW module 324 and the Tx Frame SW 303 may collectively be referred to as a Tx Frame component. The Tx Frame HW module 324 may be configured to perform symbol rate processing on transport and composite channels for FDD uplink (E-DCH and DCH). The Tx Frame HW module 324 may accept data in transport blocks from Layer 2/3 and map this data to physical channels. Data is sent to the Tx Chip HW module 325 via the SMA 320 .
The Tx Chip SW module 304 and the Tx Chip HW module 325 may be collectively referred to as the Tx Chip component. The Tx Chip HW module 325 may be configured to process coded binary data from Tx Frame HW module 324 along with control channel information to properly format data for uplink transmission through the Radio Interface. The Tx Chip component may be configured to handle transmit power control and transmit timing functions. The Tx Chip component may also be configured to processes data on a Physical Random Access Channel (PRACH), Dedicated Physical Data Channel (DPDCH)/Dedicated Physical Control Channel (DPCCH), High-Speed DPCCH (HS-DPCCH), and Enhanced DPCCH (E-DPDCH)/DPCCH. The Tx Chip component may be further configured to transmit data to the DFE HW module 326 .
The CS HW module 338 and the CS Search SW 310 may be collectively referred to as a CS component. The CS HW module 338 may be configured to perform initial cell selection (ICS) procedure. The ICS procedure includes detecting the strongest cell when no cell identifier or timing information is known, and determining whether or not Space Time Transmit Diversity (STTD) is utilized on that cell. The CS HW module 338 may be configured to provide synchronization information for the found cell. The CS HW module 338 may further be configured to perform neighbor or serving cell measurements, which comprises detection, identification, and measurement of listed and unlisted intra-frequency neighbor cells and listed inter-frequency neighbor cells, and measurement of the serving cell. Measurements may include Common Pilot Channel (CPICH) Received Signal Code Power (RSCP); CPICH received pilot energy to total spectral density ratio (Ec/Io), and determination of the first significant path for each cell. As part of a CPICH Ec/Io determination procedure, the CS HW module 338 may be configured to measure a Received Signal Strength Indicator (RSSI) on each frequency. The CS HW module 338 may further be configured to perform a targeted cell search (TCS) procedure. The TCS procedure may comprise detection and synchronization to a particular cell (used for handover to cells that have not recently been measured). The CS HW module 338 may further be configured to perform a Public Land Mobile Network (PLMN) ID search on Universal Mobile Telecommunications System (UMTS) cell in a UMTS only mode. The CS HW module 338 may further be configured to perform GSM Inter-RAT Measurements and PLMN ID search in UMTS neighbors.
The AGC SW 311 and the AGC HW module 329 may be collectively referred to as an AGC component. The AGC HW module 329 may be configured to control the signal power level seen at an Analog to Digital Converter (ADC) input, which may be coupled to the DFE HW module 326 . Alternatively the AGC component may be configured to adhere to the DigRF standard.
The AFC HW module 337 and the AFC SW 309 may be collectively referred to as the AFC component. The AFC HW module 337 may be configured to provide an estimated carrier frequency offset error signal, between the base station 120 and the WTRU 110 , to a WTRU 110 radio interface.
The AGC HW module 329 and the AGC SW module 311 collectively may be referred to as the AGC component. The AGC component may be configured to support both a primary receive path and a diversity receive path. The AFC HW module 337 may be configured to estimate and cancel the carrier frequency offset on the received signal. The AFC HW module 337 operates only on a main radio temperature controlled crystal oscillator (a single clock is distributed to both radios).
The RIP and DFE SW module 305 and the DFE HW module 326 may collectively be referred to as the radio interface component. The radio interface component may be configured to connect 2G/3G radios to the modem front end. The radio interface component may be configured to provide parallel transmit and receive I/Q data paths over which data is transferred between the modem and the radio. Additional control interfaces may initialize the radios and transfer control information between the radio and the modem. The radio interface component may be configured for communication via three separate radio interfaces including a 3G main radio interface, a 3G diversity radio interface, and a 2G radio interface. The radio interface component may comprise a three-wire interface for programming and enabling the receiver for each radio interface. The three-wire interface (clock, data, and enable) is a bi-directional synchronous serial bus which provides the capability to access multiple devices using an address/data protocol. This three-wire interface provides separate enables for each radio. The radio interface component may further be configured to provide the capability of enabling a second radio (via the 3-wire interface) to provide a diversity path (or multi-path) in 3G mode on the receive side in order to increase performance with HSDPA.
The RIP 305 may be programmable and is compatible with a wide variety of radios. The RIP 305 may be configured to perform data transfers and logic operations and controls the three-wire interface to any 3G radios. The RIP 305 may also provide controls on the radio interface for frequency selection and gain control, transmit power control (TPC) and power amp bias control, and for switching the antenna at the radio output between 3G and GSM mode.
The DFE HW module 326 may comprise a receive DFE (Rx DFE) and a transmit paths DFE (Tx DFE). The DFE HW module 326 may be configured to filter and correct 3G digital signals on the Rx DFE and the Tx DFE. The modem 122 may include independent DFE chains for both primary and diversity radio receivers. The Rx DFE may be configured to perform for low-pass filtering and decimating over-sampled and noise-shaped signals from an analog front end (AFE), removing DC offsets, and performing final band-selection and pulse shaping. The Tx DFE may be configured to perform pulse shaping, DC offset and IQ-amplitude correction, up sampling, and noise shaping before applying the signal to the AFE.
The Rx Chip/Rake Manager 308 may be configured to perform demodulation and channel estimation. The RX Chip/Rake Manager 308 may further be configured to decode transport channel control data, (transport format combination indicator (TFCI), HS-SCCH), indicator channels, (e.g. acquisition indicator channel (AICH), physical indicator channel (PICH), ICH), and High speed uplink packet access (HSUPA) Grant channels (E-AGCH, E-RGCH, E-HICH), and to compute feedback bits (feedback indicator (FBI), transmission power command (TPC), channel quality indicator (CQI)) to be transmitted on the uplink. The demodulated data may be provided to Rx Frame HW module 336 through SMA 320 memory. The Rx Chip/Rake Manager 308 may be configured to control hardware accelerators 330 - 335 . The Rx Chip/Rake Manager 308 may be configured to allocate and de-allocate fingers of the Rake. The Rx Chip/Rake Manager 308 may allocate Rake fingers to a cell for a path at a particular location (time delay) when the Path Searcher 331 reports the presence of a high-quality path that does not already have a Rake finger allocated to that path. Once initiated, the Rake module 335 may autonomously track the path as its location changes over time, periodically reporting the updated location and signal quality of the path to the Rx Chip/Rake Manager 308 . The Rx Chip/Rake Manager 308 may de-allocate allocated Rake fingers when the signal quality reported by the Rake finger sufficiently degrades (however, the Rx Chip/Rake Manager 308 may not drop fingers that are experiencing only relatively short fades) or are reallocated to stronger paths (and possibly to other cells). The Rx Chip/Rake Manager 308 may also be configured to detect the case of finger collision and either drop one of the two colliding fingers or organizes colliding fingers into clusters.
The Rake module 335 may be configured to demodulate data from the physical channels for dedicated, common, and shared type channels. The RX Chip/Rake manager 308 may comprise an alignment buffer for alignment of paths from the serving cell as well as from other Node-Bs in an active set and neighbor cells for measurement purposes. The Rake module 335 may perform de-scrambling and detection for multiple channelization codes.
The CE-NLMS equalizer 334 may be configured to mitigate multipath interference that may be introduced by the channel. The CE-NLMS equalizer 334 may comprise an adaptive finite impulse response (FIR) filter where the adaptation process is based on a CE-NLMS algorithm. The CE-NLMS algorithm is based on the standard LMS algorithm with a modification that is designed to combat gradient noise amplification when the magnitude of the input vector is large. The CE-NLMS equalizer 334 may be configured to support WTRU receiver diversity and Node-B transmit diversity. The CE-NLMS equalizer 334 may be configured to operate on the HS-DPDCH and HS-SCCH channels.
The ICH module 330 may be configured to detect the E-RGCH, E-HICH, AICH, PICH, and MICH channels. For the E-RGCH, the radio links in the E-DCH serving radio link set may be soft combined. For the E-HICH, for each Radio Link Set (RLS), all the radio links may be soft combined. The ICH module 330 may comprise shared hardware to support detection of these channels.
The Path Searcher 331 may be configured to detect path (multipath) locations and signal the path locations together with metrics indicating the normalized average magnitude to the Rx Chip/Rake Manager 308 . The Rx Chip/Rake Manager 308 may be configured to receive the path location information and assign Rake fingers to new paths.
The HS-SCCH/AGCH decoder 332 may be configured to perform decoding of the HS-SCCH channel. The HS-SCCH/AGCH decoder 332 may be reused for R6 upgrades to receive input from the Rake module 335 and demodulate the HSUPA DL E-AGCH channel.
The L1 Feedback module 333 may be configured to generate information that a Node-B may require from uplink channels to achieve certain link adaptation. For example, the information may comprise a downlink power control command, which is represented in TPC bits of uplink DPCCH; information for antenna weights, which is represented in the D field of FBI bits of an uplink DPCCH, that may be applied at the Node-B antennas when closed loop transmit diversity is applied; and channel quality, which may be represented in CQI bits of the uplink HS-DPCCH channel. In case of the closed loop transmit diversity (CLTD) mode, the L1 Feedback module 333 may also be configured to generate antenna weights that may be used for combining complex gains estimated by the Rake finger locations.
The Rx Frame HW module 336 and the Rx Frame SW 307 may be referred to collectively as the Rx Frame component. The Rx Frame HW module 336 may be configured to decode and de-multiplex the Coded Composite Transport Channel (CCTrCH), and process transport channels including Dedicated Channel (DCH), Broadcast Channel (BCH), Forward Access Channel (FACH), and the Paging Channel (PCH). The Rx Frame HW module 336 contains a high speed path (for HSDPA) and a regular speed path for DCH channels. The high speed path may be reused to support MBMS channels.
The Layer 1 Manager and Scheduler 302 may comprise a management and schedule entity. The management entity of the Layer 1 Manager and Scheduler 302 may be configured to perform control and status messaging to/from the higher layers (L2/3), and to indicate data availability, (e.g. data available in the SMA 320 ). The management entity may also comprise a layer 1 state machine. The scheduling entity of the Layer 1 Manager and Scheduler 302 may be configured to initiate the Layer 1 module functionality at the appropriate time and rate (e.g. slot rate scheduling, frame rate scheduling, etc.). The scheduling entity may also be configured to handle interrupts from the Layer 1 hardware and evaluate the cause of the interrupt to determine a next action. The Layer 1 Manager and Scheduler 302 may further be configured to perform power management of the Layer 1 subsystem by deciding which power islands may be enabled in which state, as will be discussed in greater detail hereafter. Power management may be used to reduce power in both active data and sleep states.
The PE 321 and DSMA 322 subsystem may be configured to provide Layer 2/3 hardware acceleration for modem transmit and receive operations. In one embodiment, the modem 122 may include three PEs 321 , each comprising a Dedicated Programmable Controller (DPC) and a specialized data path, but quantity may be scaled to support other data rates. The DPC may be programmable to operate on multiple channel types (e.g., HSDPA, HSUPA, DCH, and MBMS) and dynamically switch between processing of each type. The PE 321 data path may interface with the SMA 320 through an SMA Interface node, and the SDRAM 340 through a DSMA interface node. The DSMA 322 may be configured to provide access for multiple modules within the modem to the external SDRAM subsystem 340 . Each PE 321 may be configured to perform data movement, including the ability to gather data from various locations, perform bit alignment, and merge to a destination. Each PE 321 may also perform header interpretation, through the use of stream extract functionality. Each PE 321 may also perform header generation, through the use of cipher insert functionality. Each PE 321 may also perform cipher/de-cipher processing during data movement (when the ciphering engine option is enabled). Each PE 321 may also move data from SMA 320 to SDRAM 340 in downlink processing and move data from SDRAM 340 to SMA 320 in uplink processing
The Layer 1 Debug Agent 306 may be configured to provide a serial interface (USIF) 339 to an external processor. The processor 115 may transmit diagnostic data through the USIF module 339 .
The Layer 2/3 Protocol Stack module 301 may be configured to perform Radio Resource Control, Medium Access Control, Radio Link control, and Packet Data Convergence Protocol (PDCP) procedures. The Layer 2/3 Protocol Stack module 301 may also be configured to perform Non-Access Stratum procedures.
The Memory Controller 323 may be configured to connect on-chip controller cores, e.g., host processor, to a wide variety of external resources such as memories and peripherals, and allow flexible programming of the access parameters. The Memory Controller 323 may provide an Intel-style peripheral/device support and multiplexed access on the same bus. A plurality of memory devices may be connected to a host processor via one memory controller instance of an external bus unit.
FIG. 5 shows data flow for downlink data. Rx chip data is received in subframes or frames. The subframes or frames are demodulated into soft symbols and sent to the SMA, The SMA forwards the data to the Rx composite module, wherein the composite channels are then decomposed, de-ratematching, and de-interleaving are performed. The decomposed composite channels are then forwarded to the SMA. The SMA then forwards the data to the PE wherein the signal is then decoded, and CRC check is performed. The data may then be deciphered (if ciphering is enabled). The Headers are then stripped and PDU data is shifted from SMA to SDRAM. The PE then receives the data again and reorders and concatenates the data segments. If Point-to-Point Protocol (PPP) is being used, the data may be passed through a PPP Assist block, the PPP block may be configured to provide hardware support for some of the low-level functions required for PPP. The function of the PPP block may include byte stuffing, etc. If a “per bye” IO is needed, the signal may be passed through an Service Information Octet (SIO) assist module. The SIO assist module may be configured to handle low level interface between an application and the modem. In many cases this means that individual bytes must be manipulated. For example, many applications want to view the modem as though it is a Universal Asynchronous Receiver and Transmitter (UART). The SIO assist module may provide byte-to-word (word-to-byte) assist, monitor for access terminal command escape sequences, handle low level interface (i.e. USB) details, etc. These simple hardware assist functions may reduce the load on the main control processor.
FIG. 6 shows data flow for uplink data. Transport block sets (resident in SMA) are partitioned (when necessary). The Tx Frame component may attach CRCs, encode data, perform rate matching and interleave the signal. The resulting channel coded data is placed back into the SMA 320 (each radio frame or subframe). The Tx Chip component pulls encoded data from the SMA 320 , applies the appropriate scrambling code, spreads the data, etc. with the resulting data being streamed to the RF block (via the DFE HW module 326 ). As noted above, a PPP assist module and an SIO assist module may also be used in this procedure.
FIGS. 7A and 7B show a modem partitioned into different power domains to achieve more effective power management and power conservation. The modem 122 may be partitioned into discrete power domains called power islands. The partitioning may be based on functionality. FIGS. 7A and 7B include six power domains including a Left ARM island 701 , a Base Island 702 , an R4 Chip Island 703 , an R4 Frame island 704 , an HSPA Island 705 , and a Stand-By Domain 706 . While six power domains are shown, more or less power domains may be used based on the embodiment. The processor 115 may be configured to turn on each power domain only when its associated functionality is desired.
Referring to the power islands of FIGS. 7A and 7B , power management may be performed based on the operating mode of the modem. In a sleep mode, all power domains can be shut off during periods when no functionality is desired. The Sleep Timer 328 , which runs off of a low-frequency crystal, may remain continuously powered. The processor 115 may be configured to program when the Sleep Timer 328 will turn off the other power domains and it may program the length of time the Sleep Timer 328 may wait before turning the power domains back on (wake-up). At each wake-up event, the Timing Manager 327 may resynchronize any timing manager counters. If no activity is required, sleep can be re-initiated. In one embodiment, the memories may remain powered on in low retention modes during sleep mode.
In Deep Sleep Mode, during long periods inactivity, (where synchronization of the timing manager 327 counter is not required), the modem 122 may be configured to remain a reset state. This may be performed by asserting a reset pin. During Deep Sleep mode all power islands may be powered off. A Wake-up procedure is not activated until the reset pin is de-asserted. After a reset, the modem 122 may be re-booted from an image that is already loaded in the processor's 115 TCM memories. Thus avoiding the need for a complete re-boot.
For Active Mode/Coarse Clock Gating, the hardware accelerators 119 may be partitioned into discrete clock domains. Each discrete clock domain may be enabled/disabled by the processor 115 , a hardware accelerator 119 , or both. Each discrete clock domain may be turned on only when its associated functionality is desired. Hardware accelerators may autonomously gate their clocks (i.e. turn off) at completion of their scheduled process.
In another embodiment, in order to reduce the hardware, various components that are commonly used in a UMTS modem may be shared or reused during various modem operating modes. The components that are shared may include, for example, a High Speed-Shared Control Channel (HS-SCCH) decoder for HS-SCCH decoding and Enhanced Dedicated Channel (E-DCH) Absolute Grant Channel (E-AGCH) decoding; a Rake Annex which handles the E-DCH HARQ Acknowledgement Indicator Channel (E-HICH), E-DCH Relative Grant Channel (E-RGCH) and E-AGCH and Multimedia Broadcast Multicast Service (MBMS); a Low Speed Frame Processing which handles R4 and MBMS; High Speed Frame Processing for High Speed Downlink Packet Access (HSDPA) and MBMS; an IR Buffer for HSDPA and MBMS; a Protocol Engine for HSDPA/High Speed Uplink Packet Access (HSUPA)/DCH/MBMS; L1 Feedback (Continuous Quality Improvement (CQI) and Transmit Power Control (TPC) generation) (Common Signal to Interference Ratio (SIR) estimator), and/or ICH (MICH/PICH/AICH).
Although features and elements are described above in particular combinations, each feature or element can be used alone without the other features and elements or in various combinations with or without other features and elements. The methods or flow charts provided herein may be implemented in a computer program, software, or firmware incorporated in a computer-readable storage medium for execution by a general purpose computer or a processor. Examples of computer-readable storage mediums include a read only memory (ROM), a random access memory (RAM), a register, cache memory, semiconductor memory devices, magnetic media such as internal hard disks and removable disks, magneto-optical media, and optical media such as CD-ROM disks, and digital versatile disks (DVDs).
Suitable processors include, by way of example, a general purpose processor, a special purpose processor, a conventional processor, a digital signal processor (DSP), a plurality of microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs) circuits, any other type of integrated circuit (IC), and/or a state machine.
A processor in association with software may be used to implement a radio frequency transceiver for use in a wireless transmit receive unit (WTRU), user equipment (UE), terminal, base station, radio network controller (RNC), or any host computer. The WTRU may be used in conjunction with modules, implemented in hardware and/or software, such as a camera, a video camera module, a videophone, a speakerphone, a vibration device, a speaker, a microphone, a television transceiver, a hands free headset, a keyboard, a Bluetooth® module, a frequency modulated (FM) radio unit, a liquid crystal display (LCD) display unit, an organic light-emitting diode (OLED) display unit, a digital music player, a media player, a video game player module, an Internet browser, and/or any wireless local area network (WLAN) or Ultra Wide Band (UWB) module.
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A method and apparatus for optimization of a modem for high data rate applications comprise a plurality of hardware accelerators which are configured to perform data processing functions, wherein the hardware accelerators are parameterized, a processor is configured to selectively activate accelerators according to the desired function to conserve power requirements and a shared memory configured for communication between the plurality of hardware accelerators.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention involves a process for manufacture of a triboelectrically charged nonwoven material and its application.
[0003] 2. Description of Related Art
[0004] Such filter media are composed of a fiber blend comprising at least two different fiber polymers, which are so different in the electro-negativity of their surface that they are provided with electrostatic charges during web manufacture through carding and through the subsequent bonding by means of a mechanical needle process. Such media have already been described in documents EP 0 246 811 and EP 0 674 933 and are widely used as so-called “triboelectrically charged electret filters” for aerosol filtration purposes.
[0005] In order to produce filter media on the basis of these processes, the fiber finish must be washed off the fibers prior to carding, and all the antistatically active constituents as wall as auxiliary agents, which normally ensure a good workability of the fibers on carding machines, must be removed.
[0006] However, this entails certain drawbacks like a significantly poorer workability of the washed fiber blend compared with standard fibers coated with fiber finish, and it has been impossible so far to produce “triboelectrically charged electret filters” on the basis of fine fibers (mean fiber titer <1.7 dtex).
[0007] Problems arise particularly when the web is manufactured in accordance with document EP 0 246 811 using a carding engine. A comb, permitting to separate the web from the card and to transfer it on to a conveyor, is used as a card doffer system of the card cylinder. Although strong electrical charges are repeatedly released on the card doffer as a result of the combing mechanism, thus resulting in frequent failures of the fleece stacker plate, this technology has prevailed over the usual roll doffer system.
[0008] Web bonding has been performed by mechanical needling on the basis of the processes described so far. On webs exhibiting a higher mass per unit area, proper bonding is achieved by mechanical fiber interlacing, even if the noodles leave unwanted channels, thus reducing the filtering efficiency of the nonwoven material.
[0009] With webs featuring a low mass per unit area, the needling technology is unable, however, to achieve proper bonding properties. If the mass per unit area falls below 100 g/m 2 , the thin web will offer the needles only a weak resistance, and it will therefore be difficult to interface the fibers in such a way that they trigger a sufficiently high force flow of the fibers.
[0010] This is why the needling technology process can produce light “triboelectrically charged electret filters” (mass per unit area <50 g/m 2 only if it is reinforced by a carrier which will offer a sufficient resistance during the needling process of the loose web fibers.
[0011] Carrier materials are usually lightweight fabrics, scrims and nonwovens (preferably spunbonded nonwovens). Although these media only provide a negligible contribution to the filtration of fine aerosols, they are primarily used to establish a connection between the web and the carrier, and to meet the minimum requirements in terms of tensile strength for this nonwoven material.
[0012] The disadvantages inherent to the use of carriers are the costs involved as well as a poorer porosity of the filter media.
[0013] Even if lightweight webs can sufficiently be bonded by using a carrier material on the basis of the processes described here, the regularity of the web structure (fiber distribution) remains unsatisfactory. When using standard fiber blends of 2 to 3 dtex and applying cross-laying technology, the web already presents an open and uneven aspect as a result of the coarse fibers and matting technology applied because cross-laying technology causes the web to be deposited with a V-shape on to the feeding device leading to the bonding unit, and creates therefore corresponding nonhomogeneity inside the fleece. Moreover, the irregularities are intensified by the mechanical needling process, as the needles cause entire sections of the web to be shifted, thus forming larger perforations.
[0014] However, an irregular web structure is inappropriate for filter applications because an uneven fiber distribution or even perforations strongly affect the filtering efficiency.
[0015] The low density of lightweight triboelectrically charged nonwovens appeared to be a further drawback. In connection with heavy needlefelts, a density of 0.25 g/cm 3 can be achieved only by means of mechanical needling. However, this value is strongly reduced if webs of less than 10 m/m 2 are bonded by means of needle technological means. In this case, the fibers will form large loops on both surfaces and produce voluminous nonwovens with a density of 0.03-0.07 g/cm 3 .
[0016] The low density of lightweight triboelectrically charged needlefelts poses no problems as long as they are used in a plane shape. Should they however be arranged inside filter components, a maximum of filtration area will have to be efficiently accommodated within a limited space. In such cases, voluminous media are at a serious disadvantage as compared with thinner products.
SUMMARY OF THE INVENTION
[0017] It is an object of the invention to provide a process for the manufacture of lightweight triboelectrically charged nonwovens and their applications.
[0018] These and other objects of the invention are achieved by drying a fiber blend consisting of polyacrylnitrile fibers with a titer of ≦1.7 dtex and of polyolefine fibers with a titer of ≦1.7 dtex, freed from lubricating and antistatic agents, down to a moisture content of <1% by weight, and by carding it into a triboelectrically charged web featuring a mass per unit area of 15-80 g/m 2 on a longitudinal or randomizing card. In this case, the web is taken off by two simultaneously running rolls and a transfer roll, thus causing the web to be deposited in machine direction on to a conveyor, and the bonding procedure takes place directly inside a bonding unit, the unbonded web being forwarded via 1 to 3 points of transfer only.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The use of a longitudinal or randomizing card and the laying of the web in carding direction make it possible to prevent the fleece from being distorted in the cross lapper and the weight from fluctuating as a result of the V-shaped depositing plate.
[0020] The usual systems incorporating a comb or a doffer roll exhibiting a small diameter are not selected for separating the web from the carding engine, but a roll doffer system equipped with two simultaneously running rolls featuring a larger diameter (>200 mm), the first one acting as a compacting roll and the second one as a doffer roll, plus a fluted transfer roll. It is surprising to observe that this doffer system made it possible to card finely titered fiber blends with a high fleece regularity as well, and to place them on to the depositing belt.
[0021] In order to prevent the carded web from being elongated in machine direction after being laid down on the conveyor belt, it is necessary to opt for a short distance between the card and the bonding unit, and there must be only a minimum number of points of transfer between the card and the bonding unit. Ideally, a continuous conveyor belt should guide the web directly from the card to the bonding unit.
[0022] The best results are attained through bonding operations based on a water-jet needling process making it possible to bond lightweight and finely titered triboelectrically charged webs properly, without affecting significantly the structure of the web.
[0023] Benefits are also provided, as an alternative, by grid-shaped thermal bonding of the web by means of an ultrasonic calendering machine or by using heated calender rolls.
[0024] The bonding processes, water-jet needling procedures and thermal grid-shaped bonding operations involved in the present invention provide not only the benefit of preventing the destruction or perforation of the web as a result of the bonding process, but also the advantage of producing a more compacted nonwoven material.
[0025] Nonwovens manufactured in this way are thinner than equivalent mechanically needled products with the same mass per area unit, and they can therefore be mounted easily into filter components (in a pleated form, for example).
[0026] With regard to the grid-shaped thermal bonding process, preference is given to processes which will lead to a minimum compacting as well as minimum thermal stresses of the web. Grid-shaped bonding involving the ultrasonic calender engine is particularly suited for this purpose, but other types of grid-shaped bonding processes may be applied by means of heated calender rolls. In order to achieve the highest possible porosity, a bonding area ranging from 6% to 30% should be selected for the nonwoven to feature a minimum strength of 4 N for a 50 mm wide tearing strip, so as to meet the requirements involved in handling and use.
[0027] As a rule, it is not advisable for any type of bonding to meet the stringent strength and rigidity requirements by increasing the mass per area unit or the bonding area of the triboelectrical nonwoven material.
[0028] Greater benefits are brought by the use of blends incorporating polypropylene and polyethylene fibers or core sheath fibers as polyolefine fibers, the constituents with a lower melting point acting as binding fibers. Higher strength values are achieved through the use of fibers acting as binding fibers.
[0029] Greater benefits are also provided when laminating the triboelectrically charged nonwoven produced by the present invention together with other fabrics (like grid structures, fabrics, papers, nonwovens, etc.) triggering reinforcing effects.
[0030] One advantage of the triboelectrically charged nonwoven based on the present invention is the manufacture of a multilayer filter medium, the triboelectrically charged nonwoven being preceded by a prefiltering layer made of spunbonded or drylaid nonwoven material on the primary-air side, and followed by a fine-filter layer made of a microfiber fleece and/or filter paper on the clean-air side.
[0031] The arrangement of a highly porous filter layer at primary-air end makes it possible to prevent the layer made of triboelectrically charged fibers from being clogged at an early stage, and to extend the service life of the filter medium, which is manufactured with the triboelectrically charged nonwoven based on the present invention.
[0032] The nonwovens produced on the basis of this invention bring particularly valuable advantages in applications calling for a high filter efficiency within a limited space for installation of the filter component. Filter cassettes or cartridges incorporating zigzag-shaped pleated filter media are manufactured for small-size ambient-air purification appliances, such as car interior filters or engine intake-air filters, which provide filter-related advantages when using the lightweight triboelectrically charged microfiber nonwovens. Such nonwovens are laminated together with a reinforcing nonwoven, e.g. a plastic grid or a paper, to provide them with an appropriate rigidity for pleating purposes.
[0033] The nonwovens based on the present invention ran also be successfully used as filter media for vacuum-cleaner bags. For such applications, they are produced as a laminated material together with filter papers, spunbonded nonwovens and/or microfiber nonwovens. The use of triboelectrically charged nonwovens as vacuum-cleaner bags provides the following benefits.
[0034] As highly efficient electret filters, they enhance significantly the filtering performance of customary filter media (especially filter papers). If triboelectrically charged nonwovens are arranged upstream of the paper layer in flow direction, they are also in a position to protect the paper layer against fine dust and, therefore, to improve the constancy of the vacuum-cleaner's suction performance. As laminated materials with papers, they can be pleated easily thanks to their low thickness, and processed into filter bags by means of inexpensive self-opening bag machinery.
[0035] Preferred embodiments of the invention are described in the following Examples 1 to 3:
EXAMPLE 1
[0036] A blend consisting of 60% of polyolefine bi-component fibers featuring a fiber fineness of 1.0 dtex and a staple length of 38 mm and 40% of polyacrylnitrile fibers of 40 mm/1.3 dtex fibers is formed; the fiber oiling and lubricating agents are then washed off the blend, and the fibers are dried again down to a residual moisture of <1 percent. A web featuring a mass per area unit of approx. 50 g/m 2 is formed by carding the fiber blend on a randomizing card and laid on to a takeover belt leading directly to the calender gap of a thermally heated calender, where the fleece is partially bonded using a punctiform engraving pattern (welded area of 14%). This filter medium exhibits a close distribution of the pores and, therefore, a good filter efficiency at a low mass per area unit. The mechanical strength values of the nonwoven are 10 N/50 mm (tearing strip) in machine direction and are sufficient for handling and use.
EXAMPLE 2
[0037] A blend consisting of 60% of polypropylene fibers of 1.7/40 mm, and 40% of polyacrylnitrile fibers of 1.7 dtex and 40 mm is formed; the fiber oiling and lubricating agents are then washed off the blend, and the fibers are dried again down to a residual moisture of <1 percent. A web of approx. 50 g/m 2 is formed out of this fiber blend on a randomizing card, laid on to a takeover belt, and both layers are then directed into the calender gap of a thermally heated calender, following the introduction of an extruded polypropylene grid having a weight of 11.5 g/m 2 , where the fleece is partially bonded using a punctiform engraving pattern and laminated, at the same time, with the polypropylene grid. The finished laminated material exhibits a uniform web structure with a mass per area unit of 60 g/m 2 .
EXAMPLE 3
[0038] A web with a weight of approx. 35 g/m 2 is produced on the basis of the manufacturing process specified in Example 2, brought together with an extruded polypropylene grid featuring a weight of 11.5 g/m 2 , thus producing after completion of the bonding process a nonwoven laminated material with a mass per area unit of 46 g/m 2 . The latter is equally characterized by a good fiber distribution.
COMPARATIVE EXAMPLE
[0039] The comparative example is based on a blend made of 60% of polyolefine bi-component fibers of 1.7 dtex, 40 mm, and 40% of polyacrylnitrile fibers of 1.7 dtex, 40 mm, in accordance with the production process traditionally applied so far. The fiber blend is mixed, washed and dried, as specified in Example 1. The fiber is then carded on a carding engine, the fleece thus formed is taken off the drum by means of a comb and brought over to a cross lapper which, in turn, lays the web down on a belt. A polyester spunbonded nonwoven with a mass per area unit of 30 g/m 2 is added, upstream of the needle loom, to the fleece layer featuring a weight of 40 g/m 2 . Mechanical needling of both layers produces a nonwoven material with a mass per area unit of 70 g/m 2 , which presents adequate mechanical strength values. The pattern shows a foggy and irregular web structure.
[0040] The technical values applying to these examples as well as a further comparative sample customary in trade are summed up in Table 1.
TABLE 1 Mass per Pattern area Degree of Web Qty to be unit Thickness Air permeability permeability Quotient structure measured g/m 2 Mm l/m 2 % L:(D NaCl D) index Example 1 53 0.55 1800 5.2 629 — Example 2 60 0.70 2150 10.4 294 3.2 Example 3 46 0.55 2560 12.5 373 4.9 Comparative 70 1.20 2900 15.0 160 9.4 example 1 Comparative 40 0.56 4600 45.0 182 — example 2 (customary in trade)
Testing methods
[0041] Thickness Area to be measured 10 cm 2 , measuring pressure 12.5 cN/cm 2 , loading time 1 sec.
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A process for the manufacture of a triboelectrically charged nonwoven, wherein a fiber blend made of polyacrylnitrile fibers with a titer of ≦1.7 dtex and of polyolefine fibers with a titer of ≦1.7 dtex is freed from lubricating agents and antistatic agents by washing, is dried down to a moisture content of <1% by weight and is carded on a longitudinal or randomizing card into a triboelectrically charged web with a mass per area unit of 15-80 g/m 2 . This web is taken off by two simultaneously running rolls and a transfer roll, so that the web is laid on to a conveyor in machine direction, and bonded directly inside a bonding set, the unbonded web being forwarded via 1 to 3 points of transfer only.
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RELATION TO OTHER APPLICATIONS
This application is a continuation-in-part of application Ser. No. 08/390,052, filed Feb. 17, 1995 now U.S. Pat. No. 5,555,540, entitled ASIC BUS STRUCTURE, assigned to the assignee of this application.
FIELD OF THE INVENTION
This invention relates to bus structures that couple digital signals within an integrated circuit, and more specifically to multidimensional bus structures that avoid contention damage, large current handling metal bus traces, and testing difficulties associated with prior art tristate buffer modules.
BACKGROUND OF THE INVENTION
In fabricating large application specific integrated circuits ("ASICs"), it is common practice to design the ASIC as a series of sub-sections whose nodes are interconnected with wide buses. If interconnecting requires, say 16 bits, the integrated circuit ("IC") chip may contain sixteen 1-bit wide buses, with enabling or arbitration signals determining the source of the bit coupled to the one-bit bus. The buses are low resistivity metal traces, sized to accommodate the current flow associated with the signals carried across the bus.
FIG. 1 depicts a prior art configuration wherein data are coupled to or from a one-bit bus 2 on an integrated circuit chip 4 using tristate buffer modules, 6-0, 6-1, 6-2, 6-3 (although more or less than four buffer modules may instead be used). Each buffer module defines an input/output node ("I/O") that may be coupled to one or more sub-sections or circuits on IC chip 4 by assertion of an appropriate enabling arbitration select signal.
Each buffer module has an input port, an enabling or arbitration port and an output port. For example, buffer 6-0 has an input port coupled to receive an I/O signal Dout0 from elsewhere on IC chip 4. Buffer 6-0 has an enabling port coupled to receive an output enabling or arbitration signal ARB-0, and also has an output port coupled to deliver a signal Din0. In common tristate buffer fashion, the signal Din0 will replicate the signal Dout0 only when ARB-0 is in an enabling state. In this fashion the sub-section circuit generating Dout0 can communicate one-bit of this signal across bus 2 to some other sub-section circuit also coupleable to bus 2.
If I/O signal Dout0 is to be coupled to bus 2, ARB-0 will be in an enabling state permitting buffer 6-0 to output a replica of signal Dout0. By contrast, enabling signals ARB-1, ARB-2, ARB-3 would each be in a disabling state that precluded respective buffers 6-1, 6-2, 6-3 from outputting a signal to bus 2. Only one ARB signal is to be in the enabling state at a time, which means that only one tristate buffer module is selected at any given time for coupling Dout signals to bus 2.
In the manner described, the buffer modules serve as mechanisms for coupling signals between the buffer I/O node and bus 2, the coupling being determined by the enabling ARB signals.
It is understood that if the bus is N-bits wide, there will be N buses 2, and N groups of buffers 6, each buffer having an input port, an arbitration port, and an output port. Using FIG. 1 as an example, an IC requiring a 16-bit wide bus would replicate the structure of FIG. 1 sixteen times. There would be sixteen bus 2 structures and 64 (e.g., 16×4) buffer modules 6, one such structure being present for each bit-position in the bus. However, each group of sixteen buffer modules would be coupled to the same ARB signal, with the four ARB signals thus each being coupled to blocks of sixteen buffer modules.
FIG. 2A shows a typical implementation of a tristate buffer, e.g., buffer 6-0, which typically operate from an upper power supply Vdd and a lower power supply Vss that is often ground. At its input port, buffer 6-0 receives Dout0, and at its output port outputs Din0, providing the ARB-0 enabling signal is present (e.g., is a digital "1"). Depending upon the circuit design, Dino may replicate or be an inverted version of Dout0, and buffer 6-0 may enable when ARB-0 is a digital "0".
The output of buffer 6-0 is shown coupled to a load impedance Z L that may be represented generally by a resistance R L shunted by an effective capacitive load C L . Load impedance Z L represents the load seen by the buffer output. As will be described later, Z L includes load contributions from the bus, from the three other buffer modules, and from the Din0 port of buffer 6-0 itself.
As shown in FIG. 2A, buffer 6 may be implemented with bipolar transistors, complementary metal-on-semiconductor ("CMOS") transistors, or a combination of each ("BiCMOS"). Buffer 6 typically will include two inverters I1 (here a NAND gate) and I2 coupled in series, or I3 (here a NOR gate) and I2 coupled in series. The output of the first inverter is presented as input to the second inverter, and the output of the second inverter is the buffer output, which has the same phase as the input to the first inverter.
In the CMOS implementation of FIG. 2A, each inverter comprises a P-type pull-up metal-on-semiconductor ("PMOS") transistor and an N-type MOS ("NMOS") transistor coupled in series between Vdd and Vss. For example, I1 may comprise a PMOS transistor P1 (not shown) and an NMOS transistor N1 (not shown), I2 comprises PMOS transistor P2 and NMOS transistor N2, and I3 comprises transistors P3, N3 (not shown). Because I2 drives a relatively large load, output transistors P2 and N2 will generally be larger sized devices than the transistors comprising I1 or I3.
The arbitration or enabling function may be implemented using the NAND gate (I1), INVERTER and NOR gate (I3) logic shown, or using other techniques well known to those skilled in the relevant art.
When Dout0 is a digital "1", within I1 transistor P1 turns off and N1 turns on, and the first inverter output is a digital "0". Upon receipt of this "0", in the second inverter I2, P2 turns on, N2 turns off, and the signal Din0 will be a digital "1", and buffer 6-0 sources current into bus 2. When Dout0 is a digital "0", P1 turns on, N1 turns off, and the output from the first inverter is a "1". Upon receipt of this "1", P2 in the second inverter turns off, N2 turns on, signal Din0 is a "0", and buffer 6-0 sinks current from bus 2.
FIGS. 2B-1 through 2B-4 depict voltage and current waveforms associated with output buffer 6-0. For example, although Douto is "1" before time t 0 , it is only after the enabling ARB-0 signal goes high that buffer 6-0 is enabled to provide the Din0 output signal. At time t 1 , Dout0 goes low and, since ARB-0 is still enabling buffer 6-0, the Din0 signal also goes low. In the Din0 waveform, the voltage waveform drawn in phantom represents the case of a relatively large load capacitance C L . When C L is not especially large, the output voltage waveform slews more rapidly, but can overshoot and undershoot as shown.
It is thus appreciated from the Din0 waveform that as C L increases, the output voltage slew rate (Dv/dt) decreases. To compensate for this, it is necessary to implement buffer 6-0 with larger output inverter transistors that can source or sink more current (i). (Of course, this assumes that the IC containing buffer 6 has sufficient area whereon to fabricate larger transistors.) The ability to compensate for a large C L by increasing output buffer current follows from the equation:
i=C.sub.L ΔV/Δt
Although large current handling transistors can improve output voltage slewrate, a large current capability can be detrimental. In practice, buffer 6-0 will not function perfectly because the various pull-up and pull-down transistors do not change states in perfect synchronism. The output buffer current waveform depicts the total current i o flowing through buffer 6-0. The i o current waveform drawn in phantom represents total current drawn by the buffer when the various buffer transistors are themselves large devices, e.g., devices with a relatively large drain current.
Note from this waveform that current spikes occur when the buffer transistors change states, for example at times t 0 and t 1 . These spikes are created because for a brief moment, the PMOS and NMOS transistors in each inverter are simultaneously on, thus presenting a low impedance current path between the Vdd and Vss power supplies. In addition, current spiking occurs because the load capacitance C L component of Z L is being charged toward Vdd or discharged toward Vss (depending upon the direction of the output state change).
Thus, the i o waveform in FIG. 2B-4 suggests that compensating for a large load capacitance C L by implementing buffer 6-0 with large current transistors will aggravate current spiking. Those skilled in the art will appreciate that the current spiking waveforms can contain many high frequency components that represent electromagnetic ("EM") and radio frequency ("RF") noise that can interfere with other signals implemented on the IC containing buffer 6, and with signals elsewhere in a system contain this IC.
It will be appreciated from the foregoing that the use of tristate buffers 6 presents many problems. Although the configuration of FIG. 1 is commonly used in fully customized integrated circuit chips, this configuration aggravates current spiking and the need for fabricating relatively wide bus 2 metal traces. In practice, the width of the bus 2 metal will be in the range of about 3 μm. In some applications, having to provide a sufficiently wide metal bus trace may compromise the layout of other portions of the IC due to space considerations.
The configuration of FIG. 1 is not point-to-point in that each buffer module is always coupled to more than one other buffer module, e.g., to three other buffer modules. As will now be described, this causes each buffer to see a substantial load impedance Z L , with resultant degradation of signal voltage slewrate.
Assume for example that ARB-0 enables buffer 6-0, and that ARB-1, ARB-2, ARB-3 disable buffers 6-1, 6-2, 6-3. The load Z L seen by the enabled (e.g., turned-on) buffer 6-0 includes (a) the metal trace bus 2, (b) whatever is coupled to Din0, (c) the output impedance capacitance of each of the other three disabled (e.g., turned-off) buffers, and (d) the Din1, Din2, Din3 loads contributed by each of the other three input buffers. The resultant load is the metal trace load and seven buffer loads. Since the metal trace typically is equivalent to about twelve buffer loads, the turned-on buffer must drive approximately sixteen equivalent loads. One standard equivalent load is about 0.032 Pf, which is to say that 31.3 standard equivalent loads represent approximately 1.0 pF.
Unfortunately, if the tristate buffers are to drive sixteen equivalent loads and still provide output Din signals having a sufficiently rapid voltage slewrate, the buffer current i o must be increased. This in turn requires larger-sized buffer transistors, and can increase current spiking and noise generation.
It is also apparent from FIG. 1 and FIG. 2A that no more than one output enabling ARB signal may be on (e.g., "1") at any time. Any overlap in time between enabling signals, or "arbitration contention", can cause one turned-on buffer to attempt to drive a very low impedance load that includes another turned-on buffer, and vice verse. The resultant high current flow will usually damage if not destroy IC 4.
Testing prior art tristate buffer configurations such as shown in FIG. 1 is extremely challenging, and generally cannot be accomplished using conventional automatic testing routines and equipment. It is very difficult for conventional testing routines to determine which of a group of tristate buffers is actually driving the bus at a given time. Further, conventional test routines cannot detect the occurrence of contention with any great certainty. Stated differently, to successfully test the configuration of FIG. 1, it is necessary to demonstrate that contention can never occur. The testing procedures and equipment necessary to demonstrate this are difficult to implement.
For example, although scanning test protocols are commonly used to rapidly test ICs, such routines cannot be used with tristate buffer configurations such as shown in FIG. 1. In such testing, the various flipflops within an IC are temporarily coupled together in a ring and known data patterns are passed through the ring. Unfortunately, when tristate buffers are present, random output drive signals become propagated through the ring, introducing uncertainty and, what is worse, contention into the test procedure.
To summarize, there is a need for an on-IC bus structure that avoids the contention and testing problems associated with prior art tristate buffer configurations. It should be possible to fabricate such a structure using IC and metal trace areas not exceeding what would be required to implement a tristate buffer bus configuration. Most preferably, such structure should be extendable to hierarchies of at least three-dimensions to better accommodate a larger number of nodes without using tri-state buses.
The present invention provides such a multidimensional hierarchial bus structure.
SUMMARY OF THE PRESENT INVENTION
In applicant's above-referenced patent, a two-dimensional point-to-point ring bus structure was formed without using tri-state buses. M (an integer≧2) X:1 multiplexer modules were used in which each module was associated with an input/output port that could communicate with the bus. Each module had an output port (Dout), and arbitration ("ARB") port, and X input ports ("LOCALout", "Din1", "Din2", . . . "Din X-1!"). The Dout output port of an M i module was coupled, via a portion of conductive bus, to X-1! input ports on an adjacent D i+1 module. Thus, module M 0 's Dout 0 output port was coupled to X-1! input ports on module M 1 , module M 1 's Dout 1 port was coupled to X-1! input ports of module M 2 , and so forth.
The modules were X:1 in that the output port of each module was coupled to a chosen one of that module's X INPUT ports, as determined by the state of an arbitration select signal (ARB) coupled to the module's arbitration port. The state of the arbitration select signals defined a bus signal path between the LOCAL out input port of a module coupled to the bus, and the D in input ports of other modules.
The described point-to-point configuration presented smaller equivalent loads to module outputs, permitting low module current operation and narrower width bus metallization traces. Because large current handling output transistors were unnecessary, multiplexer modules did not incur thermal damage if contention-type overlap occurred between ARB signals, and automatic testing including scan generation testing could be used.
However for relatively numbers of nodes, greater interconnect flexibility may be attained by providing a three-dimensional (or greater) hierarchial interconnect configuration. Nodes are defined on at least first and second "horizontal" (or "H") rings, the rings being coupled by at least one "vertical" (or "V") ring. Each node is identified in terms of its (H,V) coordinates in the hierarchial interconnect structure, and an M-dimensional structure will provide an M-way multiplex unit at each node. For an M=3, e.g., three-dimensional structure, each multiplex unit has three-inputs, a Localout, a Vin, and an Hin input, and couples one of these inputs to an output port in response to a Local select arbitration signal. The output signal is coupled to Hout and Vout, and to Localin. Nodes on the same horizontal level will drive their Hin signal to Vout and Hout, whereas all other nodes receive the Vin signal. The arbitration select signals may reconfigure the overall structure dynamically or statically, preferably according to demand of the nodes required interconnection. Providing additional vertical rings provides redundancy and can reduce latency time.
Other features and advantages of the invention will appear from the following description in which the preferred embodiments have been set forth in detail, in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an on-chip bus configuration using tristate buffer modules, according to the prior art;
FIG. 2A depicts a generic tristate buffer module, according to the prior art;
FIGS. 2B-1 through 2B-4 depict voltage and current waveforms for the tristate buffer module of FIG. 2A;
FIG. 3A depicts an on-chip two-dimensional ring bus structure using multiplexer modules;
FIGS. 3B-1 through 3B-4 depict voltage waveforms for a multiplexer module as shown in FIG. 3A;
FIG. 4 depicts a generic multiplexer module, such as used in FIG. 3A;
FIG. 5A is a schematic depiction of a bus interface multiplexer module and node, such as used in the two-dimensional ring bus structure of FIG. 3A;
FIG. 5B is a generic depiction of the two-dimensional ring bus structure of FIG. 3A;
FIG. 6A is a schematic depiction of a nodal bus interface multiplexer module and node used in a three-dimensional ring bus structure;
FIG. 6B is a generic depiction of a three-dimensional ring bus structure;
FIG. 7A is a schematic depiction of a nodal bus interface for each node in a full three-dimensional bus structure configured as four rings;
FIG. 7B is a generic depiction of a three-dimensional bus structure configured as four rings;
FIG. 8A depicts the nodal bus interface for each connection node N(x,0) in a partial three-dimensional bus structure;
FIG. 8B is a generic depiction of a partial three-dimensional bus structure, used with the nodal bus interface of FIG. 8A;
FIG. 9A depicts a multi-node bus configuration in which functional a subset of nodes communicates between a small number of groups;
FIG. 9B depicts the addition of a second vertical ring to the configuration shown in FIG. 9B to reduce latency.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3A depicts a single-bit ring bus 102 formed on an integrated circuit chip 104 that may be an ASIC that includes circuitry formed on sub-sections. In the embodiment of FIG. 3A, ring bus 102 includes M=4 two-way (e.g., X=2, or 2:1) multiplexer modules 106-0, 106-1, 106-2 and 106-3. Each multiplexer module defines an I/O node that may be coupled through the bus to one or more sub-sections or circuits on IC chip 104. In an IC with an N-bit wide bus, what is shown in FIG. 3A would be replicated N times, with each ARB signal coupled to N multiplexer modules.
In the embodiment shown, each multiplexer module has two input ports, and output port, and an arbitration port. The multiplexer modules are two-way in that the multiplexer output port is coupled to a chosen one of the two input ports, the coupling being determined by the state of the signal coupled to the arbitration port.
For example, multiplexer 106-0 has a first input port coupled to receive an I/O signal Din0 that is provided as an output (Dout1) by multiplexer 106-1. Multiplexer 106-0 has a second input port coupled to receive an I/O signal LOCALout0 that may be coupled to one or more subsections or circuits on the IC chip 104. Multiplexer 106-0 also has an arbitration port coupled to receive an arbitration signal ARB-0, and an output port that couples an output signal Dout0 to an input port on an adjacent multiplexer, here module 106-3.
As shown by the voltage waveforms in FIGS. 3B-1 through 3B-4, in the preferred embodiment, when ARB-0 is a digital "1", Dout0 is Din0, and when ARB-0 is a digital "0", Dout0 is LOCALout0. FIG. 4 depicts a generic implementation of multiplexer module 106-0, as comprising two NMOS field effect transistors N4, N5 and an inverter I4. Of course other implementations could be used, including implementations that invert the polarity of the arbitration signal result in Dout being Din0 when ARB-0 is a "0", and being LOCALout0 when ARB-0 is "1".
While the embodiment shown in FIG. 4 represents a unidirectional multiplexer unit, those skilled in the art will recognize that a bidirectional multiplexer unit could instead be provided. The use of bidirectional multiplexer units would permit a ring bus structure according to the present invention to operate bidirectionally. Thus, with respect to FIG. 3A, a signal coupled to D IN 0 might be passed across the ring to LOCAL OUT 0, or a signal coupled to LOCAL OUT 0 might be passed across the ring to D IN 0.
At this juncture, similarities and differences between a multiplexer module ring bus 102 configuration according to FIG. 3A, and a tristate buffer module configuration according to FIG. 1A will be pointed out.
The configurations are similar in that a chosen I/O node associated with one module may be coupled to another node associated with another module, according to the state of the arbitration select signals. In FIG. 3A, for example, if ARB-0 is "1", and ARB-1, ARB-2, and ARB-3 are "0", a Din0 signal will pass through MUX 106-1, MUX 106-2 and MUX 106-3, and will appear at the LOCALout0 node of MUX 106-0. As shown in FIG. 3A, the same Din0 signal will also be present at the nodes Din1, Din2 and Din3. As such, bus 102 is a ring, as indicated in FIG. 3A.
In contrast to the prior art, however, the ring bus configuration of FIG. 3A is point-to-point in that the output of one module is coupled only to one other module. For example, the output from module 106-0 sees the Din3 input of module 106-3, and nothing more. The internal circuitry associated with each multiplexer module isolates the module inputs from the load impedance coupled to the module output.
As such, the output transistors within each multiplexer module see a smaller Z L load than is seen by the output transistors in a tristate buffer module in the prior art. Whereas the output impedance seen by the prior art tristate buffer configuration of FIG. 1 was about sixteen equivalent loads, the output impedance seen by a multiplexer module as described herein is only about four equivalent loads. Typical signal transition time for a 2:1 multiplexer module will be about 500 ps, e.g., about twice as fast as a prior art tristate buffer.
Because the multiplexer modules are less heavily loaded, they can operate with a rapid voltage slewrate using decreased output current (since C L ΔV/Δt is decreased). As a result, the metal trace that forms the bus path between multiplexer modules may be of narrower width for a given resistivity relative to the width of a metal bus trace used in prior art FIG. 1. For example, a typical metal trace width used to implement FIG. 3A may be only 0.8 μm. The ability to use narrower metal traces advantageously provides greater flexibility when designing the IC chip layout, and can reduce the capacitive load associated with a wider metal trace.
Even if the sum of the operating current required by the four multiplexer modules shown in FIG. 3A should equal or even exceed the operating current required by a single enabled single prior art tristate buffer module, the present invention is still advantageous. In the present invention, the drive current is distributed among the various multiplexer modules, whereas in the prior art, all of the drive current is provided by the one enabled tristate buffer. As a result, it is easier to fabricate lower current multiplexer modules than large current handling tristate buffer modules.
Contention per se is not a problem with the present invention. In FIG. 3A, even if more than one ARB arbitration signal is somehow simultaneously on (e.g., "1"), neither the selected multiplexer modules nor IC 104 is damage. This is in contrast to what can result with the prior art configuration of FIG. 1, wherein two (or more) high output current tristate buffer modules may attempt to drive each other.
For the described embodiments, even if quasi-contention results in the simultaneous selection of two or more multiplexer modules, the proper "0" or "1" state of the bit coupled to bus 102 may be erroneous, but thermal damage to the buffer modules or the IC would not occur. In a multi-bit bus configuration, quasi-contention might corrupt one or more bits (e.g., a "0" might become a "1" or vice versa) but damage to the IC would not necessarily occur.
Because contention or quasi-contention does not present a problem that can damage or destroy IC 104, the described configurations may readily be tested using conventional test protocols and test equipment. For example, scanning test protocols may be used to rapidly test IC 104, in contrast to techniques that must be used to attempt to test prior art IC 4.
Although the preferred embodiment shown in FIG. 3A depicts four 2:1 multiplexer modules, as few as two 2:1 multiplexer modules may be used to implement a bus. Ring topology buses used in networks may, for example, use as many as twenty or more 2:1 multiplexer modules. Further, X:1 switching modules may be implemented other than as conventional multiplexer units.
As noted, the use of 2:1 (e.g., X=2) multiplexers per node results in the formation of a single data ring. However, for larger buses with many loads, it may be advantageous to use 3:1 (or arbitrarily X:1) multiplexers. Increasing X from 2 to 3 will increase the load per multiplier, as each multiplexer will then have to drive the node nearest it in two dimensions. However, increasing X will decrease the total number of elements in any one bus ring.
An example of such an arrangement would be a bus with 16 nodes, effectively the configuration of FIG. 3A, repeated four times, with vertically oriented ring buses passing through each node. While each node would then drive two loads (e.g., the adjacent load in the same plane, and the adjacent load "above"), the farthest distance between two loads decreases. The decrease is from 15 nodes for a single ring bus, to 6 nodes, namely three nodes in the horizontal plane and three nodes in the vertical plane.
Thus, in general, an X:1 multiplexer module configuration will define an X-dimensional cube. For the 2:1 multiplexer module configuration of FIG. 3A, X=2 and a two-dimensional planar configuration is defined. Where X=2, the output of each multiplexer module is coupled to X-1! or one input on an adjacent module. If X=3 (e.g., if 3:1 multiplexer modules are used), a three-dimensional cube configuration would be realized. In a three-way configuration, each multiplexer output (Dout) would fanout to X-1! or 2 inputs on other of the modules.
To recapitulate, the use of multiplexer modules enables bus structures to be easily implemented with relatively low current-handling multiplexer transistors. The IC chip area required to implement the described embodiments does not exceed the chip area required to implement a conventional tristate buffer configuration having the same number of input/output nodes. Because each multiplexer module sources or sinks relatively little current, the metal trace used to implement the ring bus shown in FIG. 3A may be thinner than would be the case for the bus shown in prior art FIG. 1. Because contention damage is not present, the described embodiments lend themselves to rapid testing using standard test techniques and equipment, including scanning.
Before describing three-dimensional and greater bus configurations for the present invention, it is helpful to adopt a shorthand nomenclature. FIG. 5A describes a generic node N as including, in this example, an X:2 (here X=2) multiplexer unit 106-N, whose input nodes are here denoted Local out N, D in N, whose output node is denoted D out N, and whose arbitration node is denoted as Local Select N (or ARB N). Note that the D in N input signal is shown exiting node N as a signal Local in N+1. The similarity between node N in FIG. 5A and any of the nodes in FIG. 3A will be apparent. FIG. 5B generically depicts a four-node two-dimensional ring bus structure 102, similar, for example, to what was shown in FIG. 3A.
FIGS. 6A and 6B depict a generic three-dimensional node N(H,V) and a generic three-dimensional structure, respectively. The nomenclature N(H,V) denotes a node ("N") coupled horizontally ("H") and vertically ("V") to ring structures. In FIG. 6B, for example, four "horizontal" ring structures 102-H0 (e.g., level-0 horizontal), 102-H1, 102-H2, 102-H3 (e.g., level-3 horizontal) are shown, as are four "vertical" ring structures 102-V0 (e.g., level-0 vertically), 102-V1, 102-V2, 102-V3 (e.g., level-3 vertically). In the embodiment shown, four nodes ("N(H,V)") are associated with each ring bus structure, each individual node being associated with a "horizontal" and with a "vertical" ring structure. Although the "4×4" structure of FIG. 6B is symmetrical, the present invention does not require that the hierarchy be either symmetrical, or the same on each layer level.
It is understood that although the configuration of FIG. 6B could be implemented using multi-level printed circuit boards or the like, the "horizontal" and "vertical" denominated ring structures may be considered as virtual or logical ring structures. As such, "horizontal" ring structure 102-H0 need not physically lie above and/or be "horizontally" spaced-apart from "horizontal" ring structure 102-H1. It suffices if such ring structures be logically definable, independently of the physical implementation.
Thus, node N(0,1) is connected to the zero-th horizontal ring 102-H0, and to the first vertical ring 102-V1, node 3,0 is connected to the third horizontal ring 102-H3 and to the zero-th-vertical ring 102-V0, and so on. A source node drives its Localout signal to Vout and to Hout, as shown in FIG. 6A. Nodes on the same level drive Hin to Vout and Hout, whereas all other nodes receive Vin.
Through proper generation of arbitration or local selection logical signals to the X:1 (X=3) multiplexer units 106-N shown in FIG. 6A, any node can be coupled to any node in the structure shown. At least about ten relatively straightforward point-to-point node paths may be dynamically defined.
FIGS. 7A and 7B depict the nodal bus interface and structure for a full three-dimensional bus when configured as four rings. Multiplexer 106-N in FIG. 7A is a x3 MUX unit, its inputs being Dout-N, Vin, and Hin, its select signal being ARB-N, and its output being coupled to Local in, to Hout and to Vout.
Note in FIG. 7B that the "vertical" rings are shown in phantom to indicate that the overall bus structure may be broken-up in different ways, dynamically or statically. For example, if Vin is ignored, the resultant structure has four rings, here denoted 102-H0, 102-H1, 102-H2 and 102-H3. On the other hand, if Hin is ignored, the resultant structure would have four vertical rings, drawn in phantom, 102-V0, 102-V1, 102-V2, and 102-V3.
Appropriate multiplexer signals can cause the structure of FIG. 7B (or other structures according to the present invention) to reconfigure. Such reconfiguration may be made on a timing clock cycle-by-cycle basis. For example, a 16-bit wide bus might dynamically (or statically) be reconfigured to be four horizontal 4-bit busses, and then be reconfigured to be four vertical 4-bit busses. Other reconfiguration orders could be adopted, using structures with more than 4×4 hierarchy potential, and with more nodes defined per level. Thus, in general, the present invention permits a large bus to be reconfigured to a smaller number of vertical busses or to a smaller number of horizontal busses.
FIGS. 8A depicts the nodal bus interface for each connection node N(x,0) in the partial three-dimensional bus structure shown in FIG. 8B. Note that the redundancy in FIG. 8B may be reduced by using a single horizontal ring between vertical rings. This is relatively easy to fabricate in hardware using fewer wires, but unfortunately latency time is increased.
Compare the configuration of FIG. 8B with that of FIG. 7B in traversing from node N(0,1) to node N(3,3). In FIG. 7B, four nodes were involved in the traverse: N(0,1)→N(0,2)→N(0,3)→N(1,3)→N(2,3)→N(3,3)!. In FIG. 8B, there are fewer potential horizontal connections, and node N(0,1) must transfer its date to node N(0,0) as follows, N(0,1)→N(0,2)→N(0,3)→N(0,0!. From there, data is transferred to N(3,0) along the path defined by N(0,0)→N(1,0)→N(2,0)→N(3,0)!. Finally, data passes to N(3,3) along a path N,3,0)→N(3,1)→N(3,2)→N(3,3)!, a total of eight nodes being involved in the traverse. While the above-described path can be broken into four separate vertical rings, the presence of only one horizontal ring limits flexibility of configuration. It is to be understood that for ease of fabrication and layout, a "vertical" ring may in fact be replaced with a tristate bus connecting the various "horizontal" rings.
Consider a bus structure in which there are many nodes, but where functionally a first group of nodes communicates primarily with a second group of nodes, but where occasionally a different communication configuration is desired. The structure of FIG. 9A lends itself to such a group-to-group application, wherein a first group of eight nodes is configured with a first horizontal ring 102-H0, and wherein a second group of eight nodes is configured with a second horizontal ring 102-HX. A single vertical ring, 102-V0, connects the two horizontal rings. To reduce latency, at least one additional vertical ring, here 102-V1 (shown in phantom), may be added.
FIG. 9B depicts a more complex topology to permits groups of nodes to better communicate with other groups of nodes. In FIG. 9B, nodes associated with a first horizontal ring 102-H0 can communicate readily with a second group of nodes associated with a second horizontal ring 102-H1. Communication between the first and second horizontal rings is achieved using preferably two vertical rings 102-V0 and 102-V1, to reduce latency. Communications between groups of nodes on the second and the third horizontal ring (102-H2) is facilitated by vertical rings 102-V2, 102-V3, two such rings preferably be used to reduce latency. Communication between groups of nodes on the third and fourth horizontal rings, 102-H2, 102-H3 is similarly implemented.
For ease of illustration, the configurations of FIGS. 6B, 7B, 8B, and 9B have been shown implemented with x3 input MUX units. As depicted, the resultant bus configurations are truly three-dimensional. If desired, x4 or even higher input MUX units could be used, to implement four-dimensional (or higher) bus structures.
Modifications and variations may be made to the disclosed embodiments without departing from the subject and spirit of the invention as defined by the following claims.
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A hierarchial bus structure having at least three dimensions provides improved interconnect flexibility between nodes located on one or more levels of the structure. Nodes are defined on at least first and second "horizontal" (or "H") rings, the rings being coupled by at least one "vertical" (or "V") ring. Each node is identified in terms of its (H,V) coordinates in the hierarchial interconnect structure, and an M-dimensional structure will provide an M-way multiplex unit at each node. For an M=3, e.g., three-dimensional structure, each multiplex unit has three-inputs, a Localout, a Vin, and an Hin input, and couples one of these inputs to an output port in response to a Local select arbitration signal. The output signal is coupled to Hout and Vout, and to Localin. Nodes on the same horizontal level will drive their Hin signal to Vout and Hout, whereas all other nodes receive the Vin signal. The arbitration select signals may reconfigure the overall bus structure dynamically or statically, preferably according to demand of the nodes required interconnection. Providing additional vertical rings provides redundancy and can reduce latency time. Because the multi-dimensional hierarchial structure is point-to-point, low module current may be used, the width of the metallized bus traces may be reduced, and contention-type overlap damage is minimized.
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This is a division, of application Ser. No. 590,970, filed June 27, 1975, now U.S. Pat. No. 4,024,300.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the process for making shell investment molds for the casing and solidification of superalloys therein.
2. Description of the Prior Art
Shell investment molds are employed to produce castings of a wide variety of alloys with a refractory material, compatible with the alloying being cast forming the inner mold wall. The secondary or back-up coats usually are composed of a high alumina-silicate refractory of an appropriate grain size to insure production of a useable mold. Long periods of time, up to 10 hours, coupled with high temperatures (1500°-1600° C.) caused undesirable mold defects, such as total collapse after casting the alloys, premature cracking and mold warpage. All of these, of course, produce undesirable and unacceptable castings. Mold-metal reactions, such as "pock marks," were also noted, suggesting that the inner or primary coats became contaminated with excessive amounts of SiO 2 , Na 2 O, and other fluxing agents which were not compatible with the alloy being cast.
An object of this invention is to provide a new and improved process for making shell investment molds for the casting and solidification of superalloys which overcome the deficiencies of the prior art.
An object of this invention is to provide a new and improved process for making a slurry suitable for making shell investment molds suitable for use for extended periods of time at high temperatures.
Another object of this invention is to provide a new and improved primary slurry composition for an investment mold, the material of which at the mold-metal interface is non-reactive to the metal in contact therewith.
Another object of this invention is to provide a new and improved alumina slurry to withstand the effects of mold-metal reactions at the mold-metal interface, such as required for the directional solidification of nickel-base superalloys and high-temperature nickel-base eutectic alloys requiring long solidification periods to obtain the desired cast structure.
Other objects of this invention will, in part, be obvious and will, in part, appear hereinafter.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the teachings of this invention, there is provided a material composition suitable for use in making shell investment molds. The material composition comprises a pre-selected weight of a flour mixture consisting of at least two different flour grain sizes of fused alumina. The grain sizes range from approximately 240 mesh to approximately 400 mesh, U.S. Standard or Tyler screen series.
A pre-selected weight of a colloidal silica is employed as a binder. In addition, a pre-selected volume of a wetting agent ranging from 8 to 12cc per 100 lbs of slurry mixture may be added to the mixture. The ratio of weight percent of the flour to the binder is 73:27 to 65:35. Preferably, the fused alumina flour employed is acid-washed to remove free iron contamination resulting from its manufacture and has an Al 2 O 3 purity of greater than 98%. The weight percent of silica in the colloidal silica binder is from 15 to 36 percent.
When a flour mixture consists of two different flours, the ratio of the larger grain to the smaller grain flour may vary from between 10:90 and 90:10. When the mixture consists of three different flour sizes, the first or coarse flour comprises from 70 to 75% weight percent of the mixture, the second flour comprises from 10 to 20%, and the third or smallest grain size flour comprises the remainder.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Unexpectedly, I have found that a mixture of two or more flour sizes of fused alumina provide an excellent material composite for the one or more primary coats required to form a suitable inner mold wall for the casting of metal therein and the directional solidification thereof. Fused alumina flour sizes are closely controlled by the manufacturer, since they are basically produced for other uses. Therefore, a mixture of two or more fused alumina flours is preferred to acquire a grain size distribution to decrease voids at the metal-mold interface and to produce a slurry in which settling of the refractory flour is nil. Fused alumina is chosen because of its inherent low expansion and contraction properties, high temperature capability, and resistance to attack by the materials being cast.
Preferably, the flour is a high-purity alumina greater than 98% by weight Al 2 O 3 . The flour is acid-washed to remove impurities, such as iron, which is detrimental to the formulation of a suitable primary slurry.
Grain sizes must be considered since surface finish of molds and mold permeability is important when an acceptable casting is desired. A flour mixture containing a high percentage of large grains will produce a rough inner mold wall. This roughness is reproduced on the casting surface. A flour containing a large percentage of "fines" requires an excessive amount of binder and usually causes mold wall "buckling".
The colloidal silica binder is available as a commercial product and contains 36% silica by weight. This colloidal solution is diluted with de-ionized water to vary the silica content from 36% by weight to 15% by weight. I prefer to dilute the binder to 18% by weight and employ this diluted binder in the primary slurry. Total percentage of diluted binder may vary from 27% by weight to 35% by weight of the total slurry, depending on the flour mixture employed.
Other slurry additions are required. A wetting agent to ensure proper wetting of the wax pattern by the slurry. I prefer a non-ionic wetting agent since these are compatible with the binder (colloidal silica) employed. These agents are readily available commercially. Also, a defoaming agent may be required if excessive foam is noted on the slurry during the mixing operation. If good slurry mixing practices are followed, foaming will not be a serious problem. I have employed Antifoam 60, manufactured by the General Electric Company, in the amounts of 0.005% by weight to 0.008% by weight of the slurry, directly to the slurry. I have found 8cc to 12cc of wetting agent per 100 lbs. total weight of the slurry will induce good wetting properties to the slurry.
The following flour mixtures have been employed and yield satisfactory primary slurries. All percentages are by weight percent and all flours are fused alumina, U.S. Standard sieve size, acid washed.
______________________________________Mix #1: Mix #6 240 mesh 50% 240 mesh 65% 400 mesh 50% 320 mesh 35%Mix #2: Mix #7: 240 mesh 66% 240 mesh 85% 320 mesh 34% 400 mesh 15%Mix #3: Mix #8: 240 mesh 50% 240 mesh 70% 320 mesh 50% 320 mesh 25%Mix #4: 400 mesh 5% 240 mesh 90% Mix #9: 320 mesh 10% 240 mesh 85%Mix #5: 320 mesh 15% 320 mesh 90% Mix #10: 400 mesh 10% 240 mesh 10% 320 mesh 90%______________________________________
An unsatisfactory primary slurry resulted when the following mixtures were employed:
Mix #11: 240 mesh 100% Mix #12: 320 mesh 100%
Primary slurries containing 100% 240 mesh Al 2 O 3 flour produced fragile shells which cracked on dewaxing. Penetration of molten metal and casting roughness, which was unacceptable, resulted when the molds which did not crack on dewaxing were employed. Primary slurries containing 100%, 320 grain size flour, were difficult to keep in suspension without excessive stirring and produced mold defects such as mold wall "buckling".
The following is illustrative of the preparation of primary slurry compositions of this invention wherein I have selected Mix #4 containing 240 mesh fused alumina at 90% and 320 mesh fused alumina at 10% by weight of the flour mixture as a particular illustration. Total weight of the slurry (flour and binder) is 100 lbs. The dry flours are blended together for approximately 1/2 hour. Total weight of the binder is 27% by weight. The binder is colloidal silica diluted with de-ionized water to 18% silicon content. Therefore, 27 lbs. of this mixture is diluted binder and 73 lbs. is flour mixture #4.
Approximately 90% of the total weight of the flour mixture was added to all of the binder which is contained in a suitable mixer. The constituents were mixed together until the viscosity of the slurry became stabilized. The remainder of the flour mixture was then added to the slurry. The slurry of flour and binder were allowed to mix slowly overnight.
After mixing overnight, the specific gravity and viscosity of the slurry was checked. I prefer a specific gravity of from about 2.36 to about 2.42 and a viscosity of from 7 to 10 seconds with a #5 Zahn cup. An adjustment may be made at this time if specific gravity land viscosity are not at desired levels. Additionally, a non-ionic defoamer may be added, in amounts previously stated, if foaming is a problem at this time.
A wetting agent is added only after the specific gravity and viscosity are at the desired levels for the slurry. Amounts of from about 8cc to about 12cc per 100 lbs. appear to be sufficient to induce good wetting properties. I allow from about 10 to 15 minutes for the wetting agent to be properly mixed throughout the slurry.
Several wax patterns were fabricated, cleaned and dried by standard established procedures well known to those skilled in the art. The wax patterns were then dipped into the primary slurry and the excess slurry was allowed to drain. When draining was completed, the bubble-free slurry coat was ready for graining. Graining was accomplished by means of fluid bed equipment. I prefer 70 grain fused alumina, acid washed, of 98% or greater purity as the grain employed for the graining or sand coat. This size grain forms an excellent grain coat to receive the next slurry dip coat. The wax pattern or cluster was allowed to air dry at room temperature for at least two hours.
When properly dried, the wax patterns or cluster was then dipped in the primary slurry and again coated with the 70 grain Al 2 O 3 . Again, the cluster was allowed to dry in air at room temperature for at least two hours. This procedure completed the application of the two primary coats which I prefer in making an investment mold. It is to be noted that when desired, more than two primary coats may be applied.
Secondary coats are then applied after the primary coats are dry enough to accept them. This is usually in about two hours after the last primary coat is applied. Secondary grain coats and slurry coats are applied in the same manner as the primary grain and slurry coats. However, the composition differs. For this shell mold composite the secondary slurry consists of 240 mesh fused alumina flour, acid washed, and 36 grit size fused alumina as the grain coat. I prefer to add four secondary coats each of which consists of one slurry dip and one 36 grain application. Drying time between each coat is at least thirty minutes. The binder is colloidal silica, of which 36 percent by weight is silica. The binder is not diluted. The ratio of undiluted binder to flour is 30:70. A slurry with a specific gravity of from about 1.9 to about 2.1 and a viscosity of approximately 6-7 seconds #5 Zahn cup is desired. A binder comprising about 30 percent by weight silica was also found to be suitable for making the secondary coating.
A "seal" coat consisting of the secondary slurry mixture is applied as the final coat. The purpose of the seal coat is to keep the last grain coat in place.
Preferably, I desire the shell investment mold for the aformentioned high temperature applications to be composed of two primary slurry coats each grained with 70 mesh fused alumina, four secondary slurry coats each grained with 36 mesh fused alumina, and one seal coat of secondary slurry. The complete shell is dried at room temperature, preferably overnight or for at least 12 hours. The shells are now ready for dewaxing.
Any standard technique well known to those skilled in the art may be employed for dewaxing. I prefer to employ the "flash dewax" technique. After dewaxing, the shells are fired in air at 1000° C. for 1.5 hours and allowed to furnace-cool. The composition of the material of shell mold of the completed shells may then be stored for future use or employed immediately in the casting and solidification of super alloys.
Shell investment molds fabricated in the manner described heretofore are pre-heated to 1680°-1700° C. and the superalloy materials previously described are cast therein and directionally solidified. The resulting castings are superior in quality of surface finish and composition of matter than those obtained by use of prior art molds.
Particularly, it has been discovered that the novel mold compositions, particularly the compositions of the primary slurry coatings, enable the formation of a metal-mold barrier layer to be formed. It is this novel barrier, which is formed in a controlled prevailing furnace atmosphere, that is reducing for silica, which enables excellent surface finishes to be obtained for the castings. The reducing atmosphere enables alumina to dissolve into the silica and remove the silica from the mold-metal interface.
Upon drying the material the primary and secondary coatings have approximately the following composition:
(1) Primary coating
the alumina to silica ratio by weight percent is from about 89:11 to approximately 95:5
(2) Secondary coating
the alumina to silica ratio by weight percent is from about 84:16 to approximately 93:7. Overall, alumina comprises from 80 to 99.9 percent by weight of the total mold material after drying.
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A composition for making shell investment molds for the casting and solidification of superalloys therein embodies preparing a primary slurry composition of a mixture of three different flour grain sizes of fused alumina and a silica binder. The flour grain sizes range from approximately 240 mesh to approximately 400 mesh, U.S. Standard or Tyler screen series.
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BACKGROUND
In fluidic systems, such as those used in the downhole drilling and completion industries, for example, devices and methods to allow a port that is initially closed to be subsequently opened are useful. It is also useful to have devices and methods that are able to move one component relative to another. Devices and methods, therefore, that allow an operator to perform both actions, relative movement of components and opening of a previously closed port, with a single input parameter are also useful.
BRIEF DESCRIPTION
Disclosed herein is an openable port. The port includes a body, a sleeve movable relative to the body, and a plug disposed at the sleeve that is extrudable through the sleeve. And the sleeve is substantially occluded to flow therethrough by the plug prior to extrusion of the plug and is open to flow therethrough after extrusion of the plug.
Further disclosed herein is a method of opening a port. The method includes, pressuring up to a first pressure against a plugged sleeve disposed at a body, moving the sleeve relative to the body, pressuring up to a second pressure against the plugged sleeve disposed at the body, and extruding a plug through the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
FIG. 1 depicts a cross sectioned view of an openable port disclosed herein shown in an un-extended and un-extruded position;
FIG. 2 depicts a cross sectioned view of the openable port of FIG. 1 shown in an extended and extruded position; and
FIG. 3 depicts a partial cross sectioned perspective view of a support employed in the openable port of FIG. 1 .
DETAILED DESCRIPTION
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring to FIGS. 1 and 2 , an embodiment of an openable port disclosed herein is illustrated generally at 10 . The openable port 10 includes, a body 14 , two collars 16 A, 16 B slidably engaged with the body 14 , a sleeve 18 slidably engaged with the collar 16 B, and a plug 22 , seatingly engagable with a seat 26 on the sleeve 18 . In this embodiment the body 14 is sealably fixed to a wall 30 of a tubular 34 , such as a casing or well bore liner as is used in downhole hydrocarbon recovery or carbon dioxide sequestration industries, for example. Seals 38 , illustrated herein as o-rings form seals between the body 14 , collars 16 A, 16 B and the sleeve 18 , while allowing them to slide relative to one another. The plug 22 , shown here as a ball, seals against the seat 26 thereby allowing pressure to build thereagainst. At selected forces, established by frictional engagement between the body 14 , collars 16 A, 16 B and the sleeve 18 (or optionally by force failing members 42 , such as shear screws shown, for example), the sleeve 18 will move relative to the collar 16 B, the collar 16 B will move relative to the collar 16 A, and the collar 16 A will move relative to the body 14 (from the positions shown in FIG. 1 to the position shown in FIG. 2 ). Additionally, at a selected force the plug 22 will extrude through the sleeve 18 by either deforming the seat 26 , deforming the plug 22 or deforming both the seat 26 and the plug 22 , thereby opening a port 46 in the sleeve 18 . Alternate embodiments are contemplated that have the sleeve 18 directly slidable engaged with the body 14 without the collar 16 A or 16 B located therebetween.
The foregoing structure allows an operator to perform several actions via the single action of pumping fluid. The several actions include: telescopically extending the sleeve 18 relative to the collar 16 A, telescopically extending the collar 16 B relative to the collar 16 A, telescopically extending the sleeve 18 relative to the collar 16 B and extruding the plug 22 through the sleeve 18 . Upon completion of these actions, the operator can continue pumping fluid, which would then flow out of the tubular 34 in the direction of arrow 48 through the port 46 in the sleeve 18 . The openable port 10 could be used in a downhole wellbore application, for example, where it is desired to pump proppant into a formation 50 where there is an open annular space 54 between the wall 30 of the tubular 34 and the formation 50 . By extending the collars 16 A, 16 B and sleeve 18 radially beyond the body 14 the proppant can be pumped directly into openings 58 in the formation 50 where it is intended to be pumped rather than into the annular space 54 . Although the embodiment disclosed herein includes the two collars 16 A and 16 B, alternate embodiments could employ more than two or fewer than two collars, depending upon the dimension of radial extension that is desired.
Forces required to extend the sleeve 18 and the collars 16 A, 16 B can be set to be less than a force required to extrude the plug 22 through the sleeve 18 . This force relationship assures that the sleeve 18 and collars 16 A, 16 B extend before the plug 22 is extruded. Such a force relationship may be desirable since extruding the plug 22 first allows fluid within the tubular 34 to flow through the port 46 making building pressure to extend the sleeve 18 and collars 16 A, 16 B more difficult.
The body 14 , collars 16 A, 16 B, sleeve 18 and plug 22 can all be made of metal, as can the seals 38 . However, other materials may be used for any of these components including making the seals 38 and plug 22 of a polymeric material such as an elastomer to facilitate the sealing, sliding and extruding discussed above.
Referring to FIG. 3 , the seat 26 can be integrally formed as part of the sleeve 18 or can be formed on a separate part such as a support 62 that is attached to the sleeve 18 by methods such as press fitting, welding and threadably engaging, for example. In this embodiment the support 62 includes the seat 26 and a plate 66 with one or more holes 70 therethrough that define flow passageways. The holes 70 allow fluid to flow therethrough and provide pressure against the plug 22 when seated against the seat 26 to build the forces needed to extrude the plug 22 through the port 36 .
Additionally, the plate 66 includes an alignment feature 74 that aligns the plug 22 with the seat 26 . The alignment feature 74 can be a hole through the plate 66 (as illustrated), an indentation in the plate 66 , or a plurality of raised protrusions on the plate 66 . The plate 66 can also include sufficient flexibility to act as a biasing member to hold the plug 22 against the seat 26 in a seated configuration to aid in developing pressure there against. Flexibility of the plate 66 can cause the openable port 10 to serve as a one way valve prior to extrusion of the plug 22 through the seat 26 by flexing to allow the plug 22 to move away from the seat 26 in response to a differential pressure across the openable port 10 being greater on an outside of the tubular 34 than on the inside of the tubular 34 .
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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An openable port includes a body, a sleeve movable relative to the body, and a plug disposed at the sleeve that is extrudable through the sleeve. And the sleeve is substantially occluded to flow therethrough by the plug prior to extrusion of the plug and is open to flow therethrough after extrusion of the plug.
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TECHNICAL FIELD
The present invention relates to a power generation system and method, and especially relates to a power generation system and method which employ a solid oxide fuel cell on the exhaust side of the engine.
BACKGROUND OF THE INVENTION
Alternative transportation fuels have been represented as enablers to reduce toxic emissions in comparison to those generated by conventional fuels. At the same time, tighter emission standards and significant innovation in catalyst formulations and engine controls has led to dramatic improvements in the low emission performance and robustness of gasoline and diesel engine systems. This has certainly reduced the environmental differential between optimized conventional and alternative fuel vehicle systems. However, many technical challenges remain to make the conventionally-fueled internal combustion engine a nearly zero emission system having the efficiency necessary to make the vehicle commercially viable.
Alternative fuels cover a wide spectrum of potential environmental benefits, ranging from incremental toxic and CO 2 emission improvements (reformulated gasoline, alcohols, LPG etc.) and to significant toxic and CO 2 emission improvements (natural gas, DME etc.). Hydrogen is clearly the ultimate environmental fuel, with potential as a nearly emission free internal combustion engine fuel (including CO 2 if it comes from a non-fossil source). Unfortunately, the market-based economics of alternative fuels or new power train systems are uncertain in the short to mid-term.
The automotive industry has made very significant progress in reducing automotive emissions for both the mandated test procedures and the “real world”. This has resulted in some added cost and complexity of engine management systems, yet those costs are offset by other advantages of computer controls: increased power density, fuel efficiency, drivability, reliability and real-time diagnostics.
Future initiatives to require zero emission vehicles appear to be taking us into a new regulatory paradigm where asymptotically smaller environmental benefits come at a very large incremental cost. Yet, even an “ultra low emission” certified vehicle can emit high emissions in limited extreme ambient and operating conditions or with failed or degraded components.
What is needed in the art is a power generation system having essentially zero emissions, high efficiency, and compatibility with existing fuels and infrastructure.
SUMMARY OF THE INVENTION
The present invention relates to a power generation method and system. The system comprises: an engine, having an intake and an exhaust; an air supply in fluid communication with said engine intake; a fuel supply in fluid communication with said engine intake; and at least one SOFC, having an air intake in fluid communication with said air supply, a fuel side intake, a SOFC effluent and an air effluent, said SOFC fuel side intake in fluid communication with said engine exhaust.
The method comprises: supplying at least a first portion of fuel and a first portion of air to an engine; reacting said first portion of fuel and said first portion of air in an engine to produce an engine effluent; introducing said engine effluent to a fuel intake of a SOFC; introducing a second portion of air to an air intake of said SOFC; and ionizing oxygen in the second portion of air such that the ionized oxygen migrates to the fuel side of the SOFC where it reacts with said engine effluent to produce an SOFC effluent.
These and other features and advantages of the present invention will be apparent from the following brief description of the drawings, detailed description, and appended claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawing, which is meant to be exemplary, not limiting, and where mass flows are shown with solid lines and power flows are illustrated with broken lines:
The FIGURE is a schematic depiction of another embodiment of a system of the present invention utilizing a SOFC on the exhaust side of an engine.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a power generation system and methods for using the same. Generally, the system may comprise at least one solid oxide fuel cell (“SOFC”), an engine, one or more heat exchangers, and optionally, one or more compressors, an exhaust turbine, a catalytic converter, preheating device, plasmatron, electrical source, and conventional connections, wiring, control valves, and a multiplicity of electrical loads, including, but not limited to, lights, resistive heaters, blowers, air conditioning compressors, starter motors, traction motors, computer systems, radio/stereo systems, and a multiplicity of sensors and actuators etc.
In one embodiment of the present invention disclosed in the FIGURE, the SOFC is employed on the exhaust side of an engine. The system is intended to be capable of operating in two modes described herein as “normal” and “standby”. In the standby mode, the SOFC is operated independently of the engine at relatively low power levels. In the normal mode, at least a portion of the fuel 31 and at least a portion of the air 1 enter an engine 125 , with the air optionally first compressed in compressor 100 to pressures up to or exceeding about 3 atmospheres (absolute pressure), with about 1.5 to about 2.0 atmospheres preferred. Within the engine, the fuel is burned in the presence of air. Under most operating conditions, the engine is operated between stoichiometric and the rich limit, producing an engine effluent comprising nitrogen, carbon dioxide, oxygen and water, in combined amounts of up to or exceeding about 99 volume percent (vol. %), with between about 91 vol. % and about 99.4 vol. % common, and lesser amounts possible, and small amounts of carbon monoxide (typically about 0.5 vol. % to about 5 vol. %), hydrogen (about 0.1 vol. % to about 3 vol. %), and hydrocarbons, which includes unburned fuel and by-products, (up to about 0.5 vol. %), with greater amounts of these constituents possible if desired.
From the engine, the engine effluent 35 ′ is directed into the fuel side of a SOFC. In star-up modes or under conditions where heat must be added to the SOFC, air 9 may also be injected to the engine effluent 35 ′ or the engine may be run lean. Under conditions where additional fuel is desired for the SOFC, extra fuel may be injected late in the combustion process, into the engine affluent 35 ′, or may be vaporized or atomized in the heat exchanger 115 and supplied directly as fuel 34 to the fuel side of the SOFC. Meanwhile, the remainder of the air stream 10 is directed to the air side of the SOFC where oxygen in the air ionizes to O −2 , producing electricity. The electricity is directed from the SOFC 110 via line 56 to as electrical source 140 such as a battery, capacitor, motor/generator, combination thereof, and or other device, while the oxygen ions migrate across the ceramic electrolyte to the fuel side where they react with the fuel and engine effluent to form mostly water and carbon dioxide.
The SOFC effluent 21 ′ and/or the oxygen depleted air 23 ′ can optionally pass through a turbine 130 which recovers:energy from the stream(s). The SOFC effluent 21 ′ and oxygen depleted air 23 ′ then preferably passing through a catalytic converter 135 prior to catering the heat exchange 115 . Within the heat exchanger 115 , the SOFC effluent 21 ′ and oxygen depleted air 23 ′ are cooled, typically to temperatures below about 300° C. while heating the fuel 31 and air 1 to temperatures typically exceeding about 300° C. The exhaust stream 43 from the heat exchanger 115 can then be vented to the environment.
Alternatively, for cold start-up and warn up conditions, the SOFC preferably performs a reforming function where all or a portion of the SOFC effluent 21 ′ and/or oxygen depleted air 23 ′ can be combined with the fuel stream 31 as it enters the engine 125 . Introducing SOFC effluent 21 ′ and/or oxygen depleted air 23 ′ to the engine intake helps improve the efficiency of the ultra-dilute combustion within the engine, thereby reducing engine emissions, especially hydrocarbons and nitric oxides. Under conditions where all or part of the SOFC is maintained at an elevated temperature, this intake reforming function is particularly effective. This function is further defined in commonly assigned U.S. Pat. No. 6,230,494, which is hereby incorporated by reference.
As stated above, the air entering the system is preferably compressed prior to introduction into the SOFC 110 , however, the compressor is not essential since the engine itself can act as a pump, enabling elimination of the compressor. The compressor, however, allows increased power output and reformate, i.e. engine effluent 35 ′, output of the engine. The particular type of compressor employed in the system Is dependent upon the particular application. For example, a conventional compressor capable of compressing to moderate pressures (up to about 3 atmospheres) is typically employed in turbocharged engines, with the pressure employed controlled to optimize the power output and efficiency of the SOFC and the engine as a system. For uses within a vehicle, the pressure can be up to or exceeding about 2 atmospheres (absolute pressure), with about 1 to about 2 atmospheres (absolute pressure) preferred. Possible compressors include, but are not limited to, mechanical devices driven, for example, by direct connection to the exhaust turbine or by a mechanical supercharger, or can be operated independently via electricity or hydraulics.
The SOFC employed with the present invention can be any conventional SOFC capable of ionizing oxygen. The SOFC comprises an electrolyte having catalyst disposed on both the fuel and air side of the electrolyte. Possible catalysts include those capable of ionizing oxygen and reacting the ionized oxygen with conventional fuels, including, but not limited to, noble metal-based catalysts and alloys thereof, among others. It is envisioned that multiple SOFCs can be employed, in series or in parallel on the exhaust side of the engine, or even on the induction side of the engine.
Within the SOFC, the ionization of the oxygen produces electricity which can be directly utilized by the vehicle to power various electrical parts, including, but not limited to, lights, resistive heaters, blowers, air conditioning compressors, starter motors, traction motors, computer systems, radio/stereo systems, and a multiplicity of sensors and actuators, among others. Unlike conventional motor vehicles, the electricity produced by the SOFC is direct current which can be matched to the normal system voltage of the vehicle, thereby avoiding the requirements for devices such as diodes, voltage conversion and other losses, such as resistive losses in the wiring and in/out of the battery, associated with conventional vehicle systems and traditional hybrid electrical systems. This high efficiency electricity allows efficient electrification of the vehicle, including functions such as air conditioning and others, allowing weight, fuel economy and performance advantages compared to conventional hybrid electric mechanization and conventional internal combustion engine systems.
During start-up and for cabin heating, the SOFC can be operated at high adiabatic temperatures, e.g. up to about 1,000° C., subject to catalyst limitations, with typical operating temperatures ranging from about 600° C. to about 900° C., and preferably about 650° C. to about 800° C. Consequently, at least one heat exchanger is preferably employed to cool the SOFC effluent and conversely heat the air prior to entering the SOFC, with conventional heat exchangers generally employed.
The fuel utilized in the system is typically chosen based upon the application, and the expense, availability, and environmental issues relating to the fuel. Possible fuels include conventional fuels such as hydrocarbon fuels, including, but not limited to, conventional liquid fuels, such as gasoline, diesel, ethanol, methanol, kerosene, and others; conventional gaseous fuels, such as natural gas, propane, butane, and others; and alternative or “new” fuels, such as hydrogen, biofuels, Fischer Tropsch dimethyl ether, and others; and combinations thereof The preferred fuel is typically based upon the type of engine employed, with lighter fuels, i.e. those which can be more readily vaporized and/or conventional fuels which are readily available to consumers, generally preferred.
The other major component beside the SOFC which is typically employed by the system of the present invention to produce tractive power for a vehicle is the engine. Within the engine, SOFC effluent, air, and/or fuel are burned to produce energy, while the remainder of unburned fuel and reformed fuel is used as fuel in the SOFC. The engine can be any conventional combustion engine including, but not limited to, internal combustion engines such as spark ignited and compression ignited engines, including, but not limited to, variable compression engines.
Similar to the engine, the turbine can be employed to recover energy from the engine effluent to produce tractive power and further to recover energy to operate the compressor(s) and preferably to generate electricity for various uses throughout the system and/or vehicle. The turbine employed can be any conventional turbine useful in automotive or power generation applications. In a preferred embodiment, the turbine and/or compressor may be accelerated or decelerated by a motor/generator to increase the compression (when required to increase the compression for optimal system performance) or to decrease compression (when excessive energy is available in the exhaust gases). For example, a high speed electrical machine can be linked to the turbine and compressor.
After passing through the turbine, the SOFC effluent preferably enters a catalytic converter in order to attain extremely low, nearly zero emissions of hydrocarbons and nitric oxide. The catalytic converter is typical of those used in automotive applications, including those employing (1) noble metals and alloys thereof, such as platinum, rhodium and palladium catalysts and alloys thereof, among others and/or (2) particulate filtering and destruction.
Optional equipment which additionally may be employed with the present system includes, but is not limited to, sensors and actuators, heat exchangers, a battery, fuel reformer, burner, phase change material, thermal storage system, plasmatron, a desulfurizer, or combination thereof Where the desulfurizer may be employed if the fuel is rich in sulfur, or if the catalyst employed in the SOFC is particularly intolerant to sulfur, such as nickel-based catalysts, among other conventional equipment. In contrast to conventional vehicles and even to prior art systems which employ fuel cells, the system of the present invention does not require the use of a battery. Although a small battery may be employed as a sort of back-up system, it is not necessary. The engine may act as a peaking device for high power modes (analogous to a battery).
The various embodiments of the present invention provide advantages over the prior art in that they: (1) provide electrical power that is “cheaper” than shaft power (in terms of fuel consumption); (2) reduce or eliminate the need for batteries (the SOFC can operate with the engine off to supply electric accessories and modest tractive power; (3) provide an efficiency benefit since conventional fuel reformers consume electricity, and the SOFC of the present invention may perform the reforming function and an emission destruction, while producing electricity; (4) nearly zero emissions due to the ability to combust extremely dilute mixtures on the cold start and to consume unburned and partially burned fuel which is always produced in combustion (especially rich combustion), e.g. intended to meet or exceed SULEV standards of 0.010 gallons per mile (g/mi) hydrocarbons, 1.0 g/mi carbon monoxide, 0.02 g/mi nitric oxide, and 0.01 g/mi particulate; (5) increase overall system efficiency, up to or exceeding about 60% at light load and about 45% at heavy load; and (6) are compatible with advanced combustion systems such as homogeneous charge compression ignition—a “clean” diesel technology where premixed fuel is ignited by compression pressure and temperature; and (7) allow combustion of fuels with extremely low particulate emissions by trapping and consuming particulate in the SOFC and catalytic converter.
The embodiments of the present system and method, although mostly described in relation to utilization within a vehicle, can be utilized in numerous applications, including, but not limited to: cogeneration of heat and electric power, distributed electric power generation, such as small scale power plants for commercial/industrial/marine applications, and portable power generation, such as military/construction/recreational applications, among others.
It will be understood that a person skilled in the art may make modifications to the preferred embodiment shown herein within the scope and intent of the claims. While the present invention has been described as carried out in a specific embodiment thereof, it is not intended to be limited thereby but is intended to cover the invention broadly within the scope and spirit of the claims.
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The present system and method relate to power generation utilizing an exhaust side solid oxide fuel cell. Fuel is burned in an engine in the presence of air. The engine exhaust passes through a solid oxide fuel cell where it is consumed in the production of electricity and ionization of oxygen in an air stream also introduced to the solid oxide fuel cell. The solid oxide fuel cell effluent fuel stream and/or air stream can be recycled through the engine, directed through a turbine to recover additional energy therefrom, and/or passed through a catalytic converter. The resulting system exhaust has negligible to zero amounts of nitric oxides, hydrocarbons, carbon monoxide, and particulates.
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This is a divisional of application Ser. No. 07/619,377 filed on Nov. 18, 1990, now U.S. Pat. No. 5,184,381.
BACKGROUND OF THE INVENTION
This invention relates generally to fibrous synthetic polymers. More specifically, the invention relates to the production of fluid entangled filaments.
In the synthetic fiber industry, it has long been recognized that yarn bundles should be coherent for processing at high rates of speed. Initially, such yarns were made by twisting. But twisted yarn is expensive and complicated to produce.
Responding to the need for inexpensive coherent yarn filaments, fiber manufacturers discovered that yarns could be interlaced. Later it was recognized that interlacing was a means to mix fibers of different types, such as color or dye affinity. U.S. Pat. No. 3,846,968 to Sheehan et al. demonstrates a mixed fiber application of interlacing.
An interlaced yarn is characterized by points of entanglement, called nodes, which are separated by spaces of unentangled filaments. Commonly, individual yarn filaments are interlaced by exposing the filament bundle to a localized fluid jet. U.S. Pat. Nos. 2,985,995 and 3,110,151, both to Bunting, Jr., et al. describe several methods of inducing interlacing by fluid impingement. These patents show what is referred to herein as a hard tight node (see U.S. Pat. No. 2,985,995, FIG. 25). One such interlacer has openings at various angles of a rotary wheel design. The rotary wheel turns with the yarn and creates an even spacing which can result in patterning of yarns having different color components in the final product. For the purposes of the present invention, "even" spacing means essentially equal distance between nodes. The Bunting, Jr., et al. patents teach that more than one interlacer can be used in series and that the spacing of nodes can be varied between random and periodic by adjusting the fluid temperature, processing speed and finish. To accomplish these objectives, the Bunting, Jr., et al. interlacers are designed for free movement of the filaments in the yarn passage.
Many methods for interlacing filaments refer to the node spacing as random or irregular. However, for certain applications of yarns made from two or more contrasting filaments with, for example, different dye affinities or which are precolored differently, for example heather carpets, as presented in U.S. Pat. Nos. 4,223,520 to Whitted et al., 4,570,312 to Whitener, Jr., and 4,697,317 to Nelson, it is important that the nodes be regularly spaced. Otherwise, the nodeless gaps show up in the carpet as stria or short sections. A series of stria can appear as a streak, like the dashes in the road form a center line. As used herein, "regular" nodes are nodes with unequal spacing having no gaps between them above 6 cms.
There are some methods designed to address certain problems with random nodes. For example, U.S. Pat. No. 3,115,691 to Bunting, Jr., et al. describes a single interlacing apparatus having two jet streams therein. According to the patent, the arrangement results in a greater degree of entanglement.
U.S. Pat. No. 3,426,406 to McCutchan, Jr. describes an interlacing apparatus designed to overcome randomness and streaking. At least one pair of opposed fluid conduits having a common longitudinal axis which intercepts and is perpendicular to the axis of an elliptical yarn passageway achieves the objective.
U.S. Pat. No. 3,474,510 to Torsellini describes a method to overcome randomness in the prior devices by exposing the yarn moving under tension to fluid pulses. The pulses occur at constant time intervals and act on the yarn from different directions.
U.S. Pat. No. 3,563,021 to Gray describes the use of cooperating tandem jets to achieve a uniformly interlaced yarn. The oscillation of the filament bundle produced by the first jet acts to traverse the yarn between the orifices of the other jet.
U.S. Pat. Nos. 4,064,686 and 4,223,520, both to Whitted et al., are directed to an interlaced yarn having alternatingly twisted nodes. That is, one node is twisted counterclockwise, the next is twisted clockwise and so on. This is achieved by using diametrically opposed fluid passages in the entangling apparatus. The stretching in the interlacing apparatus can be changed by adjusting the tension so that some portions are stretched more than others and, upon dyeing, cause a color differential.
In addition, there are several methods for producing novelty yarns by various entangling procedures. One such yarn is disclosed in U.S. Pat. No. 3,846,968 to Sheehan et al. The yarn has a particular structure from being entangled in the entangling apparatus.
U.S. Pat. No. 4,152,885 to Cox, Jr., describes an interlocked yarn wherein at least one of the individual filaments in the bundle encircles the other filaments to interlock the filaments together. The yarn is made by feeding the filament bundle into a fluid medium flowing opposite of the direction of bundle travel.
U.S. Pat. No. 4,152,886 to Nelson describes a yarn which is intermittently debulked by passing a stream of heated gas through the yarn while it is under tension. The process achieves varying levels of bulking and debulking.
U.S. Pat. No. 4,697,317 to Nelson is directed to a randomly-spaced, tightly entangled nub yarn and the process and apparatus for making the same. As a starting point, the process uses crimped and interlaced supply yarn. Nelson uses the term "nub" to denote what is referred to herein as a hard node. According to this Nelson patent, the nubs can be up to 1 inch (2.54 cm) long.
Although the above patents often result in filaments with node spacing such as the even node spacing produced by the rotary wheel interlacer of U.S. Pat. No. 3,110,151, such node spacing is not an answer to the problem of stria caused by nodeless gaps. As an illustration, exactly even node spacing can result in patterning in some carpet constructions which resembles that experienced from the twist cabled ends of multicolored bulked continuous filament (BCF).
A further problem encountered in producing interlaced yarn which is suitable for applications requiring uniformity, such as carpet applications, is that air entangling conditions which are severe enough to insure regular nodes also produce excessively tight nodes. These hard nodes, like the "nubs" of Nelson, reduce carpet yarn cover in carpet applications, give the carpet a harsh hand and also make tufting difficult. Thus soft node yarn is desirable for both mixed fiber and unmixed (homogeneous) fiber yarns. For homogeneous yarns, soft nodes maintain consistent coherence without sacrificing cover with hard knots, or affecting the carpet tufting by nubbiness in the face or picks from hard nodes in the tufting needles.
Previously known means to soften the nodes result in undesirable effects. For example, reduction of fluid flow rate or increased process speed causes unacceptably irregular spacing between nodes which can, as noted, cause streaking due to stria. On the other hand, at a given fluid flow rate, slowing down the process speed makes the nodes harder and also limits production rate. Reducing the yarn tension can cause a high degree of yarn fuzziness which then interferes with further handling like tufting. Also, low tensions make consistency difficult to maintain and the process difficult to control.
Thus, there remains a need for interlaced multifilamentary yarn which has soft, regular nodes. In addition, there remains a need for such yarn which can be processed at speeds in the range of about 300 to about 2,000 m/min.
SUMMARY OF THE INVENTION
Accordingly, one embodiment of the present invention is a multifilamentary yarn composed of a plurality of periodically interlaced synthetic polymeric filaments which is characterized by regular node spacing and a yarn harshness of less than about 100.
A second embodiment relates to an apparatus for preparing regular soft nodes in multifilamentary yarns composed of synthetic polymeric filaments which includes at least two interlacers defining an integral continuous yarn passageway therethrough arranged in series such that each interlacer operates independently of the other and so that yarn tension exceeding 100 gms per 1000 denier does not result.
In a third embodiment, a process for preparing periodically entangled yarn from unentangled multifilamentary yarn includes subjecting an advancing yarn to a first interlacing action sufficient to create a number of randomly spaced interlaced nodes between spaces of non-interlaced gaps of a first length, followed by subjecting the yarn to a second interlacing action sufficient to create additional nodes in non-interlaced gaps thereby leaving gaps of a second length wherein the nodes have a harshness of no more than about 2.0.
It is an object of this invention to provide an improved multifilamentary interlaced yarn.
It is a further object of this invention to provide an improved apparatus for preparing interlaced multifilamentary yarn.
It is a still further object of this invention to provide an improved process for preparing interlaced multifilamentary yarn.
Related objects and advantages will be apparent to one ordinarily skilled in the relevant art after reviewing the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of harsh yarn having hard nodes.
FIG. 2 is a schematic view of irregular yarn having unacceptably large nodeless gaps.
FIG. 3 is a schematic view of soft yarn having soft regularly spaced nodes made according to the present invention.
FIG. 4 is a side plan view of an apparatus according to the present invention and shown with a first interlacer design.
FIG. 5 is an alternate interlacer arrangement according to the present invention.
FIG. 6 is a side plan view of an apparatus according to the present invention and shown with a second interlacer design and adapted for concurrent drawing and bulking.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to specific embodiments of the invention and specific language which will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications, and such further applications of the principles of the invention as discussed are contemplated as would normally occur to one skilled in the art to which the invention relates.
An easily discernible difference between the harshness of soft nodes and hard nodes can be felt by pulling the respective yarns between the thumb and forefinger of a human hand. Yarn harshness is, however, a fairly qualitative characteristic which has, to some extent, eluded quantitative definition. To advance an understanding of the present invention, a novel method for determining the harshness of entangled yarn relative to the hardness or softness of the nodes is set forth herein. This test is the subject of commonly owned U.S. Pat. No. 5,195,313. The difference between soft and hard nodes is quantified by what is hereafter referred to as The Yarn Harshness Test.
In The Yarn Harshness Test, a value is assigned to the ratio of the node length to the width or diameter. This ratio is referred to as the node harshness. Lower numbers indicate softer nodes. Node dimensions can be determined with, for example, a calibrated microscope or a pocket scope. With reference to FIG. 1, yarn 10 is shown having nodes 11. Node length (L) is defined as the space between the beginning 12 of nodal entanglement and the end 13 of nodal entanglement. Node width (W) is defined, for the present purposes, as the distance between top 14 of a node shown in the orientation of FIG. 1 and bottom 15 of that node. For accuracy, a number of nodes are assigned a harshness and the average harshness determined. In most cases, nodes in any yarn will be an approximately Gaussian distribution of harshness. The average of node harshness correlates to carpet hand, yarn cover and tufting performance and provides a comparison factor with respect to these properties for yarns having equal numbers of nodes per meter. To assign Yarn Harshness, the number of nodes per meter is multiplied by the average individual node harshness. Visual counting is one method to determine nodes per meter.
Yarns with large gaps or unentangled sections such as that illustrated in FIG. 2 may yield low yarn harshness numbers. These yarns may tuft and feel like the soft node product but are unlikely to yield satisfactory carpet uniformity if different color or dye affinity filaments are used in individual yarns. Therefore, a Standard Yarn Streak Potential Test may be used as a second factor to determine the suitability of yarns for specified end uses. The Standard Yarn Streak Potential Test is described in U.S. Pat. No. 4,894,894 to Coons, III et al. which is hereby incorporated by reference for the Standard Yarn Streak Potential Test defined therein. This test can be used to estimate yarn uniformity by measuring the yarn DL. DL is a measurement of the color space value or lightness or darkness of a sample compared to a standard. The measurement system, CIE L*a*b*, was developed by the International Commission on Illumination. The standard used in the Standard Yarn Streak Potential Test is established from an average of readings on the standard sample. Then the standard deviation of a chosen sample's observed DL is compared against the averaged standard to give a reliable quantitative estimate of striations in the sample when tufted and overall propensity of a yarn to streak in full width carpet.
A first embodiment of the present invention relates to a yarn having a low yarn harshness and, where the yarn is made of mixed filaments, a low streak potential. FIG. 3 illustrates yarn 25 of this first embodiment. Yarn 25 has what is referred to herein as soft nodes 26. These soft nodes are characterized by an average node harshness of no more than about 2.0 which yields a Yarn Harshness of no more than about 100. The gaps are spaced approximately, although not necessarily exactly, uniformly with internodal spacings of no more than about 6 cms. Where the yarn is made of mixed filaments, uniformity in the final yarn use is insured if the differential lightness (DL) standard deviation remains less than about 6 as determined by the Standard Yarn Streak Potential Test.
A second embodiment of the present invention relates to an apparatus for interlacing the yarn in the method of the present invention. Interlacing apparatus 30 is illustrated in FIG. 4. The apparatus can be used in nearly any air entangling process that normally results in tight nodes. Exemplary processes are described in U.S. Pat. No. 4,223,520 to Whitted et al. and U.S. Pat. No. 4,570,312 to Whitener, Jr. Even entangling processes that have nearly the opposite goal, i.e., preparation of compact or hard nodes, may benefit when the apparatus of the present invention is used. Two examples of these processes are U.S. Pat. No. 4,064,686 to Whitted et al. and U.S. Pat. No. 4,152,886 to Nelson. In all of these processes, the apparatus is used by substituting for the interlacer called for therein.
Turning now to apparatus 30 in more detail, FIG. 4 shows apparatus 30 installed with the apparatus of the process disclosed in U.S. Pat. No. 4,570,312 to Whitener, Jr. That patent is hereby incorporated by reference for the process taught therein and for purposes of illustrating how the present apparatus may be used in interlacing operations. It will be recognized that the illustration of the present invention with the process of U.S. Pat. No. 4,570,312 is not intended to limit the scope of the invention but is intended to enhance an understanding of the invention. As shown, apparatus 30 is mounted on housing 29 in the position of the interlacing head and includes interlacers 32 and 33 arranged in series. One suitable interlacer for use in the present apparatus is described in U.S. Pat. No. 4,841,606 to Coons, III, which is hereby incorporated by reference as an example of a useful interlaced. (See FIG. 5.) Guide pin 35 is optional. Each interlacer 32 and 33 includes a yarn passageway 39 and 41, respectively, and air jet/orifice inlet 43 and 37, respectively. Air jet/orifice inlets 43 and 37 are connected to air supply 50 through conduits 51 and 52, respectively. Yarn passageways 39 and 41 include yarn inlets 42 and 36, respectively, and yarn outlets 44 and 38 in continuous communication therewith.
Yarn 31 is shown moving through a set of interlacers 32 and 33 in the direction of the arrows. Untangled multifilamentary yarn enters interlacing apparatus 30 through apparatus feed port 34 and may contact pin 35, if pin 35 is present. The yarn then enters the inlet port 36 of interlacer 33 where yarn 31 is subjected to a stream of forced fluid. The fluid enters yarn passageway 41 at air inlet 37. The action of the fluid causes entangling of the yarn. The yarn then exits first interlacer 33 through outlet port 38. As shown, the action of first interlacer 33 results in the formation of random nodes 40.
Continuing in its path, yarn 31 then enters second interlacer 32 through its yarn inlet 42 where yarn 31 is subjected to fluid impingement in yarn passageway 39 through inlet 43. Yarn 31 then exits second interlacer 32 through yarn outlet 44. As a result, additional nodes 46 are formed in portions of yarn 31 left unentangled by first interlacer 33. For this reason, the interlacers should operate independently. Yarn 31 then exits interlacing apparatus 30 through apparatus exit port 45.
Fluid is supplied to interlacers 32 and 33 from fluid supply 50. Air is one suitable fluid. Conduits 51 and 52 supply a predetermined fluid pressure to respective interlacers 32 and 33. As shown, individual conduits 51 and 52 may join so that after junction 53 they form a main fluid supply conduit 55.
For maximum effectiveness, interlacer 32 and interlacer 33 should be arranged to operate independently. This means that the action of first interlacer 33 will not interfere with the interlacing action of second interlacer 32. In the illustration of FIG. 4, because of the effectiveness of the total interlacing action, each interlacer is supplied with relatively low air flow/pressure. Where the interlacer of U.S. Pat. No. 4,841,606 is used, the apparatus of the present invention obtains enhanced efficiency. The notches present in the yarn passageway of that interlacer guide the yarn into the region of fluid impingement. It is contemplated that any interlacer having means to guide the yarn into the fluid jet will achieve some degree of improved efficiency over interlacers which allow the yarn to move freely through the cross section of the interlacer. The interlacers should preferably be aligned with the air orifice or jet perpendicular to the thread path. The yarn most preferably passes directly over the air jet (43 and 37 in FIG. 4). It is presently believed that interlacers which operate based on free movement of the yarn in the entanglement chamber like that taught in Bunting, Jr., et al. can not be used advantageously in the present invention.
The overall air usage with two (2) interlacers is only slightly higher than with that of a single interlacer. The optimum air pressure varies according to yarn speed and denier. For example, the following air pressures are suitable under the conditions: 3,000 denier-55 psig; 4,000 denier-70 psig; 5,000 denier-85 psig; and 6,000 denier-100 psig at 750 yds/min.
Air pressure is adjusted for yarn denier and physical properties. In the absence of adjustable air pressure, the interlacer units can be equipped with various jet orifice sizes for yarn denier and physical properties. The first interlacer, as noted, makes many nodes but leaves gaps. The second interlacer is, of course, not effective where nodes already exist. It adds nodes only where the first interlacer left gaps. It should be noted that more than two independent interlacers could be used to further insure that no exceptionally large gaps pass through and cause yarn having unsuitably high streak potential.
The arrangement of the two (2) independent interlacers must not create excessive yarn tension, as high tension can pull soft nodes into hard nodes. Accordingly, the interlacers are arranged to provide yarn angling for efficient interlacer operation with tension high enough to make the process controllable without fuzziness but below a tension which causes hard nodes. In this regard, the portion of the yarn passageway within each interlacer should be oriented to operate nearly completely independently, for example, between about 90° and about 120° with reference to the longitudinal axes of the passageways. For instance, the longitudinal axes interlacers 32 and 33 of FIG. 4 are oriented in an approximately 90° angle. Presently, it is considered most preferable if the yarn enters and leaves each interlacer at an angle of about 45° for a total yarn angle of 180° (from feed port 34 to exit port 45 in the variation of FIG. 4).
In the variation of FIG. 5 showing three interlacers, the longitudianl axis of the yarn passageway of each interlacer perferably remains about 90° (as illustrated). The yarn enters and leaves each interlacer perferably at an angle of about 45° for a total yarn angle of about 180°, i.e., the yarn reverses the direction of travel in going through the apparatus.
A further variation on the second embodiment of the present invention concerns the provision of an additional mechanism for concurrently drawing (orienting) and bulking (crimping) the yarn. This modification is exemplified in Example 2. Advantageously, by combining the drawing and bulking steps with entangling, the product yarn is more economical to make. Previously, processes which similarly combined steps were very limited by the speed at which effective entangling and blending of the multicolored filaments could be insured. Furthermore, the combination of this variation with air obviates expensive, messy and dangerous steam. One manner of carrying out this modification is illustrated in FIG. 6. For the following description, reference is made to U.S. Pat. No. 4,894,894 which has previously been incorporated by reference for the Streak Potential Test taught therein and which is now hereby incorporated by reference for the process and apparatus taught therein. In general, the drawing and bulking take place as described in the patent, but with the entangling apparatus of the present invention substituted for the intermixing jet taught therein.
Illustrated in FIG. 6 is a schematic which is exemplary of an apparatus according to the variation of the second embodiment of the present invention wherein the yarn is concurrently drawn, bulked and analyzed. Undrawn feed yarn 61 is taken off of package 62, fed through first guide 63 and makes about three wraps around first godet 64. First godet 64 is used to pretension the yarn. The yarn is then drawn between second godet 65 and third godet 66. The yarn makes seven or eight wraps around both second godet 65 and third godet 66. Yarn 61, now drawn, is then bulked in tube 67. One useful tube is described in U.S. Pat. No. 3,908,248. Now bulked yarn 61 then travels over direction changing roll 68 and tension device 69 after which the yarn contacts a fourth godet 70 and a fifth godet 72. The bulked yarn is overfed from fourth godet 70 to fifth godet 72. Between these godets (70 and 72) is situated interlacer apparatus 71 of the present invention. As shown, interlacer apparatus 71 includes two interlacers (in partial cross section to illustrate the shape of the yarn passageway therethrough). In communication, with interlacers 73 and 74 is air supply 75. After exiting the fifth godet, yarn 61 passes over another direction changing roller 76 and onto transverse rolls 77 of a winder. Yarn package 78 is then built up upon a package 2. Package 78 is driven by friction roll 79. In this manner the final yarn is entangled, drawn and bulked in a single integrated process. The yarn produced has superior streak resistance (when made of multicolored filaments or filaments with different dye affinities) and increased processibility from the presence of soft nodes.
A third embodiment of the present invention is a process for preparing soft node yarn. This process involves subjecting a multifilamentary yarn to a first interlacing jet followed by subjecting the yarn to at least a second interlacing jet which operates completely independently of the first jet. One or more additional jets may be used. This process results in yarn having a node harshness of less than about 2.0. One such process, which is presently preferred, is described above in connection with the apparatus of the second embodiment. The process may include the drawing and bulking steps, for example, as accomplished with the apparatus shown schematically in FIG. 6.
The invention will now be further described by reference to the following more detailed examples. The examples are set forth by way of illustration only and are not intended to limit the scope of the invention.
EXAMPLE 1
Nylon 6 bulked continuous filament yarn prior to entangling is prepared by melt spinning, drawing, and crimp bulking. The yarn comprises three individual components at 1115 denier with 58 trilobal filaments each. The three components include two white and one precolored black ends. This yarn comprising black and white multifilaments is fed into a Gilbos IDS-AE6 entangling apparatus equipped with two interlacing jets (U.S. Pat. No. 4,841,606) oriented such that the axis of the yarn passageways intersect at a 90° angle. The interlacers have the following dimensions: 0.250 in×0.186 in×0.155 in. The speed is 600 m/min. Air is supplied to each interlacer at 45 psig resulting in a total flow rate of 33 SCFM. The yarn is under tension, as measured after the interlacers, of 255 gms. The resulting yarn has 46 nodes/meter (average of 3 meters) and a node harshness (average of 30 nodes) as defined herein of 1.8 with a standard deviation of 0.9. The Yarn Harshness is 83. The standard streak potential is less than 6 DL.
One sample of this yarn is tufted into level loop 1/10 gauge carpet of 28 oz/yd 2 . The carpet had no face picks.
Another sample of this yarn is tufted into 1/10 gauge carpet with face weight of 20 oz/yd 2 . Upon inspection, none of the carpet backing is visible through the face yarn.
EXAMPLE 2
Two entanglement interlacers of U.S. Pat. No. 4,841,606 are used in the process illustrated in U.S. Pat. No. 4,894,894 to achieve the arrangement illustrated in FIG. 5. Two white and one precolored black undrawn nylon 6 feed yarns having a total denier each of 3200 are drawn and bulked (crimped) together at 1650 meters per minute. Air is supplied at 140 psig (88 SCFM) to the interlacer pair. The resulting yarn has a node harshness of 1.7 with a standard deviation of 0.8. The streak potential is less than 6 DL.
One sample of this yarn is tufted into level loop 1/10 gauge carpet of 28 oz/yd 2 . The carpet had no face picks.
Another sample of this yarn is tufted into 1/10 gauge carpet with face weight of 20 oz/yd 2 . Upon inspection, none of the carpet backing is visible through the face yarn.
COMPARATIVE EXAMPLE A
A multifilamentary black and white yarn is prepared and interlaced according to the process described in Example 1 except that the entangling apparatus is equipped with a single interlacing jet. Air is supplied at 85 psig resulting in a flow rate of 28 SCFM. The yarn tension measured after the interlacers is 270 gms. The resulting yarn has 49 nodes/meter (average of 3 meters). The node harshness (average of 30) is 3.6 with a standard deviation of 1.2 with the resulting yarn harshness of 176. The standard streak potential is 5.8.
One sample of this yarn is tufted into level loop carpet of 28 oz/yd 2 . The carpet has 3 face picks per 5 yds 2 . This carpet has a rough feel and uneven texture. The tufting apparatus requires frequent operator repair.
Another sample of this yarn is tufted into carpet with low face weight of 20 oz/yd 2 . The carpet backing is visibly apparent relative to the yarn prepared in Example 1 and Example 2, due to inadequate cover by the tight hard nodes.
COMPARATIVE EXAMPLE B
Interlaced yarn is prepared according to Comparative Example A but with 45 psig air pressure supplied to the single interlacer. The node harshness is 1.7 with a standard deviation of 0.9 and having a Yarn Harshness of 70.
The yarn is tufted into carpet which appears striated and streaky and has a standard streak potential of 9.0.
COMPARATIVE EXAMPLE C
Yarn is prepared according to U.S. Pat. No. 4,894,894 using the steam interlacer defined therein. Nodes are not present due to the continuous nature of the entanglement. However, the yarn has a Yarn Harshness of 400.
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Described are a multifilamentary yarn composed of a plurality of periodically interlaced synthetic polymeric filaments which is characterized by regular node spacing and a yarn harshness of less than about 100 and an apparatus and process for making the same.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention generally relates to an isocyanate-terminated polysiloxane material and more particularly to an isocyanate-terminated polysiloxane material for use as a curing agent, hardener or co-reactant in coatings.
[0003] 2. Description of Related Art
[0004] A typical two-component polyurethane system consists of an isocyanate-reactive polymer and an isocyanate or polyisocyanate. “Two-component” (also known as 2K) simply describes a paint system that is composed of a base paint and a hardener both of which are packaged separately. Before application of the paint, the base paint is mixed with the hardener in a predetermined ratio to initiate a chemical reaction. This paint mixture remains usable for a period of time known as pot life which varies depending on the formulation. The chemical reaction proceeds until gelation finally occurs. A two-component polyurethane, for example, may be composed of a polyol as the base and a polyisocyanate as the hardener.
[0005] Polysiloxanes have found their way into many areas including medical and non-medical fields. Medical applications of polysiloxanes include prostheses, artificial organs, facial reconstruction, catheters, artificial skin, contact lenses, and drug delivery systems. Non-medical applications include high-performance elastomers, membranes, electrical insulators, water repellants, anti-foaming agents, mold release agents, adhesives and protective coatings, release control agents for agricultural chemicals, and hydraulic, heat-transfer, and dielectric fluids. The use of polysiloxanes in coatings is increasing due to their ability to impart desirable characteristics such as improved chemical resistance, improved weatherability, improved flexibility, increased hydrophobicity and greater permeability to gases (while remaining impermeable to particles) compared to other polymers. In addition, polysiloxanes have lower surface energy (i.e. lower surface tension) and can therefore, provide higher slip properties and greater wettability which is why silicones have been primarily used as coating additives. This can bring lower viscosities in coatings and reduce the need for solvents which will lower the volatile organic content (VOC) of the coating system. However, alone polysiloxanes do not produce a desirable coating as they are very brittle.
BRIEF DESCRIPTION OF THE INVENTION
[0006] It has been discovered that polysiloxanes can be beneficially incorporated into isocyanate to produce a isocyanate-terminated polysiloxane material that retains the isocyanate functionality. The resulting isocyanate-terminated polysiloxane can preferably be used as a hardener for a two-component polyurethane system by further reacting it with an isocyanate-reactive polymer, such as a polyol. This preferably allows the beneficial incorporation of polysiloxanes into traditional coating systems such as acrylics, polyesters, epoxies and urethanes has allowed for the strengths of both inorganic and organic coatings to harmoniously produce a useable and robust coating.
[0007] In another aspect of the invention, the preferred isocyanate-terminated polysiloxane material can be preferably formed by partially hydrolyzing a methoxy-functional methyl phenyl polysiloxane resin to form a silanol functional resin and then reacted with a polyisocyanate to yield an isocyanate-terminated polysiloxane hardener where one of the NCO groups is reacted with the OH group that is directly bonded to a silicon. The isocyanate-terminated polysiloxane hardener contains at least one but more preferably two isocyanate groups that can react with an isocyanate-reactive functional group of a third component.
BRIEF DESCRIPTION OF FIGURES
[0008] For a more complete understanding of the present invention and for further advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings in which:
[0009] FIG. 1 is a graph of a FTIR analysis of an unaltered methyl phenyl polysiloxane intermediate resin from Example 1 showing the percent transmittance on the ordinate axis and the wavelength in cm −1 on the abscissa axis;
[0010] FIG. 2 is a graph of a FTIR analysis of a 20% hydrolyzed methyl phenyl polysiloxane intermediate resin from Example 1 showing the percent transmittance on the ordinate axis and the wavelength in cm −1 on the abscissa axis;
[0011] FIG. 3 is a graph of a GC analysis of the distillate from the hydrolysis reaction of a methyl phenyl silicone intermediate from Example 1;
[0012] FIG. 4 is a graph of a FTIR analysis of an isocyanate-terminated polysiloxane hardener of Example 1 showing the percent transmittance on the ordinate axis and the wavelength in cm −1 on the abscissa axis;
[0013] FIG. 5 is a graph of a FTIR analysis of the isocyanate-terminated polysiloxane hardener of Example 1 mixed with an acrylic polyester polyol showing the percent transmittance on the ordinate axis and the wavelength in cm −1 on the abscissa axis;
[0014] FIG. 6 is a graph comparing the gloss of a standard white acrylic polyester coating versus white and red acrylic polyester polysiloxane coating according to the invention showing the gloss in percent at sixty degrees on the ordinate axis and time in hours on the abscissa axis;
[0015] FIG. 7 is a graph comparing the DL and DE values of the standard white acrylic polyester coating versus white and red acrylic polyester polysiloxane coating according to the invention showing the DL and DE values on the ordinate axis and time in hours on the abscissa axis.
[0016] FIG. 8 is a graph comparing the DE values of the standard white acrylic polyester coating versus white and red acrylic polyester polysiloxane coating according to the invention showing the DE values on the ordinate axis and time in hours on the abscissa axis.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present invention can be better understood by the following discussion of the manufacture and use of certain preferred embodiments. All data disclosed below regarding time, temperature, amount of components, concentration in % by weight, etc. are to be interpreted as also including all values lying in the range of the respective measuring accuracy known to the person skilled in the art. Unless otherwise stated, technical grades of the various materials were used in the preferred embodiments.
[0018] The invention will be described in connection with addition of polysiloxane compound to an acrylic polyester polyurethane system. Specifically, the silanol functional polysiloxane is reacted with preferably one of the isocyanate groups of a polyisocyanate to form a polyisocyanate-terminated siloxane hardener. This hardener will then be reacted with a hydroxylated resin. For example, the polyisocyanate-terminated siloxane hardener can be reacted with an acrylic polyol to form an acrylic polyester polysiloxane coating. However, one of skill in the art will recognize that the invention can be used to form other isocyanate-terminated siloxane hardeners and can be used on other isocyanate-reactive polymers, such as acrylics, polyesters, epoxies and urethanes, to form coatings and other materials.
[0019] Preferably, the silanol functional polysiloxane resin is formed by partially hydrolyzing a methoxy-functional methyl phenyl polysiloxane resin. The resulting silanol functional polysiloxane resin is then reacted with a polyisocyanate to yield an isocyanate-terminated polysiloxane hardener where one of the NCO groups is reacted with the OH group that is directly bonded to a silicon. The isocyanate-terminated polysiloxane hardener contains at least one but more preferably two isocyanate groups that can react with an isocyanate-reactive functional group of a third component.
[0020] The polyisocyanate-terminated siloxane compound is preferably formed using the following reaction of a silanol functional polysiloxane resin, shown as compound 1, where n≧1, R 1 , R 2 and R 3 individually represents the same or different methyl, phenyl or alkyl group and R 4 represents any cycloaliphatic or aromatic isocyanate trimer or adduct based on hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), diphenylmethane diisocyanate (MDI) and toluene diisocyanate (TDI). The polysiloxane resin is reacted with a polyisocyanate shown as compound 2 to form the polyisocyanate-terminated siloxane compound, shown as compound 3. This polyisocyanate-terminated siloxane compound can then be reacted with a, isocyanate-reactive polymer, such as a hydroxylated resin, to form a two-component polyurethane.
[0000]
[0021] The preferred silicone resin is a methoxy-functional methyl phenyl polysiloxane intermediate Wacker Chemie AG SY 231 (also available as Xiameter RSN3074) (MW1000-1500). Xiameter is a registered trademark of and is available from Dow Corning of Midland, Mich. It is preferred due to its low viscosity (100-150 cps) and 1:1 methyl to phenyl group ratio and 0-20% alkoxy functionality. Other preferred intermediates include Silres IC 232 (alkoxy content 0-20%), Silres IC 368 (alkoxy content 0-20%) and Silres IC 836 (MW 1200-1500). Silres is a registered trademark of and available from Wacker Chemie AG of Munich, Germany. Additional silicone resins that are available from Dow Corning include RSN0217 (MW 1500-2500), RSN0220 (MW 2000-4000), RSN0233 (MW 2000-4000), RSN0249 (MW 2000-4000), RSN0255 (MW 2500-4500), RSN0409 (MW 2000-7000), RSN0431 (MW 2000-7000), RSN0804 (MW 2000-7000), RSN0805 (MW 200,000-300,000), RSN0806 (MW 200,000-300,000), RSN0808 (MW 200,000-300,000), RSN0840 (MW 2000-7000), RSN6018 (MW 1500-2500) (also known as Dow Corning® Z-6018) and RSN5314 (alkoxy content 30-40%) and other open-chained, cyclic or branched polysiloxanes and chlorosilanes.
[0022] The methoxy-functional methyl phenyl silicone intermediate is partially hydrolyzed. “Partially hydrolyzed” refers to 5-80% of the hydrolysable groups of the silicone intermediate (i.e. methoxy groups) are converted to hydroxyl groups. The preferred catalyst for this reaction is tetra isopropyl titanate and it is used at 0.01-1.0% weight of the silicone intermediate. The reaction is brought up to an initial temperature of 150° F. and then ramped up 10° F. every 10-15 minutes to a final temperature of 210±5° F. The reaction is held at this temperature until the predetermined amount of evolved methanol is collected. The amount of methanol (mols) expected is equivalent to the mols of water added to complete the hydrolysis. Preferably, this reaction is carried out without solvent. One equivalent of these hydroxyl groups is then reacted with three equivalents of isocyanate groups under a nitrogen atmosphere at a temperature of 130-195° F. for about one hour. The remaining available isocyanate groups are reacted with a hydroxylated resin or polyol. They can also react with amine-functional resins and resins containing the above mentioned functional groups and isocyanate-reactive species identified in paragraph 15.
[0023] The preferred catalyst for the hydrolyzation of the methyl phenyl silicone intermediate is tetra isopropyl titanate (Sigma Aldrich of St. Louis, Mo.; VWR of Radnor, Pa.; Alfa Aesar of Wardh hill, Mass. and Fischer Scientific of Hampton, N.H. Other suitable catalysts include acids and bases such as para-toluenesulfonic acid, phosphoric acid, which is available from Ricca Chemical of Arlington, Tex., sulfuric acid (Ricca Chemical) and alkali metal hydroxides (Sigma-Aldrich, VWR, Alfa Aesar); organometallic and metallic catalysts such as dibutyl tin dilaurate (which is available from Dura Chemicals Inc, of Emeryville, Calif. or OMG Americas Inc of Franklin, Pa.), tetra isopropyl titanate, cobalts and zirconiums (Sigma Aldrich, VWR, Alfa Aesar, Fischer Scientific). The percentage of catalyst added can vary from 0.01% up to 5.00% of the total formula weight.
[0024] There is no preferred polyisocyanate as any polyisocyanate trimer or a mixture of trimers can be reacted with the hydrolyzed silicone intermediate. Stability testing should be performed to determine the suitability of the chosen polyisocyanate(s). Applicable polyisocyanates include: Desmodur N3390 BA a hexamethylene diisocyanate (HDI) based polyisocyanate (NCO content 19.6±0.3%) (Bayer AG of Leverkusen, Germany), other isocyanate trimers and adducts including those based on isophorone diisocyanate (IPDI), diphenylmethane diisocyanate (MDI) and toluene diisocyanate (TDI) chemistry can be used. While the use of diisocyanates such as TDI, MDI, HDI, IPDI, and 4,4-dicyclohexylmethane diisocyanate (H 12 MDI) can be applicable to this invention, polyisocyanates containing three or more isocyanate groups are preferred. Other suitable polyisocyanates include those of the Desmodur series from Bayer AG (all NCO content values are approximate): N 75 BA (NCO 16.5%); N 100 (22.0%); N 75 MPA/X (16.5%); N 75 MPA (16.5%); N 75 BA (16.5%); N 3200 (23.0%); N 3300 (21.8%); N 3390 BA/SN (19.6%); N 3600 (23.0%); N 3790 BA (17.8%); N 3800 (11.0%); N 3900 (23.5%); XP 2580 (20.0%) XP 2675 (20.0%); N 3400 (21.8%); XP 2730 (22.7%); XP 2679 (15.4%); Z 4470 SN (11.9%); Z 4470 MPA/X (11.9); Z 4470 BA (11.9%); XP 2489 (21.0%) and NZ 1 (20.0%). Also, one can utilize the following polyisocyanates from the Vestanat series from Evonik Industries AG of Essen, Germany (all NCO content values are approximate): T 1890 E (12.0%); T 1890 L (12.0%); T 1890 M (12.0%); T 1890 SV (12.0%); T 1890/100 (17.3%); HB 2640 E (16.5%); HB 2640 MX (16.5%); HB 2640/100 (22.0%); HB 2640 LV (23.0%); HT 2500 E (19.6%); HT 2500 L (19.6%); HT 2500/100 (21.8%); and HT 2500 LV (23.0%).
[0025] Preferably, the isocyanate-terminated polysiloxane is reacted with a hydroxylated resin or polyol with an OH value of 60-170 or an OH equivalent weight of 330-940. The hardener can react with any isocyanate-reactive species including, but not limited to, diols and polyols, amines, disubstituted ureas, urethanes, carboxylic acids, imino groups, carbonamide groups, sulfhydryls, sulfonamide groups, thioamide groups and sulphonic acid groups.
[0026] The invention can be further understood by means of the following examples, which are provided to illustrate but not limit the invention.
Example 1
[0027] A 1000-mL round bottom reaction flask was equipped with a heating mantle, stirrer, a Dean-Stark trap, condenser and nitrogen purge. To the flask, 345.9 g (1.57 mol) SY 231, which is a methoxy-functional methyl phenyl polysiloxane intermediate, was added. To the intermediate was added 1.7 g of a hydrolyzation catalyst, namely tetra isopropyl titanate (which is 0.5% based on the weight of the silicone intermediate), under agitation and a nitrogen atmosphere as the catalyst is extremely air-sensitive. Following the addition of catalyst, 5.58 g (0.31 mol) water was added dropwise. Upon addition of water, the mixture turned hazy. The mixture was heated to 150° F. and then ramped up 10° F. every 10-15 min to a final temperature of 210° F. The mixture was held at this temperature until the predetermined amount of methanol (9.92 g, 0.31 mol) was collected. The distillate was analyzed by gas chromatography (GC). The GC spectrum may reveal the presence of small amounts of low molecular weight volatile materials. The mixture turned clear again after all the water had reacted. After the methanol was collected, the mixture was cooled down to 150° F. and a polyisocyanate, specifically Desmodur N 3390 BA, (656.7 g, 2.92 mol) was added under agitation at which point the mixture turned hazy again. The reaction was held at 150° F. for about an hour and then the NCO content of the mixture was checked via titration. The reaction was held for another half hour and the NCO content was checked again. This series of checks was repeated until a percent difference of less than 2% was obtained between readings. The mixture was poured off into a quart-sized can and capped with nitrogen. Product yield is estimated as at least 97%. The final product was characterized by Fourier transform infrared spectroscopy (FTIR).
[0028] The resulting product has the following structure:
[0000]
[0029] FIGS. 1 and 2 show the FTIR spectrum of the unaltered SY 231 methoxy-functional methyl phenyl polysiloxane intermediate and the 20% hydrolyzed SY 231, respectively. FIG. 1 shows a methoxy functional (corresponding to strong absorptions at 2840 and 1191 cm −1 ) methyl (corresponding to strong absorptions at 1259 cm −1 and 750-870 cm −1 range) phenyl (corresponding to the medium absorptions at 1594 and 1430 cm −1 ) silicone resin. The reduction of the peak at 1191 cm −1 (corresponding to the hydrolysable groups attached to the silicon backbone) and consequently, the appearance of a broad peak at approximately 3300 cm −1 signified that the conversion of methoxy to hydroxy functionality was successful. The broad band between 1000-1135 cm −1 corresponds to the Si—O—Si backbone. FIG. 3 shows the GC chromatograph for the distillate resulting from the hydrolysis of SY 231 which evidences that methanol is a byproduct of the reaction. There is also the presence of other low molecular weight volatile compounds. FIG. 4 shows the FTIR spectrum of the resulting isocyanate-terminated polysiloxane hardener.
[0030] The reaction between NCO and OH groups can occur under ambient conditions so it is not necessary, though it is preferred, to mix the hydrolyzed silicone intermediate and the polyisocyanate at higher temperatures to speed up the reaction. The theoretical NCO content of the isocyanate polysiloxane prepolymer formed in the above reaction scheme is approximately 12.2±0.5% (NCO average equivalent weight 330-360.) Other typical values of the preferred isocyanate polysiloxane hardener are outlined in the following table:
[0000] TABLE 1 Property Value Solids ≧90.0% NCO Content 12.0 ± 0.5% Moisture Content 0.0-0.12% Weight per Gallon 9.40-9.60 Haze Very hazy Color (BYK Gardner) 0-1 Brookfield Viscosity (spindle 4, 20 rpms) 1500-2500 cps
These property values, however, are dependent on the polyisocyanate used.
Example 2
[0031] The procedure of Example 1 was repeated except that Desmodur N3600 was used instead of Desmodur N 3390 BA. Product yield is estimated as at least 75%. Desmodur N3600 is the solvent-free version of Desmodur N 3390 BA. The resulting product has the same structure as shown in Example 1.
Example 3
[0032] The procedure of Example 1 was repeated except that Vestanat T 1890 L was used instead of Desmodur N 3390 BA. Using this IPDI trimer produced a clear hardener. Product yield is estimated as at least 90%. The resulting product has the following structure:
[0000]
Example 4
[0033] The procedure of Example 1 was repeated except that Vestanat T 1890 L (44% by total weight) and methyl amyl ketone (1% by total weight) was post-added to the example in 1 (55% by total weight) and blended together. Product yield is estimated as at least 97%.
Example 5
[0034] The isocyanate-terminated polysiloxane hardener of Example 1 was mixed with an acrylic polyester polyol with an equivalent weight of approximately 600-700 so that the ratio of polyol to hardener is 2:1. The isocyanate-terminated polysiloxane hardener of Example 1 can be blended with other isocyanate trimers such as Desmodur Z4470 SN/BA, an IPDI trimer. The addition of another trimer will consequently alter the percent NCO of the hardener and therefore the affect the polyol to hardener ratio. The hardener can also be thinned down with solvents, although alcohols and water-containing solvents are not preferred as they cause undesirable side effects. The appropriate type of solvent used is dependent upon the polyisocyanate(s) and stability testing should be conducted with the particular solvent or solvent mixtures used.
[0035] A red and a white acrylic coating were trialed using the isocyanate polysiloxane hardener of Example 1. The coatings were sprayed directly (i.e. no primer) onto steel bonderite panels (that were previously washed with acetone to remove any oils). The panels were left to dry under ambient conditions for one week and then were subjected to accelerated testing in the QUV weathering chamber (340-A lamps), Cleveland humidity chamber and salt spray chamber. The panels were monitored for changes in gloss, lightness and blistering for a period of least 3,000 hours.
[0036] FIG. 6 is a graph above that compares the gloss of the standard white acrylic polyester coating to white and red acrylic polyester coatings using an isocyanate polysiloxane of the current invention as prepared in Example 5, which are labeled as JKX81-6 and JKXZ81-18 respectively. As can be seen in FIG. 6 , the percent gloss retention of the acrylic polyester polysiloxane coating is comparable to the standard coating. Both white samples show a significant gloss decrease after 2400 hrs. The red acrylic polyester polysiloxane coating shows a gloss decrease after 950 hours but has maintained a steadier delta gloss value compared to the standard white coating.
[0037] The panels prepared according to Example 5, along with a panel similarly prepared using a conventional white acrylic polyester coating, were measured using BYK Spectro-Guide colorimeter with software CyberChrome OnColor. In particular, the panels were observed for changes in lightness or darkness (represented by “DL′” where a +DL is lighter than a standard measurement and a −DL is darker than a standard measurement); changes in red shade or green shade (represented by “Da*” where +Da* is a red shade and −Da* is a green shade); changes in yellow shade or blue shade (represented by “Db*” where +Db* is a yellow shade and −Db* is a blue shade) and changes in DE* which is represented by the formula: [(DL*)2+(Da*)2+(Db*)2] 1/2 .
[0038] As can be seen in FIG. 7 , the coatings that were cured using the isocyanate polysiloxane hardener of the current invention showed remarkably comparative DL and DE values to the standard white acrylic polyurethane formula over the period of 3,000 hours.
[0039] Under the humid conditions of the Cleveland chamber and the salt spray, the coatings also displayed great adhesion though some blistering was observed to occur starting after 500 hours, generally, and severe blistering started to occur generally around 3,000 hours.
[0040] The above descriptions of certain embodiments are made for the purpose of illustration only and are not intended to be limiting in any manner. Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading the present disclosure, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors are legally entitled.
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The invention relates to an isocyanate-terminated polysiloxane material that can preferably be used as a curing agent, hardener or co-reactant in coatings. The invention further relates to a method of manufacturing the isocyanate-terminated polysiloxane material by partially hydrolyzing a methoxy-functional polysiloxane such as a methyl phenyl polysiloxane, and reacting it with a polyisocyanate to yield the isocyanate-terminated polysiloxane hardener. The hardener can preferably be used with any isocyanate-reactive functional group of another component to form coating systems, including acrylics, polyesters, epoxies and urethanes.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a divisional of U.S. patent application Ser. No. 11/665,671, filed Apr. 18, 2007, which is a national phase entry under 35 U.S.C. §371 of International Application No. PCT/AU05/01635 filed Oct. 21, 2005, published in English, which claims priority from Australian Application No. 2004906133 filed Oct. 22, 2004, all of which are hereby incorporated herein by this reference.
FIELD OF THE INVENTION
The present invention relates to an actuating assembly principally for electric brake operation. It will be convenient to describe the invention as it relates to an electric brake actuating assembly, although it should be appreciated that the invention could have application as an actuating assembly in other related and non-related fields.
BACKGROUND OF THE INVENTION
An electric brake actuating assembly and actuator is disclosed in applicant's International application WO 03/008248, filed 16 Jul. 2002. This document discloses an arrangement in which a rotatable actuator is driven rotate by an electric motor to act on a continuous cable which extends on either side of the rotatable member. Rotation of the rotatable member in a first direction, retracts the cable on either side of the rotatable member for brake application, while rotation in a second and reverse direction extends the cable on either side for brake release.
In one embodiment of the above document, the electric motor and the rotatable member are mounted so that they can shift in order to equalize out-of-balance loads in the cable. That is, in the event that retraction of the cables causes a load in the cable portion extending on one side of the rotatable member to be greater than on the other side, the actuator and the rotatable member can shift to equalize the respective loads.
The present invention relates to an arrangement which provides an alternative to the arrangement disclosed in the above discussed document.
SUMMARY OF THE INVENTION
According to the present invention there is provided an actuating assembly, including a rotatable member and electric drive means for driving the rotatable member to rotate, the rotatable member being arranged for engagement with a cable arrangement which includes a cable disposed within a conduit and in use the cable arrangement can extend for connection with at least one device to be actuated, the rotatable member being arranged such that it is operable to pull the cable of the cable arrangement on each side of the rotatable member upon rotation of the rotatable member in a first direction, and to extend the cable on each side of the rotatable member upon rotation of the rotatable member in a second and reverse direction, the assembly further including a pair of reaction abutments one each of which is disposed on opposite sides of the rotatable member for connection of a portion of the cable arrangement and for transmission of cable load thereto, the actuator being arranged to be fixedly mounted and the reaction abutments being mounted for movement relative to the rotatable member.
According to the above embodiment, a single output actuator can be provided, whereby cable of the cable arrangement extends to a single device, such as a brake assembly or a splitting arrangement that operates a pair of brake assemblies, on one side of the rotatable member and on the other side the cable extends to connection with a reaction abutment. In this arrangement, the other of the reaction abutments is engaged by cable conduit and load is transmitted to that abutment through the conduit. Engagement of the reaction abutment by the conduit can be through suitable fittings or fasteners, or the conduit end can be in abutment with the reaction abutment. On the other side of the rotatable member, the cable can be connected to the reaction abutment in any suitable manner, such as by suitable fittings or fasteners.
According to the present invention there is further provided an actuating assembly, including a rotatable member and electric drive means for driving the rotatable member to rotate, the rotatable member being arranged for engagement with a cable arrangement which includes cable disposed within a pair of conduit sections and in use the cable arrangement can extend for connection with a pair of actuatable devices, the rotatable member being arranged such that it is operable to pull the cable of the cable arrangement on each side of the rotatable member upon rotation of the rotatable member in a first direction, and to extend the cable on each side of the rotatable member upon rotation of the rotatable member in a second and reverse direction, the assembly further including a pair of reaction abutments one each of which is disposed on opposite sides of the rotatable member and to which a respective end of each conduit section of the cable arrangement can be connected, the actuating assembly being arranged to be fixedly mounted and the reaction abutments being mounted for movement relative to the rotatable member for equalisation of cable load transmitted through the conduit sections.
The above embodiment can advantageously be employed for actuating a pair of brake assemblies of a vehicle, which assemblies are operable when actuated to apply a braking load to brake a wheel associated with each respective said brake assembly. For that purpose, the actuator is fixedly mounted to the vehicle, while the reaction abutments can be fixed as required to the actuator, or to the vehicle.
The assembly of the invention is operable with a cable arrangement which comprises either a continuous cable that extends between the pair of brake assemblies and which cooperates with the rotatable member in the required manner, or alternatively, that comprises a pair of separate cables which extend from a respective brake assembly into connection with the rotatable member. In this latter arrangement, the connection with the rotatable member can be by any suitable arrangement, such as a pin and slot or trunnion and hole arrangement.
Likewise, the rotatable member can have any suitable form and could for example take any of the forms described and illustrated in International application WO 03/008248. Accordingly, the disclosure of that International application is incorporated herein fully by cross-reference.
The reaction abutments can be mounted for movement relative to the rotatable member in any suitable manner. In one embodiment, a bridging structure is provided to connect the reaction abutments together and the bridging structure is such that movement of one of the reaction abutments results in movement of the other of the reaction abutments with the movement of the reaction abutments being in generally the same direction.
A bridging structure of the above kind can take any suitable form and for example, can include a bridging plate that extends between the reaction abutments. The plate may be solid, or it may include openings for weight reduction or other purposes, and it may also include stiffening ribs or the like. Alternatively, instead of a bridging plate, one or more bridging members may extend between the reaction abutments and for example, a pair of parallel walls, each including a reaction abutment, may be connected by a transverse member or beam which extends between the walls. A frame may alternatively be provided and this may be substantially square or rectangular, with reaction abutments formed in opposite frame members. A bracing or stiffening structure may be included in the frame. Clearly, a wide variety of connection arrangements may be employed.
However, in the preferred arrangement, a bridging plate extends between the reaction abutments and in one form that bridging plate includes an opening for receiving therethrough at least a portion of the rotatable member. The opening may take any suitable shape, such as square, oval or circular, with a requirement that the opening be sufficiently large to permit the bridging structure to move relative to the rotatable member for load equalisation. In the preferred arrangement, the rotatable member is generally circular, and the opening in the bridging structure is generally oval or oblong, with the greatest diameter of the oval extending in a direction between the reaction abutments.
The reaction abutments will be positioned suitably for attachment thereto of the conduit ends. In one form of rotatable member, the member is circular and the cable engages or is fixed to the member at generally diametrically opposite sides thereof. In this arrangement the reaction abutments will be located diagonally opposite each other.
When the rotatable member rotates, the cable of the cable arrangement may shift laterally relative to the direction of cable pull. The reaction abutments therefore must accommodate any such lateral movement. In the preferred arrangement, the rotatable member defines a circular or part circular (arcuate) periphery for cable engagement and in this arrangement, lateral cable movement can be substantially eliminated with no necessity to accommodate lateral movement.
The reaction abutments can be provided in separate members which are separately mounted in place, or they can be provided as part of an integral unit. In the preferred arrangement, each reaction abutment is formed in a lip or wall which is upstanding from a bridging plate, which connects between the respective lips or walls. This arrangement can be of a reasonably simple construction, in that it can comprise a shallow channel member, with upstanding side walls depending from a central base. The reaction abutments can then be formed in the upstanding side walls, and if an opening is required for accommodation of the rotatable member, that can be provided in the base. In this arrangement, mounting means can be provided to mount the arrangement to either other parts of the assembly, or to a relevant connection point of the vehicle. In one arrangement, a pair of plates or legs can extend from the bridging plate and connection means are provided for suitably connecting the plates or legs to other parts of the assembly or the vehicle. It is the plates or legs which facilitate movement of the reaction abutments and in the preferred arrangement, that movement is provided by the plates or legs having flexibility to flex when an unequal load is experienced. The plates or legs can be constructed of any suitable material, and for example they can be metallic, such as steel, or a plastic. If a plastic is chosen, then the structure of the reaction abutments, the bridging structure and the plates or legs can be moulded as a single unit, whereas if a metallic material is employed, then typically the component parts will be formed and thereafter connected together, such as by rivets, suitable fasteners, or by welding, soldering, or brazing.
In the preferred arrangement, the drive means comprises an electric motor which is connected by suitable electrical connection to an electrical supply and the motor either directly drives the rotatable member to rotate, or drive is through a gearbox. In the preferred arrangement, the axis of rotation of the rotatable member is transverse and preferably perpendicular to the axis of rotation of an output shaft of the electric motor.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention and to show how it may be performed, embodiments thereof will now be described, by way of non-limiting example only, with reference to the accompanying drawings.
FIG. 1 is a front, perspective, exploded view of an electric brake actuating assembly according to one embodiment of the present invention;
FIG. 2 is a top, plan view of an actuating assembly according to a second embodiment of the present invention;
FIG. 3 is a side, perspective view of a portion of the actuating assembly shown in FIG. 1 , with a cable conduit being installed;
FIG. 4 is a side, plan view of a portion of the assembly shown in FIG. 1 , with a cable conduit installed;
FIG. 5 is a side, perspective, schematic view of a further embodiment according to the present invention;
FIG. 6 is a plan view of a further embodiment according to the present invention; and
FIG. 7 is a plan view of a further embodiment according to the present invention.
DETAILED DESCRIPTION
FIG. 1 shows an assembly 10 in exploded view. The assembly 10 includes an actuator 11 which comprises an electric motor 12 and a rotatable member 13 . The electric motor 12 drives the rotatable member 13 to rotate, through a gearbox housed within a housing 14 . The housing 14 includes feet 15 for mounting the housing 14 to a rigid part of a vehicle, such as to the floor pan. Bolt holes 16 are provided for that purpose.
The rotatable member 13 has the form of that disclosed in applicant's International application WO 03/008248, such that it has a pair of lobes 17 , 18 which are spaced apart to define a passage between them. With reference to FIG. 2 , a continuous cable 19 is shown and this illustrates the route the cable takes about the lobes 17 , 18 . It should be appreciated however, that the form of the rotatable member can be other than that shown and in particular, two separate cables can be employed, one end of each of which is fixed to the rotatable member.
It will be appreciated from WO 03/008248, that the actuator 11 is operable, by rotation of the rotatable member 13 , to retract and extend the cable 19 . The cable 19 extends at either end to a pair of brake assemblies operable to brake respective vehicle wheels. The brake assemblies typically will be parking brake assemblies. The brake assemblies are actuated by retraction of the cable 19 and are released by return extension thereof.
The assembly 10 includes a bracket 20 which has a pair of legs 21 , 22 connected to a bridging plate 23 . The bridging plate 23 includes a bridging section 24 and a pair of opposed walls 25 , 26 which extend generally perpendicular to the general plane of the bridging section 24 . The bridging plate 23 is connected through the walls 25 , 26 to the legs 21 , 22 , such as by suitable threaded fasteners or rivets 27 . As shown, the bracket 20 is fabricated from metal, preferably steel, although the bracket could alternatively be moulded in one piece from plastic.
The bridging plate 23 includes a central opening 28 which can be of any suitable shape, such as oval or circular. The opening 28 is shaped and sized to accommodate passage therethrough of the rotatable member 13 of the actuator 11 . The opening is further sized and shaped so that the bracket 20 can shift by flexing of the legs 21 , 22 transverse to the general plane of the legs 21 , 22 , without interference from the rotatable member 13 . By this shifting movement, equalisation of cable forces can be achieved. However, in contrast to the arrangement of WO 03/008248, only the bracket 20 shifts to equalize cable load, rather than the actuator 11 . Accordingly, it is possible to rigidly fix the actuator to the vehicle, rather than to mount it for movement. This can facilitate a less complex mounting arrangement.
The bracket 20 includes cable openings 29 in each of the walls 25 , 26 and these are arranged to facilitate attachment of cable conduit to opposite sides of the walls 25 , 26 about the openings 29 . Each opening 29 communicates with a slot 30 that opens through the edge 31 of each of the walls 25 , 26 . The slots 30 allow for easy insertion and removal of the cable 19 into or from the openings 29 .
FIG. 3 is a view of the wall 25 through which the cable 19 extends, prior to attachment of the conduit 32 to the wall 25 , while FIG. 4 shows the conduit fixed to the wall 25 . It will be readily appreciated, that by fixing the conduit at each end, the cable can be pulled and released within the conduit, with load being transmitted through the conduit. It will be further appreciated that the opposite end of the conduit is also fixed, and load is transmitted through the conduit to the structure at each fixing end. Thus, the point at which the conduit is fixed to the wall 25 becomes one point or reaction for conduit load. The forward end of the conduit 32 shown in FIGS. 3 and 4 includes a pair of integrally formed fixing member portions 33 and 34 . The conduit 32 extends through the fixing member portions 33 and 34 and fixing of the conduit to the wall 25 involves pushing the fixing member portion 34 fully through the opening 29 , to allow the flexible barbs 35 to flex outwardly into facing relationship with the section of the wall 25 which surrounds the opening 29 . When the portion 34 is fully through the opening 29 , the portion 33 will rest against the opposite side of the wall 25 with sufficient clamping force to fix the end of the conduit to the wall 25 . The fixing member portions 33 and 34 do not need to hold tightly against the wall 25 . A loose fit is acceptable, as the portion 33 will move into firm engagement with the wall 25 upon a load being applied to the cable 19 . This arrangement is completed in relation to conduit extending from each of the openings 29 of the respective walls 25 and 26 shown in FIG. 1 .
With the conduit 32 fixed to the walls 25 and 26 , and the cable 19 threaded about the rotatable member 13 , an actuating load can then be applied to brake assemblies to which opposite ends of the cable 19 are fixed. In the arrangement shown in FIG. 1 , the cable 19 extends from the bracket orthogonally to the lengthwise axis of the motor 12 while in FIG. 2 , the cable 19 extends substantially parallel to the axis A of the motor 20 . Either arrangement can equally be employed, depending on the layout of the vehicle to which the assembly 10 is applied.
The bracket 20 is fixed to the feet 15 of the actuator 11 by threaded fasteners 36 (only a single fastener being shown in FIG. 1 ). The fasteners 36 extend through openings 37 in the legs 21 , 22 and threadably engage within openings 38 formed in the feet 15 . This is one arrangement for securing the bracket 20 in place. In an alternative arrangement, the bracket can be fixed using rivets, such as integral rivets cast into the housing 14 , and then mushroomed over when they have been passed through the openings 37 . Alternatively, the bracket can be fixed to the vehicle separately to the actuator 11 . The bridging plate can include stiffening ribs 39 to stiffen the bridging section as required.
The assembly 10 is operable such that cable loading is transmitted through the cable conduit 32 to the bridging plate 23 . Where this cable loading, or cable displacement measured on either side of the rotatable member, is equal, then the bracket 20 will remain stationary in relation to the actuator 11 . However an unequal load or displacement will cause the legs 21 , 22 to flex in the direction of the lower load. Thus, if a greater load or displacement is applied to the wall 26 , the legs 21 , 22 will flex, with the leg 22 flexing toward the leg 21 .
An unequal load or displacement can occur for a variety of reasons. For example, if the friction lining of one of the brake shoes of one of the brake assemblies has worn more than the brake shoe of the other brake assembly, then the less worn shoe will engage the braking surface first and the resistance to further travel of the brake shoe will be transmitted through the conduit back to the bracket 20 . As the other shoe will not have yet engaged the braking surface, there will be no equivalent resistance transmitted to the other side of the bracket 20 . Thus the loads on the bracket 20 will be unequal and to equalize, the bracket will shift in the direction of the shoe which has greater wear. Shifting of the bracket 20 can also be necessary if there is cable stretch more on one side of the cable than the other (this is not normally a problem with a cable that is continuous, but rather, it can occur where a pair of cables are separately attached to the rotatable member) or if the tolerance stack in the assembly is greater in the brake assembly on one side of the actuator than the other, or if there is an imbalance in the initial adjustment of the brake shoe clearance. Still further, conduit routing in which conduit extending from one side of the assembly is longer than on the other side can cause an imbalance. Differences in conduit routing can arise due to practical difficulties in achieving symmetrical layout of the conduit, such as where the actuating assembly cannot be located centrally between a pair of brake assemblies.
In the above circumstances, without equalisation, equal cable travel will result, so that one of the pair of brake assemblies will be applied to a lesser extent that the other. In extreme circumstances the parking brakes will not hold the vehicle stationary in this condition, because one of the wheels will not be properly braked.
It will be appreciated that where an unequal load occurs, the difference in cable load usually will be small, so that the amount that the legs 21 , 22 are required to flex is likewise only small. It is not expected that there would be as requirement, in normal operating circumstances, for the bridging plate to shift more than about 10 mm in either direction.
An alternative embodiment of the present invention is illustrated in FIG. 5 . This embodiment includes legs that flex about a different axis to the legs 21 , 22 of FIG. 1 . In the FIG. 5 embodiment, which is shown schematically only and without an actuator, a bracket 50 is shown. The bracket 50 has a bridging plate 51 that includes an opening 52 to accommodate a rotatable member such as the member 13 of FIG. 1 . The bridging plate 51 is connected to conduit connecting and reacting members 53 , 54 , each of which includes an opening 55 for passage therethrough of a cable (not shown). It is to be appreciated that the bridging plate 51 , could have a very similar construction to that of the bridging plate 23 of FIG. 1 .
The conduit members 53 , 54 extend downwardly from the bridging plate 51 and connected to the conduit members 53 , 54 is a pair of elongate legs 56 , 57 . A further leg 56 ′ shown in broken outline is an alternative to the leg 56 and therefore in practice, only one of these legs 56 or 56 ′ is provided. The selection of leg 56 or leg 56 ′ is dependent on the layout of the vehicle to which the bracket 50 is attached. The operation of the bracket 50 is essentially the same regardless of which of the legs 56 or 56 ′ is selected.
The bracket 50 can be fixed to an actuator such as the actuator 11 of FIG. 1 , or another suitable part of a vehicle, such as the actuator 11 of FIG. 1 , by fastening the distal ends 58 or 58 ′ and 59 of the legs 56 , 56 ′ and 57 to an actuator or other vehicle part. Holes 60 , 60 ′ are provided to receive suitable fasteners. Clearly the connection of the distal ends 58 , 58 ′ and 59 to an actuator will require a different connecting arrangement to that shown and described in FIG. 1 .
In a first arrangement of the FIG. 5 embodiment, the legs 56 and 57 can be suitably fixed at each of distal ends 58 and 59 and in that arrangement the legs 56 and 57 will each be in tension when reacting the conduit loading. In a second arrangement of the FIG. 5 embodiment, the legs 56 ′ and 57 can be fixed at each of the distal ends 58 ′ and 59 and in that arrangement, the leg 56 ′ will be in compression and the leg 57 will be in tension when the bracket 50 reacts the conduit load.
FIG. 6 represents a further embodiment of the invention which relates to an electric brake actuating assembly 70 in which only one of the cables extending from the rotatable member 71 extends to a device such as a brake assembly or a splitter of a braking system. The cable 72 is a continuous cable, although a first portion 73 extends from the rotatable member 71 for connection to a brake assembly (not shown), while a second portion 72 extends only as far as the equalizer bracket 75 . The first portion 73 is accommodated within a conduit 76 and the conduit 76 includes fixing members and 78 for fixing one end of the conduit 76 to the equalizer bracket 79 . The manner of fixing the end of the conduit 76 to the equalizer bracket 79 is the same as the arrangement illustrated in FIGS. 3 and 4 . Indeed, the arrangement of FIG. 6 is the same as that shown in FIG. 2 except that the second cable portion 74 terminates at the equalizer bracket 75 rather than extending beyond that bracket to a brake assembly.
The termination of the cable 72 at the equalizer bracket 75 can be arranged by fixing an abutment 80 to the distal end of the second portion 74 , which fixes that end to the equalizer bracket 75 .
The arrangement of FIG. 6 can be employed when only a single output actuator is required. This is in contrast to the actuators shown in the earlier figures, in which a pair of outputs are required for actuation of a separate pair of brake assemblies. The advantage of the assembly 70 , is that the bearing of the rotatable member 71 experiences a relatively low load when it rotates to retract the cable 72 . In an assembly in which a cable is fixed to a rotatable member and rotated to retract the cable, the bearing of the rotatable member is subject to a load which is proportional to that applied to the cable. However, in the assembly 70 , substantially equal but opposite and off-set cable loadings are applied to the rotatable member and reacted by the equalizer brackets 75 and 79 , so that the bearing of the rotatable member 71 experiences a very small net radial load only. Equally, the bridging plate 81 including the equalizer brackets 75 and 69 will experience a counter rotational torque which will be transmitted to the actuator body via legs equivalent to the legs 21 and 22 of FIG. 1 , equalizing or cancelling all the loads and torques internally. Thus the mounting of the actuator to the vehicle or other support does not experience any external load.
FIG. 7 illustrates an assembly 90 which is substantially identical to the assembly 70 of FIG. 6 , and therefore like parts have the same reference numerals. In this figure, the electric motor 91 extends from the assembly 90 from the opposite side to that of the assembly 70 , and this illustrates that the orientation of the motor 91 can be changed as required. Because of the change in orientation of the motor 91 , the equalizer brackets are renumbered 91 and 93 .
In the FIG. 7 embodiment, the second cable portion is connected to a rod 94 which is threaded and which extends through the equalizer bracket 93 for threaded engagement with a nut 95 . In this arrangement, the cable 72 can be slackened or tightened by hand or by tool, by threading the nut 95 up or down the rod 94 . This could be useful in an emergency in which actuation or deactuation or even re-activation of the device 90 is required, but the electric power supply or electric motor 91 has failed. The nut 95 has a knurled circumferential edge, to assist its manual rotation, although for the same purpose, the nut 95 may include a handle or crank arm.
The invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be understood that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the above description.
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An actuating assembly, including a rotatable core and an electric drive for driving the rotatable core are disclosed. The rotatable core is arranged for engagement with a cable disposed within a pair of conduit sections and the cable can connect with a pair of actuatable devices. The rotatable core is arranged to be operable to pull the cable on each side of the core upon rotation thereof in a first direction, and to extend the cable on each side of the core upon rotation thereof in a second direction. The assembly further includes a pair of reaction abutments disposed on opposite sides of the rotatable core and to which a respective end of each conduit section can be connected. The assembly is arranged to be fixedly mounted and the reaction abutments are mounted for movement relative to the rotatable core for equalisation of cable load transmitted through the conduit sections.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 62/193,936, filed on Jul. 17, 2015, entitled “System and Method for Creating Electronic Multiplayer Game Tournaments,” currently pending, the entire contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
Embodiments of the present invention relate to electronic game tournaments, and in particular, to creating online multiplayer game tournaments based on artificial intelligence.
Amusement devices having electronic games such as blackjack and poker variation card games for computers and touch screens or other types of amusement devices are generally well known in the art. Amusement devices, such as game machines, which allow a user to select games from a video display are well known in the art such as those disclosed in U.S. Pat. No. 4,856,787 (“Itkis”); U.S. Pat. No. 5,575,717 (“Houriet, Jr., et al.”); U.S. Pat. No. 5,743,799 (“Houriet, Jr., et al.”) (the entire contents of all of which are incorporated by reference herein), each of which shows a touch screen for making a game selection from a menu of games. Such game machines or amusement devices typically operate upon input of currency (i.e., coin, token, paper money, credit/debit cards or the like) and are installed in locations such as bars, restaurants, airports, shopping malls, video arcades, casinos or the like. The game choices may include card games, sports games, games of skill, games of chance, action games, trivia games or the like. Such games may also operate on mobile devices.
A popular type of gaming is tournament play, where instead of playing against a computer program, two or more players compete against each other over a predetermined amount of time (e.g., one month, one week, or the like). The tournaments typically operate with a predetermined prize fund and prize award structure. Thus, such multiplayer tournaments offer players the opportunity to play against each other for increased prizes until the tournament ends.
These tournament games may oftentimes require a player to strategize in order to achieve higher scores, and potentially, win a prize. However, some regulatory agencies (national, state or local) have “gaming” regulations which require that electronic games which award prizes be based on some element of skill. Since most electronic games, such as card games, have an apparent “random deal,” they are generally categorized as games of chance.
The definition of chance varies among municipalities. For example, some states consider a game to be a game of chance if a “preponderance of skill” does not contribute to winning. For a majority of municipalities, a game having a preponderance of skill is a game in which a player who is considered highly skilled will win over an average player at least 75.1% of the time.
In some municipalities, chance is determined by an existence of a “material element”. A material element exists if there is an element of game play that is material to the success of the game that is driven by chance. An example of a game that has a material element is Backgammon. In Backgammon, a roll of the dice is a material part of the game, and the player cannot control its outcome. Accordingly, in municipalities that use the “material element” test to determine if a game is a game of chance, Backgammon would be considered a game of chance because of the material element of the die roll.
Another material element is a lack of equivalent fairness. In a game with equivalent fairness, each player has an equal opportunity to win the game. For example, card games are oftentimes based on a shuffling of cards. The shuffling of cards is usually based on a random number seed. Each seed corresponds to a uniquely shuffled deck of cards. Some seeds correspond to deck shuffles resulting in easier game play, and potentially higher scores than other seeds. Therefore, it is possible for one player to receive, for example, more difficult seeds of game play than another player competing in the same tournament. Consequently, the game would lack equivalent fairness.
It is desirable to create a multiplayer tournament of an electronic game that is at least partially based upon player skill, by at least having equivalent fairness so as to comply with gaming regulations.
BRIEF SUMMARY OF THE INVENTION
Systems and methods for creating a plurality of seeds for a multiplayer tournament of an electronic game are disclosed. The system includes one or more amusement devices and a server including a seed generator module, a seed sorter module, and a seed selection module. The seed generator module is configured to randomly generate the plurality of seeds. Each of the plurality of seeds corresponds to a unique shuffle of cards of a game of the multiplayer tournament. The seed sorter module is configured to rate each of the plurality of seeds, and sort the plurality of rated seeds in accordance with one or more business goals. The seed selection module is configured to receive a player identifier and a tournament play count associated with a player of the multiplayer tournament, the player being associated with one of the one or more amusement devices. The seed selection module is further configured to identify a rated seed for the player in accordance with the player identifier and the tournament play count, and present the player with a game using the identified seed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
FIG. 1 is a schematic diagram of an amusement device which can run electronic tournament games in accordance with an embodiment of the present invention;
FIG. 2 is a schematic diagram of a system of amusement devices configured to play created electronic tournament games over a network;
FIG. 3 is a diagram illustrating seed generation according to an embodiment of the present invention; and
FIG. 4 is a diagram illustrating seed selection for a particular player according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Certain terminology is used in the following description for convenience only and is not limiting. Unless specifically set forth herein, the terms “a”, “an” and “the” are not limited to one element but instead should be read as meaning “at least one”. The words “right,” “left,” “lower,” and “upper” designate directions in the drawings to which reference is made. The words “inwardly” or “distally” and “outwardly” or “proximally” refer to directions toward and away from, respectively, the geometric center or orientation of the amusement device, and related parts thereof. The terminology includes the above-listed words, derivatives thereof and words of similar import.
FIG. 1 depicts an amusement device 8 that runs an electronic game. The amusement device 8 includes a controller U 1 and a memory U 2 . The amusement device 8 further includes a video display 9 which is operatively connected to the amusement device controller U 1 . Preferably, the video display 9 is a touchscreen video display configured to accept touch input.
The amusement device 8 may be controlled by the controller U 1 , the memory U 2 and a touchscreen video display driver (not shown). For purposes of simplicity, the invention will be described with respect to the amusement device 8 throughout the remainder of the description, but it should be noted that the present invention could be implemented with any variety of amusement devices 8 without departing from the spirit of the invention. For example, the amusement devices 8 may refer to, without limitation, one or more personal computers, laptop computers, personal media devices, display devices, video gaming systems, gaming consoles, cameras, video cameras, MP3 players, mobile devices, wearable devices, wearable devices (e.g., iWatch by Apple, Inc.), mobile telephones, cellular telephones, GPS navigation devices, smartphones, tablet computers, portable video players, satellite media players, satellite telephones, wireless communications devices, or personal digital assistants (PDA).
The memory U 2 preferably stores a plurality of electronic games and a system control program. The controller U 1 is operatively coupled to the memory U 2 , the input device and the display 9 (i.e., the touchscreen display 9 ). The controller U 1 controls the touchscreen display 9 based upon the system control program retrieved from the memory U 2 and based upon inputs from the input device, which, in this case, is the touchscreen display 9 . The memory U 2 can be any known or suitable memory device such as random access memory (RAM), read only memory (ROM), flash RAM, hard disk, optical disk, or the like. As used herein, the system control program refers to all of the software functions outside of the game or music files including an operating system, display control, input control, sound drivers and the like. Other input devices which may be connected to the amusement devices 8 include a pushbutton(s), a track-ball or touchpad, a mouse, a joy-stick, a foot-pedal, a voice recognition system, a keypad or keyboard and the like. But, preferably, the input device is the touchscreen display 9 .
The amusement device 8 may optionally include a communication interface 10 to connect to other amusement devices 8 to permit tournament play and/or remote accounting, remote prize awarding and the like. For example, as shown in FIG. 2 , according to embodiments of the present invention, a system 200 includes a communication network 202 which operatively couples various amusement devices 8 and a remote server 204 . According to this embodiment, the remote server 204 may include a memory (not shown) storing one or more electronic games, artificial intelligence, and other components necessary for tournament game play. For example, the remote server may include an AI seed generator module 301 , a business based seed sorter module 303 , and a seed selection module 305 .
The communication network 202 may include any suitable circuitry, device, system, or combination of these (e.g., a wireless or hardline communications infrastructure including towers and communications servers, an IP network, and the like) operative to create the communications network 202 . The communication network 202 can provide for communications in accordance with any wired or wireless communication standard. For example, the communication network 202 can provide for communications in accordance with second-generation (2G) wireless communication protocols IS-136 (time division multiple access (TDMA)), GSM (global system for mobile communication), IS-95 (code division multiple access (CDMA)), third-generation (3G) wireless communication protocols, such as Universal Mobile Telecommunications System (UMTS), CDMA2000, wideband CDMA (WCDMA) and time division-synchronous CDMA (TD-SCDMA), 3.9 generation (3.9G) wireless communication protocols, such as Evolved Universal Terrestrial Radio Access Network (E-UTRAN), with fourth-generation (4G) wireless communication protocols, international mobile telecommunications advanced (IMT-Advanced) protocols, Long Term Evolution (LTE) protocols including LTE-advanced, or the like.
Further, the communication network 202 may be configured to provide for communications in accordance with techniques such as, for example, radio frequency (RF), infrared, or any of a number of different wireless networking techniques, including wireless local area network (WLAN) techniques such as IEEE 802.11 (e.g., 802.11a, 802.11b, 802.11g, 802.11n, etc.), WLAN protocols, world interoperability for microwave access (WiMAX) techniques such as IEEE 802.16, and/or wireless Personal Area Network (WPAN) techniques such as IEEE 802.15, BlueTooth™, ultra wideband (UWB) and/or the like.
Disclosed embodiments of the present invention are directed to the creation of online multiplayer tournament games, where instead of playing against a computer program, two or more players compete against each other over a predetermined amount of time (e.g., one month, one week, or the like). The tournaments operate with a predetermined prize fund and prize award structure. Thus, such multiplayer tournaments offer players the opportunity to play against each other for increased prizes until the tournament ends. A tournament may include play of only one type of electronic game (e.g., TRI TOWERS), or more than one type of electronic game (e.g., TRI TOWERS, CARD BANDITS, and the like). Preferably, a player's overall tournament score consists of the sum of the player's top five scores of any combination of types of electronic games, over the predetermined amount of time.
Each play of a game may be based on certain circumstances, such as a randomized arrangement of game pieces. In a card game, for example, the circumstances may include a randomized shuffle of the cards. As such, each play of a card game may require a shuffling of cards based on a random number seed. Each seed corresponds to a uniquely shuffled deck of cards. Artificial intelligence (“AI”) in a control program of the amusement device 8 , or server 204 , for example, may be used to generate and select particular seeds for tournament game play.
FIG. 3 is a diagram illustrating the generation of seeds according to an embodiment of the present invention. The seed generator module 301 is configured to generate a list of seeds 302 , preferably approximately 2500, however any number of seeds may be generated in keeping with the invention. The generated list of seeds 302 is input into a business based seed sorter module 303 that rates each of the seeds. For example, the business seed sorter module 303 may use AI to automatically simulate and rate each of the generated seeds 302 . Each of the generated seeds can be rated according to one or more attributes including, but not limited to, the lowest possible score found with the particular seed, the highest possible score found with the particular seed, and the average score found through simulated game plays with the particular seed.
The business based seed sorter module 303 preferably creates an ordered list of the rated seeds according to the business goals of the game. Business goals may include, but are not limited to, fair game play, player experience, and the like. For example, presenting new, or otherwise less skilled players, with lower rated seeds (e.g., seeds that have comparatively higher possible scores), prevents the less skilled players from becoming frustrated with the difficulty of the game. As a result, the player experience of new, or otherwise less skilled players, is improved. To keep players' interest as they become more experienced, the AI may provide players with more difficult seeds (e.g., seeds that have a lower possible score). As such, more experienced players are presented with bigger challenges by being given more difficult seeds with which to play. Even still, some generated seeds may correspond to card shuffles that may have highly undesirable results, being deemed impossible to solve. Through rating the seeds, the AI of the system 200 can remove these undesirable seeds from the list.
Fair game play is achieved by assigning the same seeds to each player competing in the tournament. As a result, each player is presented with the same level of difficulty resulting in equivalently fair game play. One concern, however, with having the same list of seeds for each player is that players can learn, or otherwise get an idea of circumstances of a particular play of a game prior to his or her actual turn, giving a player going second, third, and so on, an advantage over previous players of the same tournament. For example, in certain electronic card games, players may be awarded higher scores for faster game play, or for quickly completing a particular round, or play of the game. By being able to see the particular shuffle of the cards prior to his or her game actually starting, the player may be able to more quickly ascertain the more desirable moves resulting in a higher score.
To decrease, or otherwise remove, such an advantage, the business based seed sorter module 303 groups the seeds together, preferably in groups of 5, and varies the order in which each player sees each seed. For example, one player may play in a tournament with the seeds in the order, such as: Seed 0, Seed 1, Seed 2, Seed 3, Seed 4. Another player in the same tournament may be presented with games with the seeds in a different order, such as: Seed 1, Seed 0, Seed 4, Seed 3, Seed 2. With 5 seeds, there is a possibility of 5! or 120 different permutations of seed orders for game play. These 120 permutations are placed into a sequence permutation list 307 . Consequently, with this many combinations of seed orders, it is more difficult for any player to gain an advantage by looking at the shuffle of any other player, prior to his or her own play of the game.
FIG. 4 is a diagram illustrating seed selection (which may be performed, for example, by the seed selection module 305 ) of a tournament for a particular player according to an embodiment of the present invention. Each player has a record 401 that stores a unique Player ID and the number of game plays (“Play Count”) for a particular tournament. The record can be generated upon a player's registration to play a particular game.
As shown in the example of FIG. 4 , Player Y has a player ID “51603” and has a tournament play count of “7” for tournament X. In other words, Player Y has played 6 previous tournament games and is ready for game number 7 of tournament X.
The seeds are selected for a particular player of the tournament based on the player's ID and play count. Based on the Player's ID, the system 200 creates an index into the sequence permutation list. The system creates the index by calculating the modulo of the Player's ID and number of permutations of the sequence permutation list, otherwise expressed as (Player's ID) modulo 120, which is equivalent to the remainder of the Player's ID divided by 120. For example, as shown in FIG. 4 , Player Y's ID is 51603. As such, the seed selection module 305 calculates the modulo of 51603 and 120 or, 51603 mod 120, which is equal to 3. The seed selection module 305 is configured to use the number “3” to be the sequence index into the sequence permutation list. As shown in FIG. 4 , Sequence 3 uses the indices in the order: 0, 1, 3, 4, 2.
The seed selection module 305 uses the player's play count to access the seed to be used for each game of the tournament. More specifically, the seed selection module 305 operates on the play count for two parameters, a desired seed list block of the tournament X seed list and the permutation element index. The seed list block refers to the block of 5 games in which the player is currently playing. In the example illustrated in FIG. 4 , the tournament play count is “7”. Because 7 is greater than or equal to 5, but less than 10, game 7 corresponds to a game in the second block of the seed list blocks of the tournament X seed list corresponding to Seeds 5-9.
In conjunction with the sequence index, the permutation element index is used to select the specific play number within the desired block that should be used for the current play count. By taking the modulo of the play count and the number of seeds per block (e.g., 5), the seed selection module 305 determines the permutation element index. In this example, the seed selection module 305 takes the play count “7” and the number of seeds per block “5” (i.e., 7 mod 5), resulting in the permutation element index of “2”. At the intersection of the sequence index and the permutation element index 2, the seed selection module 305 determines a specific play number within the selected block. Therefore, according to the example in FIG. 4 , for Player Y, game 7 of Tournament X will be play 3 of the second block of five games, which is Seed 8.
Such a technique results in unique combinations of seeds for different players of the same tournament. For example, for the same tournament X, seeding for player Z having an ID can be calculated. As shown in the below chart, player Z will play the same seeds (or shuffled games) as player Y, albeit in a different order. As such, equivalent fairness is achieved without giving one of the competing players an unfair advantage.
Player Y (Permutation Index
Player Z(Permutation Index
list is 0, 1, 3, 4, 2)
list is 0, 1, 4, 3, 2)
Game 0
(0 <= 0 < 5, 0 Mod 5 = 0,
(0 <= 0 < 5, 0 Mod 5 = 0,
index 0 is 0) Seed 0
index 0 is 0) Seed 0
Game 1
(0 <= 1 < 5, 1 Mod 5 = 1,
(0 <= 1 < 5, 1 Mod 5 = 1,
index 1 is 1) Seed 1
index 1 is 1) Seed 1
Game 2
(0 <= 2 < 5, 2 mod 5 = 2,
(0 <= 2 < 5, 2 mod 5 = 2,
index 2 is 3) Seed 3
index 2 is 4) Seed 4
Game 3
(0 <= 3 < 5, 3 mod 5 = 3,
(0 <= 3 < 5, 3 mod 5 = 3,
index 3 is 4) Seed 4
index 3 is 3) Seed 3
Game 4
(0 <= 4 < 5, 4 mod 5 = 4,
(0 <= 4 < 5, 4 mod 5 = 4,
index 4 is 2) Seed 2
index 4 is 2) Seed 2
Game 5
(5 <= 5 < 10, 5 mod 5 = 0,
(5 <= 5 < 10, 5 mod 5 = 0,
index 0 is 0) Seed 5
index 0 is 0) Seed 5
Game 6
(5 <= 6 < 10, 6 mod 5 = 1,
(5 <= 6 < 10, 6 mod 5 = 1,
index 1 is 1) Seed 6
index 1 is 1) Seed 6
Game 7
(5 <= 7 < 10, 7 mod 5 = 2,
(5 <= 7 < 10, 7 mod 5 = 2,
index 2 is 3) Seed 8
index 2 is 4) Seed 9
Game 8
(5 <= 8 < 10, 8 mod 5 = 3,
(5 <= 8 < 10, 8 mod 5 = 3,
index 3 is 4) Seed 9
index 3 is 3) Seed 8
The various illustrative logical blocks, modules, and circuits described in connection with the disclosure herein may be implemented or performed with a general-purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
It will be appreciated by those skilled in the art that changes could be made to the embodiment described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiment disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the present disclosure.
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Systems and methods for creating a plurality of seeds for a multiplayer tournament of an electronic game are disclosed. The system includes a server including a seed generator module, a seed sorter module, and a seed selection module. The seed generator module randomly generates the plurality of seeds. Each of the plurality of corresponds to a unique shuffle of cards of a game of the multiplayer tournament. The seed sorter module rates each of the plurality of seeds, and then sorts the plurality of rated seeds in accordance with one or more business goals. A seed selection module is configured to receive a player identifier and a tournament play count associated with a first player of the multiplayer tournament. The seed selection module is further configured to identify a rated seed for the first player in accordance with the player identifier and the tournament play count.
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This application is a continuation-in-part of Ser. No. 06/642,107 filed Aug. 20, 1984, now abandoned.
The following represents the state of the art of which applicant is aware, insofar as these patents are germane to the process at hand.
Patent references from prior application:
U.S. Pat. No. 85,363 Buckel, Dec. 29, 1868
U.S. Pat. No. 2,285,925 Handy, June 9, 1942
U.S. Pat. No. 2,600,944 Sam, Jun. 17, 1952
U.S. Pat. No. 2,826,245 Sellner, Mar. 11, 1958
U.S. Pat. No. 3,428,973 Hargest et al, Feb. 26, 1969
U.S. Pat. No. 3,585,639 Enicks, Jun. 22, 1971
U.S. Pat. No. 3,754,786 Boucher et al, Aug. 28, 1973
U.S. Pat. No. 3,949,435 Dionne, Apr. 13, 1976
U.S. Pat. No. 3,999,227 Ingemansson, Dec. 28, 1976
U.S. Pat. No. 4,070,721 Stasko, Jan. 31, 1978
U.S. Pat. No. 4,221,011 Flichbaugh, Sep. 9, 1980
U.S. Pat. No. 4,295,683 Dubbink et al, Oct. 20, 1981
U.S. Pat. No. 4,301,791 Franco III, Nov. 24, 1981
U.S. Pat. No. 4,367,897 Cousins, Jan. 11, 1983
U.S. Pat. No. 4,510,888 DeAngelis et al, Apr. 16, 1985
Patent made of reference for the current application:
U.S. Pat. No. 1,326,530 Radcliff, Dec. 30, 1919
U.S. Pat. No. 1,557,647 Austin, Oct. 20, 1925
U.S. Pat. No. 3,011,826 Bowring et al, Dec. 5, 1961
U.S. Pat. No. 3,278,230 Boyce et al, Oct. 11, 1966
The application for the present invention entitled the "Tensile Arc and Bridge Body Support" is a continuation in part application of the previous patent application entitled "Hypercontoured Suspended Supporting Apparatus", Ser. No. 642,107, Filed Aug. 20, 1984.
BACKGROUND OF THE INVENTION
This invention relates to improved body supports with medical and aerospace applications. Medically, these support configurations will help protect against and treat bed sores. These supports will also help reduce the discomfort associated with prolonged immobile situations and also will immobilize injured patients and thus prevent patients from further injuring themselves. In the aerospace field these support configurations will protect pilots against the high acceleration and vibration forces found in high performance aerospace vehicles.
Medical Field: Bed sores are caused primarily by pressure. Other causative factors include moisture build up and adverse skin temperature gradients. When conventional supports such as chairs, wheelchairs and beds are used, boney prominences are exposed to the highest degree of pressure and they are most susceptible to skin breakdown.
Many have attempted to redistribute pressure evenly so as to reduce the excessive pressure under boney prominences. These devices include cushion-like pads that are foam, gel, water, air or sand filled. Other devices alternate pressure such as an alternating pressure pad or beds which tilt the patient from side to side.
Many devices mentioned above, have surfaces that lack sufficient porosity, which then cause an excessive build-up of moisture against the skin. Foam and air-filled cushions lack air circulation and possess high insulating properties, both of which lead to an excessive rise in skin temperature. On the other hand, water-filled beds and cushions conduct heat away from the skin, thereby adversely reducing skin temperature. Air, water, gel and sand filled devices may leak once punctured and thus loose their effectiveness and become hazardous. Another problem associated with the above supports includes the inability to provide a safe, practical and stable support that prevents excessive patient movement while on the support. A still further problem with these supports is that they do not provide a stable support surface while transferring onto or off of these supports.
Aerospace Field: Aerospace pilots are exposed to the stress of high acceleration, impact acceleration and vibration forces. These stresses overcome the body's elastic tissue's ability to keep the body from deforming under the increased hydro-static pressure and increased weight. Rigid contoured couches, hard shell suits, water tanks, anti-"G" suits and Bowring et al (U.S. Pat. No. 3,011,826) net crew seat have been developed to better protect pilots. Bowring's support has been found to be effective in helping pilots withstand high acceleration forces. However, Bowring's support has a serious rebound problem. This rebound effect occurs because the pilot sinks in the seat during acceleration and when the acceleration stops the pilot is thrown out or rebounds out of the seat due to the recovery of the yieldable resilient support fabric. A further disadvantage is that the support is not multi-directional, it only provides support from front to back (eye balls in). Bowring's support does not protect against side to side movement, nor does it protect against back to front movement (eye balls out). A still further disadvantage is that the depth of the pilot in the seat changes significantly as the acceleration forces change.
Field of Sling Supports: Sling supports like Sam's seat device U.S. Pat. No. 2,600,944, Dionne's torso support U.S. Pat. No. 3,949,435, Bowring's net crew seat, and Dubbink's bathing chair U.S. Pat. No. 4,295,683 do not have an individually fitted frame and supporting fabric for different length and width bodies and thus physiologically critical protection against pressure is not achieved. Moreover Bowring's and Dubbink's devices are shallow supports and do not redistribute support pressure to a significant portion of the sides of the body portions. A further disadvantage of all these sling supports is that a person would have to enter these supports vertically, like in a normal seat or bed. Thus transferring into or out of these supports would be very difficult for healthy people and would be impossible and potentially injurious to most patients. A still further disadvantage is that a person's legs are either seriously squeezed together as in Dionne's support, or kept physiologically too close together thus causing contraction of the patient's legs as in Sam's device, or as in Bowring's net crew seat keeping the legs too close together in an non-optimal position.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, the primary objective of the present invention is to protect a body against physiologically damaging pressure caused by gravity.
It is a concurrent object to provide a body support that redistributes support pressure over the largest body surface area that is practically possible.
It is also a concurrent object to provide a support material which functions dynamically with the body, much like a fluid.
It is also a concurrent object to provide a device that is individually fitted to different size people.
It is a further object to provide stability and ease while sitting, reclining, lying or when one is transferred into or out of the present invention.
It is a further object to provide a device which is capable of supporting a body in multi-directions.
It is a still further object to immobilize or restrain a person and thus prevent excessive movement that might cause injury or might complicate preexisting injuries.
It is a further object to support each individual body portion in a natural or most physiologically beneficial angle in relation to all of the other body portions.
It is a further object to provide a device which controls skin moisture.
It is a still further object to provide a device which maintains and controls proper skin temperature.
It is a further object to provide a support material that is removable and launderable.
It is a further object to provide a device which is capable of administering hyperbaric oxygen directly to the skin surface that the body is lying on and also to the entire body.
It is a further object to provide monitoring devices through the support material.
It is a further object to provide openings through the support material for the purposes of evacuating bodily wastes.
It is a further object to provide a support which improves the resistance of aerospace pilots to the pressure stresses of high acceleration and vibration environments and also to eliminating the rebound effect of resilient supports.
It is a still further object of the present invention to increase comfort and safety by addressing all of the above needs.
These and other objects will be made manifest when considering the following detailed specification when taken in conjunction with the appended drawing figures wherein there has been provided a structure to contour the support surface so as to maximize the skin contact area and thus, redistribute support pressure onto the sides of each supported body portion. To understand the principle of the present invention there needs to be an understanding of the dynamic forces acting on a body floating in a fluid. A body portion floating in a fluid will have the constant force of the fluid applying constant pressure to the sides and underneath. This force which supports the body is hydro-static pressure. Because the pressure is applied to a large surface area (sides and underneath), the highest pressures are lower than would be had the body been supported mainly from underneath. Although fluid filled devices contour around a body portion the tension in the material enclosing the fluid prevents the fluid and material from contacting a large surface area of the sides of the body portion and thus, from applying significant pressure to the sides. These devices still support mainly from underneath the body. Some sling supports contour around the sides of a body, however, they do not apply significant pressure to the sides or apply too much pressure on the sides and not enough underneath the body.
The instant invention attempts to provide a practical, safe, and effective device which simulates a hydro-static force over the maximum body surface area possible, (sides and underneath), thereby lowering significantly the highest support pressures. This is made possible by the tensile arc and bridge body support. This apparatus is comprised in combination of the following;
A fitted apparatus that supports all or some of an individual's body portions that are weight bearing. That is, it is adapted to support the legs and seating area of an individual who is seated, or it is adapted to support the legs, torso, arms, and head for a person lying down or any one part or combination of the above.
The apparatus has a frame member made of a rigid tubular material that is supported and elevated off a base surface, such as above a bed, chair or the like, by rigid vertical members. The tubular frame member is located above and adjacent to, but remote from, each side of the supported body portions. The frame member, also, extends the length and width of each body portion. This frame is shaped to fit different sizes and/or made adjustable to conform to the size and shape of the selected body portions.
Attached to the rigid frame is a coextensive flexible material that is tailored in different sizes to fit deeply and tightly to the three-dimensional profile of the length and width of the selected body portions. The vertical sides of the contoured fabric are attached to the fabric supporting frame above. The fabric extends down from the frame, curves down and passes under the body portion, and curves and extends up the other side, to be attached to the frame there as the said first side. Thus forming the deep, tight, three-dimensional contour.
The framing and the fabric is dimensioned to support and suspend the body portions off the base surface.
Should the curves along the sides of the body turn into a plane, as it does on the front and back of the torso, a rigid contoured bridge would be attached to the fabric to span the plane. This bridge is required because without it the torso would collapse convexly into one continous arc from one side of the torso to the other. Generally, uniform pressure is exerted on a circular object like a leg or an arm with the use of a tensile arc support. However, a tensile material around a circular object with a planar or concave surface will apply excessive pressure on the curved surface and almost no pressure on the planar or concave surface. Since the body is elastic, the weight of it along with the lack of pressure from the unbridged tensile material underneath causes the torso to collapse into one continous arc.
It is important to note that the fabric on the sides of the body portions is in contact with most of the side surface area (as opposed to partial contact), of the body portion. Also, most importantly, a body portion placed in this support is exposed to a dynamic force similar to hydro-static pressure. When a body portion is placed inside the tensile arc and bridge support the fabric on the sides of the body portion moves inward with a constant force and since the fabric is already in contact with the sides of the body, the constant inward force translates into a constant pressure against the sides of the body portions. This redistributes and lowers the support pressure. The tension in the fabric and the pressure moving inwards is directly proportional to the weight of the body. A simple example to illustrate the above effects would be, to support a rope at both ends and let it dangle loosely in an arc, then place a weight in the middle of the arc. The result would be that the rope on either side of the weight would move closer together with a force proportional to the weight. The use of this design to effect a dynamic action for the purposes of redistributing pressure over the maximum body surface contact area is the principle of the tensile arc and bridge support.
The air or liquid-filled devices provide a dynamic support which moves with the patient. However, these air and fluid supports are unstable when transferring patients to and from them. Once on these devices, the air or fluid moves too freely, thereby causing disorientation of the patients, also, as wheelchair cushions they are more unstable during wheelchair propulsion. The present invention inherently provides a dynamic support which also moves with the patient. However the structure is sufficiently stable, unlike fluids, to support the patient securely and also to provide stability during wheelchair propulsion. Also, easy, safe, horizontal patient transferring is provided by lowering the fabric support frame to a level generally flush with the base surface underneath the patient, i.e. bed, chair or the like.
The ability of a device to support a person and prevent side to side or head to toe movement of that person is important in areas where there has been an injury such as a spinal injury and when there is great need to immobilize the patient and prevent further injury. The present invention has some inherent restraining qualities. However, additional structures can be added to the support, to further stabilize and restrain the body. These additions will be described in FIGS. 2 through 6. The immobilization of a patient can be with a portable device that is somewhat adjustable to most patients as would be required in medical ambulance transport, and also, a device that is precisely adjustable as would be required in the long term care of injured patients in hospitals. Preventing side to side movement is also important when there is an additional need to tilt or rotate the patient from side to side for the purposes of stimulating the patient and further improving his physiological functioning. Multi-direction or 360 degrees of support protection can also be incorporated into the present design for supporting a person on his back, side or on his front.
A body floating in water takes on a natural, somewhat semi-recumbent position with the legs somewhat abducted. This too can be incorporated in the present design to maximize physiological functioning.
A porous fabric can be used which is permeable to air and body fluids, thus allowing the skin to breathe. This prevents moisture build-up next to the skin due to perspiration or other bodily fluids. Burn victims on the other hand may need an impervious support material instead. Excessively hot or cold skin temperatures are both uncomfortable and potentially damaging to the skin. The permeable fabric allows room temperature air to circulate to the patient's skin. Temperature can be more actively affected by the use of an insulating jacket underneath and around the patient. Further, a more active approach would be to use a cooling or heating system when required.
Many foam, air and sand filled devices cannot be cleaned easily. With the present invention, having a removable fabric allows for laundering as necessary. Also, there are no leakage problems due to puncturing as can happen in air and fluid filled cushion devices. If puncturing should occur, the integrity of the system is maintained since no air or fluid is required in the system. The present invention also eliminates the safety problem of slippery floors such as occurs when the above mentioned devices leak.
The strucures of the present invention allow for the administration of hyperbaric oxygen therapy, or other appropriate therapy, through the permeable fabric or through an opening in the fabric. The oxygen therapy can be applied to a small area including the person's skin surface in contact with the support material or enveloping the entire person. These structures allow for the monitoring of skin capillary blood flow, or any other type of monitoring, by attaching the monitoring device through the fabric or an opening in the fabric. Also, evacuation of bodily wastes can be carried out through openings in the support material.
Gravity causes excessive support pressure while on most previous devices, especially in the high acceleration or high gravity environments of aerospace travel. The only method that substantially cancels the effects of gravity is submersion or floatation in a fluid. This is impractical and unsafe. In a fluid, as the acceleration increases the body weight and the surrounding fluid weight increase simultaneously. No deformation or displacement of body tissue takes place because of the automatically counteracting pressure of the surrounding fluid. Similarly, the present invention reacts to changes in gravity. As the acceleration increases, the body weight increases, this causes a simultaneous increase in the tension of the fabric. Little body tissue deformation or displacement occurs because of the counteracting higher tension and pressure from the fabric. Naturally an extremely strong fabric and frame would have to be used in order to withstand these heavy loads. Also, to minimize the rebound effect, a fabric with the least resiliency would be used. A further advantage of this support is its ability to protect and support the person from acceleration forces acting from side to side, front to back and back to front.
BRIEF DESCRIPTION OF DRAWING FIGURES
FIG. 1 is a cross sectional view of the width of a person's torso and the two arms and the section of the present invention supporting those body portions.
FIG. 2 is a simplified cross sectional view of the width of a body's torso supported on its side.
FIG. 3 is a cross sectional view of the profile of the head, neck, and torso of a body supported in the supine position.
FIG. 4 is a perspective view of the apparatus of FIGS. 1 and 3.
FIG. 5 is a simplified view from the top of the support of FIG. 4 without the body and showing a cross shaped bridge network.
FIG. 6 is a exploded cross sectional view of the torso support shown in FIG. 1, with the bridge spanning the plane of the torso and its method of attachment to the fabric.
FIG. 7 is a cross sectional view of the width of a torso being supported in a version of the present invention that can support a body in 360 degrees direction.
FIG. 8 is a simplified perspective view of a chair version of the present invention.
FIG. 9 is a front cross sectional view of the buttocks and groin area of the structure shown in FIG. 8.
FIG. 10 is a perspective view of a portable, size adjustable, seat version mainly for wheelchair users.
FIG. 11 is a profile view of the outline of support provide in the structure of FIG. 10.
FIG. 12 is a plan view of the fabric supporting frame of the seat version shown in FIG. 10.
FIG. 13 is a partial plan view of the size adjusting and scissor jack lifting mechanizm of the seat in FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings now wherein like reference numerals refer to like parts throughout the various drawing figures. FIG. 1 is a cross sectional view of the width of a body's torso and its two arms and the section of the framing and fabric supporting those body segments, and also the base structure 9 supporting both. A rigid frame 2 is supported above and on each side of each body portion by rigid vertical support members 3. The vertical support members are supported by a base structure 9. The rigid frame 2 is contoured or outlines the periphery of each body portion being supported. Noting the arms firs, the rigid frame 2 supports the flexible, permeable material 5, this fabric or material extends down a side of the arm, curves downward, under, and curves and extends up to the other side to be attached there to frame 2 as the said first side. Noting the torso now, the fabric supporting frame 2 again supports the fabric 5 on a side of the torso, extends down, curves under and levels to the plane of the person's back and then, extends up to the other side. As detailed before, a flexible material in tension around an object will put more pressure against the curved sides than the side or sides that are concave or planar. A rigid bridge spanning the plane area will equalize the pressure more evenly between the sides and the back. Therefore a rigid bridge 7 is attached to the fabric 2 to span the plane between the two curves 6 of the torso.
In order to facilitate patient transfer, the entire framing and bridge structure above the base surface 4 can be lowered to a position generally flush with the base surface 4. The base surface has a vinyl coated cushion 8, approximately two inches thick, that has channels cut into appropriate areas to receive the framing and bridge structure. The vertical frame supports 3 pass through openings in the base surface and into the base compartment 9. The vertical frame supports 3 are attached to and supported by a foundation 11. This foundation is supported by and attached to a lifting mechanism 10. The lifting mechanism shown is a hydraulic one, but it can easily be substituted by any other appropriate lifting mechanism. To stabilize and smooth out the level changes of the foundation 11, a rigidly connected member 12 is located at each end of the foundation 11. Attached to member 12 are wheels 13 in order to reduce the friction of up and down movement. The opposite method of mating the support frame 2 with the base surface 4, is to make the body framing stationary and instead have the base unit 9 movable up and down. The entire structure of FIG. 1 can be placed on another substructure, not shown, that would mechanically tilt or rotate the patient from side to side. The tilting would stimulate the circulatory and other bodily systems and thus further improve the benefits to the patient.
FIG. 2 shows a simplified cross sectional view of a body's torso supported on its side. Again the vertical frame members 3 supports frame member 2 which supports the fabric 5. The fabric 5 attached to the frame 2 extends down across a large plane along the back, and along the front of the torso. Without the two rigid bridges 7, a simple sling would concentrate most of the support pressure underneath the torso. Attaching the two bridges to the fabric in order to span the planes of the torso, will reduce significantly the pressure underneath the torso and redistribute it to the sides of the torso.
FIG. 2, in addition, shows a stabilizing member 15 made out of a flexible fabric that is sewn to the bottom middle section of the fabric member 5, the two ends of member 15 are attached to a rigid frame 16. Both the fabric member 15 and rigid frame member 16 extend the entire length of the body portions. The stabilizing member 15 prevents the side to side movement of the torso and also allows for the entire structure of FIG. 2 to be tilted at an angle of up to approximately 50 degrees to either side and still adequately support the patient.
FIG. 3 shows a cross sectional view of the profile of a body's head, neck and torso and the section of the present invention supporting those body parts. The legs are not needed to be shown. Again as before, the vertical member 3 supports member 2 and member 2 supports the fabric 5. Again too, the planar surface between the curves at the base of the head 6 and the curve near the coccyx 6 are bridged by a rigid contoured bridge 7. Rigid stabilizing members 17 are attached to the bridge 7 and extend to and around vertical support members 3. The member 17 functions like stabilizing member 15 of FIG. 2, however, in FIG. 3 a rigid stabilizing member would be more appropriate. Vertical member 3 passes through a hole in members 17, although they are in contact with each other they are not attached to each other. This allows for the automatic leveling of the bridge 7 and framing members 2 when the patient support frame 2 is lowered to a position generally flush with the base surface 4. Also, wrapped around vertical member 3 is a compression spring 18, that can be added as required. The spring 18 can be used to relieve some of the tension in the torso supporting fabric 5 in effect becoming a secondary supporting means for the torso. The torso has a disproportionately higher weight to side surface area ratio than the legs or arms, this causes the tension in the fabric to be greater in the torso than in the arms or legs. The use of the compression spring 18 helps equalize this tension differential.
FIG. 4 shows a perspective view of a body being supported in a recumbent position. Simply, the base 4 supports the rigid vertical members 3 and they in turn support the rigid frame members 2. As can easily be seen, the framing members 2 extend the length and width of each body portion forming one coextensive continuous frame. The frame 2 supports the fabric 5 which is contoured to the three-dimensional profile of the person's back and is also contoured to the outline of the front of the person. Thus, all sides of each body portions are supported. The fabric supporting frame 2, at the armpit and groin area 19 also is located above, and is adjacent to, the sides of those body sections. As shown in FIG. 3, stabilizing members 17 are used to prevent the patient's weight from moving the support fabric 5, and thus itself, from side to side and from head to foot.
For burn injured patients, the support fabric 5 can be impervious, to minimize body fluid loss through the skin. Also, the framing structure 2 outlining the body, can be wider than the body portions and still be adequate for supporting the patient under low uniform pressure. For injuries such as spinal cord injuries, the fabric chosen would be permeable in order to minimize perspiration and discomfort. For both patient types, a resilient elastic-like material could be used to further improve comfort and fit. In addition the support fabric 5 can have a padded or fur-like lining.
Although the support structure in FIG. 4 shows a level recumbent body in a planar frame, it will be understood that this support can be adapted with hinged members, not shown, at the joint locations of the body such as shown by reference numbers 14. This would further add to the comfort and needs of the patient.
FIG. 5 shows a view from the top of the recumbent body support of FIG. 4. The rigid bridge network 7 spans the planes of the torso. This bridge network spans the width of the torso, wider across the width of the shoulders and longest across the plane approximately between the base of the head and the coccyx. This bridge network 20 thus forms one coextensive cross-shaped rigid bridge that is attached to the support fabric 5. Below the bridge network is the stabilizing members 17. At each end of the stabilizing members, the vertical members 3 pass through and function as guides to keep the stabilizing members in alignment.
FIG. 6 is a cross sectional view of the torso support of FIG. 1, 3, 4, and 5 and the method of attaching the bridge to the fabric. The bridge 22 is composed of any suitable rigid lightweight material that is located underneath the plane of fabric 5, above the fabric is a very thin rigid material with threaded bolts fastened to its outside periphery. The bolts of the top thin plate 23 pass through holes in the support fabric 5, and through holes in the bridge 22 below. Wing nuts 25 are then threaded and tightened onto the bolts 24. This sandwiches the fabric between the plate 23 and the bridge 22. As can be observed, the width of the bridge member 22 can be much greater than the width of the plane, for it is the width of the top plate 23 that needs to precisely fit the span of the plane. On top of the thin plate 23 a thin cushion material is attached. The entire bridge network, including the cushion material 26, the thin top plate 23, and the bridge 22 will be made to contour to the profile of the back of the person' s head, neck and torso. Also, the entire bridge network can also be made of permeable materials to enhance comfort. In addition, the entire bridge network can be made of X-ray penetrable materials.
FIG. 7 is a cross sectional view of the width of the torso being supported by a version of the present invention where it is adapted to support a body in multi or 360 degree directions. Again as before, the base 4 supports vertical members 3 which in turn support members 2 and finally member 2 supports the fabric 5. Down below the body and directly opposite member 2, and attached to the member 3, is a similar functioning and positioned rigid frame member 16.
This rigid frame member 16 supports a separate supporting fabric 28 which is attached to the regular suporting fabric 5. Fabric member 28 is shown slightly slack. However, should the person be rotated 180 degrees, it would function as the original fabric. That is, the rigid frame 16 would be overhead and the slack fabric 28 would become fully tense and provide support to the torso. Likewise, should the person be rotated 90 degrees on his side, he would be supported as in FIG. 2. That is, member 2 and 16 would be over top the torso and they would support fabric members 15 which in turn would support the torso. Although members 15 shown are fabric they can be made of a rigid material as shown in FIGS. 3, 4 and 5 designated as stabilizing members 17. In any direction there is a stabilizing member of either fabric or of a rigid material that prevents side to side movement, as shown in FIG. 2 designated as fabric stabilising member 15 or as shown in FIGS. 3, 4 and 5 designated as rigid stabilizing member 17.
FIG. 8 shows a floating unsupported version of the present invention which supports mainly, the legs, seating area, and lower torso of a person's body. Here the frame 2 outlines the width and length of each supported body portion and also outlines the profile outline of the body in a semi-reclined or seated position. Although no base support structure is shown, it should be apparent that this version of the present invention can be supported on a leg frame like a conventional chair or adapted with wheels, as a wheelchair. It also will become apparent that as with the recumbent version, shown in FIGS. 1, 3, 4 and 5 the frame 2 of FIG. 8 could be adapted to be lowered to a level generally flush with a base surface underneath it for the purposes of facilitating safe and easy horizontal transferring. The backrest 30 is a rigid structure that is padded with a cushioning material. Part of the rigid backrest extends down to form a bridge 29 to span the plane of the torso that is supported by the fabric 5. The arm rest shown 31 is of the conventional type, however the arm rest along with the remainder of the conventional back rest 30 can naturally be designed with the entire concept of the present invention.
FIG. 9 shows a front sectional view of the seat section of FIG. 8, that is, where the observer is face to face with a person that would be seated in the seat of FIG. 8. The fabric 5 supporting the lower thighs is designated by #32, the fabric 5 supporting the outline of the buttocks is designated by #33. Normally the fabric is contoured around each side of the supported body portions as it is around the thighs and the sides and back of the buttocks. As described in the summary of the invention the support fabric applies constant pressure to the sides of the body and therefore would not be appropriate to have the fabric apply pressure to the genital area. To eliminate the pressure against the genitals instead of the fabric extending across the genital area 34, it is tailored to loop below that area and no pressure is applied there. However, the front lower curve of the buttocks below the genital area is still supported by the tensile curving fabric. The result is, besides support from underneath, all of the outside and inside sides of the thighs are supported, all of the right and left sides and the back of the buttocks are supported and most of the front side of the buttocks is supported. A contoured padded bridge 38 spanning the middle concave curve of the buttocks can be attached there in order to improve support in that area.
FIG. 10 is a perspective view of a portable size adjustable, seat version of the present invention. It is primarily made for parapelegics and quadrapeligics who have their own wheelchairs. The base 4 supports cross-shaped members 40 which supports channel member 39 and that in turn supports the fabric support frame 2. The fabric supporting member between the legs 36 is elevated to a lower level than fabric supporting frame 2 in order to prevent pressure on the genitals. The supporting contoured fabric is attached to the frame 2 which abuts the right and left sides of the buttocks and also abuts the back of the buttocks. From the frame 2 the fabric 5 extends down, curves inward and under and curves up simultaneously all as one coextensive material towards the front of the seat, curving up, highest to the center member 36 and being attached there, and curving up slightly under the thighs and in front of the buttocks and over a higher section of the base surface 41 and finally being attached to the front of the seat. Varying the distance between the middle member 36 and the back section of member 2, for fitting purposes, is accomplished by unlocking member 50 and adjusting appropriately and then locking it in place. As with the previous versions of this invention the fabric support frame 2 can be lowered to a position generally flush with the base surface 4. In this example instead of using a hydraulic system to lift the frame vertically, as in FIG. 1, a scissor jack type mechanism is used.
FIG. 11 shows the sectional view of the profile of a person sitting in the seat of FIG. 10, with the legs removed. This figure shows the line of support, between the legs, curving downwards from member 36, under and curving up to the fabric support frame 2. As mentioned before, in FIG. 8, the fabric supports from underneath and all of the outside side area of the buttocks and also supports most of the front side area of the buttocks without applying pressure to the genital area. The thighs are better able to withstand pressure and rest on a padded front section 41 of the base.
FIG. 12 shows of a way to adjust the width of the frame member 2, from the seat of FIG. 10, to fit the width of a person's buttocks. The frame member 2 on one side would be permanentely fitted to a side of tube 44, on the other side member 2 would be slidable in and out in tube member 44. Member 2 can easily be adapted to a single or double hip amputee, by having the fabric supporting frame 2 come around the front of the seated person's waist and be attached to the middle member 36.
FIG. 13 shows the adjustment mechanism to vary the spacing between the pair of cross-shaped support members 40, of FIG. 10. A push plate 47 is used to move the cross-shaped members 40 and member 36 to the elevated position. On both sides of the push plate 47 are channels 48. In these channels sit the push bar members 49. The push bar members 49, (only one side shown), can be adjusted to the width of an individual by loosening adjustment screw 46 and moving the push bar 49 to the correct place and then retightening the adjustment screw 46. Near the back end of the push bar 49 is the pin 51 which enters one member of the cross shaped members 40. Likewise, member 36 acts as one unit of a cross-shaped members. Attached to member 36 are rigid members 55 which act as the second member of a cross-shaped scissor type mechanism. However, due to its shorter length member 55 never extends above member 36 and members 36 and 55 do not take on a true cross-shaped appearance. The push plate 47 is drawn about an inch and a half towards the back of the seat thereby raising the outside pair of cross-shaped members 40 and inside member 36 to their appropriate elevated position and down again whenever patient transferring is needed. Many mechanisms are available to move the push plate 47 back and forth, such as, electro-mechanical, hydraulic, lever type systems, crank type systems, and the like.
Also in FIG. 13 is shown the method of attachment of the support fabric 5 to member 36. The support fabric 5 of FIG. 10 is placed between the tip of member 36 and a curved, fabric sandwich plate 53. A screw 54 is passed through a hole in the curved sandwich plate 53, and through a hole in the support fabric and finally into a threaded hole in member 36 and tightened there to keep the fabric in place.
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An individually fitted apparatus for, and method of supporting an individual by, a tensile arc and bridge body support, comprising in combination; A fitted tubular frame outlining the immediate periphery of each supported body portion and attached to the frame is a fabric that is deeply and tightly contoured to the three-dimensional profile of the body portions. The fabric extends down a side of each body portion curves and passes under, and up to the other side. A contoured rigid member is attached to the fabric that opposes a planar or concave surface of the body portions, such as the back of the torso. By suspending the individual in this support, the tensile fabric applies pressure to the convex curves of the body portions and the contoured bridge applies pressure to the planar or concave surfaces. The support surface area can be increased substantially by using this support and the support pressure would drop accordingly.
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[0001] The present application is the U.S. national stage application of International Application PCT/CN2014/088336, filed Oct. 11, 2014, which international application was published on Apr. 16, 2015, as International Publication WO2015/051762. The International Application claims priority of Chinese Patent Application 201310475989.7, filed Oct. 12, 2013, the contents of which are incorporated herein by reference in their entireties.
FIELD OF INVENTION
[0002] The present invention relates to a preparation method of a drug, specifically, the present invention relates to a preparation method of Maxacalcitol, a novel synthetic intermediate thereof, a preparation method and a use therefor.
PRIOR ARTS
[0003] Maxacalcitol (Maxacalcitol, CAS NO.: 103909-75-7), whose English chemical formula is: 22-Oxacalcitriol; (1R,3S,5Z)-4-Methylene-5-[(2E)-2-[(1S,3aS,7aS)-octahydro-1-[(1S)-1-(3-hydroxy-3-Methylbutoxy)ethyl]-7a-Methyl-4H-inden-4-ylidene]ethylidene]-1,3-cyclohexanediol, is the third generation of active vitamin D3 drug developed by Chugai Pharmaceutical Co., Ltd., and first faced to the market in Japan in 2000, its injection (Trade name: Oxarol) is used for treating the secondary hyperparathyroidism of the renal dialysis patients (SHPT); its ointment (Trade name: Oxarol) is used for treating the dry tinea skin diseases such as psoriasis. Currently, applications involving its synthesis include WO2012/122451, WO2001079166, U.S. Pat. No. 5,436,401, CN102796134 and JP20111573261.
[0004] U.S. Pat. No. 5,436,401A discloses a preparation method of Maxacalcitol, in which la-hydroxyl dehydroepiandrosterone is used as a starting material, and Maxacalcitol is given through modification on side chain and ring A, opening ring B by photochemical reaction and rearrangement under heating condition. However, 1α-hydroxyl dehydroepiandrosterone is prepared by microbial fermentation, which greatly restricts the source of the starting material, and the preparation method involves multiple reaction steps, some of which have relative low yields, which is not suitable for industrial production.
[0005] WO2012/122451 improves the preparation method of Maxacalcitol greatly and reduces the reaction steps by introducing a product as the starting material which is obtained by proper modifying an analog compound of vitamin D2. However, the improved method employs NaBH 4 when reducing the ketone at C-20 position, the main product of which is with opposite configuration, this greatly restricts the application of the process.
[0006] CN102796134 aims mainly at the shortage of the process in WO2012/122451, focuses on improving the reduction of the ketone at C-20 position disclosed in WO2012/122451, and obtains the product with single configuration through asymmetric reduction.
[0007] JP20111573261 takes vitamin D2 as the starting material, and obtains compound X according to the method in U.S. Pat. No. 4,866,048, the compound X is converted into compound V′(S configuration) and V″(R configuration) with a ratio of 35:65 under the action of lithium aluminium hydride, the compound V′(S configuration) is the target configuration (with a yield of 24% only), the synthesis efficiency is too low.
[0000]
[0008] In view of the shortcomings in the prior art, it's extremely important to find a synthesis process with fewer steps, higher yield and lower cost.
Content of the Present Invention
[0009] One of the aims of the present invention is to provide a novel key intermediate (compound III, IV, VI) and preparation method thereof.
[0010] Another aim of the present invention is to provide a novel preparation method of Maxacalcitol by using the key intermediate.
[0011] One aspect of the present invention is to provide a novel intermediate represented by Formula III used for the synthesis of Maxacalcitol:
[0000]
[0012] where R is H or a hydroxyl protection group, wherein the hydroxyl protection group includes a silicon ether protection group, preferably is a t-butyldimethylsilyl, a trimethylsilyl, a triethylsilyl, a t-butyldiphenylsilyl or a triisoprolylsilyl.
[0013] Another aspect of the present invention is to provide a preparation method of compound III, comprising in the presence of a catalyst, oxidating compound II with an oxidizing agent to afford compound III, where R is defined as above:
[0000]
[0014] As a preferred embodiment of the present invention, the oxidizing agent of the oxidation reaction is preferably oxygen; the catalyst is preferably a copper catalyst, more preferably 2,2-bipyridine copper complex.
[0015] Another aspect of the present invention is to provide a novel intermediate represented by Formula IV used for the synthesis of Maxacalcitol:
[0000]
[0016] where R is H or a hydroxyl protection group, wherein the hydroxyl protection group comprises a silicon ether protection group, preferably is a t-butyldimethylsilyl, a trimethylsilyl, a triethylsilyl, a t-butyldiphenylsilyl or a triisoprolylsilyl.
[0017] Another aspect of the present invention is to provide a preparation method of compound IV, comprising:
[0018] in the presence of a chiral auxiliary reagent, stereoselectively reducing compound III to give compound IV with specific configuration by employing a borane, where R is defined as above:
[0000]
[0019] As a preferred embodiment of the present invention, the chiral auxiliary reagent used in the reaction is preferably selected from (R)-2-methyl-CBS-oxazaborolidine, (R)-2-ethyl-CBS-oxazaborolidine or (R)-2-isopropyl-CBS-oxazaborolidine; the borane used in the reaction is preferably selected from BH 3 , borane-tetrahydrofuran complex, borane-triethylamine complex, borane-ethyl ether complex, borane-methyl sulfide complex or borane-N,N-diethylaniline complex.
[0020] As a preferred embodiment of the present invention, a mole ratio of the compound III, the chiral auxiliary reagent and the borane is preferably 1:(0.1-1):(1-2), more preferably 1:0.6:1.
[0021] As a preferred embodiment of the present invention, the reaction temperature is preferably −60° C. to 0° C., more preferably −20° C.
[0022] Another aspect of the present invention is to provide a novel intermediate represented by Formula VI for the synthesis of Maxacalcitol:
[0000]
[0023] where R is H or a hydroxyl protection group, wherein the hydroxyl protection group includes a silicon ether protection group, preferably is a t-butyldimethylsilyl, a trimethylsilyl, a triethylsilyl, a t-butyldiphenylsilyl or a triisoprolylsilyl.
[0024] Another aspect of the present invention is to provide a preparation method of compound VI, comprising:
[0025] Step 1: converting compound IV into compound V under alkaline condition:
[0000]
[0026] where R is a hydroxyl protection group;
[0027] Step 2: reacting compound V with 3-bromomethyl-2,2-dimethyloxirane to give compound VI:
[0000]
[0028] where R is a hydroxyl protection group.
[0029] The preparation method of compound VI, if it is necessary, can further comprises: de-protecting the hydroxyl protection group R of compound VI which is obtained in the step 2 to give compound VI:
[0000]
[0030] where R is H.
[0031] Wherein, the alkali in the step 1 includes sodium bicarbonate or sodium acetate.
[0032] Another aspect of the present invention is to provide a preparation method of Maxacalcitol represented by formula I:
[0000]
[0033] The preparation method comprises:
[0034] Step 1: converting compound IV into compound V under alkaline condition:
[0000]
[0035] where R is a hydroxyl protection group;
[0036] Step 2: reacting compound V with 3-bromomethyl-2,2-dimethyloxirane to give compound VI:
[0000]
[0037] where R is a hydroxyl protection group;
[0038] Step 3: converting compound VI into compound VII in the presence of lithium triisobutylhydroborate:
[0000]
[0039] where R is a hydroxyl protection group;
[0040] Step 4: reacting compound VII under the action of both N-methylmorpholine N-oxide and selenium dioxide to give compound VIII:
[0000]
[0041] where R is a hydroxyl protection group;
[0042] Step 5: de-protecting the hydroxyl protection group of compound VIII to give compound IX:
[0000]
[0043] where R is a hydroxyl protection group;
[0044] Step 6: conducting a photochemical reaction on compound IX to give Maxacalcitol represented by formula I:
[0000]
[0045] Wherein, the alkali in the step 1 includes sodium bicarbonate or sodium acetate.
[0046] In an embodiment of the present invention, a preparation method of Maxacalcitol is provided, which comprises:
[0047] conducting a photochemical reaction via uv irradiation on compound IX under the catalysis of 9-acetylanthracene, to overturn the conjugate double bond:
[0000]
[0048] in the reaction, the mass ratio of compound IX to 9-acetylanthracene is preferably 1:(0.05-1), more preferably 1:0.1.
[0049] The duration of the reaction can be 0.5 to 5 h, preferably 2 h.
[0050] The reaction temperature is preferably 0° C. to 10° C.
[0051] The reaction can be conducted in a proper organic solvent, the organic solvent can be any proper one, including but not limited to, methanol, ethanol, acetone, dioxane, acetonitrile, THF.
[0052] In a further preferred embodiment of the present invention, compound IX can be prepared according to a preparation method as below:
[0053] de-protecting compound VIII-1 in the presence of tetrabutylammonium fluoride:
[0000]
[0054] In the reaction, a molar ratio of compound VIII-1 to tetrabutylammonium fluoride is preferably 1:1-3, more preferably 1:1.5.
[0055] The duration of the reaction can be 5 h to 40 h, preferably 10 h.
[0056] The reaction temperature is preferably 65° C.
[0057] The reaction can be conducted in a proper organic solvent, the organic solvent can be any proper one, including but not limited to, methanol, ethanol, acetone, dioxane, acetonitrile, THF, preferably THF.
[0058] In a further preferred embodiment of the present invention, compound VIII-1 can be prepared according to a preparation method as below:
[0059] reacting compound VII-1 under the action of both N-methylmorpholine N-oxide and selenium dioxide:
[0000]
[0060] In the reaction, a molar ratio of compound VII-1, N-methylmorpholine N-oxide and selenium dioxide is preferably 1:(1-3):(0.2-1), more preferably 1:2:0.4.
[0061] The duration of the reaction can be 2 h to 24 h, preferably 8 h.
[0062] The reaction temperature is preferably 35° C.
[0063] In a further preferred embodiment of the present invention, compound VII-1 can be prepared according to a preparation method as below:
[0064] reacting compound VI-1 in the presence of lithium triisobutylhydroborate:
[0000]
[0065] In the reaction, a molar ratio of compound VI-1 to lithium triisobutylhydroborate is preferably 1:(1-3), more preferably 1:1.5.
[0066] The duration of the reaction can be 1 h to 10 h, preferably 3 h.
[0067] The reaction temperature is preferably 25° C., the solvent is preferably THF.
[0068] In a further preferred embodiment of the present invention, compound VI-1 can be prepared according to a preparation method as below:
[0069] reacting compound V-1 in the presence of sodium hydride and 3-bromomethyl-2,2-dimethyloxirane:
[0000]
[0070] In the reaction, a molar ratio of compound V-1, sodium hydride and 3-bromomethyl-2,2-dimethyloxirane is preferably 1:(1-3):(1-3), more preferably 1:1.2:2.
[0071] The duration of the reaction can be 1 h to 10 h, preferably is 5 h.
[0072] The reaction temperature is preferably 50° C.
[0073] The reaction can be conducted in a proper organic solvent, the organic solvent can be any proper one, including but not limited to, dioxane, acetonitrile, THF, DMF, DMSO, N,N-dimethylacetamide or N-methylpyrrolidone, etc.
[0074] In a further preferred embodiment of the present invention, compound V-1 can be prepared according to a preparation method as below:
[0075] converting compound IV-1 into compound V-1 in the presence of sodium bicarbonate:
[0000]
[0076] In the reaction, a molar ratio of compound IV-1 to sodium bicarbonate is preferably 1:(1-10), more preferably 1:6.
[0077] The duration of the reaction can be 1 h to 24 h, preferably 7 h.
[0078] The reaction temperature is preferably 80° C.
[0079] The reaction can be conducted in a proper organic solvent, the organic solvent can be any proper one, including but not limited to, 95% (v/v) ethanol, acetonitrile, ethyl acetate or anhydrous ethanol, preferably 95% (v/v) ethanol.
[0080] In a further preferred embodiment of the present invention, compound IV-1 can be prepared according to a preparation method as below:
[0081] in the presence of a chiral auxiliary reagent (R)-2-methyl-CBS-oxazaborolidine, reducing compound III-1 with a borane:
[0000]
[0082] In the reaction, a molar ratio of compound III-1, (R)-2-methyl-CBS-oxazaborolidine and borane is preferably 1:(0.1-1):(1-2), more preferably 1:0.6:1.
[0083] The reaction temperature can be −60° C. to 0° C., preferably −20° C.
[0084] The duration of the reaction is preferably 3 h.
[0085] In a further preferred embodiment of the present invention, compound III-1 can be prepared according to a preparation method as below:
[0086] reacting compound II-1 in the presence of triethylenediamine, 2,2-bipyridine and copper acetate when feeding oxygen:
[0000]
[0087] In the reaction, a molar ratio of compound II-1, triethylenediamine, 2,2-bipyridine and copper acetate is preferably 1:(1-2):(0.1-1):(0.1-1), more preferably 1:1:0.2:0.2.
[0088] The duration of the reaction can be 1 h to 20 h, preferably 5 h.
[0089] The reaction temperature is preferably 45° C.
[0090] Wherein, compound II-1 is prepared according to patent U.S. Pat. No. 4,866,048.
[0091] The synthetic route of the present invention can be summarized as below:
[0000]
[0092] Compared to the prior art, the present invention has the following advantages:
[0093] The synthetic process provided by the present invention is crafty-designed, in which vitamin D2 is used as a starting material, compound II is prepared according to the method in U.S. Pat. No. 4,866,048 and then oxidized by oxygen under copper catalysis to deliver compound III. During the oxidation process, due to the protection of sulfur dioxide for the double bond, other side reactions are reduced, which make the yield of oxidation product reach about 80%. However, during the oxidation process of the similar compounds in the prior art, the yield is relative low due to the unstability of the conjugated triple bond, for example, the yield of oxidation reaction mentioned in JP20111573261 is 67% and in reference T.L. 1994, 2295-2298 is 60%-65%. In the present invention, in the presence of a chiral auxiliary reagent, compound III is reduced stereoselectively to give compound IV with single S configuration by employing a borane, and with a high yield of nearly 100%. As sulfur dioxide protects the terminal double bond, side reaction which is the reaction between the borane and the terminal double bond can be efficiently avoided in the reduction reaction, which improves the yield. WO2012/122451 and JP20111573261 conduct the reduction reaction by employing sodium borohydride/lithium aluminum hydride, in which the majority of the product is with R configuration, the yield of product with S configuration is extremely low, furthermore, the products with two configurations have close Rf values, which leads to difficult purification. The present invention protects the double bond with sulfur dioxide, which plays an important role in the oxidation and asymmetric reduction steps, efficiently avoids other side reactions, and improves the reaction yield dramatically. Meanwhile, the following purification becomes much easier since the product with single S configuration is given. The synthesis efficiency is greatly improved, and the process cost is greatly reduced.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0094] The following examples further illustrate the present invention. It is to be understood that the preparation methods of embodiments are intended to illustrate the present invention in detail, rather than limit the scope of the present invention, any simple modification on the preparation method of the present invention based on the conception of the present invention should belongs to the scope of the present invention.
Embodiment 1
[0095] Preparation of Compound III-1
[0000]
[0096] Compound II-1 (50.7 g, 100 mmol) was dissolved in DMF (500 mL), then triethylenediamine (11.2 g, 100 mmol), 2,2-bipyridine (3.12 g, 20 mmol) and copper acetate (3.64 g, 20 mmol) were added separately at room temperature. After adding, the reaction mixture was heated to 45° C. at oxygen atmosphere, further stirred for 5 h at this temperature. After the reaction was complete, ethyl acetate was added, the mixture was filtered to remove the insolubles. The filtrate was washed by water for 3 times, dried over anhydrous sodium sulfate, and concentrated under reduced pressure, the oil was isolated and purified to obtain Compound III-1 (39.9 g, yield 81%). The compound was a mixture of two configurations (due to the protection of sulfur dioxide) and can be used directly for the next step. A small amount was taken to be isolated and purified to give a compound with configuration I (having large Rf value) and a compound with configuration II (having small Rf value).
[0097] The tested data of 1 H NMR, 13 C NMR and MS for the two isomers of compound III-1 were as below:
[0098] The isomer with small Rf value: 1 H NMR (400 MHz, d-CHCl 3 ) δ: −0.01 and −0.00 (each, s, 6H), 0.55 (s, 3H), 0.81 (s, 9H), 1.19-2.19 (m, 19H), 2.56-2.66 (m, 2H) 3.59 (s, 2H), 3.95-3.97 (m, 1H), 4.43-4.45 (d, 1H, J=9.6), 4.66-4.68 (d, 1H, J=9.2); 13 C NMR (100 MHz, d-CHCl 3 ) δ: −4.7, −4.7, 13.1, 18.1, 22.2, 22.4, 23.7, 24.2, 25.8, 29.6, 30.7, 31.3, 34.3, 39.4, 47.1, 56.3, 58.1, 63.7, 66.5, 67.5, 111.6, 126.7, 130.5, 149.3, 208.8; MS: m/z (492), Found: 493 (M+H).
[0099] The isomer with large Rf value: 1 H NMR (400 MHz, d-CHCl 3 ) δ: −0.01 and −0.00 (each, s, 6H), 0.49 (s, 3H), 0.82 (s, 9H), 1.21-2.20 (m, 19H), 2.57-2.60 (m, 1H), 2.67-2.71 (m, 1H), 3.62-3.64 (d, 2H), 3.91-3.93 (m, 1H), 4.55-4.58 (d, 1H, J=9.6), 4.62-4.79 (d, 1H, J=10.0); 13 C NMR (100 MHz, d-CHCl 3 ) δ: −4.8, −4.7, 13.4, 18.1, 22.3, 22.5, 23.3, 24.6, 25.8, 29.1, 29.7, 30.9, 31.5, 34.1, 39.1, 46.3, 56.1, 58.2, 63.4, 66.7, 66.8, 111.1, 127.0, 130.2, 148.6, 208.9; MS: m/z (492), Found: 493 (M+H).
Embodiment 2
[0100] Preparation of Compound IV-1
[0000]
[0101] Compound III-1 (49.2 g, 100 mmol) was dissolved in 400 mL anhydrous THF, (R)-2-methyl-CBS-oxazaborolidine (1 M, 100 mL) was added slowly at −20° C., followed by dripping BH 3 ·THF (1 M, 60 mL) slowly at this temperature, the reaction mixture was further stirred for 1 h after adding, and warmed to room temperature slowly, then 50 mL saturated ammonium chloride solution was added, the mixture was extracted with ethyl acetate, and concentrated under reduced pressure to give 49.5 g oil. The obtained oil was a mixture of two configurations (resulting from the protection of sulfur dioxide, C-20 having single S configuration). A small amount was taken to be isolated and purified to give a compound with configuration I (with large Rf value) and a compound with configuration II (with small Rf value).
[0102] The tested data of 1 H NMR, 13 C NMR and MS for the two isomers of compound IV-1 were as below:
[0103] The isomer with small Rf value: 1 H NMR (400 MHz, d-CHCl 3 ) δ: −0.01 and −0.00 (each, s, 6H), 0.60 (s, 3H), 0.80 (s, 9H), 1.17-1.20 (m, 6H), 1.48-2.04 (m, 16H), 2.48-2.57 (m, 1H), 3.59 (s, 2H), 3.64-3.68 (m, 1H), 3.94-3.96 (m, 1H), 4.44-4.47 (d, 1H, J=9.2), 4.64-4.66 (d, 1H, J=9.2); 13 C NMR (100 MHz, d-CHCl 3 ) δ: −4.7, 12.4, 18.1, 22.0, 23.6, 24.3, 25.0, 25.8, 29.7, 29.7, 30.7, 34.3, 39.3, 45.3, 56.1, 58.1, 58.7, 66.5, 67.6, 70.3, 110.8, 126.5, 130.7, 150.0; MS: m/z=494, Found 495 (M+H).
[0104] The isomer with large Rf value: 1 H NMR (400 MHz, d-CHCl 3 ) δ: −0.01 and −0.00 (each, s, 6H), 0.52 (s, 3H), 0.82 (s, 9H), 1.18-1.23 (m, 6H), 1.46-2.17 (m, 16H), 2.52-2.55 (m, 1H), 3.60-3.66 (m, 3H), 3.91-3.92 (m, 1H), 4.55-4.58 (d, 1H, J=10.4), 4.73-4.75 (d, 1H, J=10.4); 13 C NMR (100 MHz, d-CHCl 3 ) δ: −4.7, 12.4, 18.1, 22.0, 23.6, 24.3, 25.0, 25.8, 29.7, 29.7, 30.7, 34.3, 39.3, 45.3, 56.1, 58.1, 58.7, 66.5, 67.6, 70.3, 110.8, 126.5, 130.7, 150.0; MS: m/z=494, Found 495 (M+H).
Embodiment 3
[0105] Preparation of Compound V-1
[0000]
[0106] The crude product of compound IV-1 obtained from the previous step was dissolved in 400 mL 95% ethanol, 50 g sodium bicarbonate was added while stirring, then heated to reflux and reacted for further 2-3 h at this temperature. After the reaction was complete, the ethanol was removed under reduced pressure, ethyl acetate was used to extract. The oil was isolated and purified to give 36.4 g compound V-1, yield 84%.
[0107] The tested data of 1 H NMR, 13 C NMR and MS for compound V-1 were as below:
[0108] 1 H NMR (400 MHz, CDCl 3 ) δ: −0.03 (s, 6H, 2SiCH 3 ), 0.50 (s, 3H, CH 3 ), 0.82 (s, 9H, 3SiCH 3 ), 1.16 (d, J=6 Hz, 3H, CH 3 ), 1.18-1.23 (m, 2H), 1.35-2.22 (m, 13H), 2.38-2.43 (m, 1H), 2.57-2.61 (m, 1H), 2.79-2.83 (m, 1H), 3.64-3.67 (m, 1H, CHOH), 3.78-3.81 (m, 1H, CHOH), 4.58 (s, 1H, ═CH 2 ), 4.86 (s, 1H, ═CH 2 ), 5.81 (d, J=11.6 Hz, 1H, ═CH), 6.40 (d, J=11.6 Hz, 1H, ═CH); 13 C NMR (75 MHz, CDCl 3 ) δ: −4.7, −4.6, 12.7, 18.2, 22.2, 23.2, 23.6, 25.0, 25.9 (3C), 28.8, 31.2, 35.2, 37.5, 39.5, 44.9, 56.3, 58.7, 69.4, 70.3, 107.5, 116.5, 119.9, 136.6, 142.9, 150.0; Ms: m/z=430, found 431 (M+1).
Embodiment 4
[0109] Preparation of Compound VII-1
[0000]
[0110] Compound V-1 (43.1 g, 100 mmol) was dissolved in 430 mL anhydrous THF, 60% sodium hydride (4.8 g, 120 mmol) was added at room temperature, then stirred for 0.5 h. 3-bromomethyl-2,2-dimethyloxirane (31 g, 200 mmol) was added and the mixture was heated to reflux and reacted for further 5 h at this temperature. After the reaction was complete, the mixture was cooled to room temperature, lithium triisobutylhydroborate (150 mL, 1 M in THF) was added, and then further stirred for 3 h after adding. Saturated ammonium chloride solution 100 mL was added, the mixture was extracted with ethyl acetate, and concentrated, the obtained oil was isolated and purified to give 40.3 g compound VII-1, yield 78%.
[0111] The tested data of 1 H NMR, 13 C NMR and MS for compound VII-1 were as below:
[0112] 1 H NMR (400 MHz, CDCl 3 ) δ: −0.07 (s, 3H, SiCH 3 ), −0.06 (s, 3H, SiCH 3 ), 0.48 (s, 3H, CH 3 ), 0.83 (s, 9H, 3SiCH 3 ), 0.72-0.97 (m, 2H), 1.13 (d, J=6 Hz, 3H, CH 3 ), 1.17 (s, 3H, CH 3 ), 1.18 (s, 3H, CH 3 ), 1.19-1.27 (m, 2H), 1.35-2.22 (m, 13H,), 2.39-2.42 (m, 1H), 2.56-2.61 (m, 1H), 2.78-2.82 (m, 1H), 3.17-3.21 (m, 1H, CHOH), 3.41-3.44 (m, 1H, CHOH), 3.77-3.81 (m, 3H, OH and CHOH), 4.58 (s, 1H, ═CH 2 ), 4.86 (s, 1H, ═CH 2 ), 5.80 (d, J=11.6 Hz, 1H, ═CH), 6.39 (d, J=11.6 Hz, 1H, ═CH); 13 C NMR (75 MHz, CDCl 3 ) δ: −4.7, −4.6, 12.7, 18.2, 18.8, 22.2, 23.2, 25.9 (3C), 26.0, 28.8, 29.1, 29.4, 31.2, 35.2, 37.5, 39.6, 41.5, 44.7, 56.2, 57.1, 65.6, 69.4, 70.5, 79.0, 107.6, 116.5, 119.9, 136.5, 142.8, 150.0; Ms: m/z=516, found 517 (M+1).
Embodiment 5
[0113] Preparation of Compound VIII-1
[0000]
[0114] Compound VII-1 (41.2 g, 80 mmol) was dissolved in 500 mL dichloromethane, then N-methylmorpholine N-oxide (18.7 g, 160 mmol) and selenium dioxide (3.55 g, 32 mmol) were added, argon was introduced to replace the air in the reaction flask. The reaction mixture was heated to reflux, then further reacted for 5-6 h at this temperature. After the reaction was complete, the mixture was cooled to room temperature, water was added, and dichloromethane was used to extract. The organic phase was concentrated under reduced pressure, then the residue was isolated and purified by column chromatography, elution system was petroleum ether:ethyl acetate=10:1, to obtain Compound VIII-1 (15.7 g), yield 37%.
[0115] The tested data of 1 H NMR, 13 C NMR and MS for compound VIII-1 were as below:
[0116] 1 H NMR (400 MHz, CDCl 3 ) δ: −0.01 (s, 6H, 2SiCH 3 ), 0.46 (s, 3H, CH 3 ), 0.83 (s, 9H, 3SiCH 3 ), 1.12 (d, J=6 Hz, 3H, CH 3 ), 1.16 (s, 3H, CH 3 ), 1.17 (s, 3H, CH 3 ), 1.18-1.27 (m, 2H), 1.42-1.97 (m, 15H), 2.34-2.47 (m, 1H), 2.77-2.81 (m, 1H), 3.16-3.20 (m, 1H, CHOH), 3.41-3.44 (m, 1H, CHOH), 3.75-3.80 (m, 2H, OH and CHOH), 4.11-4.14 (m, 1H, CHOH), 4.41-4.44 (m, 1H, CHOH), 4.88 (s, 1H, ═CH 2 ), 4.99 (s, 1H, ═CH 2 ), 5.78 (d, J=11.6 Hz, 1H, ═CH), 6.42 (d, J=11.6 Hz, 1H, ═CH); 13 C NMR (75 MHz, CDCl 3 ) δ: −4.8, −4.7, 12.6, 18.1, 18.8, 22.2, 23.2, 25.9 (3C), 26.0, 28.9, 29.1, 29.4, 37.0, 39.6, 41.5, 42.9, 44.8, 56.2, 57.1, 65.6, 66.8, 70.5, 70.6, 79.0, 107.7, 116.6, 122.2, 134.6, 143.3, 153.1; Ms: m/z=532, found 555 (M+Na).
Embodiment 6
[0117] Preparation of Compound IX-1
[0000]
[0118] Compound VIII-1 (26.6 g, 50 mmol) was dissolved in 270 mL THF, Bu 4 NF (19.5 g, 75 mmol) was added, then the reaction mixture was heated to reflux and stirred further for 7-8 h at this temperature. After the reaction was complete, the heating was stopped and the mixture was cooled to room temperature, THF was removed under reduced pressure, ethyl acetate was used to extract. After concentration under reduced pressure, the obtained oil was isolated and purified to give 18 g compound IX, yield 86%.
[0119] The tested data of 1 H NMR, 13 C NMR and MS for compound IX were as below:
[0120] 1 H NMR (400 MHz, CDCl 3 ) δ: 0.54 (s, 3H, CH 3 ), 1.19 (s, J=5.6 Hz, 3H, CH 3 ), 1.23 (s, 6H, 2CH 3 ), 1.24-1.37 (m, 2H), 1.48-2.08 (m, 13H), 2.24-2.30 (m, 1H), 2.44 (s, br, 1H, OH), 2.65 (s, br, 1H, OH), 2.81-2.88 (m, 2H), 3.24-3.27 (m, 1H), 3.46-3.51 (m, 1H, CHOH), 3.82-3.90 (m, 2H, OH and CHOH), 4.19-4.23 (m, 1H, CHOH), 4.47-4.49 (m, 1H, CHOH), 4.96 (s, 1H, ═CH 2 ), 5.10 (s, 1H, ═CH 2 ), 5.89 (d, J=11.2 Hz, 1H, ═CH), 6.55 (d, J=11.2 Hz, 1H, ═CH); 13 C NMR (75 MHz, CDCl 3 ) δ: 12.8, 18.9, 22.2, 23.2, 25.8, 28.9, 29.1, 29.2, 38.7, 39.5, 41.5, 41.9, 44.8, 56.2, 57.1, 65.5, 65.6, 70.7, 70.8, 78.9, 109.5, 116.5, 122.8, 133.5, 144.0, 151.8; Ms: m/z=418, found 441 (M+Na).
Embodiment 7
[0121] Preparation of Compound I
[0000]
[0122] Compound IX (21 g) was dissolved in 3000 mL acetone, 9-acetylanthracene (2.1 g) was added. Turn on the cooling equipment, cool to below 5° C. Turn on the photochemical reaction instrument, conduct the uv irradiation reaction at 350 nm. After 0.5 h, sample was taken to monitor the reaction, and duration of the reaction was estimated according to the monitor result, which is about 2 h. After the reaction was complete, acetone was concentrated, the obtained residue was eluted through column chromatography, elution system is petroleum ether:ethyl acetate=1:1, to obtain 19.3 g Compound I, yield 92%.
[0123] The tested data of 1 H NMR, 13 C NMR and MS for compound I were as below:
[0124] 1 H NMR (400 MHz, d-DMSO) δ: 0.49 (s, 3H, CH 3 ), 1.08 (s, 6H, 2CH 3 ), 1.09 (d, J=1.6 Hz, 3H, CH 3 ), 1.22-1.28 (m, 1H), 1.39-1.65 (m, 10H), 1.79-1.84 (m, 3H), 1.93-1.99 (m, 1H), 2.15-2.20 (m, 1H), 2.35-2.37 (m, 1H), 2.78-2.81 (m, 1H), 3.18-3.21 (m, 1H), 3.25-3.31 (m, 1H), 3.60 (q, J=7.6 Hz, 1H), 3.99-4.04 (m, 1H, CHOH), 4.12 (s, 1H, OH), 4.18-4.21 (m, 1H, CHOH), 4.54 (d, J=4 Hz, 1H, OH), 4.76 (s, 1H, ═CH 2 ), 4.86 (d, J=4.4 Hz, 1H, OH), 5.23 (s, 1H, ═CH 2 ), 5.99 (d, J=11.2 Hz, 1H, ═CH), 6.18 (d, J=11.2 Hz, 1H, ═CH); 13 C NMR (75 MHz, d-DMSO) δ: 12.3, 19.1, 21.8, 22.9, 24.7, 28.3, 29.6, 29.7, 38.9, 43.1, 43.2, 44.1, 44.9, 55.5, 56.8, 64.3, 65.1, 68.2, 68.4, 76.7, 109.8, 117.8, 122.4, 135.9, 139.6, 149.5; Ms: m/z=418, found 441 (M+Na).
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The present invention provides a new method for synthesizing maxacalcitol and an intermediate thereof. According to the method, the maxacalcitol is creatively synthesized through the steps of: taking vitamin D2 as an initial raw material, obtaining a compound represented by formula II, oxidizing, chirally reducing, grafting with a side chain, introducing a hydroxyl group on the C-1 position, and photochemically overturning.
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This is a divisional of U.S. Pat. application Ser. No. 07/732,457, filed on Jul. 18, 1991and now U.S. Pat. No. 5,175,337.
BACKGROUND OF THE INVENTION
The present invention relates to a novel αcyanoacrylate and a cyanoacrylate-based adhesive composition containing same.
α-Cyanoacrylates such as methyl α-cyanoacrylate and ethyl α-cyanoacrylate are polymerized and cured rapidly by the action of a small amount of water present on the surface of a material to be bonded and afford an adhesive force of an extremely high strength, so are widely used as room-temperature one-pack type instantaneous adhesives for the bonding of metals, plastics, rubber, wood and the like.
As α-cyanoacrylate there are known propyl α-cyanoacrylate, allyl α-cyanoacrylate, propargyl α-cyanoacrylate, 2,2,2-trifluoroethyl α-cyanoacrylate, 2,2,3,3-tetrafluoropropyl α-cyanoacrylate, 2-methoxyethyl α-cyanoacrylate, 2-ethoxyethyl α-cyanoacrylate and the like in addition to the above mentioned methyl and ethyl α-cyanoacrylates.
Generally, in the case where an α-cyanoacrylate is used as an adhesive, a portion thereof voltilizes and is polymerized by water contained in the air and adheres as white powder to the surrounding portion of a bonded part (whitening phenomenon), thus impairing the appearance of the bonded material. When used in the assembly of electric and electronic parts, the volatilized monomer contaminates a contact portion and causes defective contact, or cures in a moving part, thereby causing malfunction. Moreover, the thermal stability of a cured product is not sufficient and the bonding strength is reduced rapidly over 100° C. It is known that α-cyanoacrylates having an unsaturated bond in the ester portion have improved thermal stability. In this case the cured or adhered portion is heat treated at an appropriate temperature (100° C.-150° C.) in order to improve the thermal stability. However, the adhesive properties at a high temperature are not improved.
It is the object of the present invention to overcome the above mentioned drawbacks of the prior art. More concretely, it is the object of the present invention to provide a novel compound having superior adhesive properties as an instantaneous adhesive and superior in whitening-preventing property and thermal stability including high temperature adhesive properties.
SUMMARY OF THE INVENTION
The present invention resides in a novel neopentyl α-cyanoacrylate having the chemical structural formula: ##STR1## and an adhesive containing the above compound as an essential component.
DETAILED DESCRIPTION OF THE INVENTION
The novel compound, neopentyl α-cyanoacrylate exhibits excellent instantaneous adhesive properties. It has a melting point of 40° C. and is a solid at a room temperature. It can be used itself as a hot-melt type instantaneous adhesive and also used as a liquid instantaneous adhesive in admixture of conventional one or more cyanoacrylates in the same manner as conventional instantaneous adhesives. The instantaneous adhesive containing neopentyl α-cyanoacrylate as an essential component does not induce the whitening phenomenon and is superior in thermal stability, especially in high temperature-bonding strength.
Neopentyl α-cyanoacrylate may be used alone or in combination with conventional one or more α-cyanoacrylates.
Such conventional α-cyanoacrylates are those represented by the following general formula: ##STR2## wherein R is a hydrocarbon group such as alkyl, alkenyl, or alkynyl, or an alkoxy hyrocarbon group such as alkoxyalkyl. Examples are methyl α-cyanocrylate, ethyl α-cyanoacrylate isopropyl α-cyanoacrylate, those wherein R is alkoxyalkyl, e.g. 2-methoxyethyl α-cyanoacrylate and 2-ethoxyethyl α-cyanoacrylate, those wherein R is alkenyl, e.g. allyl α-cyanoacrylate, and those wherein R is alkynyl, e.g. propargyl α-cyanoacrylate.
When using conventional cyanoacrylates in combination with neopentyl α-cyanoacrylate, the latter is preferably in an amount of 85 wt %or less, more preferably 5 to 85 wt % based on the weight of adhesive components. If the amount of neopentyl α-cyanoacrylate is more than 85 wt %, the composition becomes a solid at room temperature (i.e. 20° C.).
Neopentyl α-cyanoacrylate of the present invention may be prepared by the following reactions.
Neopentyl α-cyanoacetate having the following structural formula: ##STR3## is prepared and then it is reacted with formaldehyde or paraformaldehyde in the presence of a basic catalyst to produce a condensation polymer, and then the condensation polymer thus produced is heat-depolymerized or thermally decomposed to produce neopentyl α-cyanoacrylate.
Neopentyl α-cyanoacrylate thus obtained is a solid at a room temperature but it is desirable to add thereto a stabilizer in order to store it more stably. Examples of such stabilizer include, as anionic polymerization inhibitors, sulfurous acid (SO 2 ), sulfone compounds, organic sulfonic acids, mercaptans, trifluoroacetic acid, and fluoroboric acid, and as radical polymerization inhibitors, quinones, catechol, pyrogallol, and 2,6-di-t-butylphenol. The amount of these stabilizers differs depending on the respective inhibiting abilities, but is preferably in the range of 1 to 10,000 ppm, more preferably 10 to 1,000 ppm, relative to the monomer.
The following examples are given to illustrate the present invention in more detail. The "part" and "%" in the following description are all by weight.
EXAMPLE 1
Preparation of Neopentyl α-Cyanoacetate
51 g (0.6 mole) of cyanoacetic acid, 74 g (0.84 mole) of neopentyl alcohol, 1 g of sulfuric acid and 100 g of toluene were reacted under reflux and water produced was removed by azeotropic distillation. Thereafter, the mixture thus produced was cooled to a room temperature and filtered to remove insoluble matter. The filtrate was washed with water and dried overnight with magensium sulfate. Then, the desiccant was filtered off and the solvent was removed under a reduced pressure, followed by vacuum distillation to afford 87.1 g of neopentyl α-cyanoacrylate (b.p. 79°-81° C./3 mmHg, yield 94%).
1R (neat)cm -1 : 2262, 1751 60 MHz 1 H-NMR (CDCl 3 /TMS)
δ(ppm): 3.87 (s, 2H), 3.46 (s, 2H), 0.97 (s, 9H) 90 MHz 13 C-NMR (CDCl 3 )
δ(ppm): 162.91, 113.06, 75.41, 31.03, 25.86, 24.30.
Preparation of Neopentyl α-Cyanoacrylate
46.5 (0.3 mole) of neopentyl α-cyanoacetate, 8.1 g (0.27 mole) of paraformaldehyde, 140 g of toluene and 46.5 mg of triethylenediamine were reacted together under reflux and water was removed by azeotropic distillation. Then, 23.5 g of dioctyl phthalate, 0.465 g of hydroquinone and 0.93 g of phosphorus pentoxide were added and depolymerization allowed to take place at 150°-210° C. under a reduced pressure tO afford 21.65 g of crude neopentyl α-cyanoacrylate. Redistillation thereof afforded (8.3 g of neopentyl α-cyanoacrylate (b.p. 65°-67° C./2 mmHg, m.p. 40°-41° C., yield 36%).
60 MHz 1 H-NMR (CDCl 3 /TMS)
δ(ppm): 7.01 (s, 1H), 6.61 (s, 1H), 3.95 (s, 2H) 1.20 (s, 9H)
90MHz 13 C-NMR (CDCl 3 )
δ(ppm): 160.14, 142.78, 116.44, 114.08, 75.46, 31.22, 25.95.
EXAMPLE 2
Adhesives were prepared by mixing neopentyl α-cyanoacrylate (NPCA) and ethyl α-cyanoacrylate (ECA) as a conventional α-cyanoacrylate in such proportions as shown Table 1 below and then incorporating therein 20 ppm of BF 3 ethyl ether complex and 1,000 ppm of hydroquinone. Their adhesive properties are as set forth in Table 1.
TABLE 1______________________________________ Adhesive Properties (iron/iron)Mixing Ratio Tensile Shear Hot Tensile(parts) Strength Shear StrengthNPCA/ECA (kgf/cm.sup.2) (kgf/cm.sup.2) Whitening______________________________________ 1/100 70 5 Whitened(Comparativeexample)20/80 83 7 slightly whitened40/60 85 10 slightly whitened60/40 112 40 not whitened80/20 124 45 not whitened100/0 130 45 not whitened______________________________________
EXAMPLE 3
Adhesives were prepared by mixing neopentyl α-cyanoacrylate (NPCA) and allyl α-cyanoacrylate (ACA) as a conventional α-cyanoacrylate in such proportions as shown in Table 2 below and then incorporating therein 20 ppm of BF 3 ethyl ether complex and 1,000 ppm of hydroquinone. Their adhesive properties are as set forth in Table 2.
TABLE 2______________________________________ Adhesive Properties (iron/iron)Mixing Ratio Tensile Shear Hot Tensile(parts) Strength Shear StrengthNPCA/ECA (kgf/cm.sup.2) (kgf/cm.sup.2) Whitening______________________________________ 1/100 100 5 Whitened(Comparativeexample)20/80 110 12 slightly whitened40/60 113 23 slightly whitened60/40 129 45 not whitened80/20 130 45 not whitened100/0 130 45 not whitened______________________________________
EXAMPLE 4
Adhesives were prepared by mixing neopentyl α-cyanoacrylate (NPCA) and 2-ethoxyethyl α-cyanoacrylate (EECA) as a conventional α-cyanoacrylate in such proportions as shown in Table 3 below and then incorporating therein 20 ppm of BF 3 ethyl ether complex and 1,000 ppm of hydroquinone. Their adhesive properties are as set forth in Table 3.
TABLE 3______________________________________ Adhesive Properties (iron/iron)Mixing Ratio Tensile Shear Hot Tensile(parts) Strength Shear StrengthNPCA/ECA (kgf/cm.sup.2) (kgf/cm.sup.2) Whitening______________________________________ 0/100 74 5 slightly(Comparative whitenedexample)20/80 80 6 slightly whitened40/60 82 8 not whitened60/40 116 28 not whitened80/20 125 45 not whitened100/0 130 45 not whitened______________________________________
COMPARATIVE EXAMPLE
The adhesive properties of neopentyl α-cyanoacrylate were compared with those of n-amyl α-cyanoacrylate (n-AmCA) and iso-amyl α-cyanoacrylate (i-AmCA). The results are as set forth in Table 4.
TABLE 4______________________________________ Adhesive Properties (iron/iron) Tensile Hot Tensile Shear ShearCyano- Chemical Strength Strengthacrylate Structure (kgf/cm.sup.2) (kgf/cm.sup.2)______________________________________NPCA ##STR4## 130 45n-AmCA ##STR5## 23 0i-AmCA ##STR6## 68 0______________________________________
Testing Method
Tensile Shear Strength
Measured at 25° C. after aging 24 hours at 43°±1° C., 60±2% RH, according to JIS K6861.
Hot Tensile Shear Strength
Measureds at 150° C.×1 hr after agint 24 hours at 43°±1° C., 60±2% RH, according to JIS K6861.
Whitening
A schale which had been made clean was placed on black paper, and each adhesive was dropped one drop into the schale. After standing 24 hours at 43° C., 60% RH, the presence or the state of whitening was checked.
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A novel neopentyl α-cyanoacrylate composition is provided. The composition which includes neopentyl α-cyanoacrylate has superior adhesive properties even at high temperatures and is characterized by the absence of the whitening phenomenon.
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BACKGROUND OF THE INVENTION
I. Field of the Invention
The invention relates to a method of repairing large fixed passageways. In particular it is directed to the use of fiberglass sandwiches as a liner to effect the repair of concrete sewage and chemical pipes or tunnels which cannot be rotated.
II. Background of the Invention
Large diameter sewage and chemical pipes (at least 48 inch) are formed by utilizing cast concrete. The pipes are buried and have a life expectancy of up to eighty years. When such pipes develop leaks it is expensive to either replace or repair them.
Since these pipes are originally constructed from concrete, those of ordinary skill in the art have looked to conventional concrete techniques for means of repairing these concrete pipes. The traditional means of repairing large diameter sewage and chemical pipes is to apply a wire mesh to the interior surfaces and spray same with gunite. A limitation on this technique is that the repairs last only three to five years.
The use of fiberglass laminates has achieved substantial acceptance in a number of fields. The laminates may be used in sandwich composite construction using a lightweight core material. It is generally believed in the industry that it is not feasible to apply these laminates and/or composites in overhead applications. This applies to the repair of underground or other fixed pipes where the pipes cannot be rotated to allow conventional application of the laminates.
An object of the present invention is to provide a means of reconstructing large diameter underground pipes and ducts, thereby increasing the life of the pipe significantly. A second object of the invention is to provide a means of reconstructing large diameter underground pipes and ducts without seriously affecting the pipe and duct capacity. A third object of the invention is to provide an economical and efficient means of reconstructing large diameter passageways. A final object of the invention is to provide a means of applying a fiberglass sandwich to the overhead surface of an underground passageway, where rotation of the passageway is impossible.
SUMMARY OF THE INVENTION
A method of reconstructing a large diameter fixed passageway by applying a fiberglass sandwich to the upper portion of a 360 degree section of said passageway.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a typical fiberglass sandwich.
FIG. 2 illustrates the means of applying a fiberglass sandwich to the upper portion of an underground passageway.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The sandwich of the invention is formed and applied as follows:
Resin--The resin suitable for use is preferably a commercial grade polyester, vinvlester or epoxy resin. The resin selected will depend upon the passageway environment. The amount of resin used will be based upon the resin selected and the properties desired.
Fillers and pigments--The resins used usually do not contain fillers except as required for viscosity control or fire retardance. Up to 5 percent by weight of thixotropic agents may be added to the resin for viscosity control. Resins may contain pigments and dyes. Antimony compounds or other fire retardant agents may be added as desired for improved fire resistance. 3 Reinforcing material--The reinforcing material usually is a commercial grade of glass fiber having a coupling agent which will provide a suitable bond between the glass reinforcement and resin.
Laminate--The laminate is comprised of a surfacing mat, structural layer and corrosion barrier. The surfacing mat may be a coat of resin. The structural layer may be alternate plies of woven roving and chopped strand mat. The corrosion barrier may be three or more layers of 1.5 ounce chopped strand with a minimum total thickness of 100 mils and is completed with the application of catalysed resin. The glass content of the corrosion barrier is preferably 25 to 30% glass by weight.
Sandwich--The sandwich is comprised of a laminate, a structural core and a second laminate (see FIG. 1) The structural core must have high shear, compressive and tensile strengths and moduli at densities much lower than the facings. In addition the core should exhibit reasonably low rates of water migration, should a breach of the facing occur and the core be in contact with water. The preferably core is balsa wood.
Cut edges--All cut edges are coated with resin so that no glass fibers are exposed and all voids filled. Structural elements having edges exposed to chemical environment are made with choppedstrand glass reinforcement only.
Joints--Finished joints are built up in successive layers and are as strong as the pieces being joined. The width of the first layer is at least 2 inches. Successive layers increase uniformly to provide the specified minimum total width of overlay which is to be centered on the joint. Crevices between jointed pieces are filled with resin or thixotropic resin paste, leaving a smooth inner surface. The interior of joints may also be sealed by covering with not less than 0.100 inch of reinforced resin material.
Surface hardness--The laminate has a barcol hardness of at least 90 percent of the resin manufacturer's minimum specified hardness for the cured resin.
Physical properties--The physical properties of these laminates are dependent on the percent of fiberglass content, fiberglass type and degree of resin cure.
______________________________________TYPICAL LAMINATE PROPERTIES______________________________________Property (ASTM Test Method) A.sup.l B.sup.2 C.sup.3Laminate thickness, inches 0.15 0.32 0.43Glass content % (D-2584) 26 32 33Flexural strength PSC (D-790) 18,000 20,000 22,000Flexural modulus PSC (D-790) 700,000 800,000 900,000Tensile strength PSC (D-638) 10,000 12,000 14,000Tensile modulus PSC (D-638) 800,000 1,000,000 1,200,000______________________________________Hardness Barcol (D-2583)Density glcc (D-792)Coff of thermal expansion in/in/ C (D-696) 6 × 10.sup.-5______________________________________1. Construction: V-M-M-M-V V = Veil2. Construction: V-M-M-M-WR-M- M = Chopped Mat WR-M-V3. Construction: V-M-M-M-WR-M- WR = Woven Roving WR-M-WR-M-V______________________________________
The sandwiches are first applied to the bottom and side surfaces of the passageway. As shown in FIG. 2, in order to apply the sandwich to the overhead surfaces of the passageway a form is built which corresponds to the shape of the overhead surfaces. The top of the form is covered with plastic sheeting and the uncured sandwich is placed over the plastic sheeting. The form is raised until the laminate contacts the overhead surfaces of the passageway. The form remains in place until the sandwich cures, after which the form and plastic is removed.
It is important that the bottom and top sections of the sandwich overlap. This overlap is necessary in order to obtain a seal between the sections. The application of the sandwich in sections facilitates the use of a sandwich in rehabilitating large underground passageways.
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A method of reconstructing fixed pipe systems (which cannot be rotated) by applying a fiberglass laminate utilizing overlapping sections.
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RELATED APPLICATIONS INFORMATION
[0001] This application claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 61/288,773, filed Dec. 21, 2009, and entitled “Body Surfing Suit,” which is incorporated herein by reference in its entirety as if set forth in full.
FIELD OF THE INVENTION
[0002] The present invention relates, in general, to body surfing, and more particularly to a body surfing suit. More particularly, the present invention relates to a buoyant body suit that also improves velocity and directional control in the water.
BACKGROUND OF THE INVENTION
[0003] Body surfing is a way to enjoy the thrill of riding a wave. Body surfers, generally, simply extend their bodies horizontally, projecting their arms forward and in line with their body while allowing a breaking wave to drive them shoreward with the surf. To the body surfer, it is important to be able to ride waves of varied sizes, to enjoy a stable ride and to be able to control direction and position on a wave face. Since a body surfer rarely uses any equipment other than swim fins, it is quite difficult for a body surfer to adequately control the stability of his ride and control his direction and position on a wave face.
[0004] For a body surfing suit to work in real life, bending is key (to allow for swimming), and buoyancy in the correct location(s) is also key. It is preferable to have a buoyancy gradient that is greatest (e.g., most buoyant) at the surfer's head and tapers down toward the feet to ensure that the surfer does not plow and tumble face first.
[0005] A few body surfing suits can be found in the prior art. For example, U.S. Pat. No. 5,106,331 to Lizarazu discloses a body surfing apparatus having a garment with a rigid outer shell attached to the torso portion of the garment and an inner buoyant unit underneath the torso portion of the garment. The rigid outer shell and inner buoyant unit make up a laminated multi-layered abdominal-chest plate. The shape of the abdominal-chest plate is contoured to cover the abdomen and extend upward into the central portion of the chest. This has two major problems: (1) the chest plate does not allow adequate forward bending because the rigidity of the laminated structure is not anatomically designed to allow full bending where the body actually bends (namely, the ribcage needs to be separate from the abdomen or it severely limits bending which one needs to swim properly) and (2) the suit puts the buoyant material in the wrong place, e.g., front center of the body, which results in plowing.
[0006] Additionally, the Lizarazu body surfing suit includes a number of fins located on the rigid outer shell and on the arms and legs of the suit. The arm fins are positioned on the upper arm region, are shaped incorrectly to be functional, and the lack of smooth edge detail causes a lot of drag. The arm fins do not likely provide buoyancy, but are rather present for stability. The legs fins suffer from similar problems as the arm fins and are present only for stability.
[0007] U.S. Pat. No. 5,013,271 to Bartlett discloses a body surfing suit having buoyant material placed on the chest and in various channels located on the legs of the suit. The Bartlett body surfing suit suffers from the following problems: (1) The buoyant material is incorrectly placed anteriorly and the main component includes coverage of the chest and abdomen in one piece; this makes the suit too rigid to allow adequate bending/tucking forward which is almost a requirement when maneuvering in the water to consistently catch waves. (2) In the upper chest and back region, the buoyant material is positioned both on the front and back of the suit in pad-like structures, but is not contoured anatomically and offers little benefit beyond adding some buoyancy. The back pads are simply buoyant areas without defined, streamlined 3-D contours. (3) The upper pointed regions of the chest piece extend out near the shoulder. These points impede anterior movement of the arm during the swimming stroke. (4) The suit does not have fins to aid in stability.
[0008] The present invention seeks to overcome these limitations by providing the body surfer a means to stabilize his ride and control his direction/position on a wave.
SUMMARY
[0009] Apparatus and methods for body surfing which provide the body surfer a means to stabilize his ride and control his direction/position on a wave are described herein.
[0010] According to one aspect, a body surfing apparatus includes a body suit having a torso and legs; a plurality of fins located on the torso; and one or more fins located laterally on the legs. The fins are preferably attached to the body suit via an adhesive or mechanical means and the fins and suit are preferably covered with a buoyant layer, the buoyant layer having a minimum thickness of 2 mm.
[0011] According to another aspect, a body surfing apparatus includes a body suit having a torso, arms and legs; a plurality of fins located on the torso; and one or more fins located laterally on the legs. The fins are preferably attached to the suit via adhesive or mechanical means and the suit and fins are preferably covered with a buoyant layer, the buoyant layer having a thickness of about 5-100 mm on the torso and a thickness of about 1-75 mm on the legs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the description, serve to explain the objects, advantages, and principles of the invention. In the drawings:
[0013] FIG. 1 is a front view of a body surfing suit in accordance with an embodiment of the invention;
[0014] FIG. 2 is a side view of a body surfing suit in accordance with an embodiment of the invention;
[0015] FIG. 3 is a rear view of a body surfing suit in accordance with an embodiment of the invention; and
[0016] FIG. 4 is a front view of the booties of a body surfing suit accessory in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] After reading this description it will become apparent to one skilled in the art how to implement the invention in various alternative embodiments and alternative applications. However, all the various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of an example only, and not limitation. As such, this detailed description of various alternative embodiments should not be construed to limit the scope or breadth of the present invention as set forth below.
[0018] With reference to FIG. 1 , an embodiment of the body surfing suit 100 is shown in a front view. Body surfing suit 100 includes a body 160 having a collar 102 , a pair of sleeves 104 , and a pair of legs 106 that extend below the knees. Sleeves 104 and/or legs 106 may be short or long. In some embodiments, sleeves 104 may not be necessary. However, when used with fasteners (discussed below), sleeves 104 are preferably long, as shown in FIGS. 1-3 .
[0019] Body 160 of body surfing suit 100 is preferably constructed from neoprene or other lightweight, stretchable, water, chemical and UV resistant material. Neoprene, also known as polychloroprene, is part of a family known as synthetic rubbers or plastics. For example, this underlay/undergarment material 160 of suit 100 may be fabricated from neoprene in various thicknesses. A thicker neoprene suit provides more buoyancy and allows a surfer to body surf in colder waters (e.g., East Coast) since neoprene keeps the body temperature elevated. In some embodiments, an off-the-shelf wetsuit may be used for body surfing suit 100 .
[0020] For example, for those applications which exposure properties to temperature differences, such as those associated with diving, the neoprene may be manufactured by foaming the neoprene plastic with an inert nitrogen gas. When placed in the presence of nitrogen gas being foamed into the neoprene material, tiny enclosed bubbles create voids in the material which reduce the surface area covered. These bubbles also help reduce the density of the material, allowing it to be much more buoyant. The buoyancy factor is quite helpful when used in wakeboarding, surfing and snorkeling applications.
[0021] Body surfing suit 100 also includes a plurality of chest rails or chest fins 110 , which extend approximately from the interior border of the neck to the bottom of the rib cage of the surfer. In some embodiments, chest fins 110 are thicker at the base (proximate to body 160 ) and taper upward to a rounded, e.g., dolphin dorsal-like fin, point at the top or edge. Chest fins 110 preferably aid in gripping the side of a wave, provide directional stability as well as prevent yaw and roll.
[0022] As shown in FIGS. 1 and 2 , there are three chest fins—two laterals fins 110 a and one center fin 110 b . In some embodiments, the lateral fins 110 a are about 2-170 millimeters wide at the base and taper up to an about a 1-40 millimeter wide rounded point at the top or edge. In a preferred embodiment, lateral fins 110 a are about 40 millimeters wide at the base and taper up to an about a 15 millimeter wide rounded point at the top or edge. In some embodiments, lateral fins 110 a are about 10-150 millimeters tall, e.g., from base to edge. In a preferred embodiment, lateral fins 110 a are about 50 millimeters tall.
[0023] In some embodiments, center chest fin 110 b is about 2-150 millimeters wide at the base and tapers up to an about 1-40 millimeter wide rounded point at the top or edge. In a preferred embodiment, center fin 110 b is about 45 millimeters wide at the base and tapers up to an about 15 millimeter wide rounded point at the top or edge. In some embodiments, center fin 110 b is about 10-150 millimeters tall. In a preferred embodiment, center fin 110 b is about 40 millimeters tall.
[0024] Body surfing suit 100 also includes a plurality of fins or skeggs 120 located on at least the sleeves 104 and/or legs 106 of body 160 . As shown in FIGS. 1 and 2 , one or more fins 120 may be located on each sleeve 104 of body 160 , e.g., a fin 120 a is located laterally on the upper arm region and a fin 120 b is located laterally on the lower arm region. For example, in some embodiments, the lateral fins 120 a are about 2-120 millimeters wide at the base and taper up to an about a 1-40 millimeter wide rounded point at the top or edge. In a preferred embodiment, lateral fins 120 a are about 30 millimeters wide at the base and taper up to an about a 5 millimeter wide rounded point at the top or edge. In some embodiments, lateral fins 120 a are about 10-100 millimeters tall, e.g., from base to edge. In a preferred embodiment, lateral fins 120 a are about 50 millimeters tall.
[0025] In some embodiments, the lower arm fins 120 b are about 2-100 millimeters wide at the base and taper up to about a 1-40 millimeter wide rounded point at the top or edge. Preferably, the lower arm fins 120 b are centered laterally at the mid-portion of the forearm, between the wrist and the elbow, front to back. In a preferred embodiment, the lower arm fins 120 b are about 30 millimeters wide at the base and taper up to about a 5 millimeter wide rounded point at the top or edge. In some embodiments, lower arm fins 120 b are about 10-100 millimeters tall. In a preferred embodiment, lower arm fins 120 b are about 60 millimeters tall.
[0026] Also, as shown in FIGS. 1 and 2 , a fin 120 d is located laterally on each shin and a fin 120 c is located laterally on each thigh of body 160 . The lateral thigh fins 120 c preferably extend from the pelvis region of the surfer to the top of the knee. In some embodiments, the lateral thigh fins 120 c are about 10-250 millimeters wide at the base and taper up to about a 1-40 millimeter wide rounded point at the top or edge. Preferably, the lateral thigh fins 120 c are centered at the mid-portion of the thigh, front to back. In a preferred embodiment, the lateral thigh fins 120 c are about 75 millimeters wide at the base and taper up to about a 15 millimeter wide rounded point at the top or edge. In some embodiments, lateral thigh fins 120 c are about 10-150 millimeters tall. In a preferred embodiment, lateral thigh fins 120 c are about 60 millimeters tall.
[0027] The lateral shin fins 120 d preferably extend from the lower aspect of the tibial plateau (e.g., shin) of the surfer to the ankle. In some embodiments, the lateral shin fins 120 d are about 10-150 millimeters wide at the base and taper up to about a 1-40 millimeter wide rounded point at the top or edge. Preferably, the lateral shin fins 120 d are centered at the mid-portion of the shin, front to back. In a preferred embodiment, the lateral shin fins 120 d are about 50 millimeters wide at the base and taper up to about a 15 millimeter wide rounded point at the top or edge. In some embodiments, lateral shin fins 120 d are about 10-250 millimeters tall. In a preferred embodiment, lateral shin fins 120 d are about 85 millimeters tall. While not wishing to be bound by any particular theory, it is believed that these lateral shin fins 120 d aid in propulsion through the water, thereby reducing or eliminating the need for the surfer to wear fins on his feet.
[0028] In some embodiments, a fin 120 f is located centrally on each shin and a fin 120 e is located centrally on each thigh of body 160 . In some embodiments, the central thigh fins 120 e are about 5-120 millimeters wide at the base and taper up to about a 1-30 millimeter wide rounded point at the top or edge. Preferably, the central thigh fins 120 e are centered at the mid-portion of the thigh, side to side. In a preferred embodiment, the central thigh fins 120 e are about 60 millimeters wide at the base and taper up to about a 5 millimeter wide rounded point at the top or edge. In some embodiments, central thigh fins 120 e are about 5-250 millimeters tall. In a preferred embodiment, central thigh fins 120 e are about 100 millimeters tall.
[0029] In some embodiments, the central shin fins 120 f are about 5-120 millimeters wide at the base and taper up to about a 1-30 millimeter wide rounded point at the top or edge. Preferably, the central shin fins 120 f are centered at the mid-portion of the shin, side to side. In a preferred embodiment, the central shin fins 120 f are about 50 millimeters wide at the base and taper up to about a 5 millimeter wide rounded point at the top or edge. In some embodiments, central shin fins 120 f are about 5-250 millimeters tall. In a preferred embodiment, central shin fins 120 f are about 110 millimeters tall.
[0030] Referring now to FIG. 3 , in some embodiments, body surfing suit 100 also includes a plurality of dorsal fins 130 . In some embodiments, body surfing suit 100 includes one or more dorsal fins. As shown, suit 100 includes two dorsal fins 130 located on the shoulder blades of the surfer. In some embodiments, the dorsal fins 130 are about 10-200 millimeters wide at the base and taper up to about a 1-40 millimeter wide rounded point at the top or edge. In a preferred embodiment, the dorsal fins 130 are about 40 millimeters wide at the base and taper up to about a 10-15 millimeter wide rounded point at the top or edge. In some embodiments, dorsal fins 130 are about 10-300 millimeters tall. In a preferred embodiment, dorsal fins 130 are about 50 millimeters tall.
[0031] In some embodiments, a fin 120 h is located centrally on each calf and a fin 120 g is located centrally on each hamstring of body 160 . In some embodiments, the central hamstring fins 120 g are about 5-120 millimeters wide at the base and taper up to about a 2-30 millimeter wide rounded point at the top or edge. Preferably, the central hamstring fins 120 g are centered at the mid-portion of the hamstring, side to side. In a preferred embodiment, the central hamstring fins 120 g are about 60 millimeters wide at the base and taper up to about a 5 millimeter wide rounded point at the top or edge. In some embodiments, central hamstring fins 120 g are about 5-250 millimeters tall. In a preferred embodiment, central hamstring fins 120 g are about 100 millimeters tall.
[0032] In some embodiments, the central calf fins 120 h are about 5-120 millimeters wide at the base and taper up to about a 1-30 millimeter wide rounded point at the top or edge. Preferably, the central calf fins 120 h are centered at the mid-portion of the calf, side to side. In a preferred embodiment, the central calf fins 120 h are about 30 millimeters wide at the base and taper up to about a 5 millimeter wide rounded point at the top or edge. In some embodiments, central calf fins 120 h are about 5-250 millimeters tall. In a preferred embodiment, central calf fins 120 h are about 100 millimeters tall.
[0033] Also as shown in FIG. 3 , body surfing suit 100 includes a plurality of fasteners 210 located on the posterior of the suit to keep body surfing suit 100 on the surfer. In one embodiment, fasteners 210 are zippers 215 . A fastener 210 is preferably located on at least the torso of the body surfing suit 100 , extending from the collar 102 to the rump. Additionally, a plurality of fasteners 210 may be located on each of the limbs, such as extending from mid-calf down to the ankle on the legs and extending from elbow down to the wrist on the arms. In cases where fins and fasteners are located on the same limbs, the fins are generally centered on the limb and the fasteners are generally off-center. When fastener 210 is a zipper 215 , reinforcement areas or patches 220 may be desirable. These reinforcement areas 220 are usually located at the terminal end of the fastener 210 . Also, reinforcement areas 220 may be fabricated from any suitable material known to make a zipper stronger and resist failure.
[0034] Still referring to FIG. 3 , additional fasteners may be used to keep body surfing suit 100 on the surfer. For example, fasteners (not shown) may be included at the ends of the limbs of suit 100 . On the legs, fasteners may be stirrups; stirrups would allow the suit 100 to be pulled down and maintained in a proper position.
[0035] On the arms, fasteners (not shown) may be finger rings. It is envisioned that as few as one or as many as five finger rings may be used in each fastener. Finger rings would aid in securing the suit 100 to the hand of the surfer, keeping the correct position of the suit in the lateral to medial directions.
[0036] Alternatively, in some embodiments, the hand of the surfer is encased by a glove (not shown) that is integral to suit 100 . The glove may additionally be webbed, such that the hand of the surfer looks like a frog or duck foot when worn. These webbed gloves may be made of a thin spandex material so that it easily opens and collapses. In other embodiments, the webbed gloves will have cutoff finger tips to allow for size discrepancies.
[0037] Referring now to FIG. 4 , a body surfing accessory, booties 300 are shown. Booties 300 include a body portion 310 and a plurality of fins 320 , 330 . Body portion 310 preferably covers the ankle of the surfer and the foot of the surfer, with an opening 340 allowing the surfer's toes to be exposed. In a preferred embodiment, fin 330 represents a lateral foot fin (e.g., lateral to the foot) and fin 320 represents a top foot fin.
[0038] In some embodiments, the lateral foot fins 330 have a rounded front and taper backward in a curved arc. Lateral foot fins 330 preferably start at the base of the little toe and come forward slightly, then round at the front extending laterally about 10-300 millimeters. In a preferred embodiment, the lateral foot fins 330 extend laterally about 150 millimeters. Lateral foot fins 330 preferably are about 10-100 millimeters wide at the top of the foot tapering down to about 1-30 millimeters laterally. In a preferred embodiment, lateral foot fins 330 are about 40 millimeters wide at the top of the foot tapering down to about 15 millimeters laterally.
[0039] In some embodiments, booties 300 are fabricated from neoprene. As such, the booties 300 should easily slide onto the surfer's feet and complement suit 100 . In a preferred embodiment, there is about a 35-millimeter neoprene section transition from the ankle to the foot which will stretch to allow for size discrepancies in wearers.
[0040] In some embodiments, all of the fins are preferably fabricated from a rigid material such as a glass fiber material or injection molded plastic material. In one embodiment, the fins are fabricated from high density thermoplastic polyurethane material. Alternatively, the fins may be fabricated from a more flexible and buoyant material such as floatation foam. Such floatation foams include, for example, polyvinyl chloride (“PVC”) and polyurethane.
[0041] PVC is a polymer made by the catalytic polymerization of vinyl chloride. PVC also includes copolymers that contain at least 50% vinyl chloride. PVC molding compounds can be extruded, injection molded, compression molded, calendared, and blow molded to form a huge variety of products, either rigid or flexible, depending on the amount and types of plasticizers used.
[0042] Polyurethane foam is a two part material; polyurethane includes two different materials, polyols and isocyanates. These materials are available in liquid form and are impregnated with blowing agents in the raw materials. The materials when mixed, undergo a chemical reaction and the blowing agents are allowed to react and begin to foam, thereby creating polyurethane foam.
[0043] In some embodiments, the fins are fabricated using PVC an outer shell or form. These forms would then be able to be filled with a foam material such as polyurethane foam. Filling the form with foam would help in the reduction of unnecessary weight as well as aid in the buoyancy of the surfer in the water.
[0044] In some embodiments, the fins will be created out of a flat sheet material, which is then molded or formed. The fins will then be able to be sewn into body suit 100 , in either the form of pockets or protrusions which stick through openings or slots cut into body suit 100 . Alternately, or in addition, the fins may be attached to body suit 100 with an adhesive.
[0045] In some embodiments, suit 100 has a gradually tapering thickness (circumferentially) of buoyant foam material (e.g., buoyancy layer) which will begin with a thickness of 1-75 millimeters at the ankle region and increase up to 5-100 millimeters at the shoulder or sternum region. In some embodiments, there will be areas laterally as well as on the abdominal region which will be fin-like. Preferably, all of these areas will smoothly contour and blend into the suit 100 , making it as seamless as possible.
[0046] In some embodiments, the buoyancy layer is covered with a drag reducing layer. The drag reducing layer may be produced by dipping or spraying PVC onto the buoyancy layer.
Processing
[0047] In some embodiments, the processes which will be utilized and best fitted for this type of product are thermoforming and station filling. Thermoforming starts when a sheet of extruded plastic material of specified thickness goes into a heater or heating area. Hot plates, arranged about 6 inches away from both the top and bottom of the sheet, heat the plastic to make it soft. After the plastic is soft it is removed out of the heating area by an automated, timed carrier. Next, an aluminum mold with the profile of the product desired rises up from underneath the sheet. The mold is raised to where the sheet is actually touching the outermost edge of the mold. Next, vacuum pressure is applied through many tiny holes in the mold. This vacuum pressure pulls the hot plastic sheet material down onto the contours of the mold to form the shape of the part. The hot plastic is left on the mold to cool. Some molds have water channels running through them to help cool the part faster. After cooling, air is blow up through the small vacuum holes to release the plastic part off of the mold. Since the part was first molded out of a sheet of plastic, more than likely the part will have to be trimmed.
[0048] This trimming process can be done in several different ways. The molds which would be created for this type of setting would be a family mold which would allow for several parts or forms to be created in a single cycle. The mold would be a family mold which contains several parts which when a single sheet of plastic is heated and formed around the tool would create several usable parts out of one cycle of the machine. This thermoforming process would be the desired process to create the forms or parts which are to be either sewn into or inserted into the wetsuit which will later be filled with a urethane style foam.
[0049] The second step in the creation of the suit would be to fill the PVC forms with a foam to help reduce the weight of the suit as well as help enhance the buoyancy of the suit. Any material has the capabilities of being created into a foam. Foam is made by mixing a number of chemicals and adding a “gassing agent” that makes bubbles that make the plastic cellular. The most commonly used foam is urethane foam. This type of foam is man-made and is capable of being created in a wide range of densities. This filling process would be done by an automated system which allows for the resin and the catalyst to be injected into a mold, or in this case the PVC form, in the correct amounts. This type of mixing is known as impingement. Impingement is simply defined as the mixing of the molecules via air born injecting of both the resin and catalyst. For example, a reaction injection molding (RIM) machine could be used for the impingement process.
[0050] In RIM, once the material is in the mold, the blowing agents begin to react and cause a foaming procedure to occur. This in turn creates the foam material as desired. Once the tack time, or the time for a specific material to lose the tackiness to touch feeling, the part will be able to be removed from the mold and allowed to further complete the curing process. Those of ordinary skill in the art will realize that the process described herein for processing the present suit is for exemplary purposes only. Any process capable of producing the present suit may be used.
[0051] Benefits realized from a body surfing suit made in accordance with the present invention include the following:
[0052] (1) Typically, when body-surfing without any suit at all, the surfer needs mobility and freedom of movement before and during the moment of catching a wave. Once the wave is caught, the surfer uses his body muscles to make himself rigid. These same principles need to be followed when designing a suit, and the suit and must allow full flexibility and freedom of movement. The present suit has been designed in that way; in all anatomic areas of movement (arms, legs, waist, trunk, etc) the material has been contoured, tapered, feathered and reduced to allow for complete freedom of movement.
[0053] (2) The present suit may have smooth 3-D contours which conform to the human anatomy, allowing bending, yet enhancing it with fin-like projections (e.g., similar to the dorsal fin on a marine animal), which provides stability as well as buoyancy.
[0054] (3) The present suit may have bilateral fin-like rails that start up near the shoulder region and proceed downward and laterally end at the base of the ribcage. These fins provide stability (to prevent yaw and roll), buoyancy and make the human body more streamlined in the water.
[0055] (4) The present suit may have a central chest fin or keel which aids in stability similar to that on a surfboard.
[0056] (5) The present suit may have buoyant material enveloped around the entire upper body. In some cases, the buoyant material envelopes the suit circumferentially, like a sea mammal.
[0057] (6) The present suit may have upper and lower lateral leg fins, as well as foot fins. In some cases, the leg fins are positioned in the lateral thigh and lateral calf regions, providing stability and more lateral surface area for propulsion when the legs are kicked, increasing the volume of water displaced with each kicking stroke (kind of like swim fins but out to the side of the leg). In some cases, the lateral fins on the feet provide greater surface area for propulsion with each kicking stroke. The lateral positioning of these foot fins allows the surfer to be able to walk without tripping due to the lateral position of the fin. Another feature of the foot fins is that they have small anterior fins/projections (on top of the foot) which act as keel-like stabilizers for directional control similar to a rudder on a boat.
[0058] (7) The present suit may have no edges and be smooth in all transition areas to reduce drag. For example, the present suit may have all of the edges (edge detail) where fins attach as smooth and feathered down exactly to the contour of the body so the edges disappear into the suit. As is easily appreciated, it is desirable to reduce drag to the lowest possible tolerance for optimal performance.
[0059] (8) The present suit may compliment and enhance the human anatomy for optimal streamlined performance in the water with unimpeded mobility. For example, it may be designed to enhance the thrust and water displacement during the kicking/swimming stroke to maximize propulsion. It may be super slick with seamless (e.g., as seamless as possible) transitions to reduce drag to the bare minimum. The present suit may take a clumsy land animal (human) with all of it's inherent anatomic deficiencies for locomotion in the water, augment it's anatomy without restricting movement, and turn it into a slick marine mammal for catching and riding waves better.
[0060] (9) The present suit may have buoyancy up as far forward toward the head as possible, with a decreasing gradient of buoyancy the farther toward the feet you go (buoyancy highest at head and lowest at the feet). Thus, the present suit may put the bulk of buoyant material up near the shoulders or sternum (head region) to limit/reduce the chance of plowing.
[0061] The above description of disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to the embodiments will be readily apparent to those skilled in the art; the generic principals defined herein can be applied to other embodiments without departing from spirit or scope of the invention. For example, in some embodiments body surfing suit 100 is a short suit, meaning that legs 106 end above the surfer's knees. In such an embodiment, there may be only one set of fins 120 located on the legs 106 of suit 100 . Thus, the invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principals and novel features disclosed herein.
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Apparatus and methods for body surfing which provide the body surfer a means to stabilize his ride and control his direction/position on a wave are described herein. According to one aspect, a body surfing apparatus includes a body suit having a torso and legs; a plurality of fins located on the torso; and one or more fins located laterally on the legs. The fins are preferably attached to the body suit via an adhesive or mechanical means and the fins and suit are preferably covered with a buoyant layer, the buoyant layer having a minimum thickness of 1 mm.
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to a rotary fluid displacement apparatus and more particularly, to an improvement in a rotation preventing and thrust bearing device for an orbiting member fluid displacement apparatus.
2. Description Of The Prior Art
There are several types of fluid apparatus which utilize an orbiting piston or fluid displacing member, such as the scroll-type fluid displacement apparatus disclosed in U.S. Pat. No. 801,182 to Creux.
The scroll-type fluid displacement apparatus disclosed in this U.S. patent includes two scrolls each having a circular end plate and a spiroidal or involute spiral element. These scrolls are maintained angularly and radially offset, so that both spiral elements interfit to create a plurality of line contacts between their spiral curved surfaces and thereby to seal off and define at least one pair of fluid pockets. The relative orbital motion of the two scrolls shifts the line contacts along the spiral curved surfaces, and as a result, the volume of the fluid pockets changes. Because the volume of the fluid pockets increases or decreases dependent on the direction of the orbiting motion, the scroll-type fluid displacement apparatus is capable of compressing, expanding, or pumping fluids.
Generally, in conventional scroll-type fluid displacement apparatus, one scroll is fixed to a housing and the other scroll, which is the orbiting scroll, is eccentrically supported on a drive (or crank) pin of a rotating drive shaft to produce orbital motion. Such a scroll-type fluid displacement apparatus also includes a rotation preventing device which prevents the rotation of the orbiting scroll and thereby maintains both scrolls in a predetermined angular relationship during operation of the apparatus.
Sealing along the line contacts of such conventional scroll-type apparatus must be maintained because the fluid pockets are defined by the line contacts between the two spiral elements. As the line contacts shift along the surfaces of the spiral elements, the volume of the fluid pockets changes due to the orbital motion of the orbiting scroll. Because the orbiting scroll in such conventional scroll-type apparatus is supported in a cantilever manner, an axial tilt of the orbiting scroll also occurs. Axial tilt occurs because the movement of the orbiting scroll is not rotary motion around the center of the orbiting scroll, but is orbital motion produced by eccentric movement of the drive pin driven by the rotation of the drive shaft. Several problems result from this axial tilt, such as loss of line contact seal, vibration of the apparatus during operation, and noise caused by collisions between the spiral elements.
One simple and direct solution to these problems is the use of a thrust bearing device for carrying the axial thrust load. Thus, scroll-type fluid displacement apparatus have been provided with rotation preventing and thrust bearing devices within their housings.
One recent attempt to improve rotation preventing and thrust bearing devices for scroll-type fluid displacement apparatus is described in U.S. Pat. Nos. 4,160,629 and 4,259,043 to Hidden et al. The rotation preventing and thrust bearing devices in these U.S. patents are integral with one another. The rotation preventing and thrust bearing device described in these U.S. patents (see, e.g., U.S. Pat. No. 4,259,043 (FIG. 7)) comprises one set of indentations formed on the end surface of the circular plate of the orbiting scroll and a second set of indentations formed on an end surface of the fixed plate attached to the housing. A plurality of spheres are placed between facing indentations. Nevertheless, the indentations are formed directly on the end surface of the circular plate of the orbiting scroll or the fixed plate. The production of this type of mechanism, therefore, is very intricate.
Referring to FIGS. 1, 2, and 3, one solution to this disadvantage is described. FIG. 1 is an enlarged, cross-sectional view of a portion of a scroll-type apparatus, and FIG. 2 is an exploded perspective view of the rotation preventing and thrust bearing device 37' of FIG. 1. Rotation preventing and thrust bearing device 37' surrounds boss 273 of orbiting scroll 27. Annular steps 274 and 275, which concentrically surround boss 273, are formed at the end surface of circular end plate 271 opposite to spiral element 272. Annular step 274 is larger radially and closer to spiral element 272; annular step 275 is smaller radially and farther from spiral element 272. Similarly, annular step 113 is formed at the end surface of annular projection 112 of from end plate 11, which rotatably supports a drive shaft (not shown) and is fixedly attached to an opening portion of cup-shaped casing 12. Annular step 113 is concentric with annular projection 112.
Rotation preventing and thrust bearing device 37' include an orbital portion, a fixed portion, and bearings, such as a plurality of balls or spheres. The fixed portion includes (1) first annular race 371 which surrounds annular step 113 in a manner discussed below and (2) first ring 372 fitted against the axial end surface of annular projection 112 of front end plate 11 to overlap the end surface of first annular race 371. First annular race 371 is loosely fitted within annular step 113 because the outer diameter of first annular race 371 is designed to be slightly smaller than the diameter of an annular side wall 113a of annular step 113. First ring 372 is fixedly attached to the axial end surface of annular projection 112 by pins 373. The height of annular side wall 113a of annular step 113 is designed to be greater than the thickness of first annular race 371. The difference between the height of annular side wall 113a of annular step 113 and the thickness of first annular race 371 defines a clearance G between first annular race 371 and first ring 372.
The orbital portion includes (1) second annular race 374 which is disposed within annular step 274 in a manner discussed below and (2) second ring 375 fitted against the axial end surface of annular step 275 to overlap the axial end surface of second annular race 374. Second annular race 374 is loosely fitted within annular step 274 because the inner diameter of second annular race 374 is designed to be slightly greater than the diameter of an annular side wall 274a of annular step 274. Second ring 375 is fixedly attached to the axial end surface of annular step 275 by pins 376. Preferably, the height of annular side wall 274a of annular step 274 is greater than the thickness of second annular race 374. The difference between the height of annular side wall 274a of annular step 274 and the thickness of second annular race 374 also defines a clearance G between second annular race 374 and second ring 375 which is identical to the clearance between the first annular race 371 and the first ring 372.
First ring 372 and second ring 375 each have a plurality of pockets (or holes) 372a and 375a in the axial direction, and the number of pockets in each ring 372 and 375 is equal. Pockets 372a of first ring 372 correspond to or are mirror images of pockets 375a of the second ring 375, i.e., each pair of pockets face each other and have substantially the same size and curvature. Further, the radial distance of the pockets from the center of their respective rings 372 and 375 is the same, i.e., the centers of the pockets are located the same distance from the centers of the rings 372 and 375, respectively. Bearings, such as balls 377, are placed between facing, e.g., substantially aligned, pairs of pockets 372a and 375a.
Referring to FIG. 3, the operation of the rotation preventing and thrust bearing device 37' will be described. In FIG. 3, the center of second ring 375 is located off-center on the right side and the drive shaft rotates in a clockwise direction, as indicated by arrow A. When orbiting scroll 27 is driven by the rotation of the drive shaft, the center of second ring 375 orbits about a circle of radius R o (together with orbiting scroll 27). Nevertheless, a rotating force, i.e., a moment, which is produced by the offset of the acting point of the reaction force of compression and the acting point of the drive force, acts on orbiting scroll 27. This reaction force tends to rotate orbiting scroll 27 in a clockwise direction about the center of second ring 375. As depicted in FIG. 3, however, eighteen balls 377 may be placed between the corresponding pockets 372a and 375a of rings 372 and 375. In FIG. 3, the interaction between nine balls 377 at the top of the rotation preventing and thrust bearing device and the edges of the pockets 372a and 375a prevents the rotation of orbiting scroll 27. The magnitude of the rotation preventing forces are shown as f c1-c5 in FIG. 3. As a result of the orbital motion of orbiting scroll 27, the interaction between the nine balls 377 and the edges of the pockets 372a and 375a successively shifts in the direction of the rotation of the drive shaft.
Not only does the reaction force of compression tend to rotate orbiting scroll 27 in the clockwise direction, but it tends to move orbiting scroll 27 forward, i.e., to the left in FIG. 1, and thereby to produce an axial thrust load on an inner end of the drive shaft which is applied through bushing 34. This axial thrust load is carried by the from end plate 11 through second annular race 374, all eighteen balls 377, and first annular race 371. Therefore, each of the eighteen balls 377 comes in contact with the end surfaces of both first and second annular races 371 and 374, and rolls thereon within the corresponding pockets 372a and 375a during the orbital motion of orbiting scroll 27. As balls 377 roll on the axial end surface of first annular race 371, the first annular race 371 freely rotates on the axial end surface of the annular step 113 because of a frictional contact between balls 377 and race 371. As a result, the circular trace of balls 377 on the axial end surface of first annular race 371 is sufficiently dispersed, so that exfoliation of the axial end surface of first annular race 371 should be effectively prevented. Similarly, the second annular race 374 freely rotates on the axial end surface of annular step 274 in the same direction, so that a similar reduction in exfoliation should be achieved.
In the configuration described above, rotation preventing and thrust bearing device 37' consists of a pair of races and a pair of rings, with each race and ring formed separately. Therefore, the parts of rotation preventing and thrust bearing device 37' are easy to construct, and the most suitable material for each part may be individually selected. Generally, in order to be able to bear the axial thrust load and the interacting stress adequately, balls 377, first and second rings 372 and 375, and first and second annular races 371 and 374 are made of stiff and hard material, for example, steel. In order to reduce the weight of the apparatus, however, front end plate 11, casing 12, and the two scroll members may be made of lightweight and relatively soft material, for example, aluminum alloy.
Accordingly, as first annular race 371 freely rotates on the axial end surface of the annular step 113 of front end plate 11 during operation of the apparatus, the axial end surface of first annular race 371 and the axial end surface of annular step 113 come into frictional contact. This frictional contact causes an abnormal abrasion at the softer axial end surface of annular step 113. Therefore, the clearance G between first annular race 371 and first ring 372 becomes greater than that allowable after a short time period during operation of the apparatus, and a similar unacceptable increase occurs in the clearance G between the second annular race 374 and second ring 375. As a result, the apparatus begins to defectively operate after a short time period.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a conducting device for conducting a lubricant, such as lubricating oil or mists of lubricating oil, in the housing to at least one of the contacting surfaces between the first annular race and the first annular step and the second annular race and the second annular step.
It is also an object of the present invention to provide a reliable rotation preventing and thrust bearing device for an orbiting member fluid displacement apparatus.
It is another object of this invention to provide a reliable rotation preventing and thrust bearing device that is relatively lightweight.
It is yet a further object of this invention to provide a reliable rotation preventing and thrust bearing device that is relatively simple in design and manufacture.
An orbiting member fluid displacement apparatus according to this invention includes a housing. A fixed member is attached to the housing and has a first end plate from which a first spiral element extends into the interior of the housing. An orbiting member has a second end plate from which a second spiral element extends. The first and second spiral elements interfit at an angular and radial offset to create a plurality of line contacts to define at least one pair of sealed off fluid pockets and separate a fluid inlet from a fluid outlet. A driving mechanism includes a drive shaft, which is rotatably supported by the housing and is operatively connected to the orbiting member to produce the orbital motion of the orbiting member.
A rotation preventing and thrust bearing device is disposed between the housing and the orbiting member to prevent the rotation of the orbiting member during orbital motion, so that the fluid pockets may change volume during the orbital motion of the orbiting member.
The rotation preventing and thrust bearing device comprises an orbital portion, a fixed portion, and a plurality of bearings, such as balls or spheres. The fixed portion includes a first annular race and a first ring, which are formed separately. The first annular race is placed in a loose fit within a first annular step formed on an inner surface of the housing, e.g., the outer diameter of the first annular race is less than the inner diameter of the first annular step. The first ring is attached to the inner surface of the housing to overlap the first annular race and has a plurality of first pockets formed in an axial direction and facing the first annular race. The orbital portion includes a second annular race and second ring, which also are formed separately. The second annular race is placed in a loose fit within a second annular step formed on an end surface of the second end plate opposite the side from which the second spiral element extends, e.g., the inner diameter of the second annular race is greater than the outer diameter of the second annular step. The second ring is attached to the end surface of the second end plate to overlap the second race and has a plurality of second pockets formed in an axial direction facing the second race.
A clearance is maintained between the second ring of the orbital portion and the first ring of the fixed portion. Bearings are placed between each pair of facing and substantially aligned first and second pockets of the rings. The rotation of the orbiting member is thus prevented by the bearings which are placed in the pockets of both rings. Further, thrust load from the orbiting member is borne by the first race of the fixed portion through the bearings. First contacting surfaces are maintained between the first annular race and the first annular step. Second contacting surfaces are maintained between the second annular race and the second annular step. The orbiting member fluid displacement apparatus is provided with a conducting device which conducts a lubricant, such as a mist or spray of lubricating oil, in the housing to the first or second contacting surfaces, or both.
Other objects, advantages, and features will be apparent when the detailed description of preferred embodiments of the invention and the drawings are considered.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged, cross-sectional view of a portion of a scroll-type apparatus illustrating a prior art configuration of the rotation preventing and thrust bearing device.
FIG. 2 is an exploded perspective view of the rotation preventing and thrust bearing device depicted in FIG. 1.
FIG. 3 is a diagrammatic plan view of the rotation preventing and thrust bearing device of FIG. 1 illustrating the manner by which rotation is prevented.
FIG. 4 is a cross-sectional view of an apparatus according to a first embodiment of the present invention.
FIG. 5 is a diagrammatic, cross-sectional view illustrating the interfit of the spiral elements of the fixed and orbiting scrolls.
FIG. 6 is an exploded perspective view of the driving mechanism in the embodiment of FIG. 4.
FIG. 7 is an enlarged, cross-sectional view of a portion of the apparatus depicted in FIG. 4.
FIG. 8 is an exploded perspective view of the rotation preventing and thrust bearing device depicted in FIG. 4.
FIG. 9 is a side view of a portion of the front end plate depicted in FIG. 4.
FIG. 10 is an enlarged, cross-sectional view taken on line X--X of FIG. 9.
FIG. 11 is an enlarged, cross-sectional view taken on line XI--XI of FIG. 9.
FIG. 12 is a side view of a portion of the front end plate provided in an apparatus according to a second embodiment of the present invention.
FIG. 13 is a perspective view of one portion which is cut out along lines XIII--XIII and XIII'-XIII' from the front end plate depicted in FIG. 12.
FIG. 14 is an enlarged, cross-sectional view taken on line XIV--XIV of FIG. 12.
FIG. 15 is an enlarged, cross-sectional view taken on line XV--XV of FIG. 12.
FIG. 16 is a view similar to FIG. 13. In this figure, however, one portion of a front end plate provided in an apparatus according to a third embodiment of the present invention is illustrated.
FIG. 17 is a view similar to FIG. 15. In this figure, however, a cross-sectional view of the front end plate depicted in FIG. 16 is illustrated.
FIG. 18 is a view similar to FIG. 10. In this figure, however, a cross-sectional view of a first annular race provided in an apparatus according to a fourth embodiment of the present invention is illustrated.
FIG. 19 is a cross-sectional view taken on line XIX--XIX of FIG. 18.
FIG. 20 is a view similar to FIG. 11. In this figure, however, a cross-sectional view of a front end plate provided in an apparatus according to a fifth embodiment of the present invention is illustrated.
FIG. 21 is a view similar to FIG. 11. In this figure, however, a cross-sectional view of a front end plate provided in an apparatus according to a sixth embodiment of the present invention is illustrated.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIGS. 4-8, identical reference numerals are used to denote elements which are similar to the identically numbered elements depicted in FIGS. 1, 2, and 3. Further, in the following description, the left side of FIGS. 4 and 7 will be referred to as the front or forward side and the right side will be referred to as the rear side.
Referring to FIGS. 4-8, a fluid displacement apparatus in accordance with a first embodiment of the present invention and in particular, a scroll-type refrigerant displacement apparatus 1, is depicted. Apparatus I includes an apparatus housing 10 having a front end plate 11 and a cup-shaped casing 12 which is attached to an end surface of front end plate 11. An opening 111 is formed in the center of front end plate 11 to permit passage of a drive shaft 13 therethrough. An annular projection 112 is formed in a rear end surface of front end plate 11. Annular projection 112 faces cup-shaped casing 12 and is concentric with opening 111. An outer peripheral surface of annular projection 112 extends into an inner wall of the opening portion of cup-shaped casing 12. Cup-shaped casing 12 is fixed on the rear end surface of front end plate 11 by a fastening device(s), for example, screws (not shown). The opening portion of cup-shaped casing 12 thus is covered by front end plate 11. An O-ring 14 is placed between the outer peripheral surface of annular projection 112 and the inner wall of the opening portion of cup-shaped casing 12 to seal the mating surfaces of front end plate 11 and cup-shaped casing 12. Front end plate 11 has an annular sleeve 15 projecting from the from end surface thereof which surrounds drive shaft 13 and defines a shaft cavity.
In the embodiment depicted in FIG. 4, sleeve 15 is separate from front end plate 11. Therefore, sleeve 15 is fixed to the front end surface of front end plate 11 by screws (not shown). An O-ring 16 is placed between the end surface of from end plate 11 and an end surface of sleeve 15 to seal the mating surfaces of front end plate 11 and sleeve 15. Alternatively, sleeve 15 may be integral with front end plate 11.
Drive shaft 13 is rotatably supported by sleeve 15 through a bearing device 17 located within the front end of sleeve 15. Drive shaft 13 has a disk 18 at its inner end which is rotatably supported by front end plate 11 through a bearing device 19 located within opening 111 of front end plate 11. A shaft seal assembly 20 is coupled to drive shaft 13 within the shaft seal cavity defined by sleeve 15.
A pulley 21 is rotatably supported by a bearing assembly 22 which is mounted on the outer surface of sleeve 15. An electromagnetic coil 23 is fixed about the outer surface of sleeve 15 by a support plate 24 and is received in an annular cavity 21a of pulley 21. Armature plate 25 is elastically supported on the outer end of drive shaft 13 which extends from sleeve 15. An electromagnetic clutch thus includes pulley 21, electromagnetic coil 23, and armature plate 25. In operation, drive shaft 13 is driven by an external drive power source, for example, a vehicle engine, through a rotation force transmitting device, such as the above-described electromagnetic clutch.
A fixed scroll 26, an orbiting scroll 27, a driving mechanism for orbiting scroll 27, and a rotation preventing and thrust bearing device for orbiting scroll 27 are located within an inner chamber defined by cup-shaped casing 12. The inner chamber is formed between the inner wall of cup-shaped casing 12 and front end plate 11.
Fixed scroll 26 includes a circular end plate 261, a spiral element 262 affixed to and extending from one side surface of circular end plate 26 1, and a plurality of internally threaded bosses 263 axially projecting from the outer end surface of circular end plate 261. An end surface of each boss 263 is seated on the inner surface of an end plate 121 of cup-shaped casing 12 and is fixed to end plate 121 by screws 28. Fixed scroll 26 is thus fixed within cup-shaped casing 12. Circular end plate 261 of fixed scroll 26 divides the inner chamber of cup-shaped casing 12 into a discharge chamber 30 and a suction chamber 29 with a seal ring 31 placed between the outer peripheral surface of circular end plate 261 and the inner wall of cup-shaped casing 12. Discharge port 264 is formed through circular end plate 261 at a position near the center of spiral element 262.
Orbiting scroll 27 also includes a circular end plate 271 and spiral element 272 affixed to and extending from one side surface of circular end plate 271. Spiral element 272 and spiral element 262 of fixed scroll 26 interfit at an angular offset of 180° and a predetermined radial offset. At least one pair of fluid pockets are thereby defined between spiral elements 262 and 272. Discharge port 264 is concentric with the centrally located fluid pocket created by spiral elements 262 and 272 and the front-side circumference of discharge chamber 30. Orbiting scroll 27 which is connected to the driving mechanism and to the rotation preventing and thrust bearing device is driven in an orbital motion describing a circular radius R o by rotation of drive shaft 13 and thereby compresses fluid passing through the apparatus. Generally, radius R o of orbital motion is given by the following formula:
R.sub.o =(P/2)-t
As depicted in FIG. 5, the pitch (P) of the spiral elements may be defined by 2πrg, where rg is the involute generating circle radius, and the wall thickness of the spiral element (t) may be measured at a point other than an inner end portion of the spiral element(s). The radius of orbital motion R o is also illustrated in FIG. 5 as the locus of an arbitrary point Q on spiral element 272 of orbiting scroll 27. A point C' is the center of spiral element 272 of orbiting scroll 27, and a point C is the center of spiral element 262 of fixed scroll 26. The center C' of spiral element 272 is radially offset from the center C of spiral element 262 of fixed scroll 26 by the distance R o . Thus, orbiting scroll 27 undergoes orbital motion of a radius R o upon rotation of drive shaft 13. As orbiting scroll 27 orbits, the line contacts between spiral elements 262 and 272 move toward the center of the spiral elements along the surface of the spiral elements. Fluid pockets, which are defined between spiral elements 262 and 272, also move to the center with a consequent reduction in volume of these pockets and compression of the fluid in the fluid pockets.
The fluid, e.g., refrigerant gas containing a lubricant, which is introduced into suction chamber 29 from an external fluid circuit through an inlet port 31, is taken into fluid pockets formed between spiral elements 262 and 272 from the outer end portions of the spiral elements. As orbiting scroll 27 orbits, fluid in the fluid pockets is compressed and the compressed fluid is discharged into discharged chamber 30 from the central fluid pocket of the spiral elements through discharge port 264. The discharge fluid then flows to the external fluid circuit through an outlet port 32.
The lubricant, e.g., lubricating oil, may remain mixed with the refrigerant as long as the refrigerant remains in a liquid state. Nevertheless, when such mixed refrigerant is vaporized in an evaporator in the external fluid circuit, a substantial portion of the lubricant may separate from the refrigerant and be reduced to a fine spray or mist. This spray or mist of lubricant, e.g., lubricating oil mists, may then flow into and pass through the inner space of apparatus housing 10.
Referring again to FIGS. 4 and 6, the driving mechanism of orbiting scroll 27 will be described in greater detail. Drive shaft 13, which is rotatably supported by sleeve 15 through bearing device 17, includes disk 18 which is integrally formed on the inner end of drive shaft 13. Disk 18 is rotatably supported by front end plate 11 through bearing device 19 located within opening 111 of front end plate 11. Disk 18 includes an annular flange 181 extending radially from the periphery of a rear end surface thereof. Annular flange 181 of disk 18 is in contact with an annular inner race 191 of bearing device 19, so that the forward motion of drive shaft 13 is prevented. A drive pin 33 projects axially from an axial end surface of disk 18 at a position which is radially offset from the center of drive shaft 13. Circular end plate 271 of orbiting scroll 27 has a tubular boss 273 axially projecting from the end surface of orbiting scroll 27 opposite the surface from which spiral element 272 extends. A short axial bushing 34 fits into boss 273 and is rotatably supported therein by a bearing, such as needle bearing 35. Bushing 34 has a balance weight 341, which may have the shape of a portion of a disk or ring and extends radially from bushing 34 along a front surface thereof. An eccentric hole 342 is formed in bushing 34at a position radially offset from center of bushing 34. Drive pin 33 fits into the eccentrically disposed hole 342 together with a bearing 36. Thus, bushing 34 is driven in orbital motion by the revolution of drive pin 33 and rotates within needle bearing 35.
In this embodiment, the rotation of orbiting scroll 27 is prevented by a rotation preventing and thrust bearing device 37 which is located between the inner surface of front end plate 11 and circular end plate 271 of orbiting scroll 27. As a result, orbiting scroll 27 orbits while maintaining its angular orientation relative to fixed scroll 26.
Referring to FIGS. 7 and 8, in addition to FIG. 4, rotation preventing and thrust bearing device 37 surrounds boss 273 of orbiting scroll 27. Annular steps 274 and 275, which concentrically surround boss 273, are formed at the end surface of circular end plate 271 opposite spiral element 272. Annular step 274 is radially larger and closer to spiral element 272, and annular step 275 is radially smaller and farther from spiral element 272. Annular step 113 is formed at the end surface of annular projection 112 of front end plate 11, which rotatably supports disk 18 of drive shaft 13 through bearing device 19, and is fixedly attached to the opening portion of cup-shaped casing 12. Annular step 113 is concentric with annular projection 112.
Rotation preventing and thrust bearing device 37 includes an orbital portion, a fixed portion, and bearings, such as a plurality of balls or spheres. The fixed portion includes (1) first annular race 371 which is disposed surrounding annular step 113 in a manner discussed below and (2) first ring 372 fitted against the axial end surface of annular projection 112 of front end plate 11 to overlap the end surface of first annular race 371. First annular race 371 is loosely fitted within annular step 113 because the outer diameter of first annular race 371 in designed to be slightly less than the inner diameter of annular side wall 113a of annular step 113. First ring 372 is fixedly attached to the axial end surface of annular projection 112 by pins 373. The height of annular side wall 113a of annular step 113 is designed to be greater than the thickness of first annular race 371. Preferably, the difference between the height of annular side wall 113a of annular step 113 and the thickness of first annular race 371 defines a clearance C, between first annular race 371 and first ring 372.
The orbital portion includes (1) second annular race 374 which is disposed within annular step 274 in a manner discussed below and (2) second ring 375 fitted against the axial end surface of annular step 275 to overlap the axial end surface of second annular race 374. Second annular race 374 is loosely fitted within annular step 274 because an inner diameter of second annular race 374 is designed to be slightly greater then the outer diameter of an annular side wall 274a of annular step 274. Second ring 375 is fixedly attached to the axial end surface of annular step 275 by pins 376. The height of annular side wall 274a of annular step 274 is designed to be greater than the thickness of second annular race 374. Preferably, the difference between the height of annular side wall 274a of annular step 274 and the thickness of second annular race 374 defines a clearance G between second annular race 374 and second ring 375 which may be identical to the clearance between the first annular race 371 and the first ring 372.
First ring 372 and second ring 375 each have a plurality of pockets (or holes) 372a and 375a in the axial direction, and preferably, the number of pockets in each ring 372, 375 is equal. Pockets 372a of first ring 372 correspond to and may be mirror images of pockets 375a of second ring 375, i.e., each pair of pockets may face each other and have the same size and curvature. Moreover, the radial distance of the pockets from the center of their respective rings 372 and 375 may be the same, i.e., the centers of the pockets may be equidistant from the center of rings 372 and 375.
In this embodiment, in order to be able to adequately bear the axial thrust load and the interacting stress, balls 377, first and second rings 372 and 375, and first and second annular races 371 and 374 may be made of stiff and hard material, for example, steel. In order to reduce the weight of the apparatus, front end plate 11, casing 12, and scrolls 26 and 27 may be made of lightweight material, for example, aluminum alloy.
Referring to FIGS. 9, 10, and 11 in addition to FIGS. 4 and 7, a plurality of radial grooves 114 having semicircular cross-sections may be formed in an axial end surface of annular step 113. In this embodiment, four radial grooves 114 may be formed in the axial end surface of annular step 113, and spaced from one another at equiangular intervals. Preferably, each radial groove 114 extends across the entire width of annular step 113. Radial grooves 114 conduct lubricant, such as lubricating oil mists, in housing 10 to first contacting surfaces between first annular race 371 and annular step 113. Further, radial grooves 114 may be formed during casting of front end plate 11. After formation of radial grooves 114, the axial end surfaces of annular step 113 and annular projection 112 may be cut to form a fine surface, wherein surface roughness R a may be less than or equal to about 1.6a (ANSI B46.1-1978), continuous with radial grooves 114. In addition, one axial end surface of first annular race 371 facing the axial end surface of annular step 113 may be formed by grinding that surface to a fine surface wherein surface roughness R a may be equal to about 0.25a (ANSI B46.1-1978).
Similarly, as depicted in FIG. 8, a plurality of radial grooves 276 also having semicircular cross-sections may be formed in an axial end surface of annular step 274 of circular end plate 271 of orbiting scroll 27. In this embodiment, four radial grooves 276 may be formed in the axial end surface of annular step 274, and spaced from one another at equiangular intervals. Preferably, each of radial grooves 276 extends across the entire width of annular step 274. Radial grooves 276 conduct lubricant, such as lubricating oil mists, in housing 10 to second contacting surfaces between second annular race 374 and annular step 274. Further, radial grooves 276 may be formed during casting orbiting scroll 27. After formation of radial grooves 276, the axial end surfaces of annular steps 274 and 275 may be cut to form a fine surface, wherein surface roughness R a may be less than or equal to about 1.6a (ANSI B46.1-1978), continuous with radial grooves 276. In addition, one axial end surface of second annular race 374 facing the axial end surface of annular step 274 may be, formed by grinding to a fine surface, wherein surface roughness R a may be equal to about 0.25a (ANSI B46.1-1978).
During operation of the apparatus, as first annular race 371 rotates freely on the axial end surface of annular step 113 of front end plate 11, the hard axial end surface of first annular race 371 and the soft axial end surface of annular step 113 come into frictional contact. Nevertheless, the mists of the lubricating oil suspended in an inner hollow space of housing 10 may be effectively conducted to the contact surfaces between first annular race 371 and annular step 113 of front end plate 11 through radial grooves 114, so that a lubricant film having a sufficient thickness is formed therebetween. Consequently, the first contacting surfaces between first annular race 371 and annular step 113 of front end plate 11 are sufficiently lubricated during operation of the apparatus. In addition, when operation of the apparatus stops, a sufficient amount of the lubricating oil is retained in radial grooves 114, so that the lubricant film having the sufficient thickness is instantly formed at the contact surfaces between the first annular race 371 and the annular step 113 of front end plate 11 when operation of the apparatus resumes. As a result, exfoliation of the contacting surfaces of first annular race 371 and annular step 113 of front end plate 11 is sufficiently reduced despite the frictional contact between hard and soft metal surfaces. Accordingly, the clearance G between first annular race 371 and first ring 372 is maintained at an acceptable value during an extended period of operation of the apparatus. A similar clearance is maintained between second annular race 374 and second ring 375. Accordingly, effective operation of the apparatus is maintained for a greatly increased period.
FIGS. 12-15, 16-17, 18-19, and 20-21 illustrate structural features of an apparatus according to a second through a sixth embodiment of the present invention, respectively. In FIGS. 12-21, identical reference numerals are used to denote elements corresponding to the similar elements depicted in FIGS. 4-11. Further, the operation of each of the embodiments is similar to that of the first embodiment, so that separate explanations thereof are omitted.
Referring to FIGS. 12-15, which illustrate the construction of the apparatus according to a second embodiment, first and second annular grooves 115 and 116 each having a semicircular cross-section are formed at the axial end surface of annular step 113. First and second annular grooves 115 and 116 are concentric with annular step 113, and an inner diameter of first annular groove 115 is greater than an outer diameter of second annular groove 116. At least one first outer radial grooves 115a also having a semicircular cross-section may be formed at the axial end surface of annular step 113. Each of first outer radial grooves 115a may extend from first annular groove 115 to the annular side wall 113a of annular step 113. First outer radial grooves 115a may be spaced from one another at equiangular intervals. At least one first inner radial grooves 116a also having a semicircular cross-section may also be formed at the axial end surface of annular step 113. Each of first inner radial grooves 116a may extend from second annular groove 116 to an annular inner edge of annular step 113. First inner radial grooves 116a may also be spaced from one another at equiangular intervals and may be radially align with corresponding first outer radial grooves 115a.
First and second annular grooves 115 and 116 and first outer and first inner radial grooves 115a and 116a may be formed during casting of front end plate 11. Similar cutting and grinding processes to those described with respect to the first embodiment may be performed in the axial end surfaces of annular step 113 and annular projection 112, and one axial end surface of first annular race 371 facing the axial end surface of annular step 113, respectively. As depicted in FIG. 14, first and second annular grooves 115 and 116 may be positioned so as not to be overlapped by, e.g., to be outside of, an annular area 377a which is defined by the rolling traces of balls 377 on the axial end surface of first annular race 371. Therefore, an unnecessary flexing of first annular race 371 in first and second annular grooves 115 and 116 may be eliminated.
During operation of the apparatus, as first annular race 371 freely rotates on the axial end surface of annular step 113 of front end plate 11, the hard axial end surface of first annular race 371 and the soft axial end surface of annular step 113 come into frictional contact. Nevertheless, mists of the lubricating oil suspended in an inner hollow space of housing 10 may be effectively conducted in this embodiment in a manner similar to that described with respect to the first embodiment.
Referring to FIGS. 16 and 17 which illustrate the construction of the apparatus according to a third embodiment, at least one first outer radial grooves 115a' having a semicircular cross-section may be formed in an outer annular portion of the axial end surface of annular step 113. First outer radial grooves 115a' may be spaced from one another at equiangular intervals. At least one first inner radial grooves 116a' also having a semicircular cross-section may be formed in an inner annular portion of the axial end surface of annular step 113. First inner radial grooves 116a' may also be spaced from one another at equiangular intervals to radially align with the corresponding first outer radial grooves 115a'. First outer and first inner radial grooves 115a' and 116a' may be positioned so as not to be overlapped by, e.g., to be outside of, the annular area 377a which is defined by the rolling traces of balls 377 on the axial end surface of first annular race 371. Therefore, an unnecessary flexing of first annular race 371 in first outer and first inner radial grooves 115a' and 116a' again may be eliminated.
First outer and first inner radial grooves 115a' and 116a' may be formed during casting of front end plate 11. Similar cutting and grinding processes to those described with respect to the first embodiment may be performed in the axial end surfaces of annular step 113 and annular projection 112, and one axial end surface of first annular race 371 facing the axial end surface of annular step 113, respectively.
Further, in accordance with the first embodiment, radial grooves 114 are depicted in FIGS. 9-11 as formed in the axial end surface of annular step 113. Nevertheless, as illustrated in FIGS. 18 and 19, a rotary fluid displacement apparatus according to the present invention may include radial grooves 371a which are formed in one axial end surface of first annular race 371 facing the axial end surface of annular step 113. In particular, this modification may be applied to the grooves depicted in FIGS. 12-15 and 16-17.
Moreover, in accordance with the first embodiment, the cross-sectional view of radial grooves 114 may be semicircular as depicted in FIG. 11. Nevertheless, the present invention is not restricted thereto. The present invention may include, for example, radial grooves 114' having a rectangular cross-section, as depicted in FIG. 20, or radial grooves 114" having a triangular cross-section, as depicted in FIG. 21. These modifications may also be applied to the grooves depicted in FIGS. 12-15, 16-17 and 18-19.
This invention has been described in detail in connection with preferred embodiments. These embodiments, however, are merely exemplary, and the invention is not intended to be restricted thereto. In particular, similar constructions to those described with respect to the second through sixth embodiments discussed above may be formed in the axial end surfaces of annular step 274 or second annular race 374, as indicated in FIGS. 4 and 7. It will be understood by those skilled in the art that other variations and modifications can be made within the scope of this invention as defined by the following claims.
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The present invention discloses an orbiting member fluid displacement apparatus including a rotation preventing and thrust bearing device. The rotation preventing and thrust bearing device includes a fixed portion, an orbital portion, and bearing elements. The fixed portion includes a first annular race and a first ring, which are formed separately. The first annular race is placed in a loose fit within a first annular step in an inner surface of the housing and the first ring is attached to the housing. The orbital portion includes a second annular race and a second ring, which also are formed separately. The second annular race is placed in a loose fit within a second annular step in an end plate of the orbiting member and the second ring is attached to the end plate of the orbiting member. A plurality of pockets are formed in the rings and face one another in substantially aligned pairs. A bearing element is received in each aligned pair of pockets to prevent the rotation of the orbiting member by the bearing elements interacting with the first and second rings and to bear the axial thrust load from the orbiting member. One or more lubricant conductive grooves are formed at first contacting surfaces between the first annular race and the housing or second contacting surfaces between the second annular race and the orbiting member, or both.
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TECHNICAL FIELD
[0001] The present invention relates to a process and a novel strategy for production, isolation and purification of sucrose-6-ester, which ultimately is used as starting material in production of 1′-6′-Dichloro-1′-6′-DIDEOXY-β-Fructofuranasyl-4-chloro-4-deoxy-galactopyranoside and other chlorinated sucrose compounds.
BACKGROUND OF INVENTION
[0002] Chlorinated sucrose preparation is a challenging process due to the need of chlorination in selective less reactive positions in sucrose molecule in competition with more reactive positions. Generally, this objective is achieved by a procedure which involves essentially protecting the hydroxy group in the pyranose ring of sugar molecule by using various protecting agents such as alky/aryl anhydride, acid chlorides, orthoesters etc., and the protected sucrose is then chlorinated in the desired positions (1′-6′ &, 4) to give the acetyl derivative of the product, which is then deacylated to give the desired product 1′-6′-Dichloro-1′-6′-DIDEOXY-β-Fructofuranasyl-4-chloro-4-deoxy-galactopyranoside i.e. 4,1′, 6′ trichlorogalactosucrose (TGS). However, in these methods, substitutions at undesired position cannot be totally avoided and such products get mixed as impurities. Regio-selective substitution at desired position is possible by Regio-selective reactions either by using soluble or immobilized tin containing catalysts.
[0003] Sucrose-6-esters can also be produced as a major product by reacting sucrose and an acylating agent in the presence of pyridine analogs, picolines etc. under low temperature conditions. However, after the esterification reaction, the complete removal of pyridine and such compounds poses a major process constraint. This invention is related to the complete removal of pyridine analogs after such esterification reaction. Further purification of the sucrose esters becomes easier after the removal of the said analogs.
[0004] Thus, Sucrose-6-ester is produced by direct acetylation or benzoylation of sucrose dissolved in pyridine analog compounds. This reaction is carried out at temperature below −20° C. to −40° C. After the formation of the sucrose-6-ester, the reaction mixture containing the said ester is purified and taken for the chlorination reaction using Vilsmeier reagent.
[0005] The purification of sucrose-6-ester from the above process poses a major process constraint due to the presence of pyridine or such compounds as aromatic nitrogenous bases such as picoline, pyrrolidine, etc. They are removed conventionally by distillation. However, pyridine and its analogues are high boiling solvents too. They need to be removed under reduced pressure and they are rarely removed completely from the reaction mixture by distillation under reduced pressure. Further, handling of pyridine in distillation process is also a major bottleneck when the process is scaled up to industrial scale. The maximum permissible standards for exposure of human beings to pyridine or its analogs are very stringent. The present international standards allow the Permitted Daily Exposure (PDE) at a very low level of less than 3 mg/day. Still further, the residual solvent, pyridine and its analogs, allowed is less than 200 ppm. Hence an effective removal of pyridine or its analogs to a better extent than is possible presently is an absolute need.
PRIOR ART
[0006] Mufti et al (1983) (U.S. Pat. No. 4,380,476) have reported the conventional process of acylation in which sucrose is reacted with pyridine and acetic anhydride at a temperature of −20degree to −70degree. C. To the above reaction mixture, which still contains pyridine, chloroform was added and the contents cooled to −75.degree. C. in a dry ice/acetone bath. The chloroform was added primarily to prevent freezing of pyridine but also to slow down the reaction and thus allow better control over the reaction. Sulphuryl chloride was then added to the cooled reaction mixture dropwise over a period of 1.5 hours. The reaction mixture was then allowed to warm to room temperature and left at that temperature for 4 hours, after which time it was heated at 45.degree. C. for 12 hours and then cooled to room temperature. The mixture was poured into pre-cooled (about 4.degree. C.) 10% sulphuric acid solution (100 ml) slowly with stirring. The sulphuric acid mixture was extracted twice with chloroform and the chloroform extracts washed twice with water, with saturated sodium hydrogen carbonate solution pH 7 and then twice with water, and dried over anhydrous sodium sulphate. Pyridine got removed in the saturated sodium hydrogen carbonate washings given to chloroform extract. Further removal in water washings to chloroform extract.
[0007] Besides the conventional process of chlorination as described above, pyridine is also used for various other process steps in the production of TGS.
[0008] Thus tritylation of sucrose to block the three primary alcohol groups is accomplished by reacting sucrose with trityl chloride in a suitable solvent such as pyridine (U.S. Pat. No. 4,783,526). If pyridine is used as a solvent, the same is removed by pouring the reaction mixture after acetylation into ice water and the precipitated product filtered and dried and the procedure is repeated a number of times to remove any traces of pyridine. Pyridine is also used in acetyl migration step of 2,3,4,3′,4′-penta-O-acetyl sucrose. Process of preparation of TGS from Tetrachlororaffinose also involves use of pyridine as a solvent. U.S. Pat. No. 4,889,928 has described use of pyridine and containing 4 to 8 molar equivalents of water and toluene p-sulphonic acid or hydrochloric acid having a pH of about 5 to 6 for providing conditions for subjecting a sucrose alkyl 4,6-orthoacylate to mild aqueous acidic hydrolysis. U.S. Pat. No. 4,977,254 described use of pyridine for reaction of sugar or partly protected sugar with thionyl chloride. U.S. Pat. No. 5,449,772 has described use of pyridine as one of the inter solvents for reacting a solution of sucrose with a reagent selected from the group consisting of a trialkyl orthoester and a ketene acetal, in the presence of an acid catalyst to provide a sucrose alkyl 4,6-orthoester, U.S. Pat. Nos. 6,998,480 and 7,049,435 have mentioned use of pyridine as one of the solvents that can be used in a solvent extraction approach.
SUMMARY OF THE INVENTION
[0009] Invention as described here involves removal of pyridine from a reaction mixture or a Process Stream by reacting the same with an acid, removing water from the reaction mixture/Process Stream to ensure complete precipitation of the salt of pyridine, filtering off the precipitate to achieve removal of pyridine from the reaction system. If pyridine is required to be removed in large quantities, it is preferably removed as much as possible by distillation under reduced pressure. Rest of the pyridine remaining in the reaction mixture is removed by reacting with acid to form a salt, as mentioned before.
[0010] The pyridine salt can be reacted with alkali to regenerate and recover pyridine for re-use.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Preferred embodiment of this invention is removal of pyridine or its analogues from esterification of sucrose by an esterifying agent in presence of pyridine.
[0012] After Sucrose-6-ester has been produced as a major product by reacting sucrose and an acylating agent in the presence of pyridine, pyridine analogs including picolines etc. under low temperature conditions, the water in the system is completely removed by azeotropic distillation using cyclohexane and the pyridine from the reaction mixture is removed up to 50-60% of its initial volume by distillation. Then an equal amount of an alcoholic solvent such as isopropanol, t-butanol etc., is replenished to the reaction mixture. Dry Hydrogen chloride gas is then purged into the reaction mixture for several hours slowly at 0 to −10° C. till pH of the reaction mass was less than 3.0. Pyridine or its analogs with dry HCl gas form the respective hydrochlorides, which precipitate out of the reaction mass in solid form. When the pyridine in the reaction mass is completely converted to pyridinium hydrochloride, the mass is then filtered under nitrogen to remove the said compound.
[0013] The filtrate containing the sucrose-6-ester dissolved in the appropriate alcoholic solvent is practically free from pyridine or its analogues, much below the maximum permissible level of 0.1% of residual pyridine and its analogs and can be taken for further purification after subsequent removal of the alcoholic solvent.
[0014] The ester group can be acetyl or benzoyl. HCl may also be replaced by other acid if it could be safely handled. Further, the concept of pyridine removal by converting it into its hydrochloride form will work for any of the other processes of production of TGS where pyridine is used for purposes other than for facilitating acetylation. However the precipitation is facilitated only when the mass is taken into higher alcoholic solvents or nonpolar solventsProcess Stream to which this approach of pyridine removal can be applied may also be related to a process other than acetylation for synthesis of TGS or TGS-precursor including, but not limited to, tritylation of sucrose (U.S. Pat. No. 4,783,526), process of preparation of TGS from Tetrachlororaffinose, subjecting a sucrose alkyl 4,6-orthoacylate to mild aqueous acidic hydrolysis (U.S. Pat. No. 4,889,928), use of pyridine for reaction of sugar or partly protected sugar with thionyl chloride (U.S. Pat. No. 4,977,254), use of pyridine as one of the inert solvents for reacting a solution of sucrose with a reagent selected from the group consisting of a trialkyl orthoester and a ketene acetal in the presence of an acid catalyst to provide a sucrose alkyl 4,6-orthoester (U.S. Pat. No. 5,449,772), use of pyridine as one of the solvents that can be used in a solvent extraction approach (U.S. Pat. No. 6,998,480 and U.S. Pat. No. 7,049,435) and the like.
[0015] The examples given below are only illustrations of preferred embodiment of this invention. They shall in no way be considered to lessen the scope of the invention with respect to actual chemicals used, actual reaction conditions used and the like. Any adaptation or modification of the embodiments described here or new embodiments that are within the scope of the claims which are obvious to a person skilled in the art are considered as within the scope of this specification. Similarly, any mention of singular is also meant to cover its pleural also unless the context does not permit so. Thus, “an acid” covers use of all known acids which can be used for the purpose indicated therein. Similarly, a generic mention shall cover all the specific members of that kind. Thus “Esterification” covers acetylation, benzoylation and the like. “A pyridine analogue” covers one or more of and every analogue of pyridine comprising α-picoline, pyrrolidine and the like.
[0016] Further, even when not mentioned explicitly, mention of “Pyridine” includes mention of Pyridine analogues too, unless the context does not permit so.
Example 1
Precipitation of Pyridine Hydrochloride in Isopropanol
[0017] 20 kg of sucrose was dissolved in 200 L of pyridine at 115° C. under reflux. After complete dissolution, the mixture was cooled to room temperature and further cooled to −30° C. 9.0 L of acetic anhydride was added dropwise to carry out Acetylation. The temperature was maintained between −30 and −35° C. with constant stirring. The formation of sucrose-6-acetate was monitored by TLC.
[0018] At the end of 4-5 hours, the reaction was terminated by addition of 2 L of water. Then the water was removed azeotropically using cyclohexane. Then the reaction mass was subjected to vacuum distillation where 112 L of pyridine was recovered. The reaction mass was then replenished with 112 L of isopropanol and chilled to −7° C.
[0019] Dry HCl gas was purged into the reaction mass till the pH reached 2.5-3.0. The formation of Pyridinium hydrochloride was indicated by solids precipitations. The mixture was held at −10° C. for 5-6 hours and then filtered through the nutsch filter.
[0020] The filtrate was analyzed for pyridine content and was found to be less than 0.1%, which is far less than the pyridine removal that is possible otherwise than the method of this invention.
[0021] The isopropanol was evaporated off and a thick mass of sucrose-6-acetate was obtained. It was seen that the thick mass contained unreacted sugar up to the maximum level of 2 percent of the mass and the 6-acetyl sucrose obtained was 72%
Example 2
Precipitation of Picoline Hydrochloride in t-Butanol
[0022] 500 g of sucrose was dissolved in 4 L of α-picoline at 100° C. After complete dissolution, the mixture was cooled to room temperature and further cooled to −34° C. 360 g of benzoic anhydride was dissolved in 1.5 L of DMF and was added dropwise to carry out benzoylation. The temperature was maintained between −30 and −35° C. with constant stirring. The formation of 6-O-benzoyl sucrose was monitored by TLC.
[0023] At the end of 7-8 hours, the reaction was terminated by addition of 50 ml of water. Then the water was removed azeotropically using cyclohexane. Then the reaction mass was subjected to vacuum distillation where 1.8 L of α-picoline was recovered. The reaction mass was then replenished with 1.8 L of t-butanol and chilled to −12° C.
[0024] Dry HCl gas was purged into the reaction mass till the pH reached 2.5-3.0. The formation of α-picoline hydrochloride was indicated by solids precipitations. The mixture was held at −10° C. for 5-6 hours and then filtered through the nutsche filter.
[0025] The filtrate was analyzed for α-picoline content and was found to be less than 0.05%
[0026] The t-butanol was evaporated off and a thick mass of sucrose-6-benzoate was obtained. It was seen that the thick mass contained unreacted sugar up to the maximum level of 2 percent of the mass.
Example 3
Recovery of Pyridine from Pyridine Hydrochloride
[0027] The pyridine hydrochloride formed from Example 1 (120 kg) was suspended in 360 L of DM water and stirred thoroughly. Sodium hydroxide solution was added and the pH was adjusted to 9.0. The solution was then stirred for 60 minutes. The pyridine formed was fractionated through conventional distillation system. The pyridine recovered from the input for the batch was 90%.
[0028] The same process can be followed to recover α-picoline from α-picoline hydrochloride.
Example 4
Chlorination of Sucrose-6-acetate
[0029] 31.5 kg of PCl 5 was added to 60 kg of DMF at room temperature and the Vilsmeier reagent was allowed to form. The POCl 3 generated in situ reacts with excess of DMF present and forms the second Vilsmeier. Both the Vilsmeier was mixed thoroughly and then cooled to 0° C.
[0030] 10 kg of sucrose-6-acetate equivalent was dissolved in 30 L of DMF and was added to the reaction mass drop wise under stirring. After the complete addition of the 6-acetyl sucrose solution, the reaction mass was stirred for 30 minutes and was allowed to attain ambient and then further stirred for 60 minutes.
[0031] Then the reaction mixture was heated to 85° C. and was maintained for 60 minutes. The reaction mixture was then heated to 100° C. and maintained for 6 hours and then further heated to 115° C. and maintained for 2 hours.
[0032] The chlorinated reaction mass was then neutralized using calcium hydroxide slurry in water and the pH was adjusted to 7.0. The formation of TGS was analyzed by HPLC and the overall yield obtained was 40%.
Example 5
Removal of Pyridine from Trityl Chloride Reaction
[0033] 10 kg of sucrose was dissolved in 60 L of pyridine at 70° C. 27.0 kg of Trityl chloride was added to the reaction flask and heated to 65° C. and maintained for 16 hrs. Then the reaction mass was cooled to 25-30° C. 6.0 kg of Acetic anhydride was added and stirred for 13-14 hrs for acetylation. 32 L of pyridine was removed by distilling under vacuum at 55° C.
[0034] t-butanol was added three times in volume to the reaction mass and HCl gas was purged for the conversion of pyridine to its hydrochloride. The precipitate started forming slowly and mass was kept stirring for 5 hours. The precipitate was then filtered through a nutsche filter and the filtrate was subjected to distillation under vacuum at 55-60° C. The solids then precipitated as the t-butanol concentration decreased in the filtrate and the solids were taken for further processing for the manufacture of TGS.
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A process of removal of pyridine or a pyridine analogue from a composition or a Process Stream in a process of production of 4,1′, 6′ trichlorogalactosucrose is described comprising reacting pyridine with an acid, the said acid being used preferably in gaseous form, achieving complete precipitation of the salt of pyridine in higher alcoholic solvents and non-polar solvents, filtering off the precipitate of the said salt of pyridine to achieve removal of pyridine from the reaction system and optionally regenerating and recovering pyridine by reacting the said salt with alkali.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for providing a bio prevention cycle for an automatic clothes washer, and more particularly to methods and systems for preventing the build-up of microorganisms or other materials in an automatic clothes washer or similar appliances.
Under normal usage of an automatic clothes washer, detergent residues build up with minerals and soils, which harden on the washer, often in areas that the consumer cannot see. This is particularly true when a consumer uses a higher sudsing detergent. These soils then form an excellent medium for supporting and growing bacteria, fungi, and other microorganisms. Consumers rarely see such microorganisms, but the washer will eventually release or have a foul odor due to these microorganisms.
It would therefore be an improvement in the art if there was provided a method or system for killing the microorganisms which are existing in an automatic clothes washer.
SUMMARY OF THE INVENTION
The present invention provides an improvement in the art by providing methods and systems for an automatic washer which will kill microorganisms that are present in the washer.
In an embodiment of the invention, an appliance having an enclosure arranged to receive articles to be treated also includes a water container and a steam chamber with a steam outlet. A water dispenser is arranged to dispense water from the water container to the steam chamber. A heating element is thermally associated with the steam chamber. A control is arranged to selectively operate the heating element. A steam path extends between the steam outlet and the enclosure. A chemical dispenser is positioned along the steam path. The heating element heats water in the steam chamber to create steam, and the chemical dispenser adds a chemical to the steam as the steam passes through the steam path.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of an automatic washer embodying the principles of the present invention.
FIG. 2 is a schematic partial view of the interior of one embodiment of the disinfecting unit of the automatic washer of FIG. 1 , consistent with methods and systems embodying the principles of the present invention.
FIG. 3 is a perspective view of one embodiment of the exterior of the disinfecting unit.
FIG. 4 is a flow diagram of the steps performed by the disinfecting unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is useful in many different types of appliances having a washing or cleaning cycle, such as clothes washers, dish washers, clothes refreshers, dry cleaning appliances, etc., in which various types of articles are to be treated. For the purposes of disclosing an embodiment of the invention, the environment of a clothes washer is used, although the invention is not limited to such an appliance, or to the particular type of clothes washer illustrated.
In FIG. 1 there is illustrated an appliance in the form of an automatic washer generally at 10 embodying the principles of the present invention. The washer has an outer cabinet 12 with an openable lid 13 which encloses an imperforate wash tub 14 for receiving a supply of wash liquid. Concentrically mounted within the wash tub is a wash basket 16 for receiving a load of materials to be washed and a vertical axis agitator 18 . A motor 20 is provided which is drivingly connected to the agitator 18 to rotatingly drive it in an oscillatory or rotary manner, and is also selectively connectable to the basket 16 for simultaneous rotation with the agitator 18 . The assembly of the tub 14 , wash basket 16 , agitator 18 , and motor 20 is mounted on a suspension system 22 . A plurality of controls 26 are provided on a control console 28 for automatically operating the washer through a series of washing, rinsing, and liquid extracting steps.
The washer also includes a disinfecting unit 30 , which may be connected to an external water supply via a conduit 32 and to the wash tub 14 , or elsewhere in the enclosure formed by the outer cabinet 12 , via a conduit 34 . The location for the disinfecting unit 30 is only schematically illustrated, and it could actually be located in a variety of different locations in the cabinet 12 , where space permits, or even remote from the cabinet, such as in an adjacent cabinet or appliance. The invention can also be used with clothes washers that do not include a vertical agitator, such as those that agitate by other mechanisms, such as nutating plates, baffles on the basket, etc., as well as horizontal axis washers which provide agitation via tumbling. Other washing or cleaning appliances do not agitate the materials being washed or cleaned, but rather provide sprays or mists of water or other cleaning, washing, refreshing and rinsing fluids.
FIG. 2 provides the details of the disinfecting unit 30 . The disinfecting unit 30 includes a water container 36 , a heating element 38 , a steam chamber 40 , a chemical or biocide container 42 , and a mixing chamber 44 . The mixing chamber 44 includes a projection which may be in the form of a wire 46 attached to a chemical dispenser 48 . The chemical dispenser 48 may be electrically or mechanically controlled, although a control is not necessary in all embodiments. The water container 36 may be automatically filled via the conduit 32 from an external water supply, such as that used to supply water to other parts of the washer 10 .
In other embodiments, the water container 36 may include an openable cap 50 ( FIG. 3 ) and the user of the washer may refill the water container manually. The chemical container 42 may also include an openable cap 52 to permit refilling of the chemical. In some embodiments, the chemical container may contain a long term supply, such as a supply that should last for 10 years under normal usage. The chemical container 42 might be a cartridge that is removable and replaceable, with a fresh supply of chemical, separately from the remainder of the disinfecting unit 30 . In still other embodiments, the entire disinfecting unit 30 is removable and replaceable with a fresh unit, so that no refilling is necessary, or so that accessibility for refilling is improved.
The water container 36 includes a water dispenser 54 , which also may be electrically or mechanically controlled, to cause drops of water to be dispensed into the steam chamber 40 , preferably located below the water container. The heating element 38 is thermally associated with a portion of the steam chamber 40 to heat the water drops that have entered the steam chamber. Although depicted as being at the bottom of the steam chamber 40 , one skilled in the art will recognize that the heating element 38 could be associated with the steam chamber in a number of configurations. For example, the heating element 38 could surround the steam chamber 40 , or it could be located in the center of the chamber. When the heating element 38 is located at the bottom of the steam chamber 40 , the water drops from the water container 36 will fall on a surface 56 heated by the heating element, and will quickly be converted to steam.
A passageway 58 allows steam to flow along a path from the steam chamber 40 to the mixing chamber 44 . The chemical dispenser 48 allows chemical drops from within the chemical container 42 to flow along the wire 46 into the mixing chamber 44 . These drops will coat a large surface area of the wire 46 , allowing for quick and efficient absorption or adsorption of the chemical by the steam in the mixing chamber 44 . One skilled in the art will recognize that other configurations or arrangements to dispense the chemical into the mixing chamber 46 can be used. For example, the chemical could be a solid that dissolves upon contact with the steam, or the chemical could automatically travel down the wire without the dispenser, like a wick.
A wide variety of chemicals may be used with the invention, including various pesticides, for example, common EPA registered antimicrobials, such as the full list of “MICROBAN” products. Also, hydrogen peroxide and its variations, silver, copper or zinc ions, chlorine bleach, and in some instances, simply steam.
The steam chamber 40 may have a collection sump 60 for receiving any condensate from the steam that has not exited the steam chamber. The mixing chamber 44 may have a bottom wall or floor 62 which is sloped downwardly towards the passageway 58 , also to allow condensate, or excess chemical liquid, to flow into the collection sump 60 in the steam chamber 40 . If the disinfecting unit 30 is permanent or refillable, the sump may have an openable drain to allow removal of collected liquids from time to time. Alternatively, a liquid moving mechanism, such as a pump or piston, could be used to redirect the condensate back to the surface 56 heated by the heating element 38 to assure that all of the chemical and water is dispensed with the steam.
In operation, when a disinfecting cycle is initiated, the water dispenser 54 , operated by a control 61 , permits drops of water to leave the water container 36 and fall into the steam chamber 40 . The heating element 38 , also operated by the control 61 , heats the water in the steam chamber 40 until steam is formed (step 63 , FIG. 4 ). The steam exits through the passageway 58 to enter mixing chamber 44 . The chemical dispenser 48 controllably allows chemical drops to enter the mixing chamber 44 via the wire 46 . The chemical drops are absorbed or adsorbed (depending on the solubility of the chemical in water) by the steam in the mixing chamber 44 , so that the steam becomes impregnated with the chemical (step 64 ). The impregnated steam enters the wash tub 14 through the conduit 34 (step 65 ).
The heating element 38 continues to heat the water until the temperature in the wash tub 14 reaches a threshold temperature for a given duration (step 66 ). Temperature sensors 70 provided at appropriate locations within the appliance, which communicate with the control 61 , measure the temperature in the region of the wash tub. The threshold temperature may be 65° C., 70° C., 75° C. or higher for durations of 5 minutes, 10 minutes, 15 minutes, or longer to kill the microorganisms. Preferably, the temperature will be elevated to 67-70° C. for 10 minutes, as determined by a clock 74 in the control 61 . With increased temperatures, the duration may be shortened and with decreased temperatures, the duration may be increased. After the threshold temperature is reached for the given duration, the control 61 terminates operation of the heating element 38 to stop the heating of the water (step 76 ) and terminates the dispensing of water and chemical. For some chemicals, such as silver, copper or zinc ions, would allow for ambient temperatures to be used, rather than elevated temperatures for some given period of time.
The steam impregnated with the chemical is used to thermally and/or chemically kill any microorganisms that exist in the appliance, or to provide other chemical treatment in the appliance, such as scale removal. The steam is able to transport the chemical to areas that are not typically reachable by other means, e.g., by rinsing the washer tub or basket with chemically treated water. In a washer environment, the present invention allows for treatment of the inside and outside of the basket, the tub, the sump, and all of the hoses.
The bio prevention (or other chemical treatment) cycle can be performed as an automatic cycle by the control operating the washer 10 , such as at the end of each complete wash cycle. Alternatively, or in addition, the bio prevention cycle could be initiated by the user via a manual selection on a control panel of the washer.
The use of the present invention could also provide for reduced water usage in a wash cycle. The water usage savings could come from the utilization of steam as the vehicle to deliver heat to the wash load, rather than a deep water fill. Less energy would be required to heat a smaller volume of water into steam for the heating, in addition to using less water in the wash cycle.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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An appliance having an enclosure arranged to receive articles to be treated also includes a water container and a steam chamber with a steam outlet. A water dispenser is arranged to dispense water from the water container to the steam chamber. A heating element is thermally associated with the steam chamber. A control is arranged to selectively operate the heating element. A steam path extends between the steam outlet and the enclosure. A chemical dispenser is positioned along the steam path. The heating element heats water in the steam chamber to create steam, and the chemical dispenser adds a chemical to the steam as the steam passes through the steam path.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/204,288, filed Aug. 16, 2002, now U.S. Pat. No. 7,734,570 which is a National Stage entry of International Patent Application Serial Number PCT/US01/04877, filed Feb. 16, 2001, which claims benefit of priority from U.S. Provisional Patent Application Ser. No. 60/182,749, entitled Collaborative Linking System with Bi-directed Variable Granularity Search Engine, filed Feb. 16, 2000, all incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
Generally, the present invention relates to networked computer systems. More specifically, the present invention relates to computer systems and search engines used to selectively link members from any of a plurality of classes of users via any of a plurality of network enabled, wired or wireless, computers (or electronic devices).
BACKGROUND OF THE INVENTION
Internet usage has become immense and promises to be much larger in the amount of information stored and made available to it users. In fact, the quantity of accessible information content and the number of requests for information are growing much more rapidly then the ability to deliver the desired information. This delivery is limited by the power of the available processors, database machines, and communication bandwidth available and limited by the ability of the humans and their local computers (or electronic devices) to receive and process the data returned. Considerable research has been carried out to create more efficient search engines that attempt to minimize the actual data access, data communications, and querying required to satisfy the user's real need.
The great thrust of the Internet is characterized by the thrust of the “World Wide Web,” suggesting that all of the information stored, worldwide, can be accessed by all of the users, worldwide via increasing numbers and types of wired or wireless computers, such as workstations, personal computers, cell phones, pagers, and personal organizers, just to name a few. Research, applications, and usage have been concentrated on this worldwide accessibility, such that the reach and access of a Web user seems limitless.
However, with the apparent focus on increasing a user's reach and access to volumes of data, the Internet and World Wide Web, at times, is a forum of scarcely tapped potential on a community level. That is, consumers and product and service providers have realized only marginal benefits from the Web in their mutual conduct of community level business transactions.
It is believed that as much as 85% of a consumer's purchases occur within 20 miles of the consumer's residence. Yet, presently, the Web does not link local consumers with local providers of goods and services in a scalable and efficient manner.
SUMMARY OF THE INVENTION
The present invention is a network-based collaborative linking system having bi-directed, variable granularity search engines configured to selectively link one or more members from a first class of users with one or more members from at least one other class of users. Each class member may interact with the collaborative linking system using a wired or wireless computer. Wherein, the word “computer” as used herein is to include, but is not limited to, those wireless devices, like cell phones, personal organizers, and pagers, which are network enabled and which allow their users (or class members) to interact with a network to send and receive messages, for example. In the case of pagers and personal organizers (i.e., receive only devices), it may be used to receive solicited or unsolicited advertisements, or announcements or e-mail with limited text, as an example. However, for the most part, messages may be include text, graphics (static and dynamic), or audio information, or some combination thereof.
In its simplest form, the collaborative linking system links members of a first class with members of a second class, wherein members of the second class generally seek information or data from members of the first class. Also, members of the first class may seek and use certain information related to members of the second class to facilitate more efficient and focused information providing. Each class may be generally characterized according to the application for which the collaborative linking system is to be applied. For example, in an e-commerce application, all members of the first class may be characterized as “providers” and all members of the second class maybe characterized as “consumers”.
The collaborative linking system may impose a general structure or framework on classes (e.g., consumers and providers), to facilitate efficient processing. Providers may selectively map their provider information into the framework and consumers may then search for provider information in a logical manner. By selectively mapping into certain areas of the collaborative linking system, a provider imposes a filter on its entry. From a consumer's perspective, by defining certain search criteria, within the context of the framework, the consumer defines a filter into the collaborative database for obtaining information. Given that the consumer can define and redefine his search criteria, the consumer can control the granularity of the search.
Within each class, members of that class may be grouped into subclasses, according certain criteria. Subclasses mayor may not be hierarchical. That is, a subclass is constructed in accordance with certain criteria. Other than the criteria that defines the class generally (e.g., all providers), the other criteria that defines one subclass may be independent of the criteria that defines every other subclass. For example, a subclass of providers selling pizza may be independent from a subclass of providers selling skateboards, but they may both be part of an independent subclass of providers targeting consumers under the age of 21 years old. However, in a hierarchical context, an auto dealer subclass may be further subclassified into certain makers of automobiles (e.g., Chevrolet, Ford, etc.). In most embodiments, the collaborative linking system will include some combination of independent and hierarchical subclassifying.
Consumers may be similarly subclassified, either independently, hierarchically, or some combination thereof. As an example, consumers may be independently subclassified into age groups, that is, age group 1, or age group 2, or age group 3, or “all ages”, and independently, they may be subclassified as male, or female, or both. Generally, the criteria of providers correspond to the criteria of consumers, such that the more refined the criteria (or search criteria) of a consumer the smaller the solution set of providers that will satisfy the consumer's criteria. Similarly, the more refined the criteria (or search criteria) of a provider the smaller the solution set of consumers that will satisfy the provider's criteria.
Classes, and their members, may be defined in any of a variety of manners, as dictated by the application for which the collaborative linking system is to be used. A member may be an individual, an organization, or some other type of entity. Preferably, the collaborative linking system is a Web-based system implemented over the Internet for e-commerce purposes. However, the collaborative system may also be implemented with other types of networks, such as, for example, a wide area network (WAN), local area network (LAN), or Intranet of an organization or affiliation or some combination thereof, and need not be restricted to e-commerce. Additionally, classes and their members may have different system privileges and the system may employ various known security mechanisms.
The collaborative linking system includes a plurality of wired and/or wireless computers (e.g., workstations, personal computers (PCs), cell phones, pagers, electronic personal organizers, Web enabled television, or other such interactive electronic devices) linked to one or more content servers and content databases of provider, and potentially consumer, information. The provider database content may include relatively static data, as well as short-term “promotional” or time critical dynamic data that may be of interest to consumers. In the preferred form, a control center having one or more control servers and associated control databases, serves as an entry point for selectively distributing and managing the distribution of providers' data to the content servers and content databases. The control center also establishes and manages, to some degree, the high level framework within which the classes operate. In addition to provider and consumer databases that may be provided as part of the collaborative linking system, third party databases may be linked to the system and the data therein used to facilitate improved satisfaction of the objectives of the collaborative linking system. For example, third party databases including directory listings, maps, SIC codes, Zip codes, telephone exchange numbers, and/or directions for getting from one place to another may be linked to, or imported into, the collaborative linking system.
A collaborative linking system program code is executable by one or more of said content servers and includes one or more bi-directed, variable granularity search engines. A search engine facilitates searches of, for example, provider content databases according to consumer's defined filters (i.e., search criteria). Based on a first level of search criteria, the search engine determines the appropriate one or more content servers and associated content databases most likely to satisfy the user's search. By continuing to add search criteria, additional (or more refined) filters are applied by the search engine to the content databases; thus, the user's search is further refined.
The collaborative linking system includes a plurality of user interfaces (UI) to facilitate the interaction of each of several types of users and computers (e.g., PC, cell phone, or pager) with the system. Preferably, each UI is generated from program code executed within a standard Web browser, on a user's workstation or PC, but the actual UI implementation will often vary as a function of the type of device with which a user interacts with the collaborative linking system. Each UI may be established with specific user privileges, having different levels of access and security. For example, a system administrator UI (SAUI) is provided to facilitate the configuring and maintenance of the system. A developer's UI (DUI) may also be provided for initial development and integration of system components and for performing functions similar to those accomplished using the SAUI. Preferably the SAUI and DUI are part of the control center. The control center is, for the most part, a logical center of the system and mayor may not have all of its components physically collocated. Access to the control center may be local, remote, or some combination thereof, depending on the embodiment. In various embodiments, the collaborative linking system also includes UIs for billing and account management, which may be part of the SAUI or part of a separate UI.
A provider UI (PUI) may also be provided to allow each provider to directly add, modify, delete, and map the provider's information into the system's content servers and databases. As an alternative or a companion to the provider's direct entry, the system administrator may add, modify, delete, and map provider data into the system via the SAUI. Using the PUI a provider can also, preferably, establish a provider account on the collaborative linking system and take advantage of, for example, non-static information providing features of the system, such as, for example, offering specials to consumers.
To facilitate a consumer's interaction with the collaborative linking system, a consumer UI (CUI) is provided. The CUI facilitates a consumer's search for provider information by enabling the consumer to enter and create filters (i.e., search criteria) used to efficiently migrate through the collaborative linking system content servers and content databases to optimally locate relevant provider data, both static and dynamic. Screens displayed and information provided within the consumer's Web browser are a function of the framework, the providers' mapping of data into the framework, and the consumer's search criteria. Where appropriate, the UI screens generated by the collaborative linking system may include Web site and e-mail links.
A consumer may optionally enter consumer information into the collaborative linking system via the CUI and avail himself of an automatic linking capability that links providers and consumers as a function of a certain amount of synergy between the two. For example, the consumer's information may indicate that the consumer is an avid hiker and as local providers offer specials on hiking (or related) equipment, those providers and their specials are automatically identified to the consumer (e.g., via e-mail). Additionally, the collaborative linking system may selectively link consumers and providers using information obtained about the consumer's purchasing practices (or using other consumer related information), such that the consumer receives unsolicited provider promotional announcements. Preferably, a consumer may opt out of the distribution of unsolicited provider promotional announcements.
As will be appreciated by those skilled in the art, the various user interfaces may vary depending on the particular type of computer used. For example, the CUI for a PC may differ from the CUI for a cell phone, which may also differ from the CUI of an electronic organizer, and so on. Differences may be realized for each type of UI, among various types of computer devices.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects of this invention, the various features thereof, as well as the invention itself, may be more fully understood from the following description, when read together with the accompanying drawings, described:
FIGS. 1-10B are diagrams illustrating the entity types and relationships of the preferred embodiment of a collaborative linking system, in accordance with the present invention;
FIGS. 11A-16 are architecture-based diagrams of portions of the collaborative linking system of FIGS. 1-10 ; and
FIGS. 17-24 are screen display diagrams of the user interface of the collaborative linking system of FIGS. 1-16 .
For the most part, and as will be apparent when referring to the figures, when an item is used unchanged in more than one figure, it is identified by the same alphanumeric reference indicator in all figures.
Trademarks of various entities are used herein as examples and do not indicate any specific relationship to the present invention. The trademarks used herein remain the property of their respective owners and nothing herein is intended to alter those property rights.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the preferred form, the collaborative linking system is applied in a Web-based e-commerce context. In such a context, a first class of users includes “providers”, having members that include a plurality of retailers, service providers, restaurants, and so on. For the most part, in the preferred embodiment, a provider may be any type of entity found in a typical Yellow Pages phone book, for example. A second class of users includes “consumers”, having members that include individuals, businesses, and so on. Preferably, providers and consumers interact with the collaborative linking system via any of a variety of wired or wireless types of computers (e.g., workstations, personal computers (PCs), cellular telephones, pagers, electronic personal organizers, Web enabled televisions, or other types of electronic devices).
Members of each class (i.e., providers and consumers) may be grouped into subclasses based on additional criteria. Sub classifying may be either independent, relationship-based or some combination thereof. An example of relationship-based sub classifying is a hierarchical approach, but subclasses may be related in some other manner. In contrast, if a subclass is independent, it has no particular relationship to any other subclass within its class. Generally, a provider seeks to be linked to consumers in search of the provider's products or services. Similarly, a consumer seeks to be linked to providers that provide the products or services that the consumer desires. In some situations a provider may be a consumer, for example, in a business-to-business transaction. FIGS. 1-10B depict the entities and relationships of the preferred embodiment of the collaborative linking system.
The collaborative linking system of the preferred embodiment implements a structure that defines a first level of criteria for linking providers and consumers. In an e-commerce context, recognition that most people shop in their immediate vicinity for many products and services, such as for perishables, items or services they need in a relatively short time, and items they prefer to inspect before purchasing, leads to a preference for a geography-based framework or structure. Therefore, consumers and providers are linked, at a first level, in relation to a predetermined geographic region. For the most part, the provider's choice of geographic preference is more or less static, over a period of time, because of the general “bricks and mortar” aspect of providing products and services from a physical location. On the other hand, the consumer has greater physical mobility, so the collaborative linking system provides the capability to allow the consumer to dynamically specify his current geographic point of interest.
As an architectural implementation, a plurality of content servers and associated content databases are linked together under the general management of a control center and made accessible via the Internet and Web, as shown in FIGS. 11A-16 . Additionally, third party databases, information sources (and related functional code), functionality, networks, and systems may be linked to, or imported into, the collaborative linking system, such as databases including directory listings, maps, SIC codes, ZIP codes, telephone exchange numbers, directions for how to get from one place to another, credit information, financial account information and so forth. The content servers and databases are defined according to a geographic region, within the larger geography-based framework. Each provider maps its provider information into those geographical content servers and databases (i.e., “business places”) that correspond to that provider's consumer base and/or that provider's storefront locations. A consumer searching for a particular product or service dynamically chooses a geographic region within which to search, that is, the consumer chooses a certain one or more content servers and databases. Preferably the content servers are physically located proximate to or within the geographic region that they serve. This geography-based architecture imposed on providers and consumers provides at least two performance benefits. First, if the consumer is searching a content server and database that is in or near his geographic location, transmission times between the consumer and the content server will be relatively short, due to fewer relays in the transmission path, among other things. Second, the server's response time (to the consumer's search request) will be relatively short, since the content database being searched contains only the data for that geographic region. Also, the more refined the consumer's search, the faster the search results are presented. Of course, in other embodiments, a geography-based structure need not be imposed; the choice of structure is made in light of several considerations and will vary depending on the application for which the collaborative linking system is used. Generally, the structure is chosen to enhance or optimize performance. In other architectures, content servers and databases may be dynamically allocated as a function of the availability of system resources.
A geographic region may be defined in any of a variety of manners, such as, for example, by postal codes, by telephone area codes and exchanges, by a circle defined by longitude and latitude values, by a set of points each with a longitude and latitude value, by governmental census tracks identifiers, or by a set of other geographic regions (places). The provider information (or data) may include information relating to the provider's location (e.g., the store's address), store hours, products and services offered and current promotions. The product information may include make, model, features, price, and quantity on hand. Additionally, providers may be rated and consumers may search for providers meeting a certain minimum rating threshold, for a given product of service.
While a user is most likely to inquire about providers in his geographic region, the user may optionally expand his search to include adjacent geographic regions or to search in remote geographic regions. Additionally, consumers may generally be willing to travel farther within their general geographic area for some products than for others. For example, the geographic region (or business place) for auto dealerships may be larger (in the consumer's mind) than the geographic region for pizza parlors. Thus, a provider may wish to list a particular place of business (e.g., an auto dealership) in multiple surrounding areas. Using the Internet and Web as a communications network, a consumer may seamlessly transition between business places, expand or contract a search, or change the product/service being searched.
In a broad context, the collaborative linking system is implemented for a large group of business places (i.e., towns), wherein each business place includes a plurality of businesses (or providers) offering products and services. A combination of business places may form a higher level business place. For example, a large geographic region may be the United States (“U.S.”), which may include a plurality of separate business places (or geographic sub-regions). A provider that has a presence (e.g., store or franchise) in many locations throughout the U.S. may then pick and choose within which business places to advertise each store. Presumably, the provider advertises in those regions where the provider has a physical presence. Additionally, a provider may pick and choose within which business places certain products will be promoted. For example, a department store provider may, in the month of January, promote snow scrapers in Massachusetts and sun glasses in Florida, but not vice versa. However, if the provider is a mail order business with no traditional storefronts, that provider may chose to advertise only in business places having consumers that have demonstrated a demand for the provider's mail order products or may advertise in all business places.
In the preferred embodiment, the collaborative linking system includes the control center, having access to the control servers and control databases. The control center accomplishes the system administration, management, maintenance, modifications, upgrades, and so forth of the collaborative linking system, as well as establishing the basic framework of the system. The control center provides a mechanism for the storage and subsequent mapping of provider data into business places (i.e., business place content servers and databases) and administration of links to third parties (e.g., provider Web sites or third party databases or services). Although, third parties need not link to the collaborative linking system through the control center; they may link to a proximate content server. In the preferred embodiment, providers seeking to offer promotions (e.g., advertise sales or distribute coupons), derive or collect consumer information or derive other benefits beyond a static listing from the collaborative linking system are referred to as “syndicators”, and derive such benefits by establishing an account that is managed through the control center. Other providers may simply have their static information (e.g., non-promotional information) provided to consumers.
The collaborative linking system provides a mechanism for providers to use consumer information to tailor or otherwise influence their marketing approach. For example, geographically related consumer information may be added into the system, such as average household income, number of homeowners, political and religious affiliations and other census information, and so on for a geographic region. Additionally, other consumer related information (e.g., number of “hits”, consumer preferences, and consumer activity patterns) may be collected by the system, as part of consumer's use of the collaborative linking system. This information may then be used by providers in determining which products and specials are to be offered in a given geographic region, which types of ads are most effective, and which ads are most effective relative to the time of day, among other things. Use of this information may be by overt provider selection, or as an automated function of the application of automated filters. For example, a kitchen appliance company may only promote certain appliances in the towns where the company has a distributor and where new home construction is higher than 5%. Once a town's new home sales drop below 5%, the collaborative linking system may automatically cease promotions on those appliances in that town.
In the preferred embodiment, the collaborative linking system user interface is comprised of at least three user-type interfaces: a system administrator user interface (SAUI), a provider user interface (PUI), and a consumer user interface (CUI). That is, the SAUI includes a plurality of displays useful by system administrator personnel for monitoring, data gathering, troubleshooting, analyzing, modifying, upgrading, configuring, enhancing, testing, and otherwise operating and maintaining the collaborative linking systems and the information thereon. The SAUI may also be used for billing and account management purposes. Also, the SAUI may be used to add, modify, and delete provider and consumer data and to establish and maintain links to third party systems and databases. Access to certain aspects of the collaborative linking system for system administration purposes may vary as a function of predetermined user privileges. For the most part, system administration is conducted via the control center.
The PUI allows a provider to access information related to that provider on the collaborative linking system. In the preferred form, the collaborative linking system databases are populated with relatively static provider data within a geographic context for substantially each provider in a selected business place. As previously discussed, such relatively static provider data typically includes a provider name, address, and telephone number (which may collectively be referred to as a “listing”). Such information is entered into the system via the SAUI or by the provider via the PUI. Using the PUI, a provider may “register” with or establish an account on the collaborative linking system and subsequently view, add, delete, or modify its provider data. Registered providers are required to logon to the collaborative linking system in order to interact with their provider data. Using the PUI, for example, a provider may define promotional specials, change or update provider data and view statistical information related to their listing and specials. Appendix A (and its figures), attached hereto and incorporated herein by reference in its entirety, describes an embodiment of the PUI.
For the consumer, the collaborative linking system CUI provides, preferably, a hierarchical, link or text-based search approach to finding providers relative to a chosen geographical region, as a first level criterion. Decreasing recall and increasing accuracy of results is achieved with the addition of subsequent criteria by the consumer, as indicated in the CUI screen prints of FIGS. 17-24 . In the preferred embodiment, the consumer interacts with the collaborative linking system via a standard Web browser. The consumer may directly access a business place Web site, associated with a particular business place (e.g., the town of Wellesley, Mass.) to find providers in that business place. Additionally, the consumer may broaden the search to include other business places or migrate to other business places. As a function of the user's search, the collaborative linking system generates and displays within the CUI provider information and data, and may additionally provide information about companion providers or promotions. For example, if a consumer searches for pizza places in Wellesley, Mass., the CUI may provide a list of all pizza places in that town. Additionally, the user interface may provide indications of specials or promotions offered by certain providers (e.g., icons, conspicuous text, and/or sound messages). Also, as a function of the consumer's search, companion specials or promotions may also be included within the CUI, for example, a promotion by a local convenience store on soft drinks. Additionally, provider specials and promotions may provide virtual links to the provider's own Internet pages.
Additionally, a consumer's interests or other consumer information may be registered with the collaborative linking system. In such a case, a consumer may be linked (or matched) with providers as part of an “opt-in” service, as a function of a synergy between the consumer and the providers. For example, the consumer's interests may correspond to one or more provider's offers; consequently, the consumers and providers are linked by the collaborative linking system. Preferably, the collaborative linking system maintains the anonymity of the consumer with respect to the provider when linking the two. Further aspects of this service may be better understood and appreciated in the context of the embodiment described in Appendix B attached hereto and incorporated herein by reference in its entirety.
As will be appreciated by those skilled in the art, the various UIs may vary, depending on the type of computer or electronic device with which they are to be used. For example, the CUI for a PC may differ from the CUI for a cell phone, and so on. Additionally, the various UIs may be defined in other manners without departing from the present invention.
The invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. For example, mapping of provider information may be dynamically accomplished and editable. Also, automated filters may be applied to effect the dynamic mapping of provider information. Additionally, third party databases may be linked into the collaborative linking system and used by providers to select consumers or by consumers to select providers. In other embodiments, the definition of the geographic regions may vary as a function of the product or service being searched, rather than be relatively statically defined. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by appending claims rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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The present invention is a system and method for shortening response time and reducing resource utilization in an electronic advertising and customer enquiry system, operating in an interactive communications and distributed database environment. The system is designed to enable customers ( 01 ) to easily find product and service offerings that match their requirements for immediate local accessibility (A 1 ), as well as the customer's ( 01 ) specific product desires. Where a perfect match does not exist, slightly less satisfactory solutions are offered. Such product offerings and customer ( 01 ) desires have static and dynamic characteristics that effect their electronic publication, enquiry, matching, and subsequent response.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the protection of utility meters and more particularly it concerns novel structure and methods for reducing the maintenance expenses associated with the replacement and refurbishing of utility meters. The term "utility meters" herein is to be understood as meaning any meter for measuring the flow of a fluid, including gas, water and electricity.
2. Description of the Related Art
Utility meters are used by public utility companies to measure the consumption of a resource, such as gas, water or electricity, by a consumer. The meter is connected into the line which supplies the resource at the premises of the consumer so that the fluid being consumed passes through the meter and its quantity is measured. This measurement is seen as a reading in a window on the face of the meter; and it is read periodically by a representative of the utility company. Based on this reading, the utility company prepares billing to the consumer.
From time to time it is necessary to disconnect the meter so that it can be cleaned, repainted and recalibrated. The disconnected meter is replaced with a new meter; and the disconnected meter is then taken to the utility company's facilities where it can be cleaned, repainted and recalibrated.
Gas meters are generally disconnected for cleaning, repainting and recalibration after approximately twenty five years of service. Because of this long duration of service, and because of the ambient conditions at the meter's installed location, a considerable amount of dirt, grime and corrosion accumulates on its housing; and it becomes very difficult to clean. The cleaning operation is highly labor intensive; and it must be carried out carefully so as not to damage the metering mechanism inside the meter housing.
U.S. Pat. No. 4,327,760 and No. 4,532,688 relate to arrangements for gas meter replacement without interruption of service. Specifically, according to these patents, a gas tight bag is placed over a meter which is to be removed from a customer's premises. A replacement meter is also positioned inside the bag. The bag is then sealed tightly to gas input and output lines near their connection to the meter; and the bag is tightly closed so that gas cannot leak out when the meter is disconnected. Thereafter, fittings which connect the meter to the gas input and output lines are manipulated through the bag; and the meter is disconnected from the lines. The replacement meter, which is already in the bag, is then attached to the gas input and out put lines; and the bag, with the original meter, is then removed.
U.S. Pat. No. 4,582,220 relates to a molded plastic cover for a gas meter. The cover has a window for reading the meter. U.S. Pat. No. 5,503,271 relates to a cover for enclosing and protecting an electric meter during transportation and storage. U.S. Pat. No. 5,286,110 relates to a flexible package having a tamper-resistant seal.
None of the foregoing patents is concerned with the problem of cleaning and refurbishing meters which have accumulated a large amount of grime and corrosion over a long period of time.
SUMMARY OF THE INVENTION
The present invention, in one aspect, involves a fluid meter installation which comprises a fluid meter connected to fluid input and output lines; and a cover which encloses the meter. The cover is transparent in a region over the meter indicators so that the meter can be read without need to remove it from the cover. The cover also has openings to permit circulation of air around, and drainage of condensation from, the meter. In addition, the enclosure has a large closeable opening through which the meter may be removed. This closeable opening is constructed such that it cannot be opened without producing a permanent indication of its having been opened.
In one embodiment, the closeable opening may be provided with a seal that must be broken in order to open the enclosure.
In another aspect, the invention involves a novel method of maintaining a fluid meter. This novel method includes the steps of placing the meter inside a protective cover which has a transparent area in registry with a readout from the meter, and which has openings to permit circulation of air around, and drainage of condensation from, the meter. Fluid inlet and outlet lines are inserted through openings in the enclosure and are connected to the meter within the enclosure. The enclosure is then closed in a manner such that the meter may not be removed without producing a permanent indication on said enclosure of such removal.
In a further aspect, the invention involves a novel method of maintaining a fluid metering facility. This novel method involves the steps of placing a meter in a protective enclosure, closing the enclosure in a manner such that the meter cannot be removed except by producing a permanent indication of such removal. Inlet and outlet lines are brought through openings in the enclosure and are connected to the meter. The meter, with its enclosure is thereafter removed from the facility. The enclosure is then opened; and the meter is removed for reconditioning. The meter is then placed in a new enclosure and is reconnected to fluid lines which extend through openings in the new enclosure.
In a yet further aspect the present invention involves a novel meter cover in the form of a flexible bag having a transparent region to allow the reading of a meter enclosed within the bag. The bag has air inlet openings to allow air to circulate inside the bag, and drain openings to allow drainage of condensate that forms within the bag. The bag has a further opening to allow a meter to be placed inside the bag. There is also provided a closure element which maintains the further opening closed. The closure element cannot be opened without causing a permanent indication that it has been opened.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a gas meter which may be used in the present invention;
FIG. 2 is a front elevation view of a flexible bag which forms a cover according to the present invention;
FIG. 3 is a front elevational view showing the insertion of the meter of FIG. 1 into the enclosure of FIG. 2;
FIG. 4 is a front elevational view showing the meter fully enclosed within the cover; and
FIG. 5 is an enlarged section view taken along line 5--5 of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a gas meter 10 comprises upper and lower housings 12 and 14 which are held together by bolts (not shown) extending through peripheral flanges 16 and 18. The upper housing is formed with inlet and outlet connection pipes 20 and 22 through which gas to be metered flows into and out from the meter 10. A gas flow measuring device (not shown) is located within the housings 12 and 14 and is actuated by the flow of gas into and out from the meter. The amount of this gas flow is recorded and is registered on dial or other visible indicator (also not shown). A window 24 on the upper housing permits one to read the indicator at any time during operation of the meter. A meter cover 26 is attached to the upper housing 12 by bolts 28. This cover may be removed to gain access to and make repairs on the gas flow measuring device. Only authorized persons are permitted to remove the cover 26; and to be sure that it has not been tampered with, a frangible seal 30 is placed across the cover 26 and the upper housing 12. This seal must be broken in order to remove the cover 26.
Turning now to FIG. 2, there is shown a cover 32 in the form of a flexible bag. The bag 32 is shown in flattened condition in FIG. 2. This bag is preferably made of a static free, low density clear polyethylene plastic about 0.004 inches (1 millimeter) thick. The bag 32 is large enough to enclose the gas meter 10 of FIG. 1. Preferably the bag 32 is 18 inches centimeters) high and 171/2 inches (44 centimeters) wide, which is sufficient to enclose a standard gas meter. The bag 32 is closed along its upper edge 34 and is initially open along the full length of its lower edge 36. Several upper vent holes 38 are provided near the upper edge 34 of the bag; and several drain holes 40 are provided near its lower edge 36. The vent holes 38 allow air to enter into the bag and to circulate around its interior; and the drain holes 40 allow condensate which may form in the interior of the bag to be drained away. Preferably the outer surface of the bag 32 is provided with a label area 41 which contains information relevant to the meter 10. Also, the label area may be constructed to permit writing thereon to provide additional information regarding installation date, etc. of the meter.
As shown in FIG. 3, the bag 32 has a lower edge 36 which forms a large opening. The meter 10 is inserted into the bag 32 through this opening. This is preferably done at a meter reconditioning or supply facility. The lower edge 36 of the bag 32 is then closed and sealed; and the bag 32, with the meter 10 contained therein, is brought to the customer's premises. Then, as shown in FIG. 4, openings are made in the upper region of the bag; and gas flow lines 40 and 42 at the customer's premises are inserted into these openings. The inlet and outlet connection pipes 20 and 22 of the meter 10 are then coupled to the gas flow lines 40 and 42 to complete the meter installation.
The bag 32 is transparent and allows one to see the window 24 on the meter 10. This permits the utility company and the consumer to read the meter at all times while it is in use. It in not necessary that the entire bag 32 be transparent, provided that it is transparent in the region adjacent the meter window 24.
It will be appreciated that the meter 10 is protected by the bag 32. At the same time the vent holes 38 allow air to enter into the bag and to circulate around the meter while the drain holes 40 allow condensate to which may form on the meter housing to be drained away.
It will also be appreciated that in order to open the bag 32, it is necessary to break the seal along the lower edge. The seal is constructed such that it cannot be broken without providing a permanent indication that the bag 32 has been opened. This allows the utility company to know when there has been tampering with the meter 10.
The seal along the lower edge of the bag 32 may be of any construction that causes permanent indication of its having been broken. Preferably the seal is as shown in cross-section in FIG. 5. As can be seen, the bottom edge of the bag is formed with a forward flap 36a which extends along the lower edge 36, and a rearward flap 36b which also extends along the lower edge 36. The rearward flap 36b is longer than the forward flap 36a and it extends around the forward flap as shown in FIG. 5. A permanent self-peel adhesive with a peel strip (not shown) is placed along the flap 36b. After the meter 10 is placed in the bag 32, the bag is sealed by removing the peel strip and folding the elongated flap 36b around, and pressing it against, the front flap 36a so that it adheres to the front flap. The adhesive is such that it cannot be pulled away from the front flap 36a once it has been adhered to the flap. Thus, if one attempts to remove the meter 10 from the bag 32 by opening the seal along the lower edge 36, the bag cannot be resealed; and the seal cannot be opened without a permanent indication of its having been opened. Thus, the utility company will have an indication that the meter 10 has or my have been tampered with.
Other means which will provide a permanent indication of opening of the bottom of the bag 32 can be used, such as a tie strip which extends through holes in the bottom of the bag. The tie strip should be sealed in such a way that it must be broken in order to release it from the bag.
During the time that the meter 10 is operating, it is contained inside the enclosure or bag 32; and it is therefore protected by the bag from corrosion and accumulation of dirt, grime, etc. At the same time the meter may be read at periodic intervals. When the meter is due for reconditioning, it can be removed by a representative of the utility company and then taken out of the bag 32. Since the meter has been protected it may be cleaned and calibrated without difficulty. Thereafter, the meter 10 may be placed in a new bag 32 and reinstalled at the same or another consumer's facility.
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A gas meter installation wherein a gas meter is contained within a protective bag during normal operation and wherein the bag may not be opened to obtain access to the meter without causing a permanent indication of such opening.
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BACKGROUND
Personal media players that enable users to store and render a variety of media content such as music, photographs, and video are enjoying widespread popularity as performance and features such as storage capacity and continue to increase while maintaining attractive pricing. In addition to the market for the personal media players themselves, accessories such as earphones, chargers, car kits, and carrying cases, are presenting significant opportunities for manufacturers and retailers to develop additional revenue sources within the large media player market. One example of a popular personal media player accessory is a dock with which a user may connect the player to another device such as a personal computer, television, or other electronic device to communicate and share data, for example.
Personal media players are often offered with a variety of different features to enable sale at varying price points. It is not unusual for a manufacturer to offer multiple product types or lines to help tailor a personal media player to a specific target market segment. However, it is not always efficient or possible for retailers to carry a lot of device-specific accessories for each different personal media player. As a result, accessory manufacturers are motivated to develop products that are applicable to a wide variety of personal media players while maintaining both backwards and forwards compatibility, respectively, with older and newer models of players. However, most manufacturers want to avoid user perception that a particular accessory is “universal” which often connotes a compromised product that is not very well tailored to that user's specific media player.
This Background is provided to introduce a brief context for the Summary and Detailed Description that follow. This Background is not intended to be an aid in determining the scope of the claimed subject matter nor be viewed as limiting the claimed subject matter to implementations that solve any or all of the disadvantages or problems presented above.
SUMMARY
An adaptive dock for use with media players of varying form factors is provided by an arrangement in which a device connector is located on a moveable sled that is located in the dock's base unit which houses the functional elements such as electronics required to implement communication between the media and an external device such as a personal computer. A device-specific dock insert is arranged for removable engagement with the base unit to allow the base to have applicability to different media players by using the appropriately configured insert. The insert includes a device receiving space having an opening that is located to expose the media player's accessory connector so that it may be mateably engaged with the device connector when the player is inserted into the dock. The insert further includes an actuator that slidably engages with a cam that is located on the sled to impart a lateral motion to the sled as the insert is placed downward into the dock's base unit so as to align the device connector on the sled with the opening in the insert.
In an illustrative example, the device-specific dock insert includes tabs that are configured to be removable engaged with the base unit in a snap fit configuration. The insert further includes a rib that engages in a mating slot adjacent to the device connector on the sled to lock the sled in place when the insert is placed into the base unit. The interaction between the actuator and the cam can impart relatively large motions to the sled while the interaction between the rib and slot provides relatively fine final positioning of the sled and device connector as the insert is snapped into its installed position in the base unit.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an illustrative media player docking environment in which a personal media player is coupled to a personal computer using a dock;
FIGS. 2A and 2B show several illustrative personal media players that vary by size, capabilities, and the location of the docking connector;
FIG. 3 shows an illustrative adaptive docking arrangement in which a device-specific dock insert is removably engagable with an adaptive dock;
FIGS. 4A , 4 B, and 4 C are respective front, side and top views of an illustrative laterally moveable sled that is housed in the dock and arranged to interface with the device-specific dock insert shown in FIG. 3 ;
FIG. 5A is an isometric view of the sled shown in FIGS. 4A , 4 B and 4 C;
FIG. 5B shows the sled as that is fixedly coupled to a printed circuit board assembly which includes a device connector;
FIG. 6A is an isometric view of the rear and top surfaces of the dock base unit which shows an opening for a cam that interfaces with actuators on the device-specific dock insert and a laterally extending slot through which the device connector is exposable;
FIG. 6B is an isometric view of the dock base unit as assembled with its internal components including the sled, printed circuit board assembly, and device connector;
FIGS. 7A , 7 B, and 7 C are respective top, front, and side views of a first illustrative device-specific dock insert;
FIGS. 8A , 8 B, and 8 C are respective top, front, and side views of a second illustrative device-specific dock insert;
FIGS. 9A , 9 B and 9 C show a sequence of views of the dock insert actuators in operative engagement with the cam on the sled, where such engagement may impart lateral motion to the sled; and
FIG. 9D is a side view of downwardly extending ribs as engaged in rib-receiving slots that are adjacently disposed to the device connector on the printed circuit board assembly.
Like reference numerals indicate like elements in the drawings.
DETAILED DESCRIPTION
FIG. 1 shows an illustrative media player docking environment 100 in which a personal media player 105 is coupled to a personal computer (“PC”) 110 using a dock 116 . Docking the personal media player 105 to the PC 110 typically enables them to operatively communicate, for example, to synchronize data and share media content. The dock 116 also typically provides a charging functionality to charge an onboard battery in the personal media player 105 when it is docked. In some scenarios, the PC 110 is used to acquire and/or store media content such as music, video, software, games, etc., from local or online sources that can then be loaded onto the personal media player 105 using the dock 116 . In other scenarios, the dock 116 is used to enable the personal media player 105 to be used as a data or playback source to render its content to the PC 110 or another device (not shown) such as a television or stereo system. Dock 116 is generally configured to position the docked personal media player 105 so that its display 122 may be readily seen and the controls 125 conveniently accessed.
The personal media player 105 may take any of a variety of common forms, for example, MP3 player (Moving Pictures Expert Group, MPEG-1, audio layer 3), portable multimedia player, pocket PC, smart phone, mobile phone, handheld game device, personal digital assistant, or other type of electronic device that can store and/or render media content such as audio, video, or multimedia. And while a PC 110 is shown in the illustrative environment 100 in FIG. 1 , other devices may be coupled to the personal media player in some implementations of the present adaptive dock including a television, audio and stereo system, game console, multimedia center, set-top box, and the like.
Dock 116 is coupled to the PC 110 , in this illustrative example, using a cable 130 that typically contains a multiplicity of conductors for carrying data, power, and control signals, for example. Cable 130 is typically coupled to an input/output (“I/O”) port on the PC 110 such as a USB (Universal Serial Bus) or IEEE-1394 (Institute of Electrical and Electronics Engineers) port (not shown).
A pair of mating connectors are utilized to implement the connection between the personal media player 105 and the dock 116 as shown in FIGS. 2A and 2B . One of the connectors in the pair, commonly referred to as an accessory or output connector, is disposed in the personal media player, as indicated by reference numeral 202 . A mating device connector 207 is disposed in the dock 116 . The connectors 202 and 207 are typically configured and respectively oriented so that they are operatively coupled when a user inserts the personal media player 105 into the dock 116 through an opening into a device receiving space 212 . As shown in FIGS. 2A and 2B , the device connector 207 is located within the device receiving space 212 .
As a result of design and/or packaging factors, the accessory connector 202 may not necessarily be positioned about the centerline of the personal media player 105 . As shown in FIG. 2A , the personal media player 105 is arranged in small form factor where the accessory connector 202 is offset to the left of the centerline. The device connector 207 is correspondingly offset within the device receiving space 212 which is configured in dimension to be relatively close fitting to the personal media player 105 to support it in the desired orientation while docked in dock 116 .
As shown in FIG. 2B , the personal media player 105 is configured as a large form factor as compared with that shown in FIG. 2A . In this illustrative example, the large form factor personal media player 105 uses an accessory connector 202 that is approximately centered about its centerline. The device connector 207 is, accordingly, centered within the device receiving space 212 which is configured to be larger than that shown in FIG. 2A to accommodate the large form factor personal media player 105 . It is emphasized that the connector configurations shown in FIGS. 2A and 2B are merely illustrative, and the particular form factors of the personal media player 105 and device receiving space 212 within dock 116 , as well as the amount of connector offset may vary according to the requirements of a specific implementation.
In order to accommodate a variety of form factors and accessory device configurations, dock 116 is arranged to be adaptive by a base unit 303 , as shown in FIG. 3 , which interfaces with one of several device-specific dock inserts 306 . The device-specific dock insert 306 is removably couplable to the base unit 303 and includes a device receiving space 212 that is configured to fit a particular device form factor. The device receiving space 212 is further arranged to include an opening 310 through which the device connector 207 may pass. Opening 310 is located within the device receiving space 212 to accommodate the position of the accessory connector 202 (i.e., whether centered or offset from the centerline). In this illustrative example, the device-specific dock insert 306 is removably coupled to the base unit 303 using tabs 316 which mateably engage with corresponding recesses in the base unit (not shown) using a snap fit engagement.
The device-specific dock insert 306 further includes actuators 320 that are configured to project substantially downward from the bottom surface of the insert. Actuators 320 are configured to slidably interact with a cam that is provided by a laterally moveable sled, as described below, in order to impart lateral motion to the device connector so as to align it with the opening 310 . Accordingly, the lateral location of the actuators 320 on the device-specific dock insert 306 will typically vary according to the lateral location of the opening 310 within the device receiving space 212 .
FIGS. 4A , 4 B, and 4 C are respective front, side and top views of an illustrative laterally moveable sled 404 that is housed in the dock base unit 303 and arranged to interface with actuators 320 of the device-specific dock insert 306 shown in FIG. 3 . FIG. 5A is an isometric view of the sled 404 .
The sled 404 comprises a horizontally planar base 412 from which a planar cam support 417 projects substantially orthogonally therefrom. As shown, base 412 includes slots 419 that capture posts 422 that are incorporated into the base unit 303 . The location and orientation of the slots 419 allow lateral motion of the sled 404 with respect to the base unit 303 through slideable motion over the posts 422 (as indicated by the arrows in FIGS. 4A and 4C ), but back and forth motion of the sled 404 is constrained. In alternative implementations other motion-constraining features may be utilized such as tracks or guides.
Projecting outward from the cam support 417 is a substantially triangular shaped cam 424 that is oriented, when the sled 404 is installed in the base unit 303 , to slidably engage with one or both of the actuators 320 on the device-specific dock insert 306 when the insert 306 is snapped into the base unit 303 .
FIG. 5B shows the sled 404 as fixedly coupled to a printed circuit board assembly (“PCBA”) 506 which is operatively coupled to the device connector 207 . PCBA 506 is configured with circuitry (not shown) to implement various electronic features and functionalities provided by the dock 116 ( FIG. 1 ). An I/O facility of the PCBA 506 (not shown) provides functional connectivity to the PC 110 via cable 130 , as shown in FIG. 1 . It is emphasized that the PCBA 506 is merely illustrative, and variations in PCBA layout, size, and orientation may vary from that shown in FIG. 5B as may be required by a specific requirement of an application of the present adaptive docking.
FIG. 5B also shows a set of slots 513 that are located on either side of the device connector 207 in a connector support member 525 which includes beveled surfaces that function to guide mating ribs on the device-specific dock insert 306 into the slots 513 . The mating ribs project downwards from the bottom surface of the device-specific dock insert 306 . The ribs are shown in FIGS. 7A-7C and FIGS. 8A-8C below and described in the accompanying text.
FIG. 6A is an isometric view of the rear and top surfaces of the dock base unit which shows a laterally extending opening 602 for the cam 424 that interfaces with actuators on the device-specific dock insert and a laterally extending slot 606 through which the device connector 207 is exposable. FIG. 6B is an isometric view of the dock base unit 303 as assembled with its internal components including the sled 404 , PCBA 506 , and device connector 207 . As shown, the cam 424 is accessible to the actuators 320 ( FIG. 3 ) on the device-specific dock insert 306 through the opening 602 when as the adapter is seated onto the base unit 303 .
FIGS. 7A , 7 B, and 7 C are respective top, front, and side views of a first illustrative device-specific dock insert 706 . In a similar manner to the device-specific dock insert 306 shown in FIG. 3 , insert 706 includes device receiving space 712 through which an opening 710 is positioned in accordance with the location of the accessory connector 202 ( FIG. 2A ) in the personal media player 105 . In this illustrative example, the device receiving space 712 and opening 710 are configured to interface with the small form factor personal media player shown in FIG. 2A in which the accessory connector 202 is offset from the centerline of the player. Actuators 720 are thus offset with respect to the centerline of the insert to be able to move the sled 404 through slideable engagement with the cam 424 ( FIGS. 4A-4C ) into a position which facilitates mateable coupling between the accessory connector 202 in the personal media device 105 ( FIG. 1 ) and the device connector 207 . Tabs 716 are provided which mateably engage with corresponding recesses in the base unit 303 ( FIG. 3 ) using a snap fit engagement.
A pair of ribs 723 are positioned on either side of opening 710 and project downward from the bottom of the device receiving space 712 . Ribs 723 are utilized to provide the fine positioning of the sled 404 with respect to the device-specific dock insert 706 via removal engagement with the corresponding slots 513 adjacent to the connector 207 as shown in FIG. 5B as the insert 706 is snap fit into final position in the base unit 303 . Once the ribs 723 are so engaged, the sled 404 is locked in a fixed position.
FIGS. 8A , 8 B, and 8 C are respective top, front, and side views of a second illustrative device-specific dock insert 806 in which the device receiving space 812 and opening 810 are configured to interface with the large form factor personal media player shown in FIG. 2B in which the accessory connector 202 is substantially centered with the centerline of the player. Actuators 820 are accordingly spaced symmetrically about the centerline of the device-specific dock insert 806 . Tabs 816 and ribs 823 are arranged and perform similar functions as those elements shown in FIGS. 7B and 7C .
FIGS. 9A , 9 B and 9 C show a sequence of views of the dock insert actuators (such as actuators 820 shown in FIGS. 8B and 8C ) in operative engagement with the cam 424 on the sled 404 which may impart lateral motion to the sled 404 . Note that some elements including the dock insert opening, PCBA, device connector, and base unit are not shown for clarity. FIG. 9A shows the actuators 820 prior to be slidably engaged with the cam 424 . When a user begins to place the device-specific dock insert 806 into the base unit, as shown in FIG. 9B , the downward motion of the insert forces one of the actuators 820 to bear against the cam 424 and push the sled 404 laterally as the actuator 820 follows the cam's profile. As shown in FIG. 9C , the lateral motion continues until the ribs 823 touch down upon the supporting portion of the connector 207 which guides the ribs into the slots 513 as shown in FIG. 5B and FIG. 9C . The interaction between the actuator 820 and cam 424 can thus impart relatively large motions to the sled 404 while the interaction between the ribs 823 and slots 513 provide relatively fine final positioning as the device-specific dock insert 806 is snapped into its installed position in the base unit.
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.
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An adaptive dock for use with media players of varying form factors is provided by an arrangement in which a device connector is located on a moveable sled that is located in the dock's base unit. A device-specific dock insert is arranged for removable engagement with the base unit to allow the base to have applicability to different media players by using the appropriately configured insert. The insert includes a device receiving space having an opening that is located to expose the media player's accessory connector. The insert further includes an actuator that slidably engages with a cam that is located on the sled to impart a lateral motion to the sled as the insert is placed downward into the dock's base unit so as to align the device connector on the sled with the opening in the insert.
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FIELD OF THE INVENTION
[0001] The present invention relates to telecommunications in general, and, more particularly, to accessing private branch exchange features from a remote telecommunications terminal.
BACKGROUND OF THE INVENTION
[0002] FIG. 1 depicts a schematic diagram of telecommunications system 100 in the prior art. Telecommunications system 100 comprises affiliated off-premises telecommunications terminals 101 - 1 through 103 -N, wherein N is a positive integer; unaffiliated off-premises telecommunications terminal 102 ; affiliated on-premises telecommunications terminals 103 - 1 through 103 -N; private branch exchange telephone system 104 ; and telecommunications network 105 , interconnected as shown.
[0003] The terms “affiliated” and “unaffiliated,” as they apply to the off-premises terminals, refer to whether an off-premises terminal is affiliated with an on-premises terminal (i.e., a terminal served by private branch exchange 104 ). The relationship of an on-premises terminal (e.g., terminal 103 - 1 , etc.) with an affiliated off-premises terminal (e.g., terminal 101 - 1 , etc.) is described below and with respect to FIG. 2 , with regards to extending a received call to one or both terminals.
[0004] Private branch exchange 104 is capable of switching incoming calls from telecommunications network 105 (e.g., the Public Switched Telephone Network, etc.) via one or more transmission lines to any of on-premises terminals 103 - 1 through 103 -N. Private branch exchange 104 is also capable of handling outgoing calls from any of on-premises terminals 103 - 1 through 103 -N to telecommunications network 105 via one or more transmission lines that connect private branch exchange 104 to telecommunications network 105 .
[0005] Private branch exchange 104 is capable of also extending an incoming call to a telephone number in telecommunications network 105 , in addition to switching the incoming call to on-premises terminal 103 - n , wherein n has a value between 1 and N, inclusive. The telephone number that is extended-to in telecommunications network 105 corresponds to an affiliated terminal 101 - n.
[0006] In addition, private branch exchange 104 is capable of providing telecommunications features that enable the forwarding of calls, the transferring of calls, conferencing, etc.
[0007] FIG. 1 also depicts the address spaces that are relevant to telecommunications network 100 in the prior art. The term “address space” refers to an addressable region of telephone service. Address space 111 represents the addressable region served by telecommunications network 105 . Address space 112 represents the addressable region served by private branch exchange 104 .
[0008] Private branch exchange 104 exists in both address space 111 and address space 112 , and acts as a “bridge” between the two address spaces. When a calling party places a call to someone served by private branch exchange 104 , the calling party uses a dialing sequence that includes a telephone number that belongs to telecommunications network 105 and residing in address space 111 . As part of the dialing sequence, the calling party also uses an extension number that allows access to one of the on-premises telecommunications terminals that reside within address space 112 .
[0009] Thus an on-premises telephone number is one that exists within the address space of the private branch exchange, and an off-premises telephone number is one that exists within the address space of the Public Switched Telephone Network.
[0010] FIG. 2 depicts a flowchart of the tasks that are relevant to processing an incoming call in the prior art. To accomplish tasks 201 through 203 , private branch exchange 104 maintains a table that correlates telecommunications network number to private branch exchange extension. Table 1 depicts an illustrative table that correlates telecommunications network number to private branch exchange extension.
TABLE 1 Extension-to-Number Database Private Branch Telecommunications Exchange Extension Network Number 732-555-0102, x11 201-555-1236 732-555-0102, x12 908-555-3381 . . . . . . 732-555-0102, x99 212-555-6784
[0011] At task 201 , private branch exchange 104 receives a call from telecommunications network 105 , where the call is originated by unaffiliated telecommunications terminal 102 .
[0012] At task 202 , private branch exchange 104 extends the call to a first telephone number. The first telephone number exists in the address space of the private branch exchange, namely address space 112 , and can be associated with one of on-premises terminals 103 - 1 through 103 -N. The first telephone number is represented as the private branch exchange extension in Table 1.
[0013] At task 203 , private branch exchange 104 also extends the call to a second telephone number. The second telephone number exists in the address space of telecommunications network 105 , namely address space 111 , and can be associated with an affiliated, off-premises terminal such as affiliated telecommunications terminal 101 - n.
[0014] Referring to the example in Table 1, the call, placed to 732-555-0102, extension 11 (i.e., shown in the first row), is connected to private branch exchange extension 11 and is also forwarded to telecommunications network number 201-555-1236.
SUMMARY OF THE INVENTION
[0015] The present invention enables a user to access a telecommunications feature of a private branch exchange (e.g., call forwarding, automatic callback, etc.) by calling, from an affiliated off-premises telecommunications terminal, a telephone number that routes to the private branch exchange and that corresponds to the feature. In accordance with the illustrative embodiment, some telephone numbers assigned to the private branch exchange, referred to as feature name extensions, correspond to telecommunications features provided by the private branch exchange, as above, while other telephone numbers assigned to the private branch exchange allow access to on-premises telecommunications terminals.
[0016] In the illustrative embodiment of the present invention, the private branch exchange maintains a table that couples the telephone number, including the extension, of each on-premises telecommunications terminal with the telephone number of a corresponding off-premises telecommunications terminal (e.g., an employee's office phone number with his or her cell phone number, etc.) A particular, off-premises telecommunications terminal is permitted to access telecommunications features via feature name extensions only when the terminal is affiliated (i.e., when the terminal's telephone number is coupled with an on-premises telephone number). When a feature name extension is called by an affiliated off-premises terminal, the telecommunications feature that corresponds to the feature name extension is activated or deactivated, as appropriate. For example, the feature name extension “555-1111” might activate automatic callback, and the feature name extension “555-2222” might deactivate automatic callback.
[0017] Telecommunications features that are activated or deactivated can apply to:
the off-premises terminal that calls the corresponding feature name extension; a current call that involves the off-premises terminal; a future call that is directed to the off-premises terminal; a future call that is placed by the off-premises terminal; the corresponding on-premises terminal (i.e., the on-premises terminal whose telephone number is coupled with the telephone number of the off-premises terminal); a current call that involves the corresponding on-premises terminal; a future call that is directed to the corresponding on-premises terminal; or a future call that is placed by the corresponding on-premises terminal.
Moreover, some telecommunications features might be “global” in nature and apply to all on-premises terminals, all affiliated off-premises terminals, or both.
[0026] The illustrative embodiment of the present invention also enables a user to access a telecommunications feature of a private branch exchange by specifying a uniform resource identifier (URI) via a peer-to-peer protocol such as the Session Initiation Protocol (SIP). A user sends a session-initiation message from his or her SIP-capable terminal to a uniform resource identifier that specifies (i) a telecommunications feature of the private branch exchange and, optionally, (ii) supplemental information such as an on-premises telephone number extension, a telephone number to which calls are to be forwarded, etc. The private branch exchange, upon receiving the session-initiation message, activates or deactivates the specified feature, as appropriate, provided that the sender of the message and the specified feature are recognized as legitimate by the private branch exchange.
[0027] The illustrative embodiment comprises: setting a flag that uniquely corresponds to the combination of a first telephone number and a second telephone number when a call attempt to the second telephone number is received from a first telecommunications terminal whose telephone number is coupled with the first telephone number.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 depicts a schematic diagram of telecommunications system 100 in the prior art.
[0029] FIG. 2 depicts a flowchart of tasks relevant to processing an incoming call in the prior art.
[0030] FIG. 3 depicts a schematic diagram of telecommunications system 300 , in accordance with the illustrative embodiment of the present invention.
[0031] FIG. 4 depicts a schematic diagram of private branch exchange 304 , as shown in FIG. 3 , in accordance with the illustrative embodiment of the present invention.
[0032] FIG. 5 depicts a block diagram of how user information is stored and organized in memory 403 of private branch exchange 304 , in accordance with the illustrative embodiment of the present invention.
[0033] FIG. 6 depicts a block diagram of how information is stored and organized in mapping 501 of memory 403 , in accordance with the illustrative embodiment of the present invention.
[0034] FIG. 7 depicts a block diagram of how information is stored and organized in mapping 502 of memory 403 , in accordance with the illustrative embodiment of the present invention.
[0035] FIG. 8 depicts a block diagram of how information is stored and organized in mapping 503 of memory 403 , in accordance with the illustrative embodiment of the present invention.
[0036] FIG. 9 depicts a flowchart of the salient tasks associated with activating a telecommunications feature via a feature name extension, in accordance with the illustrative embodiment of the present invention.
[0037] FIG. 10 depicts a flowchart of the salient tasks associated with activating a telecommunications feature via a feature name uniform resource identifier, in accordance with the illustrative embodiment of the present invention.
[0038] FIG. 11 depicts a detailed flowchart for task 904 , as depicted in FIG. 9 , in accordance with the illustrative embodiment of the present invention.
[0039] FIG. 12 depicts a flowchart of the salient tasks associated with an off-premises telecommunications terminal making a call in a spoofed manner, in accordance with the illustrative embodiment of the present invention.
[0040] FIG. 13 depicts a flowchart of the salient tasks associated with a spoofed “transfer on hangup” initiated by an off-premises telecommunications terminal, in accordance with the illustrative embodiment of the present invention.
[0041] FIG. 14 depicts a flowchart of the salient tasks associated with a spoofed “conference on answer” initiated by an off-premises telecommunications terminal, in accordance with the illustrative embodiment of the present invention, in accordance with the illustrative embodiment of the present invention.
[0042] FIG. 15 depicts a flowchart of the salient tasks associated with an off-premises telecommunications terminal setting one or more call-handling permissions for its corresponding on-premises telecommunications terminal, in accordance with the illustrative embodiment of the present invention.
[0043] FIG. 16 depicts a flowchart of the salient tasks associated with an on-premises telecommunications terminal setting one or more call-handling permissions for its corresponding off-premises telecommunications terminal, in accordance with the illustrative embodiment of the present invention.
[0044] FIG. 17 depicts a flowchart of the salient tasks associated with granting an off-premises telecommunications terminal access to a call appearance of a corresponding on-premises telephone number, in accordance with the illustrative embodiment of the present invention.
[0045] FIG. 18 depicts a flowchart of the salient tasks associated with handling a call attempt to an on-premises telephone number, in accordance with the illustrative embodiment of the present invention.
DETAILED DESCRIPTION
[0046] The term that appears below is given the following definition for use in this Description and the appended Claims.
[0047] For the purposes of the specification and claims, the term “call appearance” is defined as a telephone line extending between a private branch exchange and a telecommunications terminal whose extension is served by the private branch exchange. There might be more than one call appearance that is associated with an extension.
[0048] FIG. 3 depicts a schematic diagram of telecommunications system 300 , in accordance with the illustrative embodiment of the present invention. Telecommunications system 300 comprises affiliated off-premises telecommunications terminals 301 - 1 through 301 -N, wherein N is a positive integer, unaffiliated off-premises telecommunications terminal 302 ; on-premises telecommunications terminals 303 - 1 through 303 -N; private branch exchange telephone system 304 ; and telecommunications network 305 , interconnected as shown.
[0049] Affiliated telecommunications terminal 301 - n , wherein n is a positive integer between 1 and N, inclusive, is an off-premises telecommunications terminal whose telephone number is coupled with an on-premises telephone number of private branch exchange 304 . Affiliated telecommunications terminal 301 - n is capable of transmitting, via telecommunications network 105 , signaling information that can be used to control a call. For example, terminal 301 - n can be a cellular terminal that is capable of transmitting the signaling information via a cellular network that constitutes network 105 . As another example, terminal 301 - n can be a type of telecommunications terminal other than a cell phone (e.g., wireline analog telephone, Integrated Services Digital Network [ISDN] terminal, Internet Protocol terminal, etc.) that is capable of transmitting the signaling information via one or more compatible networks that constitute network 105 . Affiliated telecommunications terminal 301 - n interoperates with the rest of telecommunications system 300 to exchange information with other telecommunications terminals (e.g., terminal 302 , terminal 303 - n , etc.), as part of a call.
[0050] It will be clear to those skilled in the art how make and use affiliated telecommunications terminal 301 - n.
[0051] Unaffiliated telecommunications terminal 302 is a telecommunications terminal that is not affiliated with private branch exchange 304 . Terminal 302 is a type of telecommunications terminal (e.g., wireline analog telephone, cellular terminal, Integrated Services Digital Network [ISDN] terminal, Internet Protocol terminal, etc.) that interoperates with the rest of telecommunications system 300 to exchange information with other telecommunications terminals (e.g., affiliated telecommunications terminal 301 - n , on-premises telecommunications terminal 303 - n , another unaffiliated terminal, etc.), as part of a call.
[0052] As will be appreciated by those skilled in the art, although only one unaffiliated terminal is depicted in FIG. 3 , additional unaffiliated terminals can be present in telecommunications system 300 . It will be clear to those skilled in the art how make and use unaffiliated telecommunications terminal 302 .
[0053] On-premises telecommunications terminal 303 - n , wherein n is a positive integer between 1 and N, inclusive, is a telecommunications terminal that is connected to private branch exchange 304 and whose telephone number is within the address space of private branch exchange 304 . In accordance with the illustrative embodiment of the present invention, on-premises telecommunications terminal 303 - n , is a deskset that is capable of transmitting, via private branch exchange 304 , signaling information that can be used to control a call. Terminal 303 - n interoperates with the rest of telecommunications system 300 to exchange information with other telecommunications terminals (e.g., affiliated telecommunications terminal 301 - n , unaffiliated terminal 302 , etc.), as part of a call.
[0054] It will be clear to those skilled in the art how make and use on-premises telecommunications terminal 303 - n.
[0055] Private branch exchange 304 provides telecommunications services to its associated users within a premises (e.g., office complex, etc.). Private branch exchange 304 is connected via communications paths called “lines,” to on-premises telecommunications terminals 303 - 1 through 303 -N, as is well-known in the art. In addition, private branch exchange 304 is connected via one or more communications paths, such as “trunks” as are known in the art, to telecommunications network 305 . Private branch exchange 304 's structure is described later and with respect to FIG. 4 .
[0056] Private branch exchange 304 provides telecommunications functions to off-premises telecommunications terminals 301 and on-premises terminals 303 consistent with the functionality described earlier and with respect to FIGS. 1 and 2 . In addition, private branch exchange 304 provides functionality described below and with respect to FIGS. 9 through 18 , in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art, after reading this specification, how to make and use private branch exchange 304 .
[0057] Telecommunications network 305 provides one or more transmission paths between (i) terminal 301 - n or 302 , and (ii) private branch exchange 304 , in well-known fashion. As is well-known in the art, network 305 typically comprises one or more networking elements such as switches, routers, hubs, etc. In some embodiments, network 305 comprises the Public Switched Telephone Network (PSTN). In some other embodiments, network 305 comprises one or more packet-switched networks. It will be clear to those skilled in the art how to make and use telecommunications network 305 .
[0058] The address spaces that are relevant to telecommunications network 300 are also depicted in FIG. 3 . The term “address space” refers to an addressable region of telephone service, as described earlier and with respect to FIG. 1 . Address space 311 represents the addressable region of telecommunications network 305 (e.g., the Public Switched Telephone Network, etc.). Address space 312 represents the addressable region of private branch exchange 304 .
[0059] Also depicted in FIG. 3 is an example of the routing of a call from affiliated telecommunications terminal 301 - 1 to unaffiliated terminal 302 via private branch exchange 304 , in accordance with the illustrative embodiment of the present invention. The user of terminal 301 - 1 dials a telephone number that is associated with private branch exchange 304 , in well-known fashion. Elements in network 305 set up the first leg of the call on call path 306 - 1 . Private branch exchange 304 detects the incoming call and, in accordance with the illustrative embodiment of the present invention, determines that the dialed telephone number actually corresponds to a feature for selecting an idle call appearance, instead of corresponding to a telecommunications terminal. As a result, private branch exchange 304 provides dial tone to terminal 301 - 1 's user, who then dials the telephone number of terminal 302 . Elements in network 305 set up the second leg of the call on call path 306 - 2 to terminal 302 . In accordance with the illustrative embodiment of the present invention, private branch exchange 304 provides, as calling party information to terminal 302 , an on-premises telephone number with which terminal 301 - 1 is associated.
[0060] FIG. 4 depicts private branch exchange 304 , in accordance with the illustrative embodiment of the present invention. Private branch exchange 304 comprises switch matrix 401 , processor 402 , and memory 403 , interconnected as shown.
[0061] Switch matrix 401 is a circuit that receives signals that convey call-related data and traffic from telecommunications network 305 , forwards the call-related data to processor 402 , extends the traffic to on-premises telecommunications terminals 303 - 1 through 303 -N, extends the traffic to off-premises telecommunications terminals 301 - 1 through 301 -N, and redirects the traffic to telecommunications network 305 . Switch matrix 401 also receives signals that convey call-related data and traffic from on-premises telecommunications terminals 303 - 1 through 303 -N, forwards the call-related data to processor 402 , and forwards the traffic to telecommunications network 305 . Switch matrix also receives commands from processor 402 . It will be clear to those skilled in the art how to make and use switch matrix 401 .
[0062] Processor 402 is a general-purpose processor that is capable of receiving call-related data from switch matrix 401 , of executing instructions stored in memory 403 , of reading data from and writing data into memory 403 , of executing the tasks described below and with respect to FIGS. 9 through 18 , and of transmitting commands to switch matrix 401 . In some alternative embodiments of the present invention, processor 402 might be a special-purpose processor. In either case, it will be clear to those skilled in the art, after reading this specification, how to make and use processor 402 .
[0063] Memory 403 stores data and executable instructions, as is well-known in the art, and might be any combination of random-access memory (RAM), flash memory, disk drive memory, etc. It will be clear to those skilled in the art how to make and use memory 403 .
[0064] FIG. 5 depicts a map of the salient contents of memory 403 , which comprises on-premises/off-premises terminal mapping 501 , telephone number/feature mapping 502 , uniform resource identifier/feature mapping 503 , application software 504 , and operating system 505 . As will be appreciated by those skilled in the art, the information that is stored in memory 403 can be organized differently than what is depicted in FIG. 5 .
[0065] Mapping 501 comprises one or more records of data, wherein each record describes a coupling of an off-premises telephone number (or other identifier) for terminal 301 - n with an on-premises telephone number (or other identifier) for terminal 303 - n , for n=1 through N, in accordance with the illustrative embodiment of the present invention. Private branch exchange 304 uses mapping 501 to determine which off-premises telephone number is associated with which on-premises telephone number for the purposes of (i) extending incoming calls to off-premises terminals and (ii) identifying one or more telecommunications terminals for which to activate or deactivate a feature. The content of mapping 501 is described in detail below and with respect to FIG. 6 .
[0066] Mappings 502 and 503 also comprise records of data. Mapping 502 comprises one or more records of data, wherein each record describes an association of a telephone number with a telecommunications feature, in accordance with the illustrative embodiment of the present invention. Mapping 503 comprises one or more records of data, wherein each record describes an association of a uniform resource identifier (URI) with a telecommunications feature, in accordance with the illustrative embodiment of the present invention. The content of mappings 502 and 503 is described below and with respect to FIGS. 7 and 8 , respectively.
[0067] In accordance with the illustrative embodiment of the present invention, private branch exchange 304 looks up a telephone number stored in mappings 502 or a uniform resource identifier stored in mapping 503 in order to determine a corresponding telecommunications features. As those who are skilled in the art will appreciate, private branch exchange 304 might only have to store records for a single type of identifier (i.e., telephone number or uniform resource identifier, but not both) if the features are identified solely by the single type of identifier.
[0068] Application software 504 is the software portion of the editing system described below and with respect to FIGS. 6 through 18 . Operating system 505 is an operating system, in well-known fashion, that performs input/output, file and memory management, and all of the other functions normally associated with operating systems. It will be clear to those skilled in the art how to make and use operating system 505 .
[0069] FIG. 6 depicts the contents of mapping 501 that comprises user records 600 - 1 through 600 -N. User record 600 - n , wherein n is between 1 and N, inclusive, comprises fields 601 - n , 602 - n , 603 - n , 604 - n , and 605 - n.
[0070] Field 601 - n stores data that identifies user U n who is associated with private branch exchange 304 . U n is also associated with terminals that are served by private branch exchange 304 , including affiliated telecommunications terminal 301 - n and on-premises telecommunications terminal 303 - n . U n can be identified by name, employee ID, or some other unique identifier, in well-known fashion.
[0071] Field 602 - n stores an off-premises identifier that identifies affiliated telecommunications terminal 301 - n . For some affiliated telecommunications terminals 301 , the off-premises identifier is a telephone number (e.g., “732-555-0689”, etc.). For some other affiliated telecommunications terminals 301 , the off-premises identifier can be a media endpoint address (e.g., “sip1111@example.com”, etc.). As those who are skilled in the art will appreciate, other types and formats of identifiers can be used to identify affiliated telecommunications terminal 301 - n.
[0072] Field 603 - n stores an on-premises telephone number (e.g., “732-555-0102, ×12”, etc.) that identifies on-premises telecommunications terminal 303 - n . As those who are skilled in the art will appreciate, other types and formats of identifiers can be used to identify on-premises telecommunications terminal 303 - n.
[0073] The identifiers in fields 602 - n and 603 - n for a given user U n are said to be coupled with each other. By coupling, for example, on-premises and off-premises telephone numbers in this fashion, private branch exchange 304 provides the user with the capability to have one administered station that supports features for both a desk set (i.e., on-premises telecommunications terminal 303 - n ) and an off-premises terminal (i.e., affiliated telecommunications terminal 301 - n ). For example, if user U n is currently on a call and using the off-premises terminal, U n can transfer the call to another party via the off-premises terminal.
[0074] Field 604 - n stores one or more call permissions that are currently in effect for the on-premises/off-premises terminal pair represented in user record 600 - n . The information in field 604 - n indicates (i) which telecommunications features terminals 301 - n and 303 - n are permitted to access; (ii) whether terminals 301 - n and 303 - n are permitted to participate in or control current and future calls; and (iii) whether terminal 301 - n is permitted to access a call appearance of terminal 303 - n . For example, a call permission of field 604 - n might exclude U n 's on-premises terminal from joining an in-progress call that was extended by private branch exchange 304 to U n 's off-premises terminal.
[0075] Field 605 - n stores one or more status flags for the on-premises/off-premises terminal pair represented in user record 600 - n . Each flag tracks the current status of a feature (or pair of related features) that is either “on” or “off.” Features of this nature are referred to in the specification as “Boolean status features.” An example of an “on/off” feature pair is “Off-PBX Call Enable/Disable,” in which the corresponding status flag in field 605 - n indicates that calls are either extendable or not extendable to affiliated telecommunications terminal 301 - n.
[0076] FIG. 7 depicts the contents of mapping 502 , which comprises feature name extension list 701 and feature identifier list 702 . Feature name extension list 701 , in turn, comprises feature name extension 701 - p , for p=1 through P, where P is a positive integer. Feature identifier list 702 , similarly, comprises feature identifier 702 - p , for p=1 through P.
[0077] Feature name extension 701 - p is a telephone number in the address space of the Public Switched Telephone Network that represents a particular feature. User U n of affiliated telecommunications terminal 301 - n can enter (i.e., “dial”) feature name extension 701 - p to invoke a feature from his or her off-premises terminal. From the vantage point of the Public Switched Telephone Network, feature name extension 701 - p appears to be a (normal) telephone number and, as such, is used by the equipment in telecommunications network 305 to route the “call” to private branch exchange 304 .
[0078] Feature identifier 702 - p identifies the feature that corresponds to feature name extension 701 - p . When private branch exchange 304 receives what it recognizes to be a feature name extension, private branch exchange 304 uses identifier 702 - p to determine the feature that corresponds to the received feature name extension. Private branch exchange 304 can then invoke the corresponding feature in well-known fashion.
[0079] Each feature name extension 701 - p is associated with a corresponding feature identifier 702 - p . For example, as depicted in FIG. 7 , if private branch exchange 304 receives the feature name extension “732-555-1202,” it determines from the contents of mapping 502 that the “Conference on answer” feature should be invoked.
[0080] The tasks that are associated with determining and invoking a particular feature that corresponds to a received feature name extension are described below and with respect to FIG. 9 .
[0081] FIG. 8 depicts the contents of mapping 503 that comprises list 801 of uniform resource identifier (URI) substring, and feature identifier list 802 . List 801 , in turn, comprises URI substring 801 - q , for q=1 through Q. The parameter Q is a positive integer that equals the number of features that are accessed via uniform resource identifiers. Feature identifier list 802 , in turn, comprises feature identifier 802 - q , for q=1 through Q.
[0082] URI substring 801 - q is a string of symbols that corresponds to a particular feature. As will be appreciated by those skilled in the art, in some embodiments the URI substring might be the endpoint address of the URI, while in some other embodiments the URI substring might be a parameter/value pairing of the URI, or some other portion of the URI. A SIP-capable terminal invokes a telecommunications feature by transmitting to private branch exchange 304 (or a proxy that operates on behalf of exchange 304 ), via telecommunications network 305 , a session-initiation request with a URI that contains the substring corresponding to the feature.
[0083] Feature identifier 802 - q identifies the feature that corresponds to feature URI substring 801 - q . When private branch exchange 304 receives a URI with a recognizable URI substring, private branch exchange 304 determines the telecommunications feature that corresponds to the substring and invokes the feature, in well-known fashion.
[0084] Each feature name URI 801 - q is associated with a corresponding feature identifier 802 - q . For example, as depicted in FIG. 8 , if private branch exchange 304 receives a URI with “exclusion-fnu” in the appropriate URI substring, private branch exchange 304 determines from mapping 503 that the corresponding telecommunications feature is “Exclusion” and invokes this feature.
[0085] The tasks associated with determining and invoking a particular feature when a session-initiation request is received at private branch exchange 304 are described below and with respect to FIG. 10 .
[0086] FIG. 9 depicts a flowchart of the salient tasks associated with activating a telecommunications feature via a feature name extension, in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 9 can be performed simultaneously or in a different order than that depicted.
[0087] At task 901 , private branch exchange 304 receives a call attempt to a telephone number R from a telecommunications terminal T, in well-known fashion. In some embodiments, terminal T is an off-premises telecommunications terminal, while in other embodiments terminal T can be an on-premises telecommunications terminal. Terminal T's telephone number is received as part of the call attempt (e.g., in a calling party number message field, etc.).
[0088] At task 902 , private branch exchange 304 checks whether telephone number R is a feature name extension in mapping 502 of memory 403 . If R is a feature name extension, execution continues at task 904 , otherwise the method of FIG. 9 terminates.
[0089] At task 903 , private branch exchange 304 checks whether telecommunications terminal T's telephone number is coupled with an on-premises telephone number in mapping 501 of memory 403 . If this is the case, execution continues at task 904 , otherwise the method of FIG. 9 terminates.
[0090] At task 904 , private branch exchange 304 activates (or deactivates, as appropriate) the feature that corresponds to telephone number R. As will be appreciated by those skilled in the art, a telecommunications feature could apply to:
terminal T only; a current call that involves terminal T; a future call that is directed to terminal T; a future call that is placed by terminal T; terminal T's counterpart terminal (i.e., the on-premises terminal that corresponds to terminal T when T is an off-premises terminal, and vice versa); a current call that involves terminal T's counterpart terminal; a future call that is directed to terminal T's counterpart terminal; a future call that is placed by terminal T's counterpart terminal; all on-premises terminals; or all affiliated off-premises terminals.
[0101] FIG. 10 depicts a flowchart of the salient tasks associated with activating a telecommunications feature via a feature name uniform resource identifier, in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 10 can be performed simultaneously or in a different order than that depicted.
[0102] At task 1001 , private branch exchange 304 receives a session-initiation request (e.g., as part of a SIP “INVITE” message, etc.) that specifies a uniform resource identifier (URI) that comprises a telecommunications feature to invoke, an endpoint address, etc. The sender of the request is the endpoint to which the feature will apply, in accordance with the illustrative embodiment of the present invention. As those who are skilled in the art will appreciate, however, the endpoint sending the request might be different than the endpoint to which the feature will apply. Furthermore, the sender of the request is an off-premises telecommunications terminal, in accordance with the illustrative embodiment. As those who are skilled in the art will appreciate, however, the sender can be an on-premises telecommunications terminal.
[0103] At task 1002 , private branch exchange 304 checks whether the feature that is specified in the received URI corresponds to a telecommunications feature in mapping 503 of memory 403 . If so, execution continues at task 1003 , otherwise the method of FIG. 10 terminates.
[0104] At task 1003 , in some embodiments, private branch exchange 304 checks whether the sender of the session-initiation request matches an identifier in one of the user ID fields 601 in mapping 501 of memory 403 . If so, execution continues at task 1004 , otherwise the method of FIG. 10 terminates.
[0105] At task 1004 , private branch exchange 304 activates (or deactivates, as appropriate) the telecommunications feature that was determined at task 1002 . As will be appreciated by those skilled in the art, some telecommunications features might apply to the user U n , (identified in field 601 - n ) who sent the session-initiation request, while some other telecommunications features might apply just to one of the on-premises and off-premises telephone numbers that correspond to user U n , or might even be “global” in nature and apply to all telephone numbers within the address space of private branch exchange 304 . After task 1004 , the method of FIG. 10 terminates.
[0106] For the remainder of the disclosure, which comprises flowcharts for private branch exchange 304 , the illustrative embodiment is described with respect to feature name extensions. It will be clear to those skilled in the art, after reading this specification, how to extend these flowcharts to handle feature name uniform resource identifiers in addition to feature name extensions, and how to make and use the illustrative embodiment based on the extended flowcharts.
[0107] FIG. 11 depicts a detailed flowchart for task 904 (or task 1004 ), in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 11 can be performed simultaneously or in a different order than that depicted.
[0108] At task 1101 , private branch exchange 304 checks whether the feature that corresponds to telephone number R (or the URI of the session-initiation request) is a Boolean status feature (e.g., Calling party number block on/off, etc.) or a command (e.g., Drop last added party, etc.). If the feature is a command, execution continues at task 1103 , otherwise execution continues at task 1102 .
[0109] At task 1102 , private branch exchange 304 sets or clears, as appropriate, the flag that corresponds to the combination of the feature and telecommunications terminal T (i.e., the flag in field 605 - n that uniquely corresponds to the feature, such that terminal T's telephone number corresponds to the identifier in field 603 - n ). After task 1102 , task 904 is completed and the method of FIG. 9 terminates.
[0110] At task 1103 , private branch exchange 304 checks whether the command in question has one or more arguments (e.g., a transfer to another telephone number, etc.) or no arguments (e.g., drop last added party, etc.). If there are no arguments, execution continues at task 1104 , otherwise execution continues at task 1105 .
[0111] In some alternative embodiments, one or more of the command arguments are provided as part of received message that specifies the telecommunications feature. For example, a session-initiation request message can provide the extra digits that some features require (e.g., a forward-to number required for call-forwarding activation, etc.).
[0112] At task 1104 , private branch exchange 304 executes the command, in well-known fashion. After task 1104 , task 904 is completed and the method of FIG. 9 terminates.
[0113] At task 1105 , private branch exchange 304 transmits to telecommunications terminal T a signal (e.g., a dial tone, an audio message, etc.) that indicates that private branch exchange 304 is ready to receive input from telecommunications terminal T (i.e., the argument(s) to the command).
[0114] At task 1106 , private branch exchange 304 receives input from telecommunications terminal T, in well-known fashion.
[0115] At task 1107 , private branch exchange 304 executes the command with the input received at task 1106 as argument(s) to the command, in well-known fashion. After task 1107 , task 904 is completed and the method of FIG. 9 terminates.
[0116] FIG. 12 depicts a flowchart of the salient tasks associated with a telecommunications terminal making a call in which the calling party number (or identifier) is spoofed, in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 12 can be performed simultaneously or in a different order than that depicted.
[0117] At task 1201 , private branch exchange 304 receives a telephone number R to call from an off-premises telecommunications terminal T. In accordance with the illustrative embodiment, private branch exchange 304 receives telephone number R in accordance with FIGS. 9 and 11 : off-premises telecommunications terminal T calls the feature name extension that corresponds to the feature for making a call through private branch exchange 304 (i.e., “Select idle call appearance”); private branch exchange 304 transmits a confirmation signal to terminal T; and terminal T transmits telephone number R to private branch exchange 304 , indicating that R is the telephone number that terminal T wishes to call. As will be appreciated by those skilled in the art, in some other embodiments private branch exchange 304 might receive telephone number R from terminal T by a method that does not involve calling a feature name extension (e.g., through a menu of an interactive voice response system, etc.), and it will be clear to those of ordinary skill in the art how to make and use such embodiments after reading this specification.
[0118] At task 1202 , private branch exchange 304 checks whether off-premises telecommunications terminal T's telephone number is coupled with an on-premises telephone number in mapping 501 of memory 403 . If this is the case, execution continues at task 1203 , otherwise the method of FIG. 12 terminates.
[0119] At task 1203 , private branch exchange 304 establishes a call between off-premises telecommunications terminal T and the telecommunications terminal V with telephone number R, in well-known fashion. In establishing the call, private branch exchange 304 transmits the on-premises telephone number identified at task 1202 as the calling party number. As will be appreciated by those skilled in the art, in some alternative embodiments another on-premises telephone number (e.g., a “main office number” associated with private branch exchange 304 , etc.) might be transmitted as the calling party number and provide the desired spoofing. After task 1203 , the method of FIG. 12 terminates.
[0120] FIG. 13 depicts a flowchart of the salient tasks associated with a spoofed “transfer on hangup” initiated by an off-premises telecommunications terminal, in accordance with the illustrative embodiment of the present invention. A “transfer on hangup” enables the user of a first telecommunications terminal to transfer an existing call to a second telecommunications terminal by calling the second terminal and then hanging up. In a spoofed transfer on hangup, the calling party number of the call to the second terminal is a spoofed telephone number instead of the telephone number of the first terminal. It will be clear to those skilled in the art which tasks depicted in FIG. 13 can be performed simultaneously or in a different order than that depicted.
[0121] At task 1301 , private branch exchange 304 receives a telephone number R from an off-premises telecommunications terminal T that is engaged in a first call made through private branch exchange 304 . A second telecommunications terminal, which is possibly another off-premises telecommunications terminal, is also engaged in the call. In accordance with the illustrative embodiment, private branch exchange 304 receives telephone number R in accordance with FIGS. 9 and 11 : off-premises telecommunications terminal T calls a feature name extension that corresponds to transferring a call; private branch exchange 304 transmits a confirmation signal to terminal T; and terminal T transmits telephone number R to private branch exchange 304 , indicating that R is the telephone number that terminal T wishes to transfer the first call to. As will be appreciated by those skilled in the art, in some other embodiments private branch exchange 304 might receive telephone number R from terminal T by a method that does not involve calling a feature name extension (e.g., through a menu of an interactive voice response system, etc.), and it will be clear to those of ordinary skill in the art how to make and use such embodiments after reading this specification.
[0122] At task 1302 , private branch exchange 304 checks whether off-premises telecommunications terminal T's telephone number is coupled with an on-premises telephone number in mapping 501 of memory 403 . If this is the case, execution continues at task 1303 , otherwise the method of FIG. 13 terminates.
[0123] At task 1303 , private branch exchange 304 establishes a second call between off-premises telecommunications terminal T and the telecommunications terminal V with telephone number R, in well-known fashion. In establishing the second call, private branch exchange 304 transmits the on-premises telephone number identified at task 1302 as the calling party number. As will be appreciated by those skilled in the art, in some other embodiments of the present invention another on-premises telephone number (e.g., a “main office number” associated with private branch exchange 304 , etc.) might be transmitted as the calling party number and provide desired spoofing.
[0124] At task 1304 , private branch exchange 304 receives a first disconnection signal that indicates that the first call has been disconnected (e.g., as a result of off-premises telecommunications terminal T “hanging up”, etc.), and a second disconnection signal that indicates that the second call has been disconnected (e.g., as a result of off-premises telecommunications terminal T hanging up, etc.).
[0125] At task 1305 , private branch exchange 304 checks whether the difference in times at which it receives the first and second disconnection signals is less than or equal to a threshold δ (e.g., one second, etc.). If this is the case, execution proceeds to task 1306 , otherwise, the method of FIG. 13 terminates. Task 1305 is based on a heuristic that it is typically reasonable to conclude that the two disconnection signals were generated as a result of terminal T hanging up when the two disconnection signals are received at times that are relatively close to each other.
[0126] At task 1306 , private branch exchange 304 transfers the first call to telecommunications terminal V, in well-known fashion. After task 1305 , the method of FIG. 13 terminates.
[0127] FIG. 14 depicts a flowchart of the salient tasks associated with a spoofed “conference on answer” initiated by an off-premises telecommunications terminal, in accordance with the illustrative embodiment of the present invention, in accordance with the illustrative embodiment of the present invention. When a “conference on answer” is initiated at a first telecommunications terminal that is already engaged in a first call, the first terminal calls a second telecommunications terminal, and once the call is “picked up” at the second terminal, the second terminal is bridged into (or equivalently, “conferenced into” or “added to”) the existing first call. In a spoofed conference on answer, the calling party number of the call to the second terminal is a spoofed telephone number instead of the telephone number of the first terminal. It will be clear to those skilled in the art which tasks depicted in FIG. 14 can be performed simultaneously or in a different order than that depicted.
[0128] At task 1401 , private branch exchange 304 receives a telephone number R from an off-premises telecommunications terminal T that is engaged in a first call made through private branch exchange 304 . A second telecommunications terminal, which is possibly another off-premises telecommunications terminal, is also engaged in the call. In accordance with the illustrative embodiment, private branch exchange 304 receives telephone number R in accordance with FIGS. 9 and 11 : off-premises telecommunications terminal T calls a feature name extension that corresponds to initiating a “conference on answer”; private branch exchange 304 transmits a confirmation signal to terminal T; and terminal T transmits telephone number R to private branch exchange 304 , indicating that R is the telephone number of the terminal to conference into the first call. As will be appreciated by those skilled in the art, in some other embodiments private branch exchange 304 might receive telephone number R from terminal T by a method that does not involve calling a feature name extension (e.g., through a menu of an interactive voice response system, etc.), and it will be clear to those of ordinary skill in the art how to make and use such embodiments after reading this specification.
[0129] At task 1402 , private branch exchange 304 checks whether off-premises telecommunications terminal T's telephone number is coupled with an on-premises telephone number in mapping 501 of memory 403 . If this is the case, execution continues at task 1403 , otherwise the method of FIG. 14 terminates.
[0130] At task 1403 , private branch exchange 304 establishes a second call between off-premises telecommunications terminal T and the telecommunications terminal V with telephone number R, in well-known fashion. In establishing the second call, private branch exchange 304 transmits the on-premises telephone number identified at task 1402 as the calling party number. As will be appreciated by those skilled in the art, in some other embodiments of the present invention another on-premises telephone number (e.g., a “main office number” associated with private branch exchange 304 , etc.) might be transmitted as the calling party number and provide desired spoofing.
[0131] At task 1404 , private branch exchange 304 receives telecommunications terminal V's answer signal to the second call and, in response, bridges terminal V into the first call, in well-known fashion. After task 1404 , the method of FIG. 14 terminates.
[0132] FIG. 15 depicts a flowchart of the salient tasks associated with an off-premises telecommunications terminal setting one or more call-handling permissions for its corresponding on-premises telecommunications terminal, in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 15 can be performed simultaneously or in a different order than that depicted.
[0133] At task 1501 , private branch exchange 304 receives information from an off-premises telecommunications terminal T for setting one or more call-handling permissions for the on-premises terminal with which T is coupled. In accordance with the illustrative embodiment, private branch exchange 304 receives this signal in accordance with FIGS. 9 and 11 : off-premises telecommunications terminal T calls a feature name extension that corresponds to setting call permissions; private branch exchange 304 transmits a confirmation signal to terminal T; and terminal T transmits digits to private branch exchange 304 that indicate the call-handling permissions. As will be appreciated by those skilled in the art, in some other embodiments private branch exchange 304 might receive call-handling permissions from terminal T by a method that does not involve calling a feature name extension (e.g., through a menu of an interactive voice response system, etc.), and it will be clear to those of ordinary skill in the art how to make and use such embodiments after reading this specification.
[0134] At task 1502 , private branch exchange 304 checks whether off-premises telecommunications terminal T's telephone number is coupled with an on-premises telephone number R in mapping 501 of memory 403 . If this is the case, execution continues at task 1503 , otherwise the method of FIG. 15 terminates.
[0135] At task 1503 , private branch exchange 304 sets call-handling permission(s) in mapping 501 of memory 403 for the on-premises telecommunications terminal with telephone number R, based on the information received at task 1501 , in well-known fashion. After task 1503 , the method of FIG. 15 terminates.
[0136] FIG. 16 depicts a flowchart of the salient tasks associated with an on-premises telecommunications terminal setting one or more call-handling permissions for its corresponding off-premises telecommunications terminal, in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 16 can be performed simultaneously or in a different order than that depicted.
[0137] At task 1601 , private branch exchange 304 receives information from an on-premises telecommunications terminal T for setting one or more call-handling permissions for the off-premises terminal with which T is coupled. In accordance with the illustrative embodiment, private branch exchange 304 receives this signal in accordance with FIGS. 9 and 11 : on-premises telecommunications terminal T calls a feature name extension that corresponds to setting call permission; private branch exchange 304 transmits a confirmation signal to terminal T; and terminal T transmits digits to private branch exchange 304 that indicate the call-handling permissions. As will be appreciated by those skilled in the art, in some other embodiments private branch exchange 304 might receive call-handling permissions from terminal T by a method that does not involve calling a feature name extension (e.g., through a menu of an interactive voice response system, etc.), and it will be clear to those of ordinary skill in the art how to make and use such embodiments after reading this specification.
[0138] At task 1602 , private branch exchange 304 checks whether on-premises telecommunications terminal T's telephone number is coupled with an off-premises telephone number R in mapping 501 of memory 403 . If this is the case, execution continues at task 1603 , otherwise the method of FIG. 16 terminates.
[0139] At task 1603 , private branch exchange 304 sets call-handling permission(s) in mapping 501 of memory 403 for the off-premises telecommunications terminal with telephone number R, based on the information received at task 1601 , in well-known fashion. After task 1603 , the method of FIG. 16 terminates.
[0140] FIG. 17 depicts a flowchart of the salient tasks associated with granting an off-premises telecommunications terminal access to a call appearance of a corresponding on-premises telephone number, in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 17 can be performed simultaneously or in a different order than that depicted.
[0141] At task 1701 , private branch exchange 304 receives a signal from an off-premises telecommunications terminal T that requests access to a call appearance of its corresponding on-premises telephone number. In accordance with the illustrative embodiment, private branch exchange 304 receives this signal when off-premises telecommunications terminal T calls a feature name extension that corresponds to accessing call appearances. As will be appreciated by those skilled in the art, in some other embodiments private branch exchange 304 might receive this signal from terminal T by a method that does not involve calling a feature name extension (e.g., through a menu of an interactive voice response system, etc.), and it will be clear to those of ordinary skill in the art how to make and use such embodiments after reading this specification.
[0142] Private branch exchange 304 receives from terminal T the type of call appearance to be accessed. The appearance that is requested by terminal T can be: (i) handling an active call, (ii) handling a held call, or (iii) idle. Active calls, calls on hold, and idle call appearances are well-known in the art.
[0143] At task 1702 , private branch exchange 304 checks whether off-premises telecommunications terminal T's telephone number is coupled with an on-premises telephone number R in mapping 501 of memory 403 . If this is the case, execution continues at task 1703 , otherwise the method of FIG. 17 terminates.
[0144] At task 1703 , private branch exchange 304 checks whether the call-handling permissions for terminal T and optionally, for one or more other terminals allow terminal T to gain access to the requested active, held, or idle call appearance of telephone number R, and if so, grants terminal T access in well-known fashion. After task 1703 , the method of FIG. 17 terminates.
[0145] If terminal T requested access to an appearance that is handling a held call and if there is more than one held call associated with telephone number R, private branch exchange 304 , in some embodiments, grants access to the held call appearance that is found first (e.g., on the lowest numbered call appearance, etc.).
[0146] FIG. 18 depicts a flowchart of the salient tasks associated with handling a call attempt to an on-premises telephone number, in accordance with the illustrative embodiment of the present invention.
[0147] At task 1801 , private branch exchange 304 receives a call attempt to a telephone number R of an on-premises telecommunications terminal T, in well-known fashion.
[0148] At task 1802 , private branch exchange 304 checks the value of a simultaneous ring flag in field 605 - n , where n is the index that corresponds to on-premises telephone number R. The flag indicates whether the corresponding off-premises terminal is to be sent and alerted of the call attempt, in addition to sending the call attempt to on-premises telecommunications terminal T. If the value of this flag is true, then execution continues at task 1804 , otherwise execution continues at task 1803 .
[0149] At task 1803 , private branch exchange 304 transmits the call attempt received at task 1801 to on-premises telephone number R only, in well-known fashion. After task 1803 , the method of FIG. 18 terminates.
[0150] At task 1804 , private branch exchange 304 transmits the call attempt received at task 1801 to both on-premises telephone number R and the off-premises telephone number R′ that is coupled with telephone number R, as indicated in mapping 501 of memory 403 . When the call attempt is transmitted to both R and R′, both telecommunications terminal T and the off-premises terminal whose telephone number is R′ will “ring” until one of these two terminals answers the call, in well-known fashion. After task 1804 , the method of FIG. 18 terminates.
[0151] At task 1805 , private branch exchange 304 transmits a ringback signal to telecommunications network 305 , in well-known fashion. The ringback is intended for the originator of the call. The ringback signal is independent of the status of the simultaneous ring flag, in accordance with the illustrative embodiment of the present invention. In some alternative embodiments, private branch exchange 304 provides the status of the flag to telecommunications network 305 , and the actual ringback to be provided to the originator of the call is determined by a telecommunications service provider.
[0152] As part of a strategy for providing ringback, it is typically advantageous for embodiments of the present invention to withhold the fact that a call is extended to an off-premises telecommunications terminal, assuming that the telecommunications service provider that handles the call offers advanced ringback services. For example, co-pending U.S. patent application Ser. No. 10/______ titled “Location-Based Ringbacks” and filed on Jan. 4, 2005 (under attorney docket: 630-084us), which is incorporated by reference, discloses a telecommunications system in which a call originator receives a ringback signal that is based on the location of the called terminal. In order to maintain the illusion that a user who answers the call off-premises is actually on-premises, therefore, private branch exchange 304 's extension of the call to the off-premises terminal should not be visible to the outside telecommunications network (i.e., network 305 ).
[0153] In some embodiments, private branch exchange 304 bases the ringback information on the location of on-premises telecommunications terminal T, such as when the terminal T is wireless and is roaming the area that is served by private branch exchange 304 .
[0154] It is to be understood that the above-described embodiments are merely illustrative of the present invention and that many variations of the above-described embodiments can be devised by those skilled in the art without departing from the scope of the invention. For example, in this Specification, numerous specific details are provided in order to provide a thorough description and understanding of the illustrative embodiment of the present invention. Those skilled in the art will recognize, however, that the invention can be practiced without one or more of those details, or with other methods, materials, components, etc.
[0155] Furthermore, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the illustrative embodiment. It is understood that the various embodiments shown in the Figures are illustrative, and are not necessarily drawn to scale. Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that a particular feature, structure, material, or characteristic described in connection with the embodiment(s) is included in at least one embodiment of the present invention, but not necessarily all embodiments. Consequently, the appearances of the phrase “in one embodiment,” “in an embodiment,” or “in some embodiments” in various places throughout the Specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments. It is therefore intended that such variations be included within the scope of the following claims and their equivalents.
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An apparatus and methods are disclosed that enable a user to access a telecommunications feature of a private branch exchange (e.g., call forwarding, automatic callback, etc.) by calling, from an off-premises telecommunications terminal, a telephone number that routes to the private branch exchange and that corresponds to the feature. When the telephone number is called, the corresponding telecommunications feature is activated or deactivated, as appropriate. For example, calling “555-1111” from might activate automatic callback, and calling “555-2222” might deactivate automatic callback.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to drilling machine guidance systems and, more particularly, but not by way of limitation, it relates to an improved guidance system for use in horizontal drilling apparatus of the type used in mining operations.
2. Description of the Prior Art
There are numerous prior art guidance systems for use with drilling apparatus, both horizontal drilling machines and vertical or well drilling apparatus. U.S. Pat. No. 3,362,750 discloses a mining apparatus having programmed cutting direction and attitude controls, and this teaching utilizes a comparator for sensing a departure of the cutting machine from its programmed direction thereafter to correct the deviations. The system utilizes a plurality of pendulums and related comparator circuitry for sensing program deviations. U.S. Pat. No. 3,326,008 relates to an electrical gopher which is utilized to bore horizontal cable holes. This device utilizes a plurality of synchro motors to maintain its guidance direction. Still other forms of circuitry are utilized in the prior art, especially that art which is related to position keeping within vertical boreholes and well drilling apparatus; however, none of the prior art approaches are similar to the present circuit apparatus nor do they offer the attendant functions and advantages for operation of a push drill remotely guided through a mineral stratum.
SUMMARY OF THE INVENTION
The present invention contemplates a remote control system for a push drill of the type used for drilling relatively long distances through a mineral stratum. In a more limited aspect, the invention consists of an instrument package which is integrally connected into the push drill string for control communication back to an operator position. The system utilizes accelerometer sensing to determine pitch and roll of the drill instrument while gamma ray count is utilized to determine vertical positioning of the push drill relative to overlying and underlying rock formations, e.g., shale formations adjacent coal seams. Control signals are then processed in the instrument package for transmission back along a control cable to the operator position, whereupon output indication enables the operator to hydraulically control the push drill to accomplish attitude correction during progression through the mineral stratum.
Therefore, it is an object of the present invention to provide remote control apparatus for guiding a mining push drill from an operating position that may be a great distance therefrom.
It is also an object of the present invention to provide an electronic guidance system for a push drill that is remotely guided by an operator using electrical signal indications returned to the mineral stratum face by a long electrical cable extending from the hydraulically controlled push drill.
It is yet another object of the invention to provide a system for guidance of a push drill through a coal seam utilizing the natural radioactivity of the surrounding shale deposits or strata.
Finally, it is an object of the invention to provide an improved remote control instrument package for integral inclusion into the push drill string of operative elements.
Other objects and advantages of the invention will be evident from the following detailed description when read in conjunction with the accompanying drawings which illustrate the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view in side elevation of the push drill assembly as it extends from an operating position;
FIG. 2 is a block diagram illustrating the operative association of elements;
FIG. 3 is a schematic diagram of the operator control unit and interconnections; and
FIG. 4 is a schematic diagram of the instrument package of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a push drill assembly 10, as constructed in accordance with the present invention to include control instruments, as interconnected via control line 12 to an operating position 14. The push drill unit 10 includes a retraction hold unit 16, as rigidly connected via drill stem 18 to a hold unit 20 which, again, is connected by drill stem 18 into a drill assembly 22 having a forward output shaft 24 and drill head 26. The push drill assembly 10 is the particular subject matter of U.S. Pat. No. 3,888,319 in the name of Bourne et al. as issued on June 10, 1975, and particulars of that structure are fully brought out in that disclosure.
The push drill assembly 10 is a self-propelling drill unit capable of directional drilling control under proper instrumentation. The drill unit 22 includes a roll control unit 28, drill motor 30 and deflection unit 32, and the control instrumentation package may be carried as indicated by instruments 34. The push drill assembly 10 is connected back to the operating position 14 by means of hydraulic hoses 36 and 38, and an electrical cable 40. Hydraulic hose 36 provides drive pressure to drill motor 30 while hydraulic hose 38, actually three hoses in number, provide control actuation to the hold and deflection units.
As shown in FIG. 2, the operating position 14 includes a battery pack and charging circuit 44 connected through an operator control unit 46 and remote cable 40 to instruments 34. The battery pack and charging circuit 44 is a conventional form of circuit as energized by A-C source 42 to utilize full wave rectifiers and respective EVEREADY rechargeable alkaline cells, Type No. 565, to provide continual power supply output. A power output of positive 18 volts, common and negative 18 volts is supplied via three conductors to the operator control unit 46. The A-C power source 42, is used to charge the battery pack at the surface of a mine, but it is not used during guidance operations.
Referring to FIG. 3, the operator control unit 46 receives power supplied at a connector 48 via leads 50, 52 and common lead 54, the power leads also being connected directly through an eight pin connector 56 for connection to push drill supply cable 40, as will be described. The negative 18 volt lead 52 is connected to ZERO ADJUST potentiometers 58 and 60, pitch and roll respectively, which return via respective resistors 62 and 64 to the positive 18 volt lead 50. The center tap of PITCH potentiometer 58 is connected via a conductor 66 through connector 56 and cable 40, and the center tap of ROLL potentiometer 60 is connected via conductor 68 to connector 56. Operator indication of RATE, PITCH and ROLL appears on meters 70, 72 and 74, respectively. Meter 70, 15ma D-C, connects through a gain potentiometer 76 and lead 78 to connector 56; in like manner, meters 72 and 74 (each 10ma-0-10ma) connect through gain potentiometers 80 and 82 and respective leads 84 and 86 for connection at connector 56.
Output from connector 56 is then by drill control cable 40 to the instrument unit 34 within drill unit 22, as shown in FIG. 4. The control cable 40 may be on the order of 1000 to 2000 feet in length. Connector input from drill control cable 40 is applied at receptacle 88, as like conductors bear the same designators as were input at connector 56 (Fig. 3). The power leads 50, 52 and 54 are applied directly to a 12 volt regulator 90, a standard form of regulator circuit, which provides regulated voltage output, i.e., positive 12 volts at a terminal 92 and negative 12 volts at terminal 94. Common connection of 12 volt regulator 90 is indicated as ground in the circuit of FIG. 4.
Positive 12 volt output and common connection from 12 volt regulator 90 are also provided on respective leads 96 and 98 to a high voltage power supply 100 for energization, i.e., 1200 volts, via shielded lead 102 to a BICRON counter tube 104, a scintillation detector. The high voltage power supply 100 is a 100:1 step-up DC-DC transformer type, Model K-15, as is commercially available from Venus Scientific of Farmingdale, N.Y. The BICRON counter tube 104 is a commercially available gamma ray counter tube, Model 2M2P that is available from the Bicron Corporation of Newbury, Ohio. Gamma count output in the 2 volt range is then present on a lead 106 through a coupling capacitor 108 and resistor 110 to one input of an integrated circuit pre-amplifier 112, IC Type 715393. Output from amplifier 112 is taken at junction 114 via lead 116, and control feedback from junction 114 through resistor-capacitor network 118 is applied to the input 120. A diode 115 provides for removal of any negative voltage spikes.
The gamma count output on lead 116 is then applied to a threshold limiting circuit 122, an integrated circuit dual NOR gate, Type CD 4001. Input on lead 116 to NOR gate 124 is latched to condition by NOR gate 126 with output present at junction 128 only when exceeding the bias present at junction 129. The output signal is then applied through resistor 130 to an input 132 of an integrator 134, an integrated circuit operational amplifier, Type MC 1741. Integration of output at junction 136 is effected by feedback through a capacitor-resistor timing network 138 to input 132. The integrated output signal is applied on lead 140 to a resistor network consisting of resistor 142 in series with a calibration potentiometer 144 and a common connected resistor 146.
Potentiometer 144 provides a gamma count calibration adjustment as signal is applied to an input 148 of a VA converter 150, a D-C amplifier, as biased by a voltage divider consisting of resistors 152, 154 and 156 to provide reference input at input 158. The converter 150 is once again the integrated circuit Type MC 1741 with output provided at a junction 160 and feedback through resistor-capacitance network 162 to the input 148. Output in the form of current indication from junction 160 is then present on lead 78 for return to receptacle 88 and control cable 40 to gain potentiometer 76 and RATE meter 70 of the operator control unit 46 (See FIG. 3). Thus, meter 70 will read the instantaneous rate of gamma count as sensed by BICRON counter tube 104.
The BICRON counter tube 104 is preferably mounted and shielded to view upward or downward from the instrument unit 34, depending upon initial installation and the particular type of drilling surveillance. It is now established that gamma radiation produced by the radioactive decay or uranium, thorium, potassium-40, as is naturally present in shale rock, is attenuated by coal in a logarithmic manner with a half-thickness value of approximately 7 inches. Also, shale formations are nearly always present above and below coal seams or strata and these strata will contain the necessary radioactive elements. Thus, sensing of this natural radioactivity provides a means for enabling a meter indication that will allow the drill operator to hydraulically change the push drill's position relative to adjacent strata for guidance through the mineral stratum.
The pitch of the push drill assembly 10 is sensed by an accelerometer 164 with output signal provided through a dropping resistor 166 to input 168 of a VA converter amplifier 170 (DC amplifier), Type MC 1741. Reference input is applied via lead 66 from ZERO ADJUST potentiometer 58 in the operator control unit 46 (FIG. 3) as applied to amplifier input 172. Control feedback is applied from the output via resistor-capacitor network 174 to the input 168, and amplifier output is applied on lead 84 through receptacle 88 and the control cable 40 for representation on pitch meter 72 at control unit 46. The accelerometer 164 is a static displacement form known as the Columbia Type SA 107 as made available by Columbia Research Laboratories. The accelerometer 164 provides a steady D-C output proportional to angle such that an adjusted meter 72 range of 0-5 volts will be indicative of pitch change from 0° to 90°. Accelerometer 164 may be suitably mounted in instrument unit 34 to sense the longitudinal angular deviation.
The roll sensing is carried in like manner as a similar type of accelerometer 176 provides input to identical circuitry at amplifier input 178 of a D-C amplifier 180 (also Type MC 1741). A reference input 182 is connected to lead 68, control cable 40 and control unit ZERO ADJUST potentiometer 60 (FIG. 3), and output on lead 86 is similarly conducted back through control cable 40 and gain control 82 for indication at the Roll meter 74 at the control unit. (Roll accelerometer 176 is mounted to sense transverse angular deviation).
In operation, after proper ZERO ADJUST of the pitch and roll meters and rate meter 70 relative to the push drill assembly 10 with zero attitude and indication, the guidance system is ready to function. The operation will also have access to the hydraulic control mechanism at the operating position 14 so that, as he observes the operator control unit 46, he is able to actuate hydraulic controls for any of drill motor 30, deflection unit 32, roll control unit 28 or the hold assemblies to properly direct the drill head 26 through the mineral stratum. As previously stated, the BICRON counter tube 104 (FIG. 4) is preferably shielded for isolation to a selected directivity, e.g., perpendicular to the overlying shale stratum, so that variations in reading of the rate meter 70 at operating position 14 enable the operator to maintain a long hole course within the drilling stratum of interest.
The foregoing discloses a new and useful guidance system for controlling the position and attitude of a push drill through a mineral stratum. The device employs a unique combination of accelerometer sensing to determine pitch and roll of the drill instrument while also sensing the natural gamma ray radiation emanating from shale stratum above, below, banded within or adjacent to the particular mineral stratum. The guidance system has the unique capability of offering very accurate control indication while being packaged in a highly reliable yet relatively small package, an instrumentation package that is quite easily installed within the structure of the push drill assembly. It is also contemplated and a result of the logical course that indications of pitch, roll and gamma incidence or rate, as received at the remote operating position, will also be conditioned for input to computer apparatus whereupon detailed stratum analysis can be carried out with subsequent printout of three-dimensional or other mapping information. Further, it is contemplated that two uni-directional BICRON counter tubes may be utilized in 180° displacement to enable a Rate reading in each of opposite directions from the push drill assembly thereby to enable still further data compilation.
Changes may be made in the combination and arrangement of elements as heretofore set forth in the specification and shown in the drawings; it being understood that changes may be made in the embodiments disclosed without departing from the spirit and scope of the invention as defined in the following claims.
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An electronic guidance system for a push drill that is remotely guided by the operator. The system functions to maintain continual indication as to the attitude of the drilling apparatus, i.e., pitch, roll and distance to rock formations overlying or underlying the drilled stratum, with such indication being made available to the remote operator so that he can control the progression of the drilling apparatus. The drilling apparatus utilizes an instrument package adjacent the drilling mechanism which samples pitch and roll data through accelerometer output, and which monitors the distance of the drill head from adjacent rock formations by means of gamma ray count.
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TECHNICAL FIELD
[0001] The present invention relates to the field of communications, and more particularly, systems and methods for correcting errors in a received frame.
BACKGROUND OF THE INVENTION
[0002] As the world has become more reliant on computers and information exchange, the need for reliable data transmission has become increasingly important. One key element in the exchange of information is the accurate and efficient transmission and reception of data across noisy transmission channels.
[0003] Signal processing methods implemented in practical communications systems are usually designed under the assumption that any underlying noise and interference is Gaussian. Although this assumption finds strong theoretical justification in the central limit theorem, the noise and interference patterns commonly present in modern mobile communications systems are far from Gaussian. Noise and interference generally exhibit “impulsive” behavior. In typical mobile communication systems, noise and interference sources often include: motor-vehicle ignition noise, switching noise from electromechanical equipment, thunderstorms, and heavy bursts of interference. Current signal processing systems are not designed to handle these non-Gaussian noise sources. Accordingly, these systems may perform poorly, and might even fail, in the presence of impulsive noise.
[0004] Channel noise and interference can be effectively modeled as the superposition of many small and independent effects. In practice, these effects do not always follow a Gaussian distribution. This situation appears to contradict the central limit theorem. For many years, engineers have been unable to explain this apparent contradiction. Consequently, many of the techniques developed to cope with impulsive noise were mainly ad hoc, largely based on signal clipping and filtering prior to application of a Gaussian-based technique.
[0005] Clipping the amplitude of an input signal is only effective if the amplitude of the input signal is above or below specific threshold values. These threshold values are typically determined by the limits of hardware used in a receiver in a communication system. Accordingly, the threshold values are often chosen in order to take advantage of the full dynamic range of analog to digital (A/D) converter(s) used in such a receiver. However, if impulsive noise added to the input signal does not cause the amplitude of a signal to exceed a specific threshold, clipping will not remove the noise. Additionally, even when noise does cause the signal to exceed a threshold, clipping only removes noise to the extent that the magnitude of the signal plus the noise is above the threshold. Accordingly, noise is not actually removed, though its effects are somewhat reduced.
[0006] When individual signals within a sequence are contaminated by noise, the sequence may not be properly decoded, thereby making communications difficult. In typical communication systems, decoding is used to identify potential communication errors. Additionally, decoding may be able to correct some, or even most, errors. Errors may be corrected by one of many error detection and correct schemes known to those skilled in the art. Typical coding and decoding schemes are able to correct errors by inserting controlled redundancy into a transmitted information stream. This is typically performed by adding additional bits or using an expanded channel signal set. These schemes allow a receiver to detect, and possibly correct, errors.
[0007] In its most simple form, one problem with noisy transmission environments is that, a certain percentage of the time, a transmitted ‘1’ is received as a ‘0’ or vice versa. There are many methods of encoding data that allow received errors to be detected or even corrected. These encoding and decoding schemes are typically optimized based on a set of underlying assumptions. Preferably, these assumptions are designed to match the conditions of a real-world communications environment. Often, systems using these schemes are designed under the assumption that the underlying noise and interference is Gaussian. When these assumptions do not match real-world conditions, the performance of these schemes may no longer be optimal. While systems which use these schemes work well a majority of the time, their performance is severely affected when conditions degrade.
[0008] One way to accommodate increased noise in a transmission channel is to build a high level of redundancy into the encoding scheme. The problem with such solutions is that adding redundancy increases the size of each transmission frame. Those skilled in the art are familiar with the tradeoffs between using highly redundant encoding schemes, which allow the detection and correction of a greater number of reception errors, and using a scheme with lower redundancy, which has a smaller frame, and thus allows a greater quantity of data to be transmitted in a given time period at the expense of being able to detect and correct few reception errors. While these solutions may be somewhat effective, the tradeoff between accuracy and speed limits optimal performance.
[0009] Another solution for reducing the effects of noise on a transmission channel is to use multiple transmission channels for each transmission. Such schemes, called diversity schemes, transmit the same data frame on multiple channels. When the data is received, each channel is checked for accuracy and a logical decision engine, or a combiner, chooses a received signal from one of the channels that is believed to be accurate. An example of a receiver system using a diversity scheme is shown in FIG. 1.
[0010] The classical goal of a system based on a diversity scheme is to provide the receiver with L versions of an information signal transmitted over independent channels. The parameter L is the diversity order of the system. There are many ways to introduce diversity into a system. Well-known examples include frequency, time and space diversity. The RAKE receiver is a diversity technique commonly employed to combat error bursts or “deep fades” over a multipath fading channel. The basic idea is that the provisioning of multiple, independent versions of a transmitted signal greatly reduces the impact of fading. One weak signal can be compensated by other strong signals. Hence, diversity addresses the issue of robust error performance in a fading environment.
[0011] There are several well-known methods used to combine the L diversity versions of a signal that reach a receiver. The most fundamental combining techniques include selection combining, equal-gain combining, and maximal-ratio combining.
[0012] These schemes may be successful in reducing the effects of noise because it is unlikely that all of the channels will be simultaneously corrupted by noise. However, the overhead (i.e., cost of additional hardware) associated with such a scheme is large because the system utilizes multiple transmitters, receivers, and broadcast channels. The use of multiple broadcast channels is also undesirable because it requires significantly more bandwidth than normal broadcast schemes.
[0013] Therefore, there is a need in the art for systems and methods for accurately and efficiently encoding and decoding transmission signals in varying transmission conditions.
SUMMARY OF THE INVENTION
[0014] The present invention overcomes the limitations of the existing technology by providing systems and methods for correcting errors in a received frame. The systems utilize a plurality of inner decoders for decoding a received frame to form a plurality of inner decoded received frames, wherein each of the plurality of inner decoders uses a different decoding scheme. Additionally, the systems use an outer decoder unit for decoding each inner decoded received frame to form outer decoded received frames and for selecting an outer decoded received frame to use as an output frame.
[0015] The present invention introduces diversity into an error detection and correction system at the receiver side by decoding a received frame using a plurality of decoding schemes. Each of these schemes are optimized for a different set of underlying assumptions. The schemes may be optimized to account for various types of noise including, but not limited to, Gaussian noise and impulsive noise. By including a plurality of decoders using a plurality of decoding schemes, the error detection and correction system may accurately detect and correct errors in a constantly changing environment having constantly changing noise patterns.
[0016] Other objects, features, and advantages of the present invention will become apparent upon reading the following detailed description of the embodiments of the invention, when taken in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a block diagram illustrating a diversity transmission structure.
[0018] [0018]FIG. 2 is an illustration of an α-k plot.
[0019] [0019]FIG. 3 is a block diagram illustrating a system for correcting errors in a received frame in accordance with an exemplary embodiment of the present invention.
[0020] [0020]FIG. 4 is a block diagram illustrating a system for correcting errors in a received frame using a Viterbi algorithm in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0021] Referring now to the drawings, in which like numerals refer to like techniques throughout the several views, exemplary embodiments of the present invention are shown.
[0022] The techniques of the present invention were developed after realizing that the conditions needed to validate the central limit theorem are not satisfied if the variance of “small and independent effects” is allowed to be unbounded (from a conceptual perspective, an infinite variance describes a highly dispersed or impulsive random variable). Without a finite variance constraint, a converging sum of normalized random variables can be proven to belong to a wider class of random variables known as “α-stable”. Thus, similar to Gaussian processes, α-stable processes can appear in practice as the result of physical principles. Furthermore, all non-Gaussian Ix-stable processes are heavy-tailed processes with infinite variance, explaining the often found impulsive nature of practical signals.
[0023] “Symmetric” α-stable random variables possess a characteristic function of the form:
Φ(ω)=e −γ|ω| α (1)
[0024] where α is called the index or characteristic exponent, and γ is the dispersion. Analogous to the variance in a Gaussian process, γ is a measure of the signal strength. The shape of the distribution is determined by α. From the above equation, it can be proven that α is restricted to values in the interval (0,2]. Qualitatively, smaller values of α correspond to more impulsive distributions. The limiting case of α=2 corresponds to the Gaussian distribution. This is the least impulsive α-stable distribution, and the only one with finite variance. A value of α=1 results in a random variable with a Cauchy distribution, which is a heavy-tailed distribution.
[0025] An estimation theory in α-stable environments can be derived from the tools of robust statistics. In general, let ρ(x) be a symmetric cost function or metric which is monotonically non-decreasing on [0,∞). For a set of samples x 1 , x 2 , . . . ,x N , the M-estimator of the location parameter, β, is defined as
β = arg min β ∑ i - 1 N ρ ( x i - β ) . ( 2 )
[0026] In the theory of M-estimators, the shape of the cost function, ρ, determines the characteristics of the estimate, β. For example, if ρ(x)=x 2 (i.e. the Euclidean metric), β becomes the least-squares estimate (i.e. the sample mean). For ρ(x)=|x|, β is the sample median. It may be shown that the cost function
ρ( x )=log( k 2 +x 2 ), (3)
[0027] where k is a constant, possesses important properties for optimizing decoder performance along the whole range of α-stable distributions. The importance of the cost function described in equation (3) is that the value of k may be tuned to give optimal estimation performance depending on the parameters of the underlying distribution. Given the parameters α and γ of an α-stable distribution generating an independently and identically distributed (i.i.d.) sample, the optimal value of k is given by a function of the form:
k (α, γ)= k (α)γ 1/α (4)
[0028] Expression (4) indicates a “separability” property of the optimal value of k in terms of the parameters α and γ. This reduces the problem of finding the functional form of k(α, γ) to that of determining the simpler form:
k (α)= k (α, 1), 0<α≦2. (5)
[0029] This function may be referred to as “the α-k plot” of α-stable distributions. Under the maximum likelihood optimality criterion, the α-k plot touches three fundamental points:
[0030] 1. For α=2 (i.e. the Gaussian distribution), the optimal value of k is k=∞, which, for the location estimation problem, makes β equal to the sample mean.
[0031] 2. With α=1 (i.e. the Cauchy distribution), the optimal value is k=1. This is a direct consequence of the definition of the cost function in Equation (3), and the fact that the resulting M-estimator is equivalent to the maximum likelihood estimator for a Cauchy distribution.
[0032] 3. When α→0 (i.e. the most impulsive distribution), the optimal value of k converges to k=0.
[0033] The above points suggest the general shape of the α-k plot illustrated in FIG. 2.
[0034] One general goal of using encoding and decoding for the transmission of data is to minimize the probability of error. In the situation where coded sequences are equally likely, this is accomplished using a “maximum likelihood” decoder.
[0035] For hard decision decoding, it is well known that a maximum likelihood decoder selects the codeword that is closest in Hamming distance to the received sequence.
[0036] It is also well known that soft decision decoding offers a performance advantage over hard decision decoding. Soft decision decoding preserves information contained in the received sequence and passes that information on to a decoding scheme. The task is to choose a cost function appropriate for soft decision decoding. For a channel with underlying noise and interference that is Gaussian, maximum likelihood decoding is achieved using a Euclidean distance cost function. However, for a channel that is not Gaussian, the choice of an appropriate cost function is not trivial and may have a significant impact on decoder performance.
[0037] The present invention introduces diversity into baseband detection and/or decoding of received information frames. In an exemplary embodiment of the present invention, different decoding schemes are used to decode transmitted signals on channels that exhibit some degree of impulsiveness.
[0038] There are many systems that employ an outer code, usually a cyclic redundancy check (CRC) code, for the purpose of frame error detection (e.g. IS-95, List Viterbi Algorithm). A received frame that passes the CRC check is accepted as containing no errors. Typically, a frame that fails the CRC check is discarded. In some systems, a retransmission request is issued when the frame fails the CRC check. In an exemplary embodiment of the present invention, the outer CRC code is used to validate different “candidate” frames. Each candidate frame is generated using a different baseband detection and/or decoding method. Hence, diversity is introduced into the system through the use of various detection and/or decoding techniques. The CRC code is a form of selection combining since the CRC determines which, if any, of the candidate frames is accepted as the final estimate of a transmitted frame. If all L candidates fail the CRC, all candidates may be discarded.
[0039] Under the assumption that the CRC code is perfect (i.e. there are no undetected errors), it is easy to see that baseband diversity with L>1 (i.e. L different methods of detection and/or decoding) exhibits performance no worse than L=1 using any one particular method of detection and/or decoding.
[0040] [0040]FIG. 3 is a block diagram of a system for correcting errors in a received frame according to an exemplary embodiment of the present invention. An RF receiver 305 receives a signal over an RF channel and distributes the received signal to a plurality of decoders 310 , 315 , 320 . Each of the decoders uses a different baseband decoding technique. In an exemplary embodiment of the present invention, one decoder is optimized for Gaussian noise, and one or more decoders are optimized for non-Gaussian noise. Typically, it is preferable for the decoders optimized for non-Gaussian noise to be optimized for impulsive noise. Each decoder 310 , 315 , 320 outputs a decoded output signal to a CRC check and select unit 325 . The CRC check and select unit 325 performs a CRC check on the outputs from the decoders 310 , 315 , 320 and selects a decoded output signal that passes the CRC check. The selected decoded output signal is sent from the CRC check and select unit as an output decision 330 .
[0041] [0041]FIG. 4 is a block diagram of a system for correcting errors in a received frame which uses a Viterbi algorithm according to an exemplary embodiment of the present invention. The system shown in FIG. 4 is designed for a communications channel with background noise that is potentially impulsive (e.g., mobile communications system). The channel coding system 410 , 415 utilizes an outer CRC code and an inner convolutional code. An input frame 405 is fed to a CRC encoder 410 for CRC encoding. Any suitable error detection or error detection/correction encoder may be used in place of the CRC encoder 410 . This first step of encoding may be referred to as outer error detection encoding. In reference to the various embodiments of the present invention, outer error detection encoding and decoding may refer to CRC encoding, parity check encoding, or any other suitable error detection or error detection/correction scheme.
[0042] In an exemplary embodiment of the present invention, the CRC encoder 410 feeds the outer encoded input frame to a convolutional encoder 415 . The present invention is operable using any decoding scheme that can be used for decoding a frame, including, but not limited to, Viterbi codes, Turbo codes, block codes, LDPC codes, Reed-Solomon codes, etc. The convolutional encoder 415 performs a second level of encoding to the input frame. This second level of encoding may be referred to as the inner error detection/correction scheme. It should be understood that while the embodiment described above used a convolutional code, any inner code may be used.
[0043] Once the input frame is encoded by both the inner error detection/correction scheme and the outer error detection scheme, it is transmitted to a desired destination. The present invention is not concerned with the actual transmission of data, but rather the detection and correction of errors incurred during transmission. In a typical data transmission system, the input frame is modulated by a modulator 420 , transmitted over a transmission channel 425 , and demodulated by a demodulator 430 once it is received at a destination.
[0044] After receipt of the transmitted frame at the destination, the received frame is decoded. In accordance with the present invention, the received frame is first decoded using multiple decoding schemes associated with the inner decoding scheme. In an exemplary embodiment of the present invention, a plurality of Viterbi decoders 435 , 440 are used. Each Viterbi decoder 435 , 440 uses a different cost function. The use of various cost (i.e. metric) functions within the Viterbi decoding unit 435 , 440 for the inner convolutional code, introduces diversity into the system. For example, L cost functions may be described by:
ρ 1 ( x )=log( k i 2 +x 2 ), i= 1,2 . . . L, (6)
[0045] where the constant k i is optimized for a particular level of impulsivity (i.e., a particular value of α). We refer to this system as having “metric diversity.”
[0046] As a simple example, and without limitation, consider L=2. A designer may choose k 1 to be optimized for a channel with no impulsivity (i.e., Gaussian noise) and k 2 for a channel with extreme impulsivity. These two extremes are represented by α=2 and α=0, respectively. Accordingly, the optimal values of k are k 1 =∞ and k 2 =0.
[0047] In an exemplary embodiment of the present invention, various decoding schemes are selected to accommodate the various noise profiles that may be encountered. As in the example above, it is generally desirable, but not critical, to select at least one decoding scheme optimized for a channel with no impulsivity (i.e., Gaussian noise) and at least one decoding scheme optimized for a channel with impulsivity. Additionally, depending on available resources and other considerations, it may be desirable to include a plurality of decoders optimized for channels having a variety of impulsiveness. For example, the decoders may be optimized ranging across the spectrum of α=2 to α=0. Such a scheme using multiple decoders, greatly increases the odds of correcting errors incurred in a frame due to noise in the transmission channel.
[0048] After the decoders 435 , 440 decode the transmitted frame, the results are fed to an outer error check/frame select unit 445 . In an exemplary embodiment of the present invention, the outer error check/frame selection unit 445 performs a CRC check and selects the results of an inner decoder that passes the CRC check. The selected frame is then outputted as the output frame 450 . Any selection routine may be used. A simple selection routine includes sequentially checking the results of each inner decoder 435 , 440 and selecting the first decoder which passes the CRC check. Alternatively, all decoders 435 , 440 may be checked and compared to assure that all frames passing the CRC check contain the same message. It is highly unlikely that multiple decoded frames will pass the CRC check but contain different messages, however this alternative technique may be desirable in systems where a low level error detection scheme, such as parity check, is used for the outer error detection scheme.
[0049] While this invention has been described in detail with reference to embodiments thereof, it will be understood that variations and modifications can be effected without departing from the spirit or scope of the present invention as defined by the claims that follow.
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The present invention provides systems and methods for correcting errors in a received frame. The present invention introduces diversity into an error detection and correction system at the receiver side by decoding a received frame using a plurality of decoding schemes. Each of these schemes are optimized for a different set of underlying assumptions. The schemes may be optimized to account for various types of noise including, not limited to, Gaussian noise and impulsive noise. The plurality of decoded frames are then validated using an outer decoder to choose a valid frame from candidate decoded frames. By including a plurality of decoders using a plurality of decoding schemes, the error detection and correction system may accurately detect and correct errors in a constantly changing environment having constantly changing noise patterns.
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TECHNICAL FIELD
The present invention relates generally to limiting leakage between components that define a high pressure space, and more particularly to implementation of a leak arrest volume around a planar sealing land between two components.
BACKGROUND
In many devices, such as fuel injectors, a plurality of components are positioned in contact with one another to define a high pressure space. These components are clamped together in an effort to prevent leakage through the planar sealing land between the components. In the case of fuel injectors, these components can be charged with sealing against leakage in the face of relatively high pressures, which can be on the order of 200 MPa or greater. Engineers have observed that when a leak develops between adjacent components, at such high pressures, it can sometimes act as a wedge to separate the two components creating an even larger leak path. In other words, as the leak penetrates the sealing land between the components, it remains at a relatively high pressure pushing the two components apart, which creates an even larger leak area. This action can cause even further component separation, resulting in even more leakage.
In the case of fuel injectors, this type of leakage is undesirable for several reasons. First, any leaked fuel that was at one time pressurized, arguably results in a waste of energy, since the fuel was pressurized from engine power but not injected into the same. In addition, leakage can undermine the ability to accurately predict the performance of a fuel injector. For instance, if fuel is being leaked that was expected to be injected, the fuel injector may be injecting less fuel than it should. In some fuel injectors, leakage can also reduce injection pressure. In addition, leakage can be a source of variable performance among a plurality of fuel injectors in a given engine. For instance, if each fuel injector exhibits substantially different leakage rates, that can cause differing fuel injector performance. In other words, the plurality of fuel injectors could be injecting different amounts of fuel based upon an identical set of control signals.
One previous strategy for dealing with sealing against leakage between fuel injector components with a planar interface, is to reduce the area of the planar surface so that more of the clamping load is concentrated in a smaller area. This strategy, for instance, is illustrated in co-owned U.S. Pat. No. 5,897,058, invented by Coldren et al. While such a strategy can be effective in many applications, other factors, such as spatial limitation features, can reduce the applicability of such a strategy. For instance, in some situations there may be so many fluid passageways, dow alignment bores and/or fastener bores that an implementation of a reduced sealing land area strategy can cause other undesirable effects, such as component distortion that may lead to even more leakage.
The present invention is directed to one or more of the problems set forth above.
SUMMARY OF THE INVENTION
In one aspect, a component sub-assembly includes a first component with a planar surface in contact with a planar surface of a second component. The first and second components define a high pressure space that passes through the planar surfaces at a perimeter. The first and second component define at least one leak arrest volume that is distributed to surround at least a majority of the perimeter.
In another aspect, a fuel injector includes a plurality of stacked components that include a first component and a second component in contact with one another in a plane. The first and second components define high pressure space that passes through the plane at a perimeter. The first and second components define at least one leak arrest volume that is distributed to surround at least a majority of the perimeter.
In still another aspect, a method of limiting leakage between components includes a step of placing a planar surface of a first component in contact with a planar surface of the second component to define a high pressure space with a perimeter. At least one leak arrest volume is defined between the first and second components. The leak arrest volume is distributed to surround at least a majority of the perimeter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectioned side diagrammatic view of the fuel injector according to one aspect of the present invention;
FIG. 2 is a sectioned side diagrammatic view of an electro-hydraulic actuator portion of the fuel injector shown in FIG. 1 ;
FIG. 3 is a top view of a valve lift spacer from the fuel injector of FIG. 1 ; and
FIG. 4 is a bottom view of the valve lift spacer of FIG. 3 .
DETAILED DESCRIPTION
Referring to FIG. 1 , a fuel injector 10 includes a direct control needle valve 11 that is operably coupled to an electro-hydraulic actuator 12 . Electro-hydraulic actuator 12 includes a three way valve 14 that is operably coupled to an electrical actuator 16 . Fuel injector 10 is connected to a source of high pressure fuel 18 via a fuel supply line 19 , and connected to a low pressure fuel reservoir 20 via a fuel transfer passage 21 . Those skilled in the art will recognize that the source of high pressure fuel 18 can come from a common rail, a fuel pressurization chamber within a unit injector or any other means known in the art for pressurizing fuel to injection levels. In addition, the injector body 22 includes at least one nozzle outlet 23 .
Within fuel injector 10 , fuel arriving from high pressure fuel source 18 travels through an unobstructed nozzle supply passage 24 to arrive at a nozzle chamber 25 , which is shown blocked from fluid communication with nozzle outlet 23 by a needle portion 30 of direct control needle valve 11 . Needle portion 30 includes an opening hydraulic surface 34 exposed to fluid pressure in nozzle chamber 25 . Direct control needle valve 11 is normally biased downward to its closed position, as shown, by the action of a biasing spring 35 acting on a lift spacer 31 , which is in contact with a top surface of needle portion 30 . Direct control needle valve 11 also includes a piston portion 32 with a closing hydraulic surface 33 exposed to fluid pressure in a needle control chamber 37 and needle control passage 39 . Opening hydraulic surface 34 is in opposition to closing hydraulic surface 33 . When three way valve 14 is in a first position, needle control chamber 37 is fluidly connected to source of high pressure fuel 18 via needle control passage 39 and a high pressure passage 40 that connects at one end into nozzle supply passage 24 . When valve 14 is at its second position, needle control chamber 37 is fluidly connected to low pressure reservoir 20 via needle control passage 39 and a low pressure passage 41 . Three way valve 14 is moved between its first position and its second position by energizing and deenergizing electrical actuator 16 . When high pressure exists in needle control chamber 37 , direct control needle valve 11 will stay in, or move toward, its downward closed position, as shown. When needle control chamber 37 is connected to low pressure, direct control needle valve 11 will lift to its upward open position if fuel pressure acting on opening hydraulic surface 34 is above a valve opening pressure, which is preferably determined by a biaser, such as the preload of biasing spring 35 . In practice, the valve opening pressure of direct control needle valve 11 is adjusted by choosing a VOP spacer 36 of an appropriate thickness. In addition, the lift distance of direct control needle valve 11 is controlled by choosing an appropriate thickness for lift spacer 31 . Those skilled in the art will appreciate that in the disclosed embodiment, needle control chamber 37 is a closed volume.
Referring to FIG. 2 , electro-hydraulic actuator 12 is shown apart from the fuel injector of FIG. 1 . Three way control valve 14 is preferably positioned in close proximity to piston portion 32 so that the volume of needle control chamber 37 is made relatively small. Those skilled in the art will appreciate that pressure changes in needle control chamber 37 can be hastened by reducing its volume. This issue is addressed by actuator 12 in at least two ways. First, three way valve 14 is positioned in close proximity to the closing hydraulic surface 33 of piston portion 32 . In addition, needle control chamber 37 is preferably designed to be defined at least in part by volume reducing surface features. Thus, those skilled in the art will recognize that some measurable amount of improved performance can be achieved by paying attention to what surface features which define needle control chamber, can be changed in order to reduce the volume of needle control chamber 37 without otherwise undermining performance. In many instances, it will be desirable to make any flow areas associated with needle control chamber 37 less restrictive than the flow areas associated with high pressure passage 40 , low pressure passage 41 , or the flow areas across seats 50 and 51 . When valve member 42 is in contact with lower seat 51 , as shown, needle control chamber 37 is fluidly connected across high pressure seat 50 to nozzle supply passage 24 via high pressure passage 40 . When valve member 42 is lifted upward into contact with high pressure seat 50 , needle control chamber 37 is fluidly connected to a low pressure area that surrounds actuator 12 across low pressure seat 51 via low pressure passage 41 . Thus, valve member 42 can be thought of as being trapped between upper seat 50 and lower seat 51 . Seats 50 and 51 can also be referred to as first and second seats, or vice versa. In order to reduce the influence of hydraulic forces on opposite ends of valve member 42 , a vent passage 83 vents armature cavity 82 to low pressure, and a vent passage 81 connects vented chamber 80 to low pressure.
Although piston 32 could be located in a common body as lower seat component 45 , it is preferably separated from the same by a relatively thin stop plate 75 and housed in its own piston guide body 76 , as shown in FIGS. 1 and 2 . Leak arrest volume(s) and vent paths could also be used to limit leakage between lower seat component 45 , stop plate 75 and guide body 76 . In such a case, needle control chamber 37 would be the high pressure space of the claims.
Valve member 42 is preferably operably coupled in a known manner to the moveable portion of an electrical actuator. In the illustrated embodiment, valve member 42 is attached to an armature 62 via a nut 66 that is threaded onto one end of valve member 42 . In particular, an armature washer 63 rests upon an annular shoulder 58 , upon which armature 62 is supported. Next, a nut washer 64 is placed in contact with the other side of armature 62 followed by a spacer 65 , against which nut 66 bears. Armature 62 and hence valve member 42 are biased downward to close low pressure seat 51 by a suitable biaser, such as biasing spring 67 . Those skilled in the art will appreciate that a hydraulically biaser could be an alternative to the mechanical bias shown. In addition, while electrical actuator 16 has been shown as a solenoid, those skilled in the art will appreciate that any other suitable electrical actuator, such as a piezo (disks and/or a bender) or a voice coil could be substituted in its place. A stator assembly 17 includes a stator 61 , a coil 60 and preferably includes a female/male electrical socket connector to better facilitate bringing electrical energy to actuator 16 via conductors (not shown) penetrating down through injector body 22 . Stator assembly 17 is preferably positioned within a carrier assembly 70 such that their respective bottom surfaces lie in a common plane. By doing so, a solenoid spacer 71 having an appropriate thickness can be chosen to provide a desired air gap between armature 62 and stator 61 . Thus, solenoid spacer 71 is preferably a categorized part that comes in variety of slightly different thicknesses that allow different valves to perform similarly by choosing an appropriate thickness to provide uniformity in the armature air gap from one actuator to another.
In order to aid in concentrically aligning upper seat 50 with lower seat 51 along common centerline 38 , valve member 42 includes an upper guide portion 54 with a close diametrical clearance (i.e. a guide clearance) with an upper guide bore 55 located in upper seat component 43 . In addition, valve member 42 also preferably includes a lower guide portion 56 having a relatively close diametrical clearance with a lower guide bore 57 located in lower seat component 45 . Thus, these guide regions tend to aid in concentrically aligning upper and lower seats 50 and 51 during the assembly of three way valve 14 as well as substantially fluidly isolating needle control chamber 37 from vented chamber 80 and/or armature cavity 82 , regardless of the position of valve member 42 . Because it is difficult to be certain, before assembly, the depth into seats 50 and 51 that valve member 42 will penetrate before coming in contact in closing that particular seat, three way valve 14 preferably employs a valve lift spacer 44 that is also a category part, and is preferably categorized in a plurality of different thickness groups. Thus, the distance that valve member 42 travels between upper and lower seats 50 and 51 is adjustable by choosing an appropriate thickness for valve lift spacer 44 .
In order to reduce the influence of fluid flow forces on the movement of valve member 42 , high pressure passage 40 and low pressure passage 41 preferably include flow restrictions 47 and 48 , respectively, that are restrictive relative to a flow area across respective seats 50 and 51 . While these flow restrictions could be located in upper seat component 43 and/or lower seat component 45 , they are preferably located in valve lift spacer 44 as shown in FIG. 2 . In particular, the flow characteristics through high pressure passage 40 can be relatively tightly controlled by including a cylindrical segment 47 having a predetermined length and flow area. Furthermore, cylindrical segment 47 is relatively restrictive to flow relative to that across upper seat 50 . Those skilled in the art will appreciate that it is easier to control and consistently machine a flow characteristic via a cylindrical segment as opposed to attempting to consistently control a flow area between stationary seat component and moveable valve member 42 . Likewise, low pressure passage 41 preferably includes a cylindrical segment 48 that is located in valve lift spacer 44 . In order to differentiate the rate at which pressure changes can occur in needle control chamber 37 , cylindrical segment 48 preferably has a different flow area relative to cylindrical segment 47 . This feature is present in the illustrated example as a strategy by which the opening rate of the direct control needle valve is slowed relative to the closure rate of the same. In other words, when direct control needle valve 11 lifts toward its open position, fluid is displaced from needle control chamber 37 through the flow restriction defined by cylindrical segment 48 . When direct control needle valve 11 is closed, high pressure fluid flows into needle control chamber 37 from high pressure passage 40 through the flow restriction defined by cylindrical segment 47 . Since cylindrical segment 48 has a smaller flow area than cylindrical segment 47 , in the illustrated embodiment, the opening rate of direct control needle valve 11 can be made slower than its closure rate, which is often desired.
In order to accommodate for the possibility of a slight angular misalignment between the centerline of valve member 42 and the respective centerlines of upper and lower seats 50 and 51 , valve member 42 preferably includes spherical valve surfaces 52 and 53 , which have a common center. Those skilled in the art will appreciate that spherical valve surfaces 52 and 53 can contact and close valve seats 50 and 51 even in the event of some minor angular misalignment between valve member 42 and its respective seats. In order to insure that the respective passageways, such as nozzle supply passage 24 , provide the proper fluid connection as shown in FIG. 2 , the stationary components of three way valve 14 preferably include dowel bores, which are present to prevent the valve from being misassembled. In order to hold three way valve 14 together, it preferably includes a plurality of fasteners that are threadably received in fastener bores located in upper seat component 43 . Nevertheless, those skilled in the art will appreciate that numerous other strategies could be employed for clamping three way valve 14 together.
Referring now in addition to FIGS. 3 and 4 , valve lift spacer 44 includes leak arrest features to limit leakage between valve lift spacer 44 and upper and lower seat components 43 and 45 . Valve lift spacer 44 includes four fastener bores 46 that allow valve 14 to be assembled. Proper alignment in the assembly of valve 14 is insured via the usage of dowels and dowel bores 90 . Valve lift spacer 44 includes a first side 91 with a first planar surface 101 that creates a sealing land in contact with a second planar surface 102 of side 92 of upper seat component 43 . When together as shown in FIGS. 1 and 2 , components 43 and 44 could be considered a component sub-assembly 15 that defines a portion of control volume 85 , which can also be considered a high pressure space when fuel pressure in the same is high. High pressure space 85 is bounded by a first perimeter 86 , while the components themselves are bounded by a perimetrical side surface 96 . In addition to control volume 85 , components 43 and 44 also define a portion of nozzle supply passage 24 and high pressure passage 40 , each of which could also be considered a high pressure space according to the present invention. In order to arrest the wedge affect of a potential leak, valve lift spacer 44 also includes a leak arrest volume 98 that encloses first perimeter 86 and is distributed around passages 24 and 40 . Leak arrest volume 98 is vented to the low pressure space adjacent perimetrical side surface 96 inside injector casing via vent passage 88 .
Those skilled in the art will appreciate that vent passages 88 may not be desirable in the case of some fuel injectors. For instance, vent passages 88 would likely be desirable for common rail applications in which the fuel injector is maintained at relatively high pressures for the long durations between injection events, but vent passages 88 could be omitted in the case of fuel injectors that are only cyclically at high pressures. Because valve lift spacer 44 is a relatively thin component, leak arrest volume 98 and vent passage(s) 88 can potentially be manufactured via a coining or stamping process at the blank stage. If vent passage(s) 88 are omitted, leak arrest volume 98 should have a sufficiently large volume that its pressure can be maintained below some predetermined level, but that pressure has the ability to decay between injection events when pressure is low.
Referring now to FIG. 4 , valve lift spacer 44 also includes a third planar surface 103 of a third side 93 in contact with a fourth planar surface 104 of a fourth side 94 of lower seat component 45 . These two components also define a portion of control volume 85 that is bounded at the sealing land by second perimeter 87 . Like the opposite side of valve lift spacer 44 , third side 93 includes a leak arrest volume 99 that is distributed to enclose second perimeter 87 and distributed to surround the other high pressure spaces defined by nozzle supply passage 24 and high pressure passage 40 . In this embodiment, leak arrest volume 99 is vented to the low pressure space adjacent perimetrical side surface 96 via vent passage(s) 89 . Those skilled in the art will appreciate that the leak arrest volumes are defined by the side surfaces of the two components so as to arrest any leakage that could develop in the sealing lands between the high pressure spaces and the leak arrest volume. Although the leak arrest volumes are shown as being defined by a planar surface of one component covering a groove in an opposing component, those skilled in the art will appreciate that the grooves could be formed in both components in order to form the leak arrest volume(s) of the present invention.
INDUSTRIAL APPLICABILITY
When fuel injector 10 is in operation, electro-hydraulic actuator 12 works in conjunction with direct control needle valve 11 to control both timing and quantity of each injection event. Each injection event is initialized by raising fuel pressure in high pressure source 18 to injection levels. In some systems, this is accomplished by maintaining a common rail at some desired pressure. Alternatively, source 18 can be a fuel pressurization chamber within a unit injector that is pressurized when a plunger is driven downward, which is usually accomplished with a cam or a hydraulic force. Because valve member 42 is biased downward to close low pressure seat 51 , direct control needle valve 11 will stay in its downward closed position due to the high pressure force acting on closing hydraulic surface 33 of piston portion 32 . Shortly before the timing at which the injection event is desired to start, electrical actuator 16 is preferably energized by supplying an excessive current to coil 60 . Because the speed at which electrical actuator 16 operates is related to the current level supplied to coil 60 , one preferably supplies the maximum available current, which can be substantially higher than an amount of current necessary to cause the armature to move against the action of the spring bias. When sufficient magnetic flux builds, armature 62 and valve member 42 are pulled upwards until spherical valve surface 52 contacts upper or high pressure seat 50 . When this occurs, needle control chamber 37 is fluidly connected to low pressure fuel reservoir 20 via low pressure passage 41 . Shortly before the desired end of an injection event, current to electrical actuator 16 is reduced or terminated to a level that allows spring 67 to push armature 62 and valve member 42 downward until spherical valve surface 53 comes in contact with low pressure seat 51 . When this occurs, high pressure fluid originating in nozzle supply passage 24 flows through high pressure passage 40 past high pressure seat 50 and into needle control chamber 37 . The high pressure force on piston 32 moves needle valve member 30 toward its closed position.
Like many fuel injectors, fuel injector 10 includes a plurality of stacked components 13 that need to be sealed against leakage at their various planar sealing land contact surfaces. In those areas where a potential leak could cause a component separation wedging affect, the present invention finds potential applicability. For instance, FIGS. 1 and 2 show valve lift spacer 44 and stop plate 75 as including leak arrest volumes that are distributed to surround high pressure spaces 37 , 85 , 40 and 24 . If the application is a common rail fuel injector, these leak arrest volumes are preferably vented (such as by vent passages 88 ) to a low pressure space via an appropriate vent paths as described earlier. In the case of cyclic pressure fuel injectors, such as cam or hydraulically driven fuel injectors, vent paths could be omitted by making the leak arrest volume large enough to have the capacity to increase in pressure during an injection event below some pre-determined pressure, while also having the ability to have that pressure decay between injection events. Those skilled in the art might also find is desirable to include leak arrest volumes and vent paths between other components that seal against leakage of nozzle supply passage 24 . In the illustrated embodiment, the leak arrest volumes and vent paths are preferably stamped or coined into valve lift spacer 44 and stop component 75 . By including vent paths, the size of leak arrest volumes in the vent passages can be relatively loosely controlled since the volume of these spaces need not be tightly controlled. After being stamped, the planar surfaces of these components can be ground in a conventional manner.
The leak arrest volume should be distributed to sufficiently surround the high pressure perimeter that a wedging affect caused by a leak is prevented from causing substantial component separation which could lead to an even larger leakage. Although the leak arrest volumes preferably enclose the high pressure space in which they are sealing against leakage, they need not necessarily do so. For instance, passages 24 and 40 are not completely enclosed by leak arrest volume 98 , but the leak arrest volume 98 is distributed to surround a majority of a perimeter around these passages.
The present invention is potentially advantageous in that leakage that exists between components can be limited by arresting a wedging affect that could cause even larger amounts of leakage. Those skilled in the art will appreciate that leakage is very undesirable in that it contributes to a number of undesirable affects, including energy wastage, altered injection amounts and variability among fuel injectors, among other potential problems. By appropriately locating leak arrest volumes according to the present invention, any leakage that does start to occur between components is prevented from substantially exacerbating into a large leak by connecting the leak to a low pressure space long before it reaches the perimetrical outer side surface that surrounds the two components. Alternatively, if the high pressure space is near the outer side surface of the components ( FIG. 3 , passage 24 ), then it may not be desirable to insert a leak arrest volume between the higher pressure space and the outer side surface of the component(s).
Although the present invention has been illustrated in the context of a fuel injector, those skilled in the art will appreciate that the concept of the present invention could find potential application in any component sub-assembly that includes a planar sealing land that is intended to prevent leakage from a high pressure space within the components.
It should be understood that the above description is intended for illustrative purposes only, and is not intended to limit the scope of the present invention in any way. Thus, those skilled in the art will appreciate that other aspects, objects, and advantages of the invention can be obtained from a study of the drawings, the disclosure and the appended claims.
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Particularly in the fuel injector art, two components may define a high pressure space that is sealed against leakage via a planar sealing land between the two components. If a leak develops in the planar contact area between the two components, it can act to wedge the two components apart, which tends to exacerbate the leakage problem, and so on. Since some leakage between the two components is almost inevitable for a variety of reasons known in the art, a strategy that arrests the leak before it can produce the component separating wedge affect would be beneficial. This can be accomplished by positioning a leak arrest volume, which may be vented, around a majority of the perimeter of the high pressure space. The usage of a leak arrest volume finds particular application in fuel injectors, especially a class of common rail fuel injectors that are maintained at high pressure during prolonged periods between injection events.
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This is a continuation-in-part of copending application Ser. No. 825,785, filed February 3, 1986, now U.S. Pat. No. 4,705,803; which in turn is a continuation of application Ser. No. 471,299, filed March 2, 1983, now abandoned.
FIELD OF INVENTION
This invention relates to a method of improving the absorption of injected antibacterial substances. More specifically, this invention relates to the use of benzylamine derivatives in combination with injected antibacterial substances to improve the absorption of said antibacterial substances after injection.
BACKGROUND OF THE INVENTION
It is known from the literature that benzylamine derivatives are useful as bronchosecretolytics in human and veterinary medicine. The best known examples of these benzylamine derivatives are N-(2-amino-3,5-dibromobenzyl)-N-methyl-cyclohexylamine hydrochloride (generic name: bromhexine) and N-(2-amino-3,5-dibromobenzyl)-trans-4-hydroxycyclohexylamine hydrochloride (generic name: ambroxol). These compounds produce a significant increase in the quantity of secretion, but it has been found that the viscosity of the secretion decreases and the concentration of solids in the fluid of the respiratory tract and their specific weight are reduced, which characterizes the benzylamine derivatives as secretolytics.
In addition, it is known from the literature that when the above-mentioned benzylamine derivatives are administered perorally together with an antibiotic, particularly oxytetracycline and erythromycin, or with a sulfonamide such as sulfadiazine, there is an increase in the infiltration of these substances into the bronchial secretion. The same also applies to the body's own immunoglobulins, that is, immunoglobulins which have not been administered. However, this increase in the concentration of the contents of bronchial secretion is not caused by any increased absorption from the intestines induced by the above-mentioned benzylamine derivatives or by any delay in excretion through the kidneys, since there is no detectable increase in blood level values after oral or intravenous administration.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a method of improving the absorption of injected antibacterial substances or combinations.
It is also an object of this invention to provide a combination of an antibacterial substance or combinations and a benzylamine derivate.
It is a further object of this invention to provide a method of improving the absorption of an injected antibacterial substance or combination by admixing said substance with an effective amount of a benzylamine derivative of the formula ##STR2## wherein R 1 is hydroxyl in the 2- or 4-position or amino in the 2-position;
R 2 is hydrogen or alkyl of 1 to 3 carbon atoms; and
R 3 is cyclohexyl hydroxy-cyclohexyl;
or a non-toxic, pharmacologically acceptable acid addition salt thereof.
These and other objects of the invention will become apparent as the description thereof proceeds.
DETAILED DESCRIPTION OF THE INVENTION
We have discovered that when a benzylamine derivative of the formula I above or a non-toxic, pharmacologically acceptable acid addition salt thereof is administered parenterally, the absorption of an antibacterial substance or combination which has been administered parenterally into the tissues and which, on its own, does not have optimum absorbability, is speeded up. Thus, according to the invention, as a result of the higher blood levels with the same dosage of the antibacterial substance, or combination better and safer therapeutic results are obtained or--if higher blood levels are not wanted--the quantity administered can be reduced by comparison with the quantity required when the substance in question is administered by itself, and consequently a significant saving is achieved. Moreover, the problem of residues is reduced since the injection site for the antibacterial substances and combinations in question is usually the tissue, which retains measurable residues of these substances longest.
Therefore, the present invention relates to the novel use of the benzylamine derivatives of the formula I and non-toxic, pharmacologically acceptable acid addition salts thereof, preferably in veterinary medicine, for increasing the absorption of antibacterial substances or combinations which have been administered parenterally into the tissue and are not readily absorbed, preferably by parenteral administration of the benzylamine derivatives at the same time.
The preferred benzylamine derivatives of the formula I are, however, those wherein R 2 and R 3 , together with the nitrogen atom to which they are attached, form an N-methylcyclohexylamino, N-ethyl-cyclohexylamino, trans-4-hydroxycyclohexylamino, or cis-3-hydroxy-cyclohexylamino group. A particularly preferred benzylamine derivative of the formula I is N-(3,5-dibromo-2-hydroxybenzyl)-trans-4-hydroxy-cyclohexylamine or a non-toxic, pharmacologically acceptable acid addition salt thereof, especially the hydrochloride.
Examples of antibacterial substances used according to the invention, optionally in the form of esters or salts thereof, include the following: antibiotics of the tetracycline group, such as oxytetracycline, oxytetracycline hydrochloride, rolitetracycline or doxycycline; difficultly soluble antibiotics of the β-lactam group, such as procaine penicillin, benethamine penicillin, benzathine penicillin, the benzathine salts of oxacillin, cloxacillin, or ampicillin, and of the cephalosporins; erythromycin and derivatives thereof, such as 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin, erythromycin lactobionate, erythromycin ethylsuccinate or erythromycin glucoheptonate; spiramycin or spiramycin adipate; tylosin or tylosin tartrate; oleandomycin; chloramphenicol or chloramphenicol succinate; thiamphenicol or thiamphenicol glycinate; sulfonamides or sodium salts thereof, such as sulfadiazine, sulfadoxine, sulfamethoxazole, sulfadimethoxine, sulfadimidine or sulfathiazole; a sulfonamide together with an agonist such as trimethoprim, for example, the sulfadimidine/sulfathiazole/trimethoprim combination, or the sodium salts thereof; and, optionally, the delayed-release forms thereof.
The invention further relates to the novel combinations which are suitable for parenteral administration into the tissue, containing a benzylamine derivative of the formula I and an antibacterial substance or combination which, by itself, does not have optimum absorbability, together with one or more conventional inert diluents or carriers, preferably those forms which are suitable for intramuscular administration. The preferred combinations are those containing (1) a benzylamine derivative of the formula I wherein R 1 is hydroxyl and R 2 and R 3 , together with the nitrogen atom to which they are attached, have the meanings defined above, preferably N-ethylcyclohexylamino, trans-4-hydroxycyclohexylamino, or cis-3-hydroxy-cyclohexylamino, and especially wherein R 1 is hydroxyl in the 2-position, and R 2 and R 3 , together with the nitrogen atom to which they are attached, are trans-4-hydroxy-cyclohexylamino, and (2) one of the above-mentioned antibacterial substances or combinations.
Particularly preferred embodiments of the invention are
(A) the combination of (1) N-(2-amino-3,5-dibromobenzyl)-N-methyl-cyclohexylamine or a non-toxic, pharmacologically acceptable acid addition salt thereof, and (2) a delayed-release oxytetracycline preparation, a delayed-release oxytetracycline hydrochloride preparation, rolitetracycline or docycycline;
(i) a difficultly soluble antibiotic of the β-lactam group, such as procaine penicillin, benethamine penicillin, benzathine penicillin or a benzathine salt of oxacillin, cloxacillin, ampicillin or a cephalosporin;
(ii) erythromycin or a derivative thereof, such as 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-ethromycin, erythromycin lactobionate, erythromycin ethylsuccinate, erythromycin glucoheptonate; spiramycin, spiramycin adipate; tylosin, tylosin tartrate; oleandomycin; thiamphenicol or thiamphenicol glycinate; or
(iii) a sulfonamide or a sodium salt thereof, such as sulfadiazine, sulfadoxine, sulfamethoxazole, sulfadimethoxine, sulfadimidine, or sulfathiazole, or a sulfonamide combination with an agonist such as trimethoprim, for example, the sulfadimidine/sulfathiazole/trimethoprim combination; or
(B) the combination of (1) N-(2-amino-3,5-dibromobenzyl)-trans-4-hydroxy-cyclohexylamine or a non-toxic, pharmacologically acceptable acid addition salt thereof, and (2)
(i) an antibiotic of the tetracycline group, such as oxytetracycline, oxytetracycline hydrochloride, rolitetracycline or doxycycline;
(ii) a difficultly soluble antibiotic of the β-lactam group, such as procaine penicillin, benethamine penicillin, benzathine penicillin or a benzathine salt of oxacillin, cloxacillin, ampicillin or a cephalosporin;
(iii) erythromycin or one of the derivatives thereof, such as 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin, erythromycin lactobionate, erythromycin ethylsuccinate, erythromycin glucoheptonate; spiramycin, spiramycin adipate; tylosin, tylosin tartrate; oleandomycin; chloramphenicol, chloramphenicol succinate; thiamphenicol or thiamphenicol glycinate; or
(iv) a sulfonamide or a sodium salt thereof, such as sulfadiazine, sulfadoxine, sulfamethoxazole, sulfadimethoxine, sulfadimidine or sulfathiazole, or a combination of a sulfonamide with an agonist such as trimethoprim, for example, the sulfadimidine/sulfathiazole/trimethoprim combination, or, optionally, a corresponding delayed-release form.
The following combinations are, however, particularly preferred:
(a) Combinations of (1) N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine or a non-toxic, pharmacologically acceptable acid addition salt thereof, or N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine or a non-toxic, pharmacologically acceptable acid addition salt thereof with (2) erythromycin, erythromycin lactobionate, erythromycin ethylsuccinate, erythromycin glucoheptonate, 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin, tylosin, tylosin tartrate, spiramycin, spiramycin adipate, oleandomycin, benethamine penicillin, benzathine penicillin, ampicillin, oxacillin, cloxacillin, rolitetracycline, doxycycline, or a salt thereof; or a sulfonamide or a salt thereof, optionally in combination with trimethoprim; and
(b) Combinations of (1) N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine or a non-toxic, pharmacologically acceptable acid addition salt thereof with oxytetracycline or a salt thereof, chloramphenicol, chloramphenicol succinate, thiamphenicol or thiamphenicol glycinate.
To demonstrate the efficacy of the invention, the absorption-promoting effect of the following benzylamine derivatives:
A=N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride;
B=N-(2-amino-3,5-dibromo-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride, and
C=N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxycyclohexylamine hydrochloride,
was tested in the following manner:
Cattle, pigs, and sheep (with the same ten animals per group) were treated once with only the antibacterial substance or combination in question and once with the combination of the benzylamine derivative together with the same antibacterial substance or combination, administered by the intramuscular route. The two treatments were given at an interval of eight days to ensure that the substance or substances administered in the first treatment had been totally eliminated. The order of treatment varied, that is, in some cases the antibacterial substance or combination (control) was administered first and in some cases the combination including the benzylamine derivative was administered first (test group). In some cases the tests were carried out as "cross-over" tests, that is, on the first occasion five animals were given the antibacterial substance or combination while five animals were given the combination including the benzylamine derivative. When the test was repeated eight days later, the treatments were reversed.
Blood samples were taken during the day at one and two hour intervals and after 24 hours, and in some cases after 32 hours as well, and in two cases (delayed-release preparations) after 48 and 72 hours also. The levels of antibiotics or sulfonamide in the blood serum were determined using conventional microbiological methods with test pathogens specific to each substance.
In each case, the areas under the blood level curves obtained were compared, as an overall measurement of antibacterial activity. This comparison showed increases in blood level for the combination of benzylamine derivatives with the antibacterial substance or combination in question, compared with the control group in question, as is shown in the following table:
TABLE 1__________________________________________________________________________ BenzylamineAntibacterial Substance (Dosage: mg/kg Derivative Type of Increase in Blood Levelor Combination of body weight) (Dosage: mg/kg) Animal (in %, compared with control)__________________________________________________________________________Erythromycin 10 A 0.3 i.m. cattle 16.1 10 C 0.6 i.m. cattle 21.4 10 A 0.6 i.m. pig 59.1 10 A 1.2 i.m. pig 31.4Erythromycin derivative 10 A 1.2 i.m. pig 15.3 10 C 1.2 i.m. pig 45.4Oxytetracycline hydro- 10 C 0.6 i.m. cattle 16.3chlorideDelayed-release oxy- 20 A 0.6 i.m. pig 109.5tetracycline preparation* 20 C 1.2 i.m. pig 80.0Tylosin 15 A 0.3 i.m. cattle 33.0 15 C 0.6 i.m. cattle 23.5Tylosin 10 A 0.6 i.m. pig 19.3 10 A 1.2 i.m. pig 30.3 10 C 0.6 i.m. pig 30.5 10 C 1.2 i.m. pig 26.1Sulfadimidine/-- 24 A 0.6 i.m. pig 29.6Sulfathiazole/-- 24 A 1.2 i.m. pig 25.1Trimethoprim 24 C 0.6 i.m. pig 29.9Combination 24 C 1.2 i.m. pig 20.3(10:10:4)__________________________________________________________________________ *Blood level monitored for 72 hours; after 48 hours it is 0.13 μg/ml for the control but 0.35 μg/ml for the test group; after 72 hours, it is 0.00 μg/ml for the control but still 0.19 μg/ml for the test group.
The benzylamine derivatives of the formula I and their non-toxic, pharmacologically acceptable acid addition salts are well tolerated. For example, the acute toxicity (LD 50 ) in the mouse is
>400 mg/kg i.p. for Compound A,
268 mg/kg i.p. for Compound B, and
>800 mg/kg i.p. for Compound C.
In view of the above-mentioned biological characteristics, the benzylamine derivatives of the formula I and their non-toxic, pharmacologically acceptable acid addition salts are, as mentioned above, suitable for improving the absorption of antibacterial substances or combinations administered parenterally into the tissue, and thus help to improve and guarantee the success of the therapy. The dosage is advantageously above 0.1 mg/kg, preferably between 0.2 and 2.0 mg/kg, while in solutions the upper limit is set by the solubility of the particular benzylamine derivative which is used. For example, in water, Compounds A to C have the following maximum solubilities:
______________________________________Compound Maximum Solubility______________________________________A 0.2 to 5.0 mg/cm.sup.3B 16.6 mg/cm.sup.3C 0.1 to 1.0 mg/cm.sup.3______________________________________
dependent upon the pH in the acid range. Obviously, higher concentrations can be achieved in oily carriers, dependent upon the solubility in oil of the benzylamine derivative and also upon whether the benzylamine derivative is suspended in suitable carriers in which it is insoluble or not sufficiently soluble.
Moreover, the benzylamine derivative is preferably administered simultaneously with a therapeutic dose of the antibacterial substance or combination which is to be used. Examples of individual doses include the following:
TABLE 2______________________________________Active Substance Dose______________________________________oxytetracycline 5 to 30 mg/kgrolitetracycline 15 to 50 mg/kgdoxycycline 2 to 5 mg/kgerythromycin 5 to 20 mg/kg9-deoxy-11-deoxy-9,11-{imino- 5 to 20 mg/kg[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycinspiramycin 10 to 50 mg/kgtylosin 5 to 20 mg/kgchloramphenicol 10 to 50 mg/kgthiamphenicol 10 to 50 mg/kgsulfadiazine 15 to 50 mg/kgsulfadiazine/sulfathiazole/- 15 to 30 mg/kgtrimethoprimsulfadoxin/trimethoprim 15 to 30 mg/kgprocaine penicillin 2,000 to 20,000 I.U./kgbenzathine penicillin 6,000 to 25,000 I.U./kgampicillin 2 to 15 mg/kgoxacillin 5 to 15 mg/kgcloxacillin 5 to 15 mg/kgoxytetracycline hydrochloride 2 to 25 mg/kg______________________________________
Examples of suitable forms for administration include injectable preparations of an aqueous, water-miscible or oily nature in which the antibacterial substances in question are dissolved or suspended in the desired concentration. The same also applies to the benzylamine derivatives or the salts thereof, depending on their solubility, while the same preparation may contain one substance in solution and the other in suspension. In those cases where an aqueous solution is desired but is not practicable due to insufficient stability, such as of the antibiotic, the injectable combination is prepared shortly before administration by dissolving or suspending the dry substance in the solvent containing the benzylamine derivative.
The benzylamine derivatives of the formula I and their non-toxic, pharmacologically acceptable acid addition salts are known; see, for example, U.S. Pat. Nos. 3,336,308, 3,536,713 and 4,113,777.
The compounds of the formula I may be obtained in the form of their non-toxic, pharmacologically acceptable acid addition salts after reaction with inorganic or organic acids. Suitable acids include, for example, hydrochloric, hydrobromic, sulfuric, methylsulfuric, phosphoric, tartaric, fumaric, citric, maleic, succinic, gluconic, malic, p-toluenesulfonic, methanesulfonic and amidosulfonic acid.
The following examples illustrate the present invention and will enable others skilled in the art to understand it more completely. It should be understood, however, that the invention is not limited solely to the particular examples given below.
EXAMPLES
EXAMPLE 1
Two-compartment preparation containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Compostion______________________________________(a) Dry ampule Antibiotic 715.0 mg(b) Solution ampule Active substance 75.0 mg Tartaric acid 37.5 mg Glycerin polyethyleneglycol 250.0 mg oxystearate Glucose 200.0 mg Water for injection q.s. ad 5.0 ml______________________________________
Method
To prepare the dry ampule, the antibiotic is dissolved in water for injection, sterilized, and freed from pyrogens by means of a suitable filter system, possibly by use of pyrogen adsorption layers, and then transferred under aseptic conditions, in the desired dosages, into 10 ml injection vials which have been cleaned and sterilized. These vials are freeze-dried in the usual way.
Next, to prepare the solution ampule, the active substance and excipients are successively dissolved in water for injection purposes, filtering is carried out in the same way as with the dry ampule solution, and the resulting solution is transferred into 5 ml ampules. For sterilization, the fused ampules and the injection vials, sealed with rubber stoppers and crimped aluminum caps, are heated at 121° C. for 20 minutes.
EXAMPLE 2
Two-compartment preparation containing 9-deoxy-11-deoxy-9,11-{imino-[2-(methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(2-amino-3,5-dibromobenzyl)-N-methyl-cyclohexylamine hydrochloride (aqueous solution) (active substance)
______________________________________Composition______________________________________(a) Dry ampule Atibiotic 3575.0 mg(b) Solution ampule Active substance 375.0 mg Tartaric acid 187.5 mg Glycerin polyethyleneglycol 1250.0 mg oxystearate 1250.0 mg Glucose 1000.0 mg Water for injection q.s. ad 25.0 ml______________________________________
Method
The ampules (a) and (b) are prepared by a procedure analogous to that of Example 1. However, the active substance is transferred into 25 ml or 30 ml injection vials.
EXAMPLE 3
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[-2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 500.0 mgActive substance 100.0 mgBenzyl alcohol 50.0 mgNeutral oil q.s. ad 5.0 ml______________________________________
Method
The antibiotic and active substance are dissolved or suspended in a mixture of the two excipients, while heating, and the resulting mixture is transferred under aseptic conditions into 5 ml-ampules which have been cleaned and sterilized.
EXAMPLE 4
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 2500.0 mgActive substance 500.0 mgBenzyl alcohol 250.0 mgNeutral oil q.s. ad 25.0 ml______________________________________
Method
The antibiotic and the active substance are dissolved or suspended in a mixture of the two excipients, while heating, and the resulting mixture is transferred, under aseptic conditions, into 25 ml injection vials which have been cleaned and sterilized.
EXAMPLE 5
Two-compartment preparation containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (aqueous suspension) (active substance)
______________________________________Composition______________________________________(a) Dry ampule Antibiotic 715.0 mg(b) Ampule containing suspension/solution Active substance 100.0 mg Polyethyleneglycol stearate 1.0 mg Sorbitol 250.0 mg Methyl hydroxyethyl cellulose 15.0 mg Water for injection q.s. ad 5.0 ml______________________________________
Method
To prepare the dry ampule, the active substance is dissolved in water for injection, sterilized, freed from pyrogens by means of a suitable filter system, possibly by use of pyrogen adsorption layers, and then transferred under aseptic conditions, in the desired dosages, into 10 ml injection vials which have been cleaned and sterilized. These vials are freeze-dried in the usual way.
Next, to prepare the ampules of suspension/solution, the excipients are dissolved in water for injection purposes, and the solution is filtered to sterilize it and to remove any pyrogens. The active substance is suspended in this solution under aseptic conditions, and the suspension is transferred, while stirring, into 5 ml-ampules which have been cleaned and sterilized.
EXAMPLE 6
Two-compartment preparation containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (aqueous suspension) (active substance)
______________________________________Composition______________________________________(a) Dry ampule Antibiotic 3575.0 mg(b) Ampule containing suspension/solution Active substance 500.0 mg Polyethyleneglycol stearate 5.0 mg Sorbitol 1250.0 mg Methyl hydroxyethyl cellulose 75.0 mg Water for injection q.s. ad 25.0 ml______________________________________
Method
The ampules (a) and (b) are prepared by a procedure analogous to that of Example 5. However, the components are transferred into 25 ml and 30 ml injection vials, respectively.
EXAMPLE 7
Injectable solution containing oxytetracycline hydrochloride (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine (active substance)
______________________________________Composition______________________________________Antibiotic 5.0 gmActive substance 0.05-0.8 gmMagnesium oxide 0.45 gmpH adjuster 1.0 gmAntioxidants 0.2 gmSolketal ® 15.0 gm1,2-Propyleneglycol 74.0 gmWater for injection q.s. ad 100.0 ml______________________________________
Method
In a suitable vessel, the antibiotic is dissolved in the corresponding quantity of water, and 1,2-propyleneglycol and then magnesium oxide are added. At the same time, a solution of Solketal® and active substance in the corresponding quantity of 1,2-propyleneglycol is prepared. The two solutions are combined, and a solution of the antioxidants in a small amount of water is added thereto. The desired pH value is obtained by adding the pH adjuster. The solution is prepared and transferred into vials in a nitrogen atmosphere and under aseptic conditions. The solution must be sterilized by filtration.
EXAMPLE 8
Aqueous suspension containing chloramphenicol or thiamphenicol (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 20.0 gmActive substance 0.05-2.5 gmSuspension stabilizers 1.6 gmEmulsifier 2.0 gmCitric acid 1.0 gmAntifoaming agent 0.2 gmMethiolate 0.005 gm1 N Sodium hydroxide solution 3.25 gmWater for injection q.s. ad 100.0 ml______________________________________
Method
Merthiolate and citric acid are dissolved in about one-third of the quantity of water and placed in a suitable vessel. The active substance, suspension stabilizers, and antifoaming agent are successively added to this solution and dissolved or suspended therein.
The emulsifier is dissolved in about one-third of the quantity of water, while heating, and added thereto. A suspension of antibiotic in water is added, with stirring, while the homogeneous suspension is adjusted to the desired pH value with 1N NaOH, having been diluted to 100 ml with the remaining water. All the excipients and active substances or solutions thereof are sterilized before use. The preparation must be made up and bottled under aseptic conditions.
EXAMPLE 9
Injection solution containing tylosin and N-(2-amino-3,5-dibromobenzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Tylosin 50.0 mgActive substance 0.5-6.0 mg1,2-Propyleneglycol 0.5 mlBenzyl alcohol 0.04 mlHydrochloric acid q.s. ad pH 4Water for injection q.s. ad 1.0 ml______________________________________
Method
The active substance is dissolved in 90 ml of a suitable mixture of 1,2-propyleneglycol and water, with stirring and ultrasonic treatment, in a current of nitrogen. Tylosin is added and dissolved to form a clear solution. After the addition of the benzyl alcohol, the mixture is adjusted to the desired pH with 1N HCl and then diluted to 100 ml with water. The solution must be prepared and bottled under aseptic conditions.
EXAMPLE 10
Injection solution containing tylosin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Tylosin 50.0 mgActive substance 0.5-6.0 mg1,2-Propyleneglycol 0.5 mlBenzyl alcohol 0.04 mlHydrochloric acid q.s. ad pH 4Water for injection q.s. ad 1.0 ml______________________________________
Method
The solution is prepared by using a procedure analogous to that of Example 9.
EXAMPLE 11
Oil suspension containing erythromycin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Erythromycin 50.0 mgActive substance 0.5-25.0 mgSodium diotylsulfosuccinate 2.0 mgNeutral oil q.s. ad 1.0 ml______________________________________
Method
Sodium dioctylsulfosuccinate is dissolved in the corresponding quantity of neutral oil while heating and stirring. After the solution has cooled to room temperature, erythromycin is dissolved therein, and active substance of a suitable particle size is added. The resulting suspension is homogenized with a suitable stirrer and bottled under aseptic conditions.
EXAMPLE 12
Suspension containing erythromycin and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine (active substance)
______________________________________Composition______________________________________Erythromycin 50.0 mgActive substance 0.5-25.0 mgNeutral oil q.s. ad 1.0 ml______________________________________
Method
The suspension is prepared using a procedure analogous to that of Example 11.
EXAMPLE 13
Injection solution containing trimethoprim, sulfadimidine, sulfathiazole, and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Trimethoprim 40.0 mgSulfadimidine 100.0 mgSulfathiazole 100.0 mgActive substance 0.5-6.0 mgGlycerol formal q.s. ad 1.0 ml______________________________________
Method
The active substance is dissolved in glycerol formal while stirring and in a current of nitrogen. Then, trimethoprim, sulfadimidine and sulfathiazole are successively dissolved therein, while stirring. The solution is then diluted with the remaining glycerol formal. The preparation must be made up and bottled under aseptic conditions and in the absence of direct light.
EXAMPLE 14
Injection solution containing trimethoprim, sulfadimidine, sulfathiazole and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Trimethoprim 40.0 mgSulfadimidine 100.0 mgSulfathiazole 100.0 mgActive substance 0.5-15.0 mgGlycerin formal q.s. ad 1.0 ml______________________________________
Method
The solution is prepared by using a procedure analogous to that of Example 13.
EXAMPLE 15
Injection solution containing spiramycin and N-(2-amino-3,5-dibromo-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Active substance 0.5-6.0 mgSpiramycin 50.0 mg1,2-Propyleneglycol 0.5 mlWater for injection q.s. ad 1.0 ml1 N Hydrochloric acid q.s. ad pH 3.8______________________________________
Method
The active substance is dissolved, while stirring, in a mixture of 1,2-propyleneglycol and water in a current of nitrogen, and the spiramycin is dissolved in the solution. The solution is adjusted to the desired pH with 1N HCl and diluted with water. The preparation must be made up and bottled under aseptic conditions.
EXAMPLE 16
Injection solution containing spiramycin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine
______________________________________Composition______________________________________Active substance 0.5-15.0 mgSpiramycin 50.0 mgGlycofurol q.s. ad 1.0 ml______________________________________
Method
A solution of spiramycin in glycofurol is prepared in a current of nitrogen and then the active substance is added to the solution in small portions, again in a current of nitrogen, and dissolved therein. The solution is bottled under aseptic conditions and in an atmosphere of nitrogen.
EXAMPLE 17
Two-compartment preparation containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(2-amino-3,5-dibromo-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________(a) Dry ampule. Antibiotic 715.0 mg(b) Solution ampule. Active substance 75.0 mg Tartaric acid 37.5 mg Glycerin polyethyleneglycol 250.0 mg oxystearate Glucose 200.0 mg Water for injection q.s. ad 5.0 ml______________________________________
Method
The ampules (a) and (b) are prepared by a procedure analogous to that of Example 1.
EXAMPLE 18
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin (antibiotic) and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 200.0 mgActive substance 2.0-20.0 mg4-Chloro-m-cresol 2.0 mgAluminum monostearate 10.0 mgNeutral oil (e.g. Miglyol ® 812 q.s. ad 1.0 mlavailable from Dynamit Nobel Co.)______________________________________
Preparation
The aluminum monostearate is dispersed in the corresponding quantity of neutral oil, while stirring and heating. After the mixture has cooled to room temperature, first the 4-Chloro-m-cresol, then the antibiotic and the active substance in a suitable particle size are added and dissolved or suspended while stirring. The resulting suspension is filled into ampules under aseptic conditions.
EXAMPLE 19
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 285.8 mgActive substance 2.0-20.0 mg4-Chloro-m-cresol 2.0 mgAluminum monostearate 10.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 18.
EXAMPLE 20
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 143.0 mgActive substance 2.0-20.0 mg4-Chloro-m-cresol 2.0 mgAluminum monostearate 10.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 18.
EXAMPLE 21
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin (antibiotic) and N-(2-amino-3,5-dibromo-benzyle-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 100.0 mgActive substance 2.0-20.0 mg4-Chloro-m-cresol 2.0 mgAluminum monostearate 10.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 18.
EXAMPLE 22
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 200.0 mgActive substance 3.0-20.0 mg4-Chloro-m-cresol 2.0 mgAluminum monostearate 10.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 18.
EXAMPLE 23
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 285.8 mgActive substance 3.0-20.0 mg4-Chloro-m-cresol 2.0 mgAluminum monostearate 10.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 18.
EXAMPLE 24
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin lactobionate (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 143.0 mgActive substance 3.0-20.0 mg4-Chloro-m-cresol 2.0 mgAluminum monostearate 10.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 18.
EXAMPLE 25
Oily suspension containing 9-deoxy-11-deoxy-9,11-{imino-[2-(2-methoxyethoxy)-ethylidene]-oxy}-(9F)-erythromycin (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 100.0 mgActive substance 3.0-20.0 mg4-Chloro-m-cresol 2.0 mgAluminum monostearate 10.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 18.
EXAMPLE 26
Oily suspension containing oxytetracyclin hydrochloride (antibiotic) and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 200.0 mgActive substance 2.0-20.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 0.7 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Production takes place under aseptic conditions and constant gas load. Sodium dioctylsulfosuccinate and 4-Chloro-m-cresol are dissolved in a suitable quantity of neutral oil while stirring. The solution is sterilized by filtration. Oxytetracyclin x HCl and the active substance are added to another suitable quantity of neutral oil while stirring, and the resulting suspension is milled to micronize the antibiotic particles. Solution and suspension are then combined, homogenized and filled into ampules under sterile conditions.
EXAMPLE 27
Oily suspension containing oxytetracyclin hydrochloride (antibiotic) and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Antibiotic 200.0 mgActive substance 3.0-20.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 0.7 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 28
Sterile solid for injection containing ampicillin and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 173.0 mgActive substance 4.0-40.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hydroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 20.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
The antibiotic and the active substance are filled under sterile conditions into injection vials which then are sealed with a pierceable rubber closure and aluminum cap.
The solvent is prepared in an appropriate volume by dissolving first polyoxyethylene hydrogenated castor oil, while stirring, in a suitable amount of WfI (water for injection), then adding sodium hydroxide and tartaric acid. After adjustment of total volume with WfI, the solution is filtered and filled into ampules. The ampules are sealed and sterilized in an autoclave.
EXAMPLE 29
Sterile solid for injection containing ampicillin and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 1,730.0 mgActive substance 40-400.0 mg______________________________________
Solvent ampules
______________________________________Composition______________________________________Tartaric acid 20.0-80.0 mgSodium hydroxide 5.0 mgPolyoxyethylene hydrogenated castor oil 200.0 mg4-Chloro-m-cresol 20.0 mgDistilled water q.s. ad 10.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 30
Oily suspension containing ampicillin and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 173.0 mgActive substance 4.0-40.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 0.7 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 31
Sterile solid for injection containing ampicillin and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 230.0 mgActive substance 4.0-40.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hydroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 20.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 32
Oily suspension containing ampicillin and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 230.0 mgActive substance 4.0-40.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 1.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 33
Sterile solid for injection containing benzathine ampicillin and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Benzathine ampicillin 276.5 mgActive substance 4.0-40.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hydroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 30.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 34
Oily suspension containing benzathine ampicillin, ampicillin sodium and N-(2-amino-3,5-dibromo-benzyl)-N-methyl-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Benzathine ampicillin 276.5 mgAmpicillin sodium 21.3 mgActive substance 4.0-40.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 1.5 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 35
Sterile solid for injection containing ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 173.0 mgActive substance 6.0-24.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hydroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 20.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 36
Oily suspension containing ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 173.0 mgActive substance 6.0-24.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 0.7 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 37
Sterile solid for injection containing ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 230.0 mgActive substance 6.0-4.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hydroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 20.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 38
Oily suspension containing ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 230.0 mgActive substance 6.0-24.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 1.0 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 39
Sterile solid for injection containing benzathine ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Benzathine ampicillin 276.5 mgActive substance 6.0-24.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hydroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 30.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 40
Oily suspension containing benzathine ampicillin, ampicillin sodium and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Benzathine ampicillin 276.5 mgAmpicillin sodium 21.3 mgActive substance 6.0-24.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 1.5 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 41
Sterile solid for injection containing ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 173.0 mgActive substance 6.0-40.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hydroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 20.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 42
Oily suspension containing ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 173.0 mgActive substance 6.0-40.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 0.7 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 43
Sterile solid for injection containing ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 230.0 mgActive substance 6.0-40.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hycroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 20.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 44
Oily suspension containing ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride
______________________________________Composition______________________________________Ampicillin × 3 H.sub.2 O 230.0 mgActive substance 6.0-40.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 1.0 mgNeutal oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
EXAMPLE 45
Sterile solid for injection containing benzathine ampicillin and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Benzathine ampicillin 276.5 mgActive substance 6.0-40.0 mg______________________________________
Solvent ampule
______________________________________Composition______________________________________Tartaric acid 2.0-8.0 mgSodium hydroxide 0.5 mgPolyoxyethylene hydrogenated castor oil 30.0 mgDistilled water q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 28.
EXAMPLE 46
Oily suspension containing benzathine ampicillin, ampicillin sodium and N-(3,5-dibromo-2-hydroxy-benzyl)-trans-4-hydroxy-cyclohexylamine hydrochloride (active substance)
______________________________________Composition______________________________________Benzathine ampicillin 276.5 mgAmpicillin sodium 21.3 mgActive substance 6.0-40.0 mg4-Chloro-m-cresol 2.0 mgSodium dioctylsulfosuccinate 1.5 mgNeutral oil (e.g. Miglyol ® 812) q.s. ad 1.0 ml______________________________________
Preparation
Analogous to Example 26.
Any one of the other compounds embraced by formula I or a non-toxic, pharmacologically acceptable acid addition salt thereof may be substituted for the particular active substance in Examples 18 through 46. Likewise, the amount of antibiotic and active substance in these illustrative examples may be varied to achieve the dosage ranges set forth above, and the amounts and nature of the inert pharmaceutical carrier ingredients may be varied to meet particular requirements.
While the present invention has been illustrated with the aid of certain specific embodiments thereof, it will be readily apparent to others skilled in the art that the invention is not limited to these particular embodiments, and that various changes and modifications may be made without departing from the spirit of the invention or the scope of the appended claims.
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An antibacterial substance which does not have optimum absorbability and is administered parentally into tissue, is administered to a host in conjunction with a benzylamine derivative of the formula ##STR1## wherein R 1 is hydroxyl in the 2- or 4-position or amino in the 2-position;
R 2 is hydrogen or alkyl of 1 to 3 carbon atoms; and
R 3 is cyclohexyl optionally substituted by hydroxyl;
or a non-toxic, pharmacologically acceptable acid addition salt thereof, to improve the absorption of the parenterally administered antibacterial substance.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a safety apparatus and, more particularly, to such a safety apparatus which interoperates with conventional machines, such as cotton lint cleaners and the like, to proscribe a secure zone about the operative components thereof so as to protect personnel from injury.
2. Description of the Prior Art
Industry is dependent upon the use of mechanical devices, and particularly heavy machinery, in performing the required processes. Typically a multiplicity of manufacturing steps must be performed in sequence at a rapid pace in order to ensure that a sufficient volume is produced consistent with the price range required of the marketplace. In order to maintain such volume while minimizing overhead expense, the industrial age has seen heavy reliance on machinery to perform the required steps. While the use of such machinery has produced increasingly dramatic increases in productivity, the hazards associated with such productivity are ever present.
For example, in the commercial production of cotton fiber, various machines are required to process the fiber prior to it being compressed into bales for sale to other industries which use the cotton fiber for the manufacture of other products. One of the machines employed in such ginning operations, and usually in banks or batteries of such machines, is the lint cotton cleaning machine. Such machines operate to remove leaf particles, motes, grass and bark left in the cotton fiber after processing by seed cotton cleaners and extractors. In most ginning operations, batteries of such lint cleaning machines are employed at two or more stages in the ginning operation.
Lint cleaning machines are characterized by the use of a condenser screen drum to form the cotton fiber into a batt which is removed from the condenser screen drum by two doffing rollers and fed through one or more sets of compression rollers. Thereafter, the batt is passed between a very closely fitted feed roller and feed plate or bar and fed onto a saw cylinder. Each set of compression rollers rotates slightly faster than the preceding series of rollers which causes the batt to be thinned to some degree. The feed roller and plate grip the batt so that a combing action takes place as the saw teeth seize the cotton fiber. The tolerances involved in the spacing of the elements of the lint cleaning machine are very small. For example, the feed plate clears the saw cylinder by only about one-sixteenth of an inch. A doffing brush assembly removes lint from the saw cylinder and passes it from the lint cleaning machine for further processing.
Since such lint cleaning machines operate at a very high velocity in substantially continuous operation during the season, their operation must be monitored so as immediately to be able to detect breakdown and to remove blockage that may develop very rapidly. Still another condition which must be monitored is that of fire caused by the cotton fiber being heated during passage through the lint cleaning machine.
The rapid development of clogging or burning cotton fiber in the area of the compression rollers is the triggering event for injury to personnel. Such accidents occur when personnel attempt to gain access to the interior of the lint cleaning machine for the removal of excess or burning cotton fiber before the saw cylinder and/or feed rollers have come to a complete stop. As a direct consequence of the high inertial load of the saw cylinder, the time required for the saw cylinder to come to a complete stop is approximately two minutes in conventional machines. The aggravation of the condition during that two minute period as witnessed by such personnel constitutes an overbearing motivation for personnel to attempt to alleviate the problem even before such movement of the saw cylinder and feed rollers is terminated.
Whereas, lint cleaning machines are not the most frequent cause of accidents in the ginning industry, the accidents resulting therefrom account for the most debilitating and costly injuries. These injuries most commonly occur from removal of the access grates of the machines by personnel prior to the machine coming to rest and the insertion of fingers between the compression rollers. Since the compression rollers draw the fingers into the machine, the most gruesome injuries can take place. In order to prevent such injuries, various prior art methods have been employed to prevent removal of the access grates. However, once the operative parts of the lint cleaning machine come to a stop, the access grates must rapidly be removed to correct the particular problem. Prior art methods have not permitted sufficiently rapid removal of the access grates and therefore are frequently not used even though available. They have thus not proved satisfactory.
Therefore, it has long been known that it would be desirable to have a safety apparatus which can be employed on machinery to prevent access to the interior thereof during an operative mode, but which permits immediate access to the interior once the machine has reached an inoperative mode; which has particular utility in use on such heavy equipment as lint cleaning machines employed in cotton ginning operations; and which operates inexpensively and completely dependably to preclude injury to personnel as a result of gaining access to the interior of such machinery prior to reaching the inoperative mode.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an improved safety apparatus.
Another object is to provide such a safety apparatus which interoperates with conventional machinery to prevent personnel from gaining access to the interior of such machinery for maintenance prior to the machinery fully reaching a passive or inoperative mode.
Another object is to provide such a safety apparatus which prevents entry to the interior thereof prior to an inoperative mode, but which permits immediate access to the interior upon such inoperative mode having been reached.
Another object is to provide such a safety apparatus which has particular utility in use on lint cleaning machines employed in the ginning industry preventing personnel from reaching into the interior portions of the machinery prior to the moving portions thereof coming to a complete halt.
Another object is to provide such a safety apparatus which requires that all operative conditions consistent with full operation to have been reached prior to being able to reactivate operation of the lint cleaning machine.
Another object is to provide such a safety apparatus which not only precludes access by personnel to the interior portions of the machine prior to that machine reaching an inoperative mode, but also interoperates with the machine to reduce the interval of time required for the machine to reach the inoperative mode after being switched off.
Another object is to provide such a safety apparatus which is fully compatible with conventional lint cleaning machinery without requiring substantial retrofitting of component parts and systems thereon.
Another object is to provide such a safety apparatus which is capable of sensing precisely when all motion within the machine ceases and at substantially the same instant permits immediate access to the interior of such machinery for maintenance by personnel.
Another object is to provide such a safety apparatus which substantially precludes injury to personnel working around such machinery.
Further objects and advantages are to provide improved elements and arrangements thereof in an apparatus for the purpose described which is dependable, economical, durable and fully effective in accomplishing its intended purpose.
These and other objects and advantages are achieved in the safety apparatus of the present invention in operation with a work object having an active mode and a passive mode, the apparatus having control means for obstructing access, in a first condition, and alternatively permitting access in a second condition, to said work objects; means for detecting when the work object is in said active mode and in said passive mode; and a control system operably interconnecting the control means and the detecting means operable when the work object is in said active mode, as detected by the detecting means, to maintain the control means in the first condition and when the work object is in the said passive mode, as detected by the detecting means, to maintain the control means in the second condition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a lint cotton cleaning machine mounting the safety apparatus of the present invention.
FIG. 2 is a somewhat enlarged transverse, vertical section taken on line 2--2 in FIG. 1.
FIG. 3 is a somewhat enlarged fragmentary plan view of the apparatus of FIG. 1 taken on line 3--3 in FIG. 1 with the access doors removed for illustrative convenience.
FIG. 4 is a schematic diagram of the electrical control system of the safety apparatus of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The safety apparatus of the present invention is generally indicated by the numeral 10 in FIGS. 1 and 4 where it is shown in a typical operative environment. It will, however, be understood that the safety apparatus of the present invention is adaptable for use in a host of operative environments and on virtually any type of machinery wherein it is desired to prevent access to the internal working parts of the machinery prior to the machinery reaching a passive or fully inoperative mode.
Referring more particularly to FIG. 1, a conventional cotton lint cleaning machine is generally indicated by the numeral 20. The cotton lint cleaning machine is conventional except, as herein noted, in that it is fitted with the safety apparatus 10 of the present invention. The cotton lint cleaning machine is mounted on a supporting surface 21 and has a main housing 22 consisting of an upper housing 23 and a lower housing 24.
Referring more particularly to FIG. 2, the cotton lint cleaning machine 20 has a condenser screen drum assembly 30 mounted for rotational movement in a drum housing 31 which is fed with cotton lint or fiber, not shown, by a supply conduit 32. A pair of doffing roller assemblies 33 are mounted for rotational movement beneath the condenser screen drum assembly at the bottom of the drum housing for rotational movement about axes of rotation substantially parallel to that of the condenser screen drum assembly.
The upper housing 23 has a front access opening 34 dimensioned to receive a front access gate or closure 35 in fitted relation within the front access opening to prevent access to a front chamber 36. The upper housing 23 has a rear access opening 44 dimensioned to receive a rear access grate or closure 45. The rear access grate is adapted to be received in the rear access opening so as to prevent access to a rear chamber 46.
A pair of compression roller assemblies 50 are mounted in the upper part of the lower housing 24 for rotational movement about axes of rotation substantially parallel to the axes of the doffing roller assemblies 33 and condenser screen drum assembly 30. The front access grate 35 and rear access grate 45 are disposed in closed positions to prevent access to the structure heretofore described while the lint cleaning machine is in operation. However, in conventional lint cleaning machines, the access grates are easily removed or are simply left loose or out of position by personnel for convenience in gaining access to the interior thereof. It is precisely this characteristic of the operation of such machines that the safety apparatus of the present invention, in the illustrative embodiment herein described, is designed to prevent.
A feed roller assembly 51 is mounted for rotational movement in the lower housing 24 immediately beneath the compression roller assemblies 50. A feed plate or bar 52 is mounted adjacent to the feed roller assembly. A saw cylinder assembly 53 is mounted for rotational movement in the lower housing beneath the feed roller assembly 51 and is bounded on one side and the lower portion thereof by saw cylinder bars 54. The lower housing has a trash discharge passage 55 and a saw cylinder access door 56.
A doffing brush assembly 60 is mounted for rotational movement about an axis of rotation substantially parallel to the axes of rotation heretofore described. The doffing brush assembly is housed within a doffing brush housing 61 leading to a fiber discharge passage 62. The lower housing has a side compartment 63 shown best in FIG. 3 to which access is gained by opening the access doors 64 shown in FIG. 1, but not FIG. 3 for illustrative convenience.
The saw cylinder assembly 53 includes a shaft 65 on which it rotates and which extends into the side compartment 63. The doffing brush assembly 60 includes a doffing brush assembly shaft 66 which also extends into the side compartment substantially parallel to the saw cylinder shaft 65. As shown in FIG. 3, a saw cylinder shaft lock assembly 67 is mounted on the lower housing and extends into the side compartment 63. The saw cylinder shaft lock assembly includes a locking wheel 68 mounted on the saw cylinder shaft 65 and having radially extending notches 69. A locking arm 70 extends into the side compartment from externally of the lower housing and has a handle 71 on the end thereof which is external of the lower housing. A locking pin 72 is mounted on the opposite end of the locking arm and adapted for selective engagement in one of the notches 69 of the locking wheel permitting the saw cylinder shaft 65 to be locked in position to prevent movement thereof, such as during maintenance of the lint cleaning machine.
The saw cylinder shaft lock assembly is used in conventional lint cleaning machines to prevent access to the saw cylinder assembly during operation of the lint cleaning machine as mandated by law. This is achieved by the saw cylinder shaft lock assembly in that the locking arm 70 engages the saw cylinder access door so as to prevent it being opened until the saw cylinder shaft comes to a complete stop and the locking pin 72 is engaged in one of the notches 69. Thereafter, personnel can open the saw cylinder access door 56 to gain access to the saw cylinder assembly. Since this structure is entirely conventional, no further description is provided herein. No such safety system conventionally exists for the front and rear access grates 35 and 45, respectively, nor is there any legal mandate that such systems be provided therefore.
The lint cleaning machine 20 is driven by a three phase main drive motor 73 shown diagrammatically in FIG. 4.
The structure heretofore described is entirely conventional. The structure hereinafter described constitutes the novel safety apparatus 10 of the present invention. The safety apparatus has a magnetic lock assembly 80 best shown in FIG. 2. The magnetic lock assembly includes a front electromagnet 81 mounted in the front access opening 34 on the upper housing 23.
A front ferrous metal strike plate 82 is mounted by any suitable means on the front access closure or grate 35 in position to be in facing engagement with the electromagnet 81 when the front access grate is in the closed position filling and thereby obstructing the front access opening 34. A rear electromagnet 83 is mounted in the rear access opening 44 on the upper housing 23. A rear ferrous metal strike plate 84 is mounted on the rear access grate 45 in position to be disposed in facing engagement with the rear electromagnet when the rear access grate is in the closed position filling, and thereby obstructing, the rear access opening. In the preferred embodiment of the invention, the electromagnets are the "Magnalock 62" manufactured by Securitron of Torrance, Calif. However, any suitable electromagnets can be employed.
The safety apparatus 10 also has a motion detector assembly 90, shown best in FIG. 3. The motion detector assembly includes a collar 91 mounted on the saw cylinder shaft 65 within the side compartment 63 of the lower housing 24. The collar mounts a pair of target members 92 on opposite sides thereof and extending outwardly therefrom one hundred and eighty degrees (180°) from each other about the collar. A mounting bracket 93 is mounted on the lower housing 24 within the side compartment. A motion detector 94 is mounted on the mounting bracket as shown in FIG. 3 in alignment with the collar 91 and therefore with the path of travel described by the target members in moving with the saw cylinder shaft 65. The motion detector has a sensing end portion 95 which extends to a position such that the target members pass in juxtaposition to the sensing end portion so as to be detectable thereby. In the preferred embodiment of the invention, the motion detector is a "Veeder-Root Motion Dector Model 77853" manufactured by Veeder-Root Digital Products of Hartford, Conn. However, any suitable motion detector can be employed.
The safety apparatus 10 further includes an augmentation means or dynamic brake assembly 110, shown in the schematic diagram in FIG. 4. The dynamic brake assembly includes a dynamic brake 111. The dynamic brake, being itself of conventional design, is not shown herein beyond the schematic representation shown in FIG. 4. In the preferred embodiment, the dynamic brake is a "Baldor/Lectron Dynamic Brake Model #B73CP manufactured by Baldor/Lectron of Torrance, Calif. However, any suitable dynamic brake can be employed.
The dynamic brake 111 has a BL1 electrical connection 112, a BL2 electrical connection 113, a T1 electrical connection 114, a T2 electrical connection 115 and a T3 electrical connection 116. Further, the dynamic brake has a number 4 electrical connection 117, a number 5 electrical connection 118, an S electrical connection 119, an S electrical connection 120, an X1 electrical connection 121 and a number 1 electrical connection 122.
The safety apparatus 10 includes electrical contacts 123, electrical contacts 124, a TR1 timer 125, a TR2 timer 126, electrical contacts 127 and an on-off switch 128.
The safety apparatus 10 has an electrical system generally indicated by the numeral 130 in FIG. 4. The electrical system includes a primary electrical supply system 131 which, in part, includes a portion of the conventional electrical system of the lint cleaning machine 20. This includes a motor starter 132 of conventional design and having three input electrical connections 133 and three output electrical connections 134. The motor starter has three electrical contacts 135 and three overload units 136. An electrical conductor 140 extends from a source of electrical energy, not shown, and is attached to a first of the three input electrical connectors 133. An electrical conductor 141 extends from the source of electrical energy and is connected to a second of the three input electrical connections 133. An electrical conductor 142 extends from the source of electrical energy and is connected to a third of the three input electrical connections 133. An electrical conductor 143 operatively interconnects a first of the three output electrical connections 134 and the main drive motor 73. An electrical conductor 144 operatively interconnects a second of the three output electrical connections 134 and the main drive motor 73. An electrical conductor 145 operatively interconnects a third of the three output electrical connections 134 and the main drive motor 73. Turning then to the portions of the electrical system 131 constituting part of the safety apparatus 10 of the present invention, an electrical conductor 150 interconnects electrical conductor 141 and the BL2 electrical connection 113. An electrical conductor 151 interconnects electrical conductor 140 and the BL1 electrical connection 112. An electrical conductor 152 interconnects the T3 electrical connection 116 and the electrical conductor 145. An electrical conductor 153 interconnects the T2 electrical connection 115 and electrical conductor 144. An electrical conductor 154 interconnects the T1 electrical connection 114 and the electrical conductor 143.
The primary electrical supply system 131 includes a timer electrical system 155 shown in FIG. 4 and constituting part of the safety apparatus 10 of the present invention. For illustrative convenience and as shown in FIG. 4, the timer electrical system includes a first timer circuit 156 linking the X1 electrical connection 121 and the S electrical connection 120, both of the dynamic brake 111, with the on-off switch 128, TR1 timer 125 and number 1 electrical connection 122. A second timer circuit 157 interconnects the first timer circuit 156 on opposite sides of the TR1 timer 125 through the TR2 timer 126 and electrical contracts 127. A second electrical contact circuit 159 interconnects the number 4 electrical connection 117 and number 5 electrical connection 118, both of the dynamic brake, through the electrical contacts 123. A first electrical contact circuit 158 interconnects the S electrical connection 119 of the dynamic brake through the electrical contacts 124 with the first timer circuit 156 between the TR1 timer 125 and the number 1 electrical connection 122 of the dynamic brake.
The electrical system 130 includes an electrical control system 161, shown in FIG. 4. The electrical control system 161 includes a step down transformer 162 operable to convert the electrical current of the electrical control system from one hundred and ten (110) volts alternating current (A.C.) to twelve (12) volts direct current (D.C.). The transformer has a positive input contact 163, a negative input contact 164, a positive output contact 165 and a negative output contact 166.
The electrical control system 161 has a switch 170 which, in actuality, is mounted in the motor starter 132. The electrical control system has an R2 electrical contact 171, a stop switch 172, a momentary contact start switch 173 and electrical contacts 174. The electrical control system has a motor starter solenoid 175 and B2 electrical contacts 176. The electrical control system 161 has three overload unit electrical contacts 177, R1 electrical relay 178, a P3 motion detector connection 179 and an R3 electrical relay 180. In the preferred embodiment, the switches 172 and 173 are actually physically located at a main console, not shown, spaced some distance from the lint cleaning machine 20. The motor starter solenoid 175 is actually physically located in motor starter 132.
The electrical control system also includes a control switch 181 which is actually physically located in a front control switch housing 182 displaying a green light 183 and a red light 184. The on-off switch 128 is actually physically located in the control switch housing and is cooperable with the control switch 181.
The electrical control system 161 further includes an electrical conductor 190 extending from a source, not shown, of electrical energy of one hundred and ten (110) volts alternating current (A.C.) to the positive input contact 163 of the transformer 162. An electrical conductor 191 extends from the source of electrical energy of one hundred and ten (110) volts alternating current (A.C.) to the negative input contact 164 of the transformer. An electrical conductor 192 interconnects electrical conductor 190 and the switch 170. An electrical conductor 193 interconnects the switch 170 and the control switch 181 of the front control switch housing 182. Electrical conductor 194 interconnects the control switch 181 and the R2 electrical contacts 171. An electrical conductor 195 interconnects the R2 electrical contacts and the stop switch 172. An electrical conductor 196 interconnects the stop switch 172 and the start switch 173. Electrical conductor 197 interconnects the start switch 173 and the motor starter solenoid 175. An electrical conductor 198 interconnects the motor starter solenoid 175 and the B2 electrical contacts 176. An electrical conductor 199 interconnects the B2 electrical contacts 176 and the three overload unit electrical contacts 177. An electrical conductor 200 interconnects the three overload unit electrical contacts 177 and electrical conductor 191.
Electrical conductor 210 interconnects the electrical conductor 196 and the electrical contacts 174. An electrical conductor 211 interconnects the electrical contacts 174 and electrical conductor 197. Electrical conductor 212 interconnects electrical conductor 194 and the R1 electrical relay 178. Electrical conductor 213 interconnects the R1 electrical relay 178 and electrical conductor 191. Electrical conductor 214 interconnects electrical conductor 190 and the P3 motion detector connection 179. Electrical conductor 215 interconnects the P3 motion detector connection 179 and the R3 electrical relay 180. Electrical conductor 216 interconnects the R3 electrical relay 180 and electrical conductor 191.
The electrical system 130 of the safety apparatus 10 includes an electrical control system 231 shown in the schematic diagram of FIG. 4. The electrical control system 231 includes R2 electrical contacts 232, B1 electrical contacts 233, R1 electrical contacts 234, R3 electrical contacts 235 and an R2 electrical relay 236, all of which are shown in FIG. 4.
The electrical control system 231 includes an electrical conductor 240 connected to the positive output contact 165 and is connected at its opposite end to the R3 electrical contacts 235. An electrical conductor 241 interconnects the B1 electrical contacts 233 and the front electromagnet 81. An electrical conductor 242 interconnects the front electromagnet 81 and the rear electromagnet 83. An electrical conductor 243 interconnects the rear electromagnet 83 and the R2 electrical relay 236. An electrical conductor 244 interconnects the R2 electrical relay 236 and the negative output contact 166 of the transformer 162. Electrical conductor 245 interconnects the electrical conductor 240 and the R2 electrical contacts 232. An electrical conductor 246 interconnects the R2 electrical contacts 232 and the red light 184. Electrical conductor 247 interconnects the red light 184 and electrical conductor 244. Electrical conductor 248 interconnects electrical conductor 240 and the B1 electrical contacts 233. Electrical conductor 249 interconnects electrical conductor 240 and the R1 electrical contacts 234. Electrical conductor 250 interconnects the R1 electrical contacts 234 and electrical conductor 241. Electrical conductor 251 interconnects the R3 electrical contacts 235 and electrical conductor 241. Electrical conductor 252 interconnects the front electromagnet 81 and electrical conductor 244. Electrical conductor 253 interconnects the rear electromagnet 83 and electrical conductor 244. Electrical conductor 254 interconnects electrical conductor 243 and the green light 183. Electrical conductor 255 interconnects the green light 183 and electrical conductor 244.
OPERATION
The operation of the described embodiment of the subject invention is believed to be clearly apparent and is briefly summarized at this point. As previously noted, the cotton lint cleaning machine 20 is of conventional design except for the addition of the safety apparatus 10 heretofore described. Accordingly, the conventional operation of the cotton lint cleaning machine will not be described herein.
However, in order for the lint cleaning machine 20 to be operable where fitted with the safety apparatus 10 as described, certain conditions must be met. The front metal strike plate 82 and the rear metal strike plate 84 must be disposed in full facing engagement with their respective front electromagnet 81 and rear electromagnet 83 to complete the electrical path to the R2 electrical relay 236 closing the R2 electrical contacts 171. This prevents the lint cleaning machine from starting with either of the access doors 35 or 45 in an opened condition. As can be visualized in FIG. 2, this can only be achieved by positioning the front access grate 35 and rear access grate 45 in the closed conditions, such as shown in FIG. 1, with respect to the front access grate. Secondly, the control switch 181 must be placed in the "on" position to complete the electrical control system 161 therethrough. When these two conditions have been met, the electrical control system 231 is completed. This is indicated by the green light 183 of the front control switch housing 182 on the front of the upper housing 23. If either of the two conditions is not met, the lint cleaning machine cannot be operated.
Actual initiation of operation of the lint cleaning machine 20, after the foregoing conditions have been met, is achieved at the main console, not shown, remote from the lint cleaning machine. At the main console, the start switch 173 is closed to complete the circuit therethrough to the motor starter solenoid 175 which operates the motor starter 132 to initiate operation of the main drive motor 73 by supplying electrical energy from the source, not shown, through the primary electrical supply system 131. The lint cleaning machine thereby operates continuously in the normal fashion without the safety apparatus in any respect interfering with such operation.
During normal operation, and for long periods of time, the lint cleaning machine 20 may be permitted to operate continuously and may be stopped at the console using switch 172 during periods of nonuse and restarted using start switch 173 without the safety apparatus 10 of the present invention interfering with such normal and conventional operation of the lint cleaning machine.
However, at times when a malfunction develops, such as clogging of the cotton fiber at the compression roller assemblies 50 or fire, operation of the safety apparatus 10 ensures that injury to personnel in such circumstances is avoided. For example, if personnel monitoring operation of the lint cleaning machine 20 witness through the front or rear access grates 35 or 45, respectively, such an emergency developing, the person immediately moves the control switch 181 adjacent to the front access grate to the "off" position. Such movement of the control switch brakes the electrical control system 161 through the control switch 181 and thus terminates the flow of electrical energy through the primary electrical supply system 131 to the main drive motor 73. Simultaneously through an electrical connection, not shown, the flow of cotton fiber to the lint cleaning machine from the gin stand is terminated. However, as previously described, the inertial load of the conventional rotational assemblies within the lint cleaning machine, and particularly of the saw cylinder assembly 53, are such that rotation of these assemblies continues for some period of time and conventionally up to two minutes after the conventional lint cleaning machine is switched off.
For the reasons previously noted, it is the objective of the safety apparatus 10 of the present invention to prevent removal of either the front access grate 35 or rear access grate 45 until all such motion has ceased. This is achieved in that the motion detector 94 through motion detector connection 179 continues to supply electrical energy through the electrical control system 161 to the R3 electrical relay 180 which maintains the R3 electrical contacts 235 in a closed condition. As a consequence, electrical energy continues to be supplied to the electromagnets 81 and 83 through the electrical control system 231 so that the electromagnets are both energized magnetically to hold their respective metal strike plates 82 and 84 so as to lock the front and rear access grates 35 and 45 in the closed conditions.
Moving of the control switch 181 to the "off" position also triggers operation of the dynamic brake assembly 110. The turning of the control switch 181 to the "off" position also moves the on-off switch 128 of the dynamic brake assembly to the "on" condition which initiates the brake sequence. The TR1 timer 125 of the dynamic brake assembly is activated briefly and then closes electrical contacts 127 to activate the TR2 timer 126. The operable effect of the TR1 timer 125 is to delay activation of the dynamic brake 111 for about five (5) seconds to permit fiber within the lint cleaning machine to pass through.
After the time has run, the dynamic brake 111 is activated. The dynamic brake then converts the alternate current (A.C.) voltage supplied thereto to direct current (D.C.) voltage. This is supplied to the main drive motor 73 along electrical conductors 153 and 154 to reverse the flow of electrical current through the rotor of the main drive motor 73, thus, resisting rotation of the stator of the main drive motor so as to bring it to a halt more quickly. Electrical conductor 152 determines when the motor has come to a stop and through the T3 electrical connection 116 terminates operation of the dynamic brake.
Since, of course, the rotor of the main drive motor 73 is linked, through drive belts, not shown, in direct driving relation to the condenser screen drum assembly 30, doffing roller assemblies 33, compression roller assemblies 50, feed roller assembly 51, saw cylinder assembly 53 and doffing brush assembly 60, the inertial load thereof in rotation is much more quickly overcome and those components are brought to a halt more quickly than would otherwise be the case. This period of time, which conventionally is approximately two minutes, with the use of the dynamic brake assembly 110 is approximately twenty seconds, which includes the five (5) second delay. While the reversal of the flow of electrical energy through the rotor to resist rotation of the stator of the main electric motor 73 produces heat in the main drive motor, this heat is quickly dissipated. Furthermore, since the safety apparatus 20 operates only in unusual or emergency circumstances to cause such heat to develop, no damage is done to the main drive motor.
When the motion detector 94 senses that there is no rotation of the saw cylinder shaft 65, R3 elecrical relay 180 causes the R3 electrical contacts 235 to open thus terminating the flow of electrical energy to the front and rear electromagnets 81 and 83 and green light 183 and the R2 electrical relay 236. Thus, the electromagnets are deenergized, the green light 183 goes out and the R2 electrical contacts 232 are closed to supply electrical energy through the electrical control system 231 to the red light 184 to indicate to personnel that there is no rotation of the components within the lint cleaning machine 20. This simultaneously permits the front and rear access grates 35 and 45, respectively, to be removed from their closed conditions to expose their respective front chamber 36 and rear chamber 46 so that the personnel can immediately gain access to the interior of the machine to deal with whatever problem has developed.
As a consequence, the safety apparatus 10 of the present invention permits the safe use of machines such as lint cleaning machines by permitting, in an emergency situation, an operator to terminate operation of the machine and deal with the emergency condition significantly more rapidly than is conventionally possible while, at the same time, ensuring that no injury is possible resulting from the machine not having come to a complete stop.
Restarting of the lint cleaning machine 20 is not possible until the conditions previously identified are met. The front and rear access grates 35 and 45 respectively must be returned to the closed conditions with the strike plates 82 and 84 again placed in facing engagement with their respective electromagnets 81 and 83. The control switch 181 of the front control switch housing 182 must be placed in the "on" position. Once both of these conditions are met, the green light 183 will be illuminated. This indicates that the lint cleaning machine 20 can be reactivated in the otherwise conventional fashion from the main console, not shown, after disengaging the saw cylinder shaft lock assembly 67 previously described.
Therefore, the safety apparatus of the present invention can be employed on machinery to prevent access to the interior thereof during an operative mode, but permits immediate access to the interior once the machine has reached an inoperative mode; has particular utility in use on such heavy equipment as lint cleaning machines employed in cotton ginning operations; and operates inexpensively and completely dependably to preclude injury to personnel as a result of gaining access to the interior of such machinery prior to reaching the inoperative mode.
Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of the invention which is not to be limited to the illustrative details disclosed.
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A safety apparatus for controlling access to a work object having an active mode and a passive mode, the apparatus having a lock assembly for obstructing access, in a first condition, and alternatively permitting access, in a second condition, to the work object; a detector for detecting when the work object is in the active mode and in the passive mode; and a control system operably interconnecting the lock assembly and the detector operable when the work object is in the active mode, as detected by the detector, to maintain the lock assembly in the first condition and when the work object is in the passive mode, as detected by the detector, to maintain the lock assembly in the second condition.
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BACKGROUND OF THE INVENTION
This invention relates to a rotating machine, and more particularly to a rotating machine whose start is effected by actuating only some of the coils which are all energized during the full drive.
Various methods have been proposed for the start of a rotating machine such as an electric motor. These methods include the type which effects the start of a rotating machine by actuating only some of the coils attached to the machine. This method comprises dividing all the coils which are to be energized during the full drive into two or circuits groups and energizing one or the other of these two or circuit groups to effect the start of the rotating machine.
FIGS. 1 and schematically indicate the conventional method which starts a 3-phase 36-slot 2-pole electric motor by actuating only some of the coils used. In FIGS. 1 and 2, the characters 1 to 36 denote the serial slot numbers of a stator (not shown). Coils are received in the slots in six groups in the following manner:
Slots 1 to 6 hold the first group of U-phase coils marked with ;
Slots 7 to 12 hold the second group of Z-phase coils marked with ;
Slots 13 to 18 hold the third group of V-phase coils marked with ;
Slots 19 to 24 hold the fourth group of X-phase coils marked with ;
Slots 25 to 30 hold the fifth group of W-phase coils marked with ;
Slots 31 to 36 hold the sixth group of Y-phase coils marked with ;
Black marks given in FIGS. 1 and 2 denote the coils which are not energized at the start of a rotating machine. For briefness of illustration, FIGS. 1 and 2 indicate only the upper coils. The lower coils (not shown) are received in the corresponding slots in a state respectively displaced from the upper coils by a prescribed coil pitch.
The field winding of the electric motor of FIG. 1 is formed of U-, V- and W-phase coils so connected as to produce three magnetic fields spaced from each other at an electric angle of 60° (FIG. 6) as counted in the circumferential direction of a cylindrical stator. The field winding of the electric motor of FIG. 2 is formed of U-, Z- and V-phase coils so connected as to produce three magnetic fields arranged adjacent to each other on one segmental section of the cylindrical stator jointly to define an electric angle of 180° (FIG. 7).
FIGS. 3 and 4 respectively typically illustrate the manner in which the coils of the various phases shown in FIGS. 1 and 2 are connected. In FIGS. 3 and 4, the characters R 1 , R 2 , S 1 , S 2 , T 1 , T 2 denote terminals for connecting the coils of the various phases. 3-phase A.C. current is supplied to the coils through said contacts.
FIG. 5 is a development diagram of coils held in the slots of the stator of the electric motor of FIGS. 1 and 3. A development diagram of the coils of the respective phases held in the slots of the stator of the electric motor of FIGS. 2 and 4 is omitted, because said coils are connected only in a different manner from FIG. 5.
Where 3-phase A.C. current is supplied to the coils of the U-, V- and W-phases to start the motor of FIGS. 1, 3 and 5, then the A.C. current flows through the coils U, V and W as indicated by the hatchings of FIG. 6. The remaining coils of the Z-, X- and Y-phases which are not supplied with the 3-phase A.C. current do not produce actual magnetic fields, but only imaginary ones. Each of these imaginary magnetic fields are formed by an opposite electromotive force induced by the magnetic fields generated by the coils of the U-, V- and W-phases, and have the opposite poles to those of the coils of the U-, V- and W-phases. At the start of the electric motor of the above-mentioned arrangement, the magnetic fields of U, V and W and imaginary magnetic fields Z, X and Y are produced. During the acceleration period after the start, therefore, an even harmonic magnetomotive force exerts a prominent effect on a fundamental harmonic magnetomotive force, eventually resulting in a decline in a magnetomotive force. Consequently a torque valley appears which results from a valley-like descent of a torque characteristic curve. Where said torque valley is positioned below a load torque, then the electric motor can not be accelerated.
A prior art electric motor in which the coils of the various phases are connected as shown in FIGS. 2 and 4 are accompanied with the drawbacks of a prior art electric motor described with reference to FIGS. 1 and 3. The hatching of FIG. 7 shows the coils which carry the A.C. current when 3-phase A.C. current is applied to the coils of the U-, Z- and V-phases of the electric motor of FIGS. 2 and 4. In this case, too, the actual magnetic fields U, Z, V and imaginary magnetic fields X, W, Y are produced, causing the even harmonic magnetomotive force to exert a noticeable effect on the fundamental harmonic magnetomotive force. Where, therefore, the resultant torque valley falls before the load torque, then the electric motor can not be accelerated as in the aforementioned case.
SUMMARY OF THE INVENTION
It is accordingly the object of this invention to provide a rotating electric machine, such as an electric motor whose start acceleration can be reliably effected by decreasing an effect exerted by the even harmonic magnetomotive force on the fundamental harmonic magnetomotive force and particularly by reducing a torque which is caused by a magnetomotive force corresponding four poles and is not synchronized with the fundamental harmonic magnetomotive force.
To attain the above-mentioned object, this invention provides a rotating electric machine which comprises:
a first circuit which is formed by connecting a first group of coils of various phases constituting 3-phase armature winding and energized at the start of the rotating electric machine; and
a second circuit which is formed by connecting a second group of coils, is so arranged as to generate an induced electromotive force having an equal magnitude to that which is produced in the first circuit, and is set in parallel with the first circuit to be energized during the full drive of the rotating electric machine.
With a rotating machine embodying this invention which is constructed as described above, a magnetomotive force applied at the start of said rotating machine has such characteristic as approximates that which appears at the full drive of said machine in which all the magnetic fields are energized. Therefore, an effect exerted by the even harmonic magnetomotive force on the fundamental harmonic magnetomotive force is reduced. Consequently the torque valley is rendered shallow, and the bottom of said torque valley is prevented from falling below the load torque, thereby assuring start acceleration.
BRIEF DESCRIPTION OF THE DRAWINGS
By way of example and to make the description clearer, reference is made to the accompanying drawings, in which:
FIGS. 1 and 2 show the arrangement of coils of various phases used with a conventional 2-pole rotating electric machine of the 3-phase and 36-slot type, which is started by energizing some of said coils;
FIGS. 3 and 4 respectively typically illustrate the manner in which the coils of various phases of FIGS. 1 and 2 are connected together;
FIG. 5 is a development diagram of the coils held in the slots of the stator of the rotating electric machine of FIGS. 1 and 3;
FIGS. 6 and 7 respectively indicate magnetic fields produces when the conventional electric motors of FIGS. 1 and 2 are started;
FIG. 8 shows the arrangement of coils used with an electric motor according to one embodiment of this invention, in which the coils of each phase are divided into two circuits, one of which is energized at the start of said electric motor and the other of which remains nonenergized at said start;
FIG. 9 typically illustrates the arrangement of the coils of the respective phases of FIG. 8 divided into two sub-groups;
FIG. 10 is a development diagram of coils held in the slots of a stator of an electric motor of FIGS. 8 and 9;
FIG. 11 shows the pattern of magnetic fields produced when the electric motor of FIG. 8 is started;
FIG. 12 indicates the arrangement of coils used with an electric motor according to another embodiment of the invention in which the coils of the respective phases are divided into two circuit, one of which is energized at the start of said electric motor and the other of which remains nonenergized at said start, though the individual coils are arranged in a different manner from FIG. 8; and
FIG. 13 is a development diagram of coils used with an electric motor modified from that of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 8 shows the manner in which the coils of each phase used with a 2-pole 3-phase 36-slot electric motor are arranged as groups U, Z, V, X, W and Y and are divided into two groups or circuits, one of which is energized at the start of said motor, and the other of which remains nonenergized at said start. To describe in detail, U-phase coils held in the slots 1 to 3 of a cylinderical stator (not shown) and constitute a first coil sub-group U 1 and U-phase coils held in the stator slots 4 to 6 constitute a second coil sub-group U 2 . Similarly, the Z-phase coils held in the stator slots 7 to 12 are divided into a first sub-group Z 1 (held in the stator slots 7 to 9) and a second sub-group Z 2 (held in the stator slots 10 to 12). The V-phase coils held in the stator slots 13 to 18 are divided into a first sub-group V 1 (held in the stator slots 13 to 15) and a second sub-group V 2 (held in one stator slots 16 to 18). The X-phase coils held in the stator slots 19 to 24 are divided into a first group X 1 (held in the stator slots 22 to 24) and a second sub-groups X 2 (held in the stator slots 19 to 21). The W-phase coils held in the stator slots 25 to 30 are divided into a first sub-groups W 1 (held in the stator slots 28 to 30) and a second sub-groups W 2 (held in the stator slots 25 to 27). The Y-phase coils held in the stator slots 31 to 36 are divided into a first sub-groups Y 1 (held in the stator slots 34 to 36) and a second sub-groups Y 2 (held in the stator slots 31 to 33). In FIG. 8, the black marks denote the coils which are not energized when the electric motor is started. For briefness of illustration, FIG. 8 indicates only the upper coils. The lower coils (not shown) are displaced from the corresponding upper coils by a prescribed coil pitch. FIG. 9 shows the manner in which the divided sub-groups of coils of the respective phases are connected to constitute a coil assembly for the drive of an electric motor. The divided coil sub-groups U 1 , X 1 are connected in series between the terminals R.sub. 1, S 1 of the first circuit. The divided coil sub-groups V 1 , Y 1 are connected in series between the terminals S 1 , T 1 of the first circuit. The divided coil sub-groups W 1 , Z 1 are connected in series between the terminals T 1 , R 1 of the first circuit. The divided coil sub-groups U 2 , X 2 are connected in series between the terminals R 2 , S 2 of the second circuit. The divided coil sub-groups V 2 , Y 2 are connected in series between the terminals S 2 , T 2 of the second circuit. The divided coil sub-groups W 2 , Z 2 are connected in series between the terminals T 2 , R 2 of the second circuit.
FIG. 10 is a development diagram of the coils held in the slots of the stator of the electric motor of FIGS. 8 and 9. Description is now given of the operation of an electric motor of FIGS. 8 and 9 according to one embodiment of this invention which is constructed as described above. Where the electric motor of FIGS. 8 and 9 according to the first embodiment is started, 3-phase A.C. voltage is impressed on either the terminals group of R 1 , S 1 , T 1 or the terminals group of R 2 , S 2 , T 2 to energize the corresponding coils. FIG. 11 shows the arrangement of the respective divided sub-groups of coils U 1 , X 1 , V 1 , W 1 , Z 1 jointly constituting the first circuit which are energized at the start of the electric motor. In FIG. 11 the energized sub-groups of coils are indicated by hatching. After the start, the electric motor is fully driven by energizing all the coils of both first and second circuits. As seen from the foregoing description, the electric motor of FIGS. 8 and 9 according to the first embodiment of this invention is started by energizing half the number of coils used for the full drive of said motor. At the start, the energized coils produce approximately the same pattern of magnetic fields as that which appears at the full drive of the motor. Therefore, the magnetomotive force applied at the start of an electric motor indicates approximately the same characteristic as that which appears at the full drive of the motor effected by energizing all the coils. Consequently, the even harmonic magnetomotive force exerts a reduced effect on the fundamental harmonic magnetomotive force, thereby rendering the torque valley shallow, namely, preventing the bottom of said torque valley falling below the load torque and assuring the start acceleration.
Comparison was made between the calculated values of the high harmonic component of a magnetomotive force applied to the electric motor of FIG. 8 according to the first embodiment of this invention and those of the high harmonic component of a magnetomotive force applied to the conventional electric motors of FIGS. 1 and 2, the results being set forth in Table 1 below.
TABLE 1______________________________________Components of Electrica magnetomotive motor offorce corre- Conventional Conventional FIG. 8sponding to the electric electric embodyingtotal number of motor of motor of thisthe S and N poles FIG. 1 FIG. 2 invention______________________________________ 2 1.00 1.00 1.00 4 -0.332 -0.499 * 6 * * * 8 0.03 0.09 *10 -0.05 -0.05 -0.212 * * *14 0.01 0.01 0.0416 0.02 -0.04 *18 * * *20 * * *22 -0.01 -0.01 -0.0124 * * *26 * * *28 -0.03 -0.11 *30 * * *32 * * *______________________________________
Calculation was made with respect to a 2-pole 36-slot electric motor in which the coil pitch was set at 62.2% and the fundamental harmonic component of a magnetomotive force was taken to be 1.00. The mark-preceding the numerals given in Table 1 above denotes that a magnetomotive force was rotated in the opposite direction to that in which the fundamental harmonic component was produced. The mark * shown in said Table 1 indicates that the component of the magneto-motive force was measured to be approximately zero. Table 1 above proves that with the electric motor constructed according to this invention, a component of a magnetomotive force corresponding to 4 poles is far more reduced than in the conventional electric motors.
With the foregoing embodiment, six coil groups were provided on the 1 pole-1 phase basis. However, this invention need not be limited to such arrangement. For instance, as shown in FIG. 12, it is possible to provide 8 coils on the 1 pole-1 phase basis. As in FIGS. 1, 2 and 8, the white marks given in FIG. 12 denote the coils which are energized at the start of the electric motor, and the black marks indicated therein represent the coils which remain nonenergized at the start of the electric motor.
With the embodiment of FIGS. 8 and 9, the coils held in the stator slots bearing the numbers of, for example, 1, 2, 3 are connected in the same serial order, as shown in the development diagram of FIG. 10. However, this invention need not be limited to this arrangement. For instance, as shown in the development diagram of FIG. 13, the coils held in the stator slots bearing the numbers of, for example, 1, 3, 5 may be connected. In other words, the coils held in the alternate stator slots can be connected for each phase. Obviously, this invention can be practised in various modifications without departing from the object of the invention.
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A rotating electric machine provided with coils of various phases constituting 3-phase armature winding which are divided into first and second groups or circuits. A first circuit formed of selected sub-groups of coils of various phases is energized at the start of the electric rotating machine. A second circuit is formed of the remaining coils of various phases which are so connected as to generate an induced electromotive force having an equal magnitude to that which is produced in the first circuit. Said second circuit is connected in parallel with the first circuit to be energized at the full drive of the rotating electric machine.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority of Japanese Patent Application No. 2004-230997, filed on Aug. 6, 2004, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a fuel nature measuring device for an internal combustion engine and an internal combustion engine having the same.
BACKGROUND OF THE INVENTION
[0003] A gasoline engine in an automobile generally has a fuel injection valve provided at an intake pipe, and fuel injected from the fuel injection valve is supplied to an intake port. However, during cold starting with no sufficient warm-up, part of the fuel injected from the fuel injection valve tends to stick to the inner wall surface of the intake port or the surface of the intake valve and fails to enter the combustion chamber. This substantially reduces the injection amount. In order to secure an air-fuel ratio equivalent to that in a sufficiently warmed-up state, the injection amount is often corrected by adding fuel in such a case.
[0004] The amount of fuel thus sticking, for example, to the inner wall surface of the intake port, without contributing to combustion varies depending on the nature of the fuel, especially the level of its volatility. Fuel nature varies among the manufacturers, the seasons, and the distribution areas even if the fuel is of the same kind. Therefore, fuel nature must be measured highly precisely in order to accurately correct the injection amount.
[0005] A known technique for measuring fuel nature takes advantage of the characteristic that the dielectric constant of fuel changes depending on the fuel nature. According to this technique, a capacitor-type detector is provided and determines whether the fuel is light gasoline or heavy gasoline based on a capacitance of the detector corresponding to the dielectric constant of the fuel (see Japanese Utility Model Laid-Open Publication No. Hei 4-8956). According to this technique, an oscillation circuit that generates a signal at a frequency corresponding to capacitance is provided to obtain the capacitance. Another known technique takes advantage of the characteristic that the refractive index, boiling point, and molecular heat of a fuel changes depending on the fuel nature (see Japanese Patent Laid-Open Publication No. Hei 4-1438). According to the disclosure of Japanese Patent Laid-Open Publication No. Hei 4-1438, an optical fiber is immersed in the fuel, and the quantity of light passed through the optical fiber is anazlyzed to obtain the refractive index.
[0006] In order to obtain the volatility of fuel based on the dielectric constant and the refractive index, a relation between the dielectric constant and refractive index of the fuel and the volatility of the fuel must be previously known. However, the relationship varies among the manufacturers of the fuel, the seasons, and the distribution areas and it is not necessarily easy to acquire accurate information between them.
SUMMARY OF THE INVENTION
[0007] The embodiments of the present invention are directed to solve the above-described and other problems and provide a fuel nature measuring device for use in an internal combustion engine that can simply determine the volatility of fuel and an internal combustion engine having the same.
[0008] A fuel nature measuring device according to one aspect of the present invention measures the nature of fuel stored in a fuel tank. The measuring device includes a measurement passage having an orifice; a gas flow generating means for generating a gas flow in the measurement passage; differential pressure detecting means for detecting a differential pressure between both ends of the orifice; evaporated fuel concentration operating means for determining the concentration of evaporated fuel based on the differential pressure detected when the measurement passage communicates with the fuel tank at its both ends and gas in the fuel tank is the gas for measurement let to flow in the measurement passage; temperature detecting means for detecting a temperature of the fuel in the fuel tank; and volatility calculation means for calculating volatility of the fuel in the fuel tank as the fuel nature based on the concentration of the evaporated fuel detected by the evaporated fuel concentration operation means and the temperature detected by the temperature detecting means.
[0009] When the volatility of the fuel changes, the characteristic line of the saturated concentration of the evaporated fuel relative to the temperature changes. Based on the evaporated fuel concentration at the present temperature, the volatility of the fuel stored in the fuel tank can be specified.
[0010] According to another aspect of the present invention, the internal combustion engine includes a canister storing an absorbent that temporarily absorbs the evaporated fuel guided from the fuel tank through a conduit; a purge passage that guides gas in the canister including evaporated fuel desorbed from the absorbent into the intake pipe of the internal combustion engine and purges the evaporated fuel; and a purge control valve provided in the purge passage to adjust a purge flow rate.
[0011] The configuration also includes another evaporated fuel concentration operation means for operating a concentration of the evaporated fuel in gas for measurement based on the differential pressure detected when the measurement passage communicates with the canister at its both ends and gas in the canister is the gas for measurement let to flow in the measurement passage.
[0012] The main means for measuring the concentration of the evaporated fuel such as the measurement passage and the differential pressure detecting means can also be used for measuring the concentration of the evaporated fuel purged from the canister. In this way, the concentration of the evaporated fuel in the purge gas as well as the volatility of the fuel can be measured without having to provide a complicated configuration.
[0013] Another aspect of the present invention includes measurement passage switching means for switching between first and second concentration measurement states. In the first concentration measurement state, the measurement passage is opened to the atmosphere at its both ends and the gas passed through the measurement passage is the air. In the second concentration measurement state, the measurement passage communicates with the fuel tank at its both ends through a gas phase portion of the fuel tank and the gas let to flow in the fuel measurement passage is the gas in the fuel tank. The evaporated fuel concentration operating means serves as operation means for operating the concentration of the evaporated fuel based on the detected differential pressures in the first and second concentration measurement states.
[0014] In addition to the differential pressure detected when the gas in the fuel tank is distributed in the measurement passage, the differential pressure detected when the concentration of the evaporated fuel is known (zero) is available, so that correction can be carried out based on the differential pressure detected in the state. In this way, the fuel nature can be obtained more accurately.
[0015] Another aspect of the present invention includes valve means for blocking the gas flow at the orifice, and the differential pressure detecting means includes a pair of lead passages having the orifice and the valve means therebetween. The configuration further includes a communication passage to allow a closed space including the canister (formed when the purge control valve is closed) to communicate with the measurement passage on the side of one of the leading passages; another valve means for blocking the communication passage; and leakage determining means for determining leakage in the closed space based on values detected by the differential pressure detecting means in first and second leakage detection states. In the first leakage detection state, the measurement passage is not blocked and the communication passage is blocked. In the second leakage detection state, the measurement passage is blocked and the communication passage is not blocked.
[0016] In the second leakage detection state, the value detected by the differential pressure detecting means changes according to the size of a leak hole in the closed space. Information on the leakage in the closed space can be obtained by comparing the detected value to the value detected in the first leakage detection state in which the air is distributed through the orifice whose cross sectional area in the passage is a prescribed value. In this way, the volatility of the fuel or the concentration of the evaporated fuel in the purge gas can be measured without having to provide a complicated configuration. In addition, the detection for the fuel leakage can be carried out.
[0017] Still another aspect of the present invention includes engine operation state detecting means for detecting the operation state of the internal combustion engine, and the fuel nature is measured provided that the internal combustion engine is in a stopped state.
[0018] When the internal combustion engine is in a stopped state, the concentration of the evaporated fuel in the gas in the fuel tank is stable, and the fuel nature can be known more accurately.
[0019] According to yet another aspect of the present invention, the engine operation state detecting means detects whether an ignition key is on or off.
[0020] Whether the internal combustion engine is in a stopped state can easily be detected.
[0021] Still another aspect of the present invention includes fuel tank state detecting means for detecting change in the state caused by fueling to the fuel tank, and the fuel nature is measured in response to the fueling to the fuel tank.
[0022] By the fueling, the fuel tank is filled with fuel supplied by a different manufacturer and distributed in a different area from the previous one and therefore, it is highly likely that the volatility of the fuel before and after the fueling changes in a discontinued manner. Therefore, the fuel nature can be obtained more accurately.
[0023] According to still another aspect of the present invention, the fuel tank state detecting means detects whether a fuel cap of the fuel tank is open or closed.
[0024] The fuel tank in the process of being filled can easily be detected.
[0025] According to still another aspect of the present invention, the fuel tank state detecting means detects an amount of the fuel in the fuel tank and it is determined that the tank is in the process of being filled when the fuel amount is increased to a predetermined reference amount.
[0026] In this way, the fuel tank in the process of being filled can easily be detected.
[0027] According to still yet another aspect of the present invention, the fuel nature is measured for every prescribed time period.
[0028] The fuel stored in the fuel tank evaporates with time starting from its low boiling point component and therefore, the volatility is gradually lowered. Since the fuel nature is measured for every prescribed period, the change with time in the volatility is available.
[0029] According to still yet another aspect of the present invention, the temperature detecting means detects a temperature at a location other than the fuel tank, and estimates the temperature of the fuel based on the temperature detected at the location other than the fuel tank.
[0030] Other temperature detecting means provided at the internal combustion engine can also be used as the temperature detecting means. In this case, the temperature is detected at a sufficient time after the internal combustion engine stops, so that the concentration of the evaporated fuel in the fuel tank can be stabilized. Since the temperatures at various parts of the internal combustion engine converge to the ambient temperature, estimation errors can be reduced.
[0031] Yet still another aspect of the present invention includes an internal combustion engine having the fuel nature measuring device according to any of the aspects described above.
[0032] Since the amount of the fuel not contributing to the combustion in the combustion chamber can accurately be determined, the air-fuel ratio can be controlled appropriately.
[0033] An internal combustion engine according to yet another aspect of the present invention includes fuel injection amount setting means for setting a fuel injection amount at the start of the internal combustion engine based on the measured fuel nature.
[0034] Since the amount of fuel coming into the combustion chamber during cold starting can accurately be determined, the optimum fuel amount can be injected, and the internal combustion engine can be started quickly. In addition, excess fuel is not injected and therefore, the amount of fuel sticking to the internal wall or the like of the intake port can be reduced, which can reduce exhaust emission at the start of the engine.
[0035] Other features and advantages of the present invention will be appreciated, as well as methods of operation and the function of the related parts from a study of the following detailed description, appended claims, and drawings, all of which form a part of this application. In the drawings:
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a schematic diagram of a fuel nature measuring device according to a first embodiment of the invention adapted to an internal combustion engine;
[0037] FIG. 2 is a flowchart of a fuel nature measuring process according to the first embodiment of the present invention;
[0038] FIG. 3 is a second flowchart of a concentration detection routine of the fuel nature measuring process of FIG. 2 ;
[0039] FIG. 4 is a timing chart illustrating various transitional states of various components of the fuel nature measuring device of FIG. 1 during the concentration detection routine of FIG. 3 ;
[0040] FIG. 5 is a top view of a part of the fuel nature measuring device of FIG. 1 in a first concentration measurement state;
[0041] FIG. 6 is a top view of a part of the fuel nature measuring device of FIG. 1 in a second concentration measurement state;
[0042] FIG. 7 is a first graph illustrating the operation of the internal combustion engine according to the first embodiment of the present invention illustrating gas flow;
[0043] FIG. 8 is a flowchart of a fuel volatility calculation routine of the fuel nature measuring process of FIG. 2 ;
[0044] FIG. 9 is a reference map for use in the fuel volatility calculation routine of FIG. 8 ;
[0045] FIG. 10 is a fourth flowchart of a fuel injection correction amount routine according to the first embodiment of the present invention;
[0046] FIG. 11 is a schematic diagram of a fuel nature measuring device according to a second embodiment of the present invention;
[0047] FIG. 12 is a schematic diagram of a fuel nature measuring device according to a third embodiment of the present invention;
[0048] FIG. 13 is a flowchart of a fuel nature measuring process according to the third embodiment of the present invention;
[0049] FIG. 14 is a schematic view of a fuel nature measuring device according to a fourth embodiment of the present invention adapted to an internal combustion engine;
[0050] FIG. 15 is a flowchart of a fuel nature measuring process according to the fourth embodiment of the present invention; and
[0051] FIG. 16 is a schematic diagram of a fuel nature measuring device according to a fifth embodiment of the present invention adapted to an internal combustion engine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] FIG. 1 illustrates a configuration of a fuel nature measuring device according to a first embodiment of the invention installed in an automobile engine. A fuel tank 11 for an internal combustion engine 1 is connected to a canister 13 through a conduit 12 , and the fuel tank 11 and the canister 13 are continuously in communication. The canister 13 is filled with an absorbent 14 and the fuel evaporated in the fuel tank 11 is temporarily absorbed by the absorbent 14 . The canister 13 is connected to an intake pipe 2 of the engine 1 through a purge passage 15 . The purge passage 15 is provided with a purge valve 16 serving as a purge control valve, and when the valve opens, the canister 13 and the intake pipe 2 communicate.
[0053] The purge valve 16 is an electromagnetic valve and has its valve travel controlled by duty control or the like using an electronic control unit (ECU) 51 that controls various parts of the engine 1 . Evaporated fuel desorbed from the absorbent 14 is purged into the intake pipe 2 by the negative pressure in the intake pipe 2 based on the valve travel and combusted together with fuel injected from an injector 5 . Hereinafter, the air-fuel mixture including the evaporated fuel to be purged is referred to as “purge gas.”
[0054] The canister 13 is connected to a purge air passage 17 that is open to the atmosphere at its tip end. The purge air passage 17 is provided with a close valve 18 .
[0055] The purge passage 15 and the purge air passage 17 can be connected through an evaporated fuel passage 21 , which serves as a measurement passage. The evaporated fuel passage 21 is connected to the purge passage 15 through a branch passage 25 . The branch passage 25 communicates with the purge passage 15 at a point that is closer to the canister 13 than the purge valve 16 . The evaporated fuel passage 21 is connected to the purge air passage 17 through a branch passage 26 that communicates with the purge air passage 17 at a point between the canister 13 and the close valve 18 . The evaporated fuel passage 21 is provided with a first selector valve 31 , an orifice 22 , a valve 33 , a pump 41 , and a second selector valve 32 in this order from the side of the purge passage 15 . The purge passage 15 can be connected to the conduit 12 through a communication passage 24 that communicates with the conduit 12 at a point closer to the canister 13 than the branch passage 25 . The purge air passage 17 can be connected to the fuel tank 11 by a communication passage 27 at the branch portion to the branch passage 26 . The communication passage 27 communicates with the fuel tank 11 above the level of the fuel regardless of the amount of fuel in the fuel tank 11 similar to the conduit 12 . Communication passages 24 and 27 are provided with valves 34 and 35 , respectively.
[0056] The purge air passage 17 and the evaporated fuel passage 21 communicate through a communication passage 28 . One end of the communication passage 28 communicates with the evaporated fuel passage 21 at a point between the valve 33 and the pump 41 , closer to the pump 41 . The other end of the communication passage 28 communicates with the purge air passage 17 at a point between the canister 13 and the communication passage 26 , closer to the communication passage 26 .
[0057] The first selector valve 31 is a three-way electromagnetic valve that selects between first and second concentration measurement states. In the first concentration measurement state, the evaporated fuel passage 21 is opened to the atmosphere at one end, which is the right end in FIG. 1 . In the second concentration measurement state, the evaporated fuel passage 21 communicates with the communication passage 25 at the end. The switching operation between the two states is controlled by the ECU 51 . When the first selector valve 31 is in a non-conductive state (off), the first concentration measurement state is attained to let the evaporated fuel passage 21 open to the atmosphere.
[0058] The second selector valve 32 is also a three-way electromagnetic valve that selects between first and second concentration measurement states. In the first concentration measurement state, the evaporated fuel passage 21 is opened to the atmosphere at the other end, which is the left end if FIG. 1 . In the second concentration measurement state, the evaporated fuel passage 21 communicates with the communication passage 26 . The switching operation between the two states is controlled by the ECU 51 . When the second selector valve 32 is in a non-conductive state (off), the first concentration measurement state is attained to let the evaporated fuel passage 21 open to the atmosphere.
[0059] The other valves 33 , 34 , 35 , and 36 are two-way electromagnetic valves, and block the respective passages in which they are provided.
[0060] The pump 41 , which serves as the gas flow generating means, is a motor pump that in operation allows gas to be distributed in and along the evaporated fuel passage 21 while the side of the first selector valve 31 serves as the intake side and has its on/off and revolution speed in operation controlled by the ECU 51 . The revolution speed is controlled to be stable at a previously set value, in other words, fixed revolution speed control is carried out.
[0061] The evaporated fuel passage 21 is connected to a differential pressure sensor 55 serving as the differential pressure detecting means through connecting pipes 231 and 232 at the ends of the orifice 22 and the valve 33 . The differential pressure sensor 55 detects the pressure difference between the ends of the orifice 22 . A detection signal for the differential pressure is output to the ECU 51 .
[0062] The fuel tank 11 is provided with a temperature sensor 56 , which serves as the temperature detecting means, that detects the temperature inside the fuel tank 11 . A detection signal for the temperature is output to the ECU 51 .
[0063] The ECU 51 has a general configuration for an engine and includes a microcomputer as a main part. The ECU 51 controls elements such as a throttle 4 that is provided at the intake pipe 2 to adjust the intake air amount, an injector 5 that injects fuel, and an ignition plug 6 that ignites an air fuel mixture. This is carried out based on the amount of intake air detected by the air flow sensor 52 provided at the intake pipe 2 , intake air pressure detected by an intake air pressure sensor 53 , and an air-fuel ratio detected by an air-fuel ratio sensor 54 provided at an exhaust pipe 3 and in response to an ignition signal, the engine speed, the temperature of engine cooling water, the accelerator opening and the like. Accordingly, an appropriate throttle opening angle, a fuel injection amount, an ignition timing and the like can be obtained. Note that the pressure detected by the intake air pressure sensor 53 is given in absolute pressure, and equal to atmospheric pressure in the subsequent description of the fuel volatility calculation routine.
[0064] FIG. 2 is a flowchart of the fuel nature determination process performed by the ECU 51 according to the principles of the first embodiment of the present invention. In step S 101 , it is determined whether a fuel volatility determining condition is established. The fuel volatility could change by fueling, or a passing of a prescribed time period or longer after the previous fueling or when the automobile having the engine is left unused for a long while in a high temperature environment and the low-boiling point component of the fuel in the fuel tank 11 is evaporated. The fuel volatility condition is so set that the volatility is to be determined when a change in the volatility is estimated for such a reason. The process of determining whether the fuel volatility determining condition is established will be described in more detail in connection with the subsequent third embodiment.
[0065] In general, when the result of the determination in step S 101 is affirmative, the process proceeds to step S 102 to carry out the concentration detection routine. When the result of the determination is negative, step S 101 is repeated. After the concentration detection routine is performed at step S 102 , the fuel volatility calculation routine is performed in step S 103 .
[0066] FIG. 3 shows the content of the concentration detection routine performed in step S 102 of FIG. 2 . FIG. 4 shows the transition of the states of various parts of the device during the concentration detection routine. In the initial state in the concentration detection routine, the purge valve 16 is “closed” and the close valve 18 is “open.” The first and second selector valves 31 and 32 are “off,” in other words, the first concentration measurement state is attained, as depicted in FIG. 5 . The valves 33 to 36 are closed or “off.” The pump 41 is “off” (A in FIG. 4 ). In FIG. 3 , in step S 201 , the valve 33 is opened to drive the pump 41 , and gas is allowed to flow through the evaporated fuel passage 21 (B in FIG. 4 ). The gas is the air distributed through the evaporated fuel passage 21 , as denoted by the arrow in FIG. 5 , and returned into the atmosphere. In step S 202 , the differential pressure ΔP 0 at the orifice 22 is detected. In step S 203 , the close valve 18 is closed and in step S 204 , the first and second selector valves 31 and 32 are turned on, while the valves 34 and 35 are opened (on) (C in FIG. 4 ). The state is therefore changed from the first concentration measurement state (shown in FIG. 5 ) to the second concentration measurement state (shown in FIG. 6 ). At this time, the purge valve 16 and the close valve 18 are closed and the valves 34 and 35 are open, so that the gas is circulated through a loop passage formed between the fuel tank 11 and the orifice 22 , as shown in FIG. 6 . The gas flow becomes an air-fuel mixture containing evaporated fuel as it is passed through the fuel tank 11 .
[0067] In step S 205 , the differential pressure ΔP 1 at the orifice 22 is detected.
[0068] The following steps S 206 and S 207 correspond to the process equivalent to the evaporated fuel concentration operation means, and the differential pressure ratio P is calculated in step S 206 based on the obtained two differential pressures ΔP 0 and ΔP 1 according to expression (1) provided below. In step S 207 , the fuel vapor concentration C is calculated based on the differential pressure ratio P according to expression (2) provided below, wherein k1 represents a constant pre-stored in the ROM of the ECU 51 together with a control program and other programs.
P=ΔP 1 /ΔP 0 (1)
C=k 1×( P− 1)(=.(Δ P 1−Δ P 0)/Δ P 0) (2)
[0069] The evaporated fuel is heavier than the air and therefore, if the gas from the fuel tank 11 contains the evaporated fuel, the density of the gas increases. For the same revolution speed and the same flow rate in the evaporated fuel passage 21 , the differential pressure at the orifice 22 is larger than the air based on the energy conservation law. As the fuel vapor concentration C increases, the differential pressure P increases. The characteristic line representing the fuel vapor concentration C and the differential pressure P is linear, as shown in FIG. 7 . Expression (2) provided above represents the characteristic line and the constant k1 is previously obtained from experiments and the like.
[0070] In the first concentration measurement state, which is shown in FIG. 5 , air distributes through the evaporated fuel passage 21 and the fuel vapor concentration is zero. Here, the differential pressure about the gas with known concentration and the differential pressure in the second concentration measurement state to allow the gas in the fuel tank 11 to be distributed in the evaporated fuel passage 21 are detected, so that detection errors can be cancelled, which results in highly precise detection.
[0071] In step S 208 , the obtained fuel vapor concentration C is temporarily stored.
[0072] The first and second selector valves 31 and 32 are turned off, and the valves 34 and 35 are closed (off) in step S 209 , the valve 33 is closed (off) in step S 210 , and the pump 41 is turned off. The state is the same as the state denoted by A in FIG. 4 , in other words, the state before the start of the concentration detection routine is regained.
[0073] FIG. 8 shows the fuel volatility calculation routine of step S 103 of FIG. 2 . First, in step S 301 of FIG. 8 , the fuel vapor concentration C obtained in the concentration routine is read.
[0074] In step S 302 , atmospheric pressure Patm is detected. The atmospheric pressure Patm is detected by the intake air pressure sensor 53 .
[0075] In step S 303 , fuel vapor pressure Pev is calculated according to expression (3) provided below. Expression (3) is based on the fact that the concentration of the evaporated fuel is the ratio of the saturated vapor pressure of the fuel to the atmospheric pressure.
Pev=Patm×C (3)
[0076] In step S 304 , the fuel temperature T is detected.
[0077] The following step S 305 is equivalent to the process performed by the volatility calculation means, and read vapor pressure RVP is calculated as the fuel volatility based on the fuel vapor pressure Pev and the fuel temperature T. As shown in FIG. 9 , the ECU 51 stores the characteristic line between the temperature T and the vapor pressure Pev in the form of a map. The fuel volatility RVP is calculated referring to the map. The obtained fuel volatility RVP is temporarily stored in a memory in step S 306 .
[0078] Now, referring to FIG. 10 , the routine of calculating a fuel injection correction amount at the start will be described. It is determined in step S 401 whether the ignition key is turned on, and if the result of this determination is affirmative, the process proceeds to step S 402 . If the result is negative, step S 401 is repeated.
[0079] Steps S 402 to S 406 are equivalent to the process carried out by the correction amount setting means, and in step S 402 , the fuel volatility RVP obtained in the fuel volatility calculation routine is read. In step S 403 , the fuel injection amount correction coefficient TAUe corresponding to the fuel volatility RVP is calculated. The calculation is carried out according to a map or the like in which the fuel volatility RVP and the fuel injection amount correction coefficient TAUe are associated with each other.
[0080] In step S 404 , the engine water temperature Tw is detected and a fuel injection correction coefficient TAUw according to the engine water temperature Tw is calculated in step S 405 . The calculation is carried out according to a map or the like in which the engine water temperature Tw and the fuel injection amount correction coefficient TAUw are associated with each other.
[0081] In step S 406 , the fuel injection correction amount KTAU is calculated according to expression (4) provided below. The fuel injection correction amount KTAU is multiplied by the injection amount TAU calculated based on the throttle opening angle and the engine speed to produce the final injection amount.
KTAU=TAUe×TAUw (4)
[0082] The map for producing the fuel injection amount correction coefficient TAUe is set so that as the fuel volatility RVP increases, the coefficient not less than 1 decreases toward 1. This is because there is little likelihood that injected fuel with high fuel volatility RVP sticks and does not contribute to combustion.
[0083] The map for producing the fuel injection amount correction coefficient TAUw is set so that as the engine water temperature Tw increases, the coefficient not less than 1 decreases toward 1. This is because when the engine water temperature Tw is high, the temperature of the intake pipe 2 is high, which makes easier the evaporation, so that there is little likelihood that injected fuel sticks and does not contribute to combustion.
[0084] In this way, the fuel injection amount is appropriately adjusted according to the volatility of the fuel, so that the air-fuel ratio can be controlled highly precisely.
[0085] Since the concentration of the evaporated fuel in the gas passing through the fuel tank 11 can be detected, the ECU 51 forms other evaporated fuel operation means at the evaporated fuel passage 21 . The operation means calculates the concentration of the evaporated fuel in the purge gas as follows. The valves 34 and 35 are closed based on the second concentration measurement state, so that the gas in the canister 13 is circulated between the canister 13 and the evaporated fuel passage 21 . Then, based on the differential pressure at the orifice 22 at the time, the concentration of the evaporated fuel in the purge gas is calculated. The concentration detection routine is substantially the same as the content shown in FIG. 3 except for how the valves 34 and 35 are set. More specifically, the concentration of the evaporated fuel in the purge gas is available based on the differential pressure ratio of the differential pressures at the orifice 22 when the air is passed through the evaporated fuel passage 21 and when the purge gas as the gas for measurement is passed through the evaporated fuel passage 21 .
[0086] In this way, the valve travel of the purge valve 16 can be set to an appropriate value, and the amount of the evaporated fuel in the purge gas can appropriately be adjusted.
[0087] The ECU 51 also forms the leakage determining means for checking leakage in a simple manner using an evaporator system as a detection space for leakage. The evaporator system defines a closed space from the fuel tank 11 through the canister 13 to the purge valve 16 in which the evaporated fuel is present while the purge valve 16 is closed. More specifically, the first and second selector valves 31 and 32 are off, the valve 33 as the valve means is opened, and the valve 36 as other valve means is closed. This defines the first leakage detection state. In this state, the pump 41 is driven, and the differential pressure detected by the differential pressure sensor 55 is obtained at prescribed intervals. The detection output represents the pressure in the evaporated fuel passage 21 toward the side of the pump 41 relative to the atmospheric pressure as the reference and gradually increases to the negative side as the pump 41 starts to be driven. When the differential pressure between the detected pressure and the previous value is not more than a predetermined reference value, the detection output (reference pressure) at the time is stored.
[0088] Then, valve 33 is closed, valve 36 is opened, and the close valve 18 is closed. This defines a the second leakage detection state. The pump 41 is driven in the state. Similarly, the differential pressure detected by the differential pressure sensor 55 is obtained at prescribed intervals. The detection output is a pressure in the evaporator system relative to the atmospheric pressure and serves as a reference. When the differential pressure between the detected pressure and the previous value is not more than the reference value, the detection output at the time is stored and compared to the reference pressure. When the evaporator system has a hole having an area as large as the orifice 22 , a pressure value equal to the reference pressure is obtained. When the evaporator system has a hole having an area larger than the orifice 22 , the detected pressure is smaller. Therefore, if the pressure is greater than the reference pressure value, it is determined that there is no leakage in the evaporator system. Otherwise it is determined that there is leakage.
[0089] Note that the difference between the detection output and the previous value, in other words, the amount of change must be at most the reference value in order to allow the detection pressure to converge.
[0090] In this way, as the air and the gas for measurement are distributed in the evaporated fuel passage having the orifice, not only the volatility of the fuel, but also the concentration of the evaporated fuel in the purge gas can be obtained. In addition, the evaporator system can be checked for leakage. Therefore, such a multi-function device can be implemented with low cost.
[0091] FIG. 11 shows a fuel nature measuring device according to the principles of a second embodiment of the present invention. The second embodiment is substantially the same as the first embodiment with except that a part of the configuration. The elements of the second embodiment that ate substantially the same as those of the first embodiment are denoted by the same reference characters, while the different elements will mainly be described.
[0092] A purge air passage 17 A is a simple passage unconnected to other conduits and closed by a close valve 18 provided therein.
[0093] An evaporated fuel passage 21 is provided with selector valves 31 and 32 at the ends similarly to the first embodiment. When the selector valves 31 and 32 are on, the evaporated fuel passage 21 communicates with the fuel tank 11 on one side, through a communication passage 28 , and, on the other side, through a communication passage 29 .
[0094] Similar to the first embodiment, an ECU 51 A can calculate the fuel volatility RVP by detecting the differential pressures at the orifice 22 . In a first measurement state, the ECU 51 A turns off the selector valves 31 and 32 to cause air to enter into the evaporated fuel passage 21 . In a second measurement state, the ECU 51 A turns on the selector valves 31 and 32 to distribute gas containing evaporated fuel from the fuel tank 11 into the evaporated fuel passage 21 .
[0095] FIG. 12 shows a fuel nature measuring device according to the principles of a third embodiment of the present invention. The third embodiment is substantially the same as the first embodiment except for a part of the configuration. The elements of the third embodiment that are substantially the same as those of the first embodiment are denoted by the same reference characters, while the different elements will mainly be described.
[0096] A fuel cap 19 at the fuel inlet of the fuel tank 11 has its open/closed state detected by a sensor 57 , which serves as the fuel tank state detecting means, so that the open/closed state of the fuel cap 19 is available to an ECU 51 B. The sensor 57 may be a switch type sensor, an optical type sensor, a capacitance type sensor, or any of various other kinds of sensors.
[0097] FIG. 13 partly shows how control is carried out by the ECU 51 B of the third embodiment of the present invention. It is determined in step S 501 whether or not the fuel cap 19 is “open.” If the result of determination is affirmative, the present time is stored in step S 505 as the concentration detection date and time. In the following step S 506 , the concentration detection routine is performed. In step S 507 , the fuel volatility calculation routine is performed. These concentration detection routine and fuel volatility calculation routine are performed similar to those of the first embodiment. After the fuel volatility calculation routine is performed at step S 507 , the process returns to step S 501 .
[0098] When the result of determination is negative in step S 501 , it is determined in step S 502 whether the ignition key is in an “on” state. If the result of determination is negative, the process returns to step S 501 . The concentration detection routine at step S 506 and the fuel volatility calculation routine at step S 507 are not performed.
[0099] When the result of determination in step S 502 is affirmative, it is determined in step S 503 whether a prescribed time period has elapsed after the previous concentration detection. This is determined based on the stored concentration detection date and time from step S 505 . If the result of determination is affirmative, the process from steps S 505 to S 507 is performed. Therefore, during the period before the next fueling, the volatility of the fuel is determined at intervals of the prescribed time period. The evaporation of the low boiling point component in fuel proceeds with time, which changes the volatility of the fuel and therefore, the fuel injection amount is adjusted appropriately in response to the change in the volatility.
[0100] If the result of determination is negative in step S 503 , it is determined in step S 504 whether the fuel temperature T is greater than the prescribed temperature T 0 . If the result of determination is affirmative, the process from steps S 505 to S 507 is performed. At the higher fuel temperatures T, the low boiling point component in combustion evaporates more easily, and the volatility of the fuel changes more rapidly. Therefore, if the prescribed time period has not elapsed after the previous concentration detection, it is highly likely that there is a significant change in the volatility. The fuel injection amount can be adjusted appropriately in response to the change in the volatility.
[0101] If the result of determination in step S 504 is negative, the process returns to step S 501 .
[0102] In this way, the fuel nature is determined in the timing when some significant change in the fuel nature is recognized, and the operation frequencies of the pump 41 , the selector valves 31 and 32 , and valves 33 to 35 can be lowered to reduce the power consumption from the batteries. This can also alleviate the calculation load.
[0103] Note that if the elapsed time after the previous concentration detection is greater than or equal to the prescribed time period, the ignition key must be on even at a temperature that is greater than or equal to the prescribed temperature T 0 . This is because the fuel is not injected during the ignition-off period, the result of fuel nature measuring process is not used for controlling the engine, and the power can be saved during the period. However, if the power consumption can be ignored, the operation may be carried out during the ignition-off period as will be described below in the fifth embodiment.
[0104] FIG. 14 shows a fuel nature measuring device according to a fourth embodiment of the present invention. The fourth embodiment is substantially the same as the first embodiment except for a part of the configuration. The elements of the fourth embodiment that are substantially the same as those of the first embodiment are denoted by the same reference characters, while the different elements will mainly be described.
[0105] A fuel level gauge 58 , which serves as the fuel tank state detecting means for detecting the fuel amount, is provided in the fuel tank 11 . The fuel level gauge 58 may be a float type device or any of other kinds of detecting devices. A detection signal from the fuel level gauge 58 is input to an ECU 51 C, so that the fuel amount is available.
[0106] FIG. 15 shows a part of the control carried out by the ECU 51 C of the fourth embodiment. It is determined in step S 601 whether the fuel amount has increased by a prescribed amount or more. If the result of determination is affirmative, steps S 605 to S 607 are performed. In steps S 605 to S 607 that are the same as the process from steps S 505 to S 507 , the present date and time are stored as concentration detection date and time (step S 605 ), the concentration detection routine is performed (step S 606 ), and the fuel volatility calculation routine is performed (step S 607 ). The fuel in the fuel tank 11 increases at the time of fueling, and the occurrence of fueling can be detected in the same manner as in step S 501 according to the third embodiment. If the result of determining whether the fuel amount increase is greater than or equal to the prescribed amount, in step S 601 , is negative, the process proceeds to step S 602 . Steps S 602 to S 604 are the same as the process from steps S 502 to S 504 according to the third embodiment. If the ignition key is “on” (step S 602 ) and the prescribed time has passed after the previous concentration detection (step S 603 ), or if the fuel temperature T attains the prescribed temperature T 0 or higher, the process of determining the fuel nature is performed (steps S 605 to S 607 ).
[0107] Note that the prescribed amount compared to the fuel amount in step S 601 must be set to a sufficiently large value, such that the appearance of a fuel increase due to the vehicle being parked on a slope is not mistaken for a fuel amount increase. The fueling is generally carried out when the fuel amount is reduced to half the full tank level and therefore, it is easy to set the prescribed value to a level that cannot allow such mistaken determination.
[0108] FIG. 16 shows a fuel nature measuring device according to the principles of a fifth embodiment of the present invention. The fifth embodiment is substantially the same as the first embodiment except for a part of the configuration. The elements of the fifth embodiment that are substantially the same as those of the first embodiment are denoted by the same reference characters, while the different elements will mainly be described.
[0109] An air flow sensor 52 in an intake pipe 2 has an intake air temperature sensor 59 that detects the temperature of intake air. The intake air temperature sensor 59 is formed as a unit in the air flow sensor 52 . A detection signal from the intake air sensor 59 is input to an ECU 51 D, so that the intake air temperature is available to the ECU 51 D.
[0110] The ECU 51 D performs control substantially the same as that by the ECU 51 according to the first embodiment, and the intake temperature sensor 59 is substituted for the temperature sensor 56 of the first embodiment. More specifically, immediately after the ignition key is turned “off,” the fuel tank 11 is approximately at the ambient temperature, while the intake pipe 2 provided in the engine room is at a high temperature. Then, the temperature of the intake pipe 2 converges toward to the ambient temperature after a sufficient period of time.
[0111] Therefore, after the elapse of a prescribed time period after the ignition key is turned “off,” the temperature detected by the intake temperature sensor 59 is considered substantially equal to the temperature of the fuel. Then, the concentration detection routine and the fuel volatility measuring routine are performed in the same manner as the first embodiment, so that the fuel nature can be determined. Note that the prescribed time period is, for example, a 5-hour period, in which the temperature of the intake pipe 2 is recognized to have converged to the ambient temperature. The convergence characteristic of the temperature of the intake pipe 2 may be obtained from experiments and the prescribed time period may be set based on the result. Therefore, it should be appreciated that the prescribed time period can be any time period less than or greater than 5 hours.
[0112] The use of the intake air temperature sensor 59 provided at the airflow sensor 52 simplifies the configuration. Any temperature detecting means provided in the vehicle having the engine may be used but the use of the intake air temperature sensor 59 is preferable because fresh air is distributed in the intake air passage 2 and therefore, the detected temperature is basically close to the temperature inside the fuel tank 11 as compared to the cooling water temperature.
[0113] It should be understood that the invention may be modified into other forms than those specifically described herein without departing from the spirit and scope of the present invention.
[0114] Furthermore, it should be appreciated that while the various processes and routines described herein have been described as including a sequence of steps, alternative embodiments including alternative sequences of these steps and/or including alternative or supplemental steps are intended to be within the scope of the present invention.
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A fuel nature measuring device for measuring the nature of fuel stored in a fuel tank includes a measurement passage, a gas flow generator, a pressure detector, an concentration operator, a temperature detector, and a volatility calculator. The measurement passage has an orifice. The gas flow generator generates gas flow in the measurement passage. The pressure detector detects a differential pressure between opposite ends of the orifice. The concentration operator determines a concentration of evaporated fuel in the fuel tank based on the differential pressure detected when the opposite ends of the measurement passage communicate with the fuel tank and the fuel flows in the measurement passage. The temperature detector determines a temperature of the fuel in the fuel tank. The volatility calculator calculates a volatility of the fuel in the fuel tank based on the concentration of the evaporated fuel and the temperature of the fuel in the tank.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2012-234419 filed on Oct. 24, 2012, the entire contents of which are incorporated herein by reference.
FIELD
The embodiments discussed herein are related to a method of controlling a mobile terminal apparatus and a mobile terminal apparatus.
BACKGROUND
In recent years, so-called positional services are becoming widespread. In the positional services, positional information of a mobile terminal apparatus is obtained using the Global Positioning System (GPS), a wireless local area network (WLAN), a baseband, and so on, and services depending on a position of the mobile terminal apparatus are provided.
Under the above-described circumstances, power consumption for positioning a mobile terminal apparatus (hereinafter referred to as a positioning power) is increasing. In particular, in the GPS, a bit rate of GPS signals from satellites is low (50 bps), and it takes about 30 minutes for receiving a GPS signal frame (1500 bits). Accordingly, compared with power consumption for obtaining state information of a mobile terminal apparatus by, for example, an acceleration, the number of steps, and so on, positioning power at the time of using GPS increases drastically. Also, in a WLAN and a baseband, a Basic Service Set Identifier (BSSID) and a cell-ID, which are obtained by a mobile terminal apparatus, have to be transmitted to a server, and thus compared with power consumption for obtaining state information of a mobile terminal apparatus, for example, an acceleration, the number of steps, and so on, positioning power increases drastically. Accordingly, it becomes important to reduce power consumption for positioning the mobile terminal apparatus.
For a mechanism to reduce power consumption, a control technique of a mobile terminal apparatus has been proposed in which, for example, a determination (hereinafter referred to as a “movement determination”) is made of whether the mobile terminal apparatus has moved or not using sensors installed on the mobile terminal apparatus, and if the mobile terminal apparatus has not been moved, positioning is not carried out, and the positional information already obtained is used.
In the above control technique, a sensor consumes power for movement determination, but positioning power, which is greater than power consumption for movement determination, is reduced, and thus it is possible to suppress power consumption of the mobile terminal apparatus as a result.
Related-art techniques have been disclosed in Japanese Laid-open Patent Publication Nos. 2011-149860, 2000-352519, and 2011-022115.
SUMMARY
According to an aspect of the invention, a method of controlling a mobile terminal apparatus includes selecting, using a processor, a sensor from a plurality of sensors installed on the mobile terminal apparatus based on both of power consumption for determining whether the mobile terminal apparatus has moved based on an output of at least any one of the sensors and power consumption for identifying a position of the mobile terminal apparatus, determining whether the mobile terminal apparatus has moved based on an output of the sensor selected in the selecting, and identifying a position of the mobile terminal apparatus when it is determined that the mobile terminal apparatus has moved in the determining.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic diagram of a hardware configuration of a mobile terminal apparatus according to a first embodiment;
FIG. 2 is a schematic diagram of functional blocks of the mobile terminal apparatus according to the first embodiment;
FIG. 3 is a schematic diagram of a movement-determination failure rate table according to the first embodiment;
FIG. 4 is a schematic diagram of a power consumption table according to the first embodiment;
FIG. 5 is a flowchart of sensor selection processing according to the first embodiment;
FIG. 6 is a schematic diagram of a movement-determination failure rate table according to a second embodiment;
FIG. 7 is a schematic diagram of a power consumption table according to the second embodiment;
FIG. 8 is a schematic diagram of functional blocks of a mobile terminal apparatus according to a third embodiment;
FIG. 9 is a schematic diagram of a movement-determination failure rate table according to the third embodiment; and
FIG. 10 is a flowchart of sensor update processing according to the third embodiment.
DESCRIPTION OF EMBODIMENTS
In a control technique of a mobile terminal apparatus according to related-art techniques, a sensor determined in advance is used for movement determination for the mobile terminal apparatus. However, movement determination of a mobile terminal apparatus is largely dependent on a kind of and a combination of sensors used, or an operation state of the mobile terminal apparatus, and so on. Accordingly, if a sensor determined in advance is used, that is to say, if a sensor to be used is fixed, a failure often occurs in movement determination depending on a kind of and a combination of the sensors. If determined that a mobile terminal apparatus has moved in spite of the fact that the mobile terminal apparatus has not moved, for example, positioning is carried out uselessly, and the power consumption increases as a result.
First Embodiment
In the following, a description will be given of a first embodiment with reference to FIG. 1 to FIG. 5 .
Hardware Configuration of Mobile Terminal Apparatus 100
A description will be given of a mobile terminal apparatus 100 according to the first embodiment. Here, Android (a registered trademark) is employed as an operating system (OS) to be installed in the mobile terminal apparatus 100 . However, an embodiment of the present disclosure is not limited to this, and an OS other than Android may be employed. Also, although not limited in particular, the mobile terminal apparatus 100 according to the present embodiment is assumed to be a mobile information processing apparatus, for example a smart phone, a tablet PC, a digital camera, and so on.
Hardware of Mobile Terminal Apparatus 100
FIG. 1 is a schematic diagram of a hardware configuration of the mobile terminal apparatus 100 according to the first embodiment.
As illustrated in FIG. 1 , the mobile terminal apparatus 100 according to the present embodiment includes a central processing unit (CPU) 101 , a main memory 102 , an auxiliary memory 103 , a clock supply circuit 104 , a voltage supply circuit 105 , a battery 106 , a power source circuit 107 , an external power supply unit 108 , a display 109 , a touch screen 110 , a network interface (I/F) 111 , and a sensor 112 as hardware modules. These hardware modules are mutually connected through a bus 113 .
It is assumed that the CPU 101 is not a baseband large scale integrated (LSI), but is a processor that executes an application program. The CPU 101 is operated by a clock signal supplied from the clock supply circuit 104 and a voltage supplied from the voltage supply circuit 105 , and controls various hardware modules of the mobile terminal apparatus 100 . Further, the CPU 101 reads various programs stored in the auxiliary memory 103 into the main memory 102 , and executes the various programs read in the main memory 102 so as to achieve various functions. Detailed descriptions will be given of the various functions later.
The main memory 102 stores the various programs to be executed by the CPU 101 . Further, the main memory 102 is used as a work area of the CPU 101 , and stores various kinds of data that is desired for processing by the CPU 101 . For a main memory 102 , for example, a random access memory (RAM), and so on may be used.
The auxiliary memory 103 stores various programs that operate the mobile terminal apparatus 100 . For the various programs, for example, application programs that are executed by the mobile terminal apparatus 100 , an OS 1000 , which is an execution environment of the application programs, and so on are provided. The control program 1100 according to the present embodiment is also stored in the auxiliary memory 103 . For the auxiliary memory 103 , a nonvolatile memory, for example a hard disk, a flash memory, and so on may be used.
The clock supply circuit 104 generates the clock signal to be supplied to the CPU 101 . The clock supply circuit 104 may be achieved, for example, by a quartz oscillator that oscillates the clock signal and a real time clock (RTC).
The voltage supply circuit 105 generates a variable voltage to be supplied to the CPU 101 on the basis of the power supplied from the power source circuit 107 . The voltage supply circuit 105 may be achieved by a voltage detector and a voltage regulator.
The battery 106 supplies power to the power source circuit 107 . The battery 106 may be achieved, for example by a battery, such as a lithium-ion battery, and so on, and a battery protection integrated circuit (IC).
The power source circuit 107 supplies the power supplied from the battery 106 to various hardware modules of the mobile terminal apparatus 100 through a power source line (not illustrated in FIG. 1 ). In this regard, if an external power source (not illustrated in FIG. 1 ) is connected to the external power supply unit 108 , the power source circuit 107 may supply the power supplied from the external power supply unit 108 to various hardware modules of the mobile terminal apparatus 100 . The power source circuit 107 may be achieved, for example by a switching regulator and a voltage regulator.
The display 109 is controlled by the CPU 101 , and displays image information to be presented to the user. The touch screen 110 is attached to the display 109 , and receives input of positional information touched by a user's fingertip, a pen point, and so on.
The network I/F 111 is controlled by the CPU 101 , and functions, for example as an interface of communication by a WLAN and a baseband.
The sensor 112 obtains the state information (state information of the user of the mobile terminal apparatus 100 ) of the mobile terminal apparatus 100 . For the sensor 112 , for example, a baseband, a pedometer, a WLAN, Bluetooth (a registered trademark), an accelerometer, a camera, an illuminance meter, a barometer, and so on may be used. In the case of using a pedometer, Bluetooth, an accelerometer, a camera, an illuminance meter, and a barometer as a sensor 112 , a number of steps, a peripheral device of Bluetooth, an acceleration, an image, an illuminance, an atmospheric pressure are detected, respectively.
In this regard, a baseband here is handled as a sensor for detecting a cell-ID transmitted from a base station of, for example, 3G (3rd Generation), and so on, and a WLAN is handled as a sensor for detecting a BSSID transmitted from an access point. However, a baseband and a WLAN according to the present embodiment are sometimes used as a positioning mechanism in the same manner as the GPS.
Functional Blocks of Mobile Terminal Apparatus 100
FIG. 2 is a schematic diagram of functional blocks of the mobile terminal apparatus 100 according to the first embodiment.
As illustrated in FIG. 2 , the mobile terminal apparatus 100 according to the present embodiment includes a positioning control unit 121 , a movement determination unit 122 , and a sensor selection unit 123 .
Any one of the positioning control unit 121 , the movement determination unit 122 , and the sensor selection unit 123 is achieved by the CPU 101 reading the control program 1100 into the main memory 102 , and executing the control program 1100 read into the main memory 102 .
In this regard, an application 130 in FIG. 2 is an application (position use application) that uses positional information, and is achieved by the CPU 101 reading the application program into the main memory 102 , and executing the application program read into the main memory 102 . A positioning driver 140 in FIG. 2 is achieved by the CPU 101 reading the kernel of the OS 1000 into the main memory 102 , and executing the application program read into the main memory 102 .
Positioning Control Unit 121
The positioning control unit 121 gives an indication of whether the mobile terminal apparatus 100 has moved or not, that is to say, a movement determination to the movement determination unit 122 on the basis of a positioning request from the application 130 . Further, the positioning control unit 121 obtains positional information of the mobile terminal apparatus 100 on the basis of the determination result by the movement determination unit 122 , and notifies the positional information to the application 130 . For example, if the determination result by the movement determination unit 122 is “moved”, the positioning control unit 121 instructs the positioning driver 140 to perform positioning, and notifies the positional information obtained by the positioning driver 140 to the application 130 . On the other hand, if the determination result by the movement determination unit 122 is “not moved”, the positioning control unit 121 notifies the latest positional information stored in a positional information storage unit 126 to the application 130 . In this regard, the latest positional information corresponds to the positional information obtained by the previous positioning.
Movement Determination Unit 122
The movement determination unit 122 gives an instruction of selection of the sensors 112 to be used for movement determination of the mobile terminal apparatus 100 to the sensor selection unit 123 with a trigger of an instruction from the positioning control unit 121 . Further, the movement determination unit 122 carries out movement determination of the mobile terminal apparatus 100 using the sensor 112 selected by the sensor selection unit 123 . Here, if the sensor selection unit 123 selects a plurality of the sensors 112 , the movement determination unit 122 carries out movement determination of the mobile terminal apparatus 100 using all of the plurality of the sensors 112 . Specifically, if a baseband, a pedometer, a WLAN, Bluetooth, a camera, an illuminance meter, a barometer, an accelerometer, and so on are selected as the sensors 112 , the movement determination unit 122 carries out movement determination of the mobile terminal apparatus 100 on the basis of a change of cell-ID, a change in radio wave intensity, a change in the number of steps, a change in the BSSID obtained by scanning, a change of peripheral device of Bluetooth, a change of an image, a change in illuminance, a change in atmospheric pressure, a change in acceleration, respectively, or a combination of these.
Sensor Selection Unit 123
The sensor selection unit 123 selects sensors 112 to be used for movement determination of the mobile terminal apparatus 100 , that is to say, sensors for use from the plurality of sensors 112 with a trigger of the instruction from the movement determination unit 122 . Specifically, the sensor selection unit 123 selects a combination of the sensors 112 to be used for movement determination on the basis of the operation state of the sensors 112 (operation state of the mobile terminal apparatus 100 ) and a movement-determination failure rate table Ta and a power consumption table Tb. In this regard, the operation state of the sensors 112 is information of whether the individual sensors 112 are capable of sensing or not. For example, if a certain sensor 112 is in a state capable of sensing (in operation), the operation state becomes “OK”, and if the sensor 112 is in a state not capable of sensing (in a sleeping state), the operation state becomes “NG”. The sensor selection unit 123 checks the operation states of the individual sensors 112 .
Movement-Determination Failure Rate Table Storage Unit 124
A movement-determination failure rate table storage unit 124 stores the movement-determination failure rate table Ta in which movement-determination failure rates of the individual sensors 112 are described. The movement-determination failure rate is a probability of failure at the time of carrying out movement determination of the mobile terminal apparatus 100 using the individual sensors 112 . In this regard, the movement-determination failure rate is determined in advance, but may be determined in consideration of, for example, a probability of not moving in reality while determined that the sensor has moved, and a probability of determination that the sensor has not moved while the sensor has actually moved.
FIG. 3 is a schematic diagram of the movement-determination failure rate table Ta according to the first embodiment.
As illustrated in FIG. 3 , in the movement-determination failure rate table Ta, the individual sensors 112 are tied to movement-determination failure rates. In the present embodiment, a baseband, a pedometer, and a WLAN are tied to movement-determination failure rates 0.3, 0.1, and 0.3, respectively. For example, if baseband is only used for movement determination of the mobile terminal apparatus 100 , it is understood that the movement-determination failure rate becomes 0.3.
Power-Consumption Table Storage Unit 125
A power-consumption table storage unit 125 stores the power consumption table Tb in which power consumption of the individual sensors 112 are described. The power consumption is an amount of power that is consumed when movement determination of the mobile terminal apparatus 100 is carried out using the individual sensors 112 .
FIG. 4 is a schematic diagram of the power consumption table Tb according to the first embodiment.
As illustrated in FIG. 4 , the power consumption table Tb ties the individual sensors 112 to average power consumption for movement detection. In the present embodiment, power consumption 1 [mW], 6 [mW], and 4 [mW] are tied to the baseband, the pedometer, and the WLAN, respectively. For example, in the case of using only the baseband for movement determination of the mobile terminal apparatus 100 , the power consumption becomes 1 [mW].
Positional Information Storage Unit 126
The positional information storage unit 126 records positional information and precision information that are obtained by positioning carried out immediately before (most recently). For the positional information, for example, longitude information and latitude information are used. However, the positional information storage unit 126 may record not only the positional information and the precision information that are obtained by the positioning immediately before, but also may tie the positional information and the precision information that are obtained by the positioning carried out before that time to positioning time.
Sensor Selection Processing
FIG. 5 is a flowchart of sensor selection processing according to the first embodiment.
As illustrated in FIG. 5 , the sensor selection unit 123 obtains the operation states of all of the plurality of sensors 112 (step S 101 ) with a trigger of an instruction from the movement determination unit 122 . For the operation state, “OK”, which is capable of sensing, and “NG”, which is not capable of sensing, are defined.
Next, the sensor selection unit 123 selects one combination out of all the combinations of the plurality of sensors 112 (step S 102 ). For example, if there are three sensors 112 , one combination is selected from seven combinations (= 3 C 1 + 3 C 2 + 3 C 3 ).
Next, the sensor selection unit 123 calculates a movement-determination failure rate in the case of using all the sensors 112 of the selected combination, that is to say, a total movement-determination failure rate (step S 103 ). The total movement-determination failure rate is a probability of failure in movement determination when all the sensors 112 of the selected combination are used. Specifically, the sensor selection unit 123 calculates the total movement-determination failure rate using the following expression (1).
f ( r TOTAL MOVEMENT-DETERMINATION FAILURE RATE =Π i=1 n MOVEMENT-DETERMINATION FAILURE RATE OF SENSOR i (1)
Next, the sensor selection unit 123 calculates a power-consumption evaluation value on the basis of the operation state of the sensor 112 , the total movement-determination failure rate, and the positioning power (step S 104 ). Specifically, the sensor selection unit 123 calculates the power-consumption evaluation value using the following expression (2).
Power-consumption evaluation value=total movement-determination failure rate×positioning power+increment of sensor power consumption (2)
In this regard, the positioning power is power to be used for positioning. In the present embodiment, it is assumed that the average positioning power is 40 [mW] on the assumption of GPS positioning. The increment of sensor power consumption is an increment of power consumption at the time of operating the sensor 112 in a sleeping state for movement determination of the mobile terminal apparatus 100 . Accordingly, the sum total power consumption of the sensors 112 in a sleeping state (operation state is “NG”) among the sensors 112 included in the selected combination becomes an increment of sensor power consumption. In this regard, in the case of using only the sensor 112 in operation for movement determination of the mobile terminal apparatus 100 , an increase of power consumption will not occur.
Next, the sensor selection unit 123 determines whether the total movement-determination failure rate is less than the movement-determination failure threshold value determined in advance (step S 105 ).
Here, if not determined that the total movement-determination failure rate is less than the movement-determination failure threshold value (No in step S 105 ), it is estimated that the probability of failure in movement determination of the mobile terminal apparatus 100 is high. Accordingly, the sensor selection unit 112 throws away the selected combination of the sensors 112 , and determines whether there is another combination of the sensors 112 or not (step S 108 ).
On the other hand, if determined that the total movement-determination failure rate is less than the movement-determination failure threshold value (Yes in step S 105 ), it is estimated that the probability of failure in movement determination of the mobile terminal apparatus 100 is low. Accordingly, the sensor selection unit 123 determines whether the power-consumption evaluation value of the selected combination of the sensors 112 is lower than the power-consumption evaluation value of a use sensor candidate, which is a combination of sensors 112 having the lowest power-consumption evaluation value, and whether the power-consumption evaluation value of the selected combination of the sensors 112 is lower than the positioning power (step S 106 ).
Here, if not determined that the power-consumption evaluation value of the selected combination of the sensors 112 is lower than the power-consumption evaluation value of the combination of the sensors 112 which are use sensor candidates, and the power-consumption evaluation value of the selected combination of the sensors 112 is lower than the positioning power (No in step S 106 ), the sensor selection unit 123 determines whether there are no combinations of the other sensors 112 or not (step S 108 ).
On the other hand, if determined that the power-consumption evaluation value of the selected combination of the sensors 112 is lower than the power-consumption evaluation value of the combination of the sensors 112 which are use sensor candidates, and the power-consumption evaluation value of the selected combination of the sensors 112 is lower than the positioning power (Yes in step S 106 ), the sensor selection unit 123 stores the selected combination of the sensors 112 as a use sensor candidate (step S 107 ).
Next, the sensor selection unit 123 determines whether there are no other combinations of the sensors 112 or not (step S 108 ).
Here, if determined that there are no other combinations of the sensors 112 (Yes in step S 108 ), the sensor selection unit 123 determines whether there is a combination of the sensors 112 stored as a use sensor candidate (step S 109 ).
Here, if determined that there is a combination of the sensors 112 stored as a use sensor candidate (Yes in step S 109 ), the sensor selection unit 123 determines the combination of the sensors 112 stored as a use sensor candidate to be a use sensor to be used for movement determination (step S 110 ).
On the other hand, if not determined that there is a combination of the sensors 112 stored as a use sensor candidate (No in step S 109 ), the sensor selection unit 123 terminates the sensor selection processing.
Also, if not determined that there are no other combinations of the sensors 112 (No in step S 108 ), that is to say, if determined that there is the other combination of the sensors 112 , the sensor selection unit 123 selects one combination again out of all the combinations of the plurality of sensor 112 (step S 102 ).
In this regard, the movement determination of the mobile terminal apparatus 100 is carried out until a positioning stop request is notified from the application 130 , and the movement determination unit 122 stops the use of the sensors 112 for movement determination with a trigger of a positioning stop request.
SPECIFIC EXAMPLE 1
In the following, descriptions will be given of examples of calculation of the total movement-determination failure rate and the power-consumption evaluation value by the sensor selection unit 123 when the baseband and the WLAN are operating among the sensors 112 of the mobile terminal apparatus 100 . Here, the movement-determination failure rates and the power consumption described in the movement-determination failure rate table Ta in FIG. 3 , and the power consumption table Tb in FIG. 4 , respectively are used. Also, it is assumed that the movement-determination failure threshold value is 0.1, and the positioning power is 2000 [mWs].
(A1) When only the baseband is selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3
Power-consumption evaluation value=0.3×40+1=13
(A2) When only the pedometer is selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.1
Power-consumption evaluation value=0.1×40+6=10
(A3) When only the WLAN is selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3
Power-consumption evaluation value=0.3×40+0=12
(A4) When the baseband and the pedometer are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3×0.1=0.03
Power-consumption evaluation value=0.03×40+1+6=8.2
(A5) When the baseband and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3×0.3=0.09
Power-consumption evaluation value=0.09×40+0=3.6
(A6) When the pedometer and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.1×0.3=0.03
Power-consumption evaluation value=0.03×40+50=7.2
(A7) When the baseband, the pedometer, and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3×0.1×0.3=0.009
Power-consumption evaluation value=0.009×40+6=6.36
As described above, when the combination of the baseband and the WLAN is selected, it is understood that the total movement-determination failure rate becomes lower than the threshold value of the movement-determination failure rate, and the power-consumption evaluation value becomes the minimum. Accordingly, if the baseband and the WLAN are operating, the baseband and the WLAN ought to be selected as use sensors.
SPECIFIC EXAMPLE 2
In the following, descriptions will be given of examples of calculation of the total movement-determination failure rate and the power-consumption evaluation value by the sensor selection unit 123 when only the baseband is operating among the sensors 112 of the mobile terminal apparatus 100 . Here, the movement-determination failure rates and the power consumption described in the movement-determination failure rate table Ta in FIG. 3 , and the power consumption table Tb in FIG. 4 , respectively are also used. Also, it is assumed that the movement-determination failure threshold value is 0.1, and the positioning power is 40[mW].
(B1) When only the baseband is selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3
Power-consumption evaluation value=0.3×40+=12
Baseband sensor's power-consumption is not added because baseband is operating, so already on.
(B2) When only the pedometer is selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.1
Power-consumption evaluation value=0.1×40+6=10
(B3) When only the WLAN is selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3
Power-consumption evaluation value=0.3×40+4=16
(B4) When the baseband and the pedometer are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3×0.1=0.03
Power-consumption evaluation value=0.03×40+6=7.2
(B5) When the baseband and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3×0.3=0.09
Power-consumption evaluation value=0.09×50+4=7.6
(B6) When the pedometer and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.1×0.3=0.03
Power-consumption evaluation value=0.03×50+6+4=11.2
(B7) When the baseband, the pedometer, and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.3×0.1×0.3=0.009
Power-consumption evaluation value=0.009×50+6+4=10.45
As described above, when the combination of the baseband and the pedometer is selected, it is understood that the total movement-determination failure rate becomes lower than the threshold value of the movement-determination failure rate, and the power-consumption evaluation value becomes the minimum. Accordingly, if the baseband is only operating, the baseband and the pedometer ought to be selected as use sensors.
According to the present embodiment, a combination of the sensors 112 to be used for movement determination of the mobile terminal apparatus 100 is determined in consideration of the operation states of the individual sensors 112 , and the increments of the movement-determination failure rate and the power consumption. Accordingly, it is possible to suppress the occurrence of useless power consumption without decreasing a success rate of movement determination of the mobile terminal apparatus 100 .
In this regard, in the present embodiment, at the time of calculating the power-consumption evaluation value, an increment of the sensor power consumption is used. However, the present disclosure is not limited to this. For example, the power-consumption evaluation value may be calculated on the basis of only the total movement-determination failure rate×positioning power. Also, at the time of calculating the power-consumption evaluation value, sensor power consumption may be used in place of an increment of the sensor power consumption. Further, a movement-determination success rate (=1−total movement-determination failure rate) may be used in place of a total movement-determination failure rate. In the case of using a movement-determination success rate, a combination of the sensors 112 that makes the power-consumption evaluation value the greatest ought to be selected.
Further, in the present embodiment, operating power of a positioning device is used as positioning power. However, the present disclosure is not limited. For example, positioning power in consideration of positioning frequency may be used. For example, if an operating frequency of GPS by a positioning request from the application 130 is 1/10 of the total time period, it is thought that power consumption of the positioning device becomes 1/10 in general. Accordingly, the positioning power one-tenth of the operating power of the positioning device may be used as the positioning power.
Also, in the present embodiment, movement determination is carried out when the power-consumption evaluation value is less that the positioning power. However, for example, when the power-consumption evaluation value is greater than the positioning power, the movement determination may not be carried out, and positioning may be carried out all the time.
Also, the GPS is used as a positioning method in the present embodiment. However, the WLAN and the baseband, and so on may be used in addition.
Second Embodiment
In the following, a description will be given of a second embodiment with reference to FIG. 6 and FIG. 7 . Note that the descriptions will be omitted of the same configuration and functions as those of the first embodiment.
FIG. 6 is a schematic diagram of a movement-determination failure rate table Tc according to the second embodiment.
As illustrated in FIG. 6 , the movement-determination failure rate table Tc according to the present embodiment describes a movement-determination failure rate for each combination of the sensors 112 . That is to say, the movement-determination failure rate according to the present embodiment is a probability of failure when movement determination of the mobile terminal apparatus 100 is carried out using combinations of the sensors 112 .
FIG. 7 is a schematic diagram of a power consumption table Td according to the second embodiment.
As illustrated in FIG. 7 , in the power consumption table Td according to the present embodiment, power consumption is described for each combination of the sensors 112 . That is to say, the power consumption according to the present embodiment is an amount of power consumed when movement determination of the mobile terminal apparatus 100 is carried out using the combinations of the sensors 112 .
SPECIFIC EXAMPLE
In the following, descriptions will be given of examples of calculation of the total movement-determination failure rate and the power-consumption evaluation value by the sensor selection unit 123 when the baseband and the WLAN are operating among the sensors 112 of the mobile terminal apparatus 100 . Here, the movement-determination failure rates and the power consumption described in the movement-determination failure rate table Tc in FIG. 6 and the power consumption table Td in FIG. 7 are used, respectively. Also, it is assumed that the movement-determination failure threshold value is 0.1, and the positioning power is 40 [mW].
(C1) When the baseband and the WLAN are selected as a combination of the sensors 112 , the movement-determination failure rate and the power-consumption evaluation value become as follows.
Movement-determination failure rate=0.12
Power-consumption evaluation value=0.12×40+(5−5)=240
(C2) When the baseband, the pedometer, and the WLAN are selected as a combination of the sensors 112 , the movement-determination failure rate and the power-consumption evaluation value become as follows.
Movement-determination failure rate=0.01
Power-consumption evaluation value=0.01×40+(11−5)=320
(C3) When the baseband, the pedometer, the Bluetooth, and the WLAN are selected as a combination of the sensors 112 , the movement-determination failure rate and the power-consumption evaluation value become as follows.
Movement-determination failure rate=0.08
Power-consumption evaluation value=0.08×40+(7−5)=260
Here, only three kinds of combinations of the sensors 112 are described. However, the other combinations ought to be calculated in the same manner.
As described above, when the combination of the baseband, the Bluetooth, and the WLAN is selected, it is understood that the movement-determination failure rate becomes lower than the threshold value of the movement-determination failure rate, and the power-consumption evaluation value becomes the minimum. Accordingly, if the baseband and the WLAN are operating, the combination of the baseband, the Bluetooth, and the WLAN ought to be selected as use sensors.
In this regard, here, although the Bluetooth in a sleeping state is started, the power-consumption evaluation value is low. This is because the Bluetooth and the WLAN are packaged in a combo chip. In this manner, for example, depending on a packaging state, a difference sometimes occurs between the power-consumption evaluation value of a combination of a plurality of sensors 112 and the power-consumption evaluation value calculated by the movement-determination failure rates of the individual sensors 112 . However, by the present embodiment, it is possible to calculate more precise power-consumption evaluation value.
Third Embodiment
In the following, a description will be given of a third embodiment with reference to FIGS. 8 to 10 . Note that descriptions will be omitted of the same configuration and functions as those of the first embodiment.
Functional Blocks of Mobile Terminal Apparatus 100 M
FIG. 8 is a schematic diagram of the functional blocks of the mobile terminal apparatus 100 M according to the third embodiment.
As illustrated in FIG. 8 , the movement determination unit 122 according to the present embodiment includes a movement-state estimation unit 127 . The movement-state estimation unit 127 estimates whether the movement state of the mobile terminal apparatus 100 M (of the user) is a walking state or an in-vehicle state on the basis of the detection result by the sensor 112 and the determination result by the movement determination unit 122 . For example, although there is no change in the count value (the number of steps) of the pedometer in operation, if determined as “have moved”, it is estimated that the user of the mobile terminal apparatus 100 M is in a vehicle. The movement-state estimation unit 127 holds movement states as the individual state probabilities estimated from the sensors 112 . For example, the movement-state estimation unit 127 holds the probability that the movement state of the user is walking as a walking-state probability, and the probability that the movement state of the user is in a vehicle as an in-vehicle state probability.
The sensor selection unit 123 according to the present embodiment selects sensors 112 to be used for movement determination of the mobile terminal apparatus 100 M, that is to say, sensors for use from the plurality of sensors 112 on the basis of the estimation result by the movement-state estimation unit 127 and the movement-determination failure rate table Te.
Specifically, the sensor selection unit 123 calculates the total movement-determination failure rate on the basis of the walking-state probability and the in-vehicle state probability that are determined by the movement-state estimation unit 127 for each estimation result using the following expression (3).
TOTAL
MOVEMENT
-
DETERMINATION
FAILURE
RATE
=
WALKING
-
STATE
PROBABILITY
×
∏
i
=
1
n
MOVEMENT
-
DETERMINATION
FAILURE
RATE
OF
SENSOR
i
+
IN
-
VEHICLE
STATE
PROBABILITY
×
∏
i
=
1
n
MOVEMENT
-
DETERMINATION
FAILURE
RATE
OF
SENSOR
i
(
3
)
Note that if it is difficult to estimate the movement state, both of the walking-state probability and the in-vehicle state probability are set to 0.5.
Further, the sensor selection unit 123 calculates the power-consumption evaluation value on the basis of the total movement-determination failure rate using the above-described expression (2).
And the sensor selection unit 123 selects a combination of the sensors 112 to be used for movement determination of the mobile terminal apparatus 100 M on the basis of the operation states of the sensors 112 (the operation state of the mobile terminal apparatus 100 M), the total movement-determination failure rate, and the power-consumption evaluation value.
FIG. 9 is a schematic diagram of the movement-determination failure rate table Te according to the third embodiment.
As illustrated in FIG. 9 , the movement-determination failure rate table Te according to the present embodiment describes a each movement-determination failure rate of each of the sensors 112 for each movement state. For example, in the case of the pedometer, the movement-determination failure rate at the time of walking is set to 0.05, and the movement-determination failure rate at the time of in-vehicle is set to 0.8. A pedometer is suitable for movement detection in a walking state, but is not suitable for movement detection in an in-vehicle state, and thus the movement-determination failure rate at the time of walking is set to low, and the movement-determination failure rate at the time of in-vehicle is set to high.
Sensor Update Processing
FIG. 10 is a flowchart of sensor update processing according to the third embodiment.
As illustrated in FIG. 10 , first, the sensor selection unit 123 performs sensor selection processing according to the first embodiment using the expression (3) in place of the expression (1) (step S 201 ). Here, it is assumed that both of the walking-state probability and the in-vehicle state probability are set to 0.5 on the assumption that it is difficult to estimate the movement state.
Next, the movement determination unit 122 carries out the movement determination of the mobile terminal apparatus 100 M using the sensors 112 selected by the sensor selection unit 123 (step S 202 ).
Next, the movement-state estimation unit 127 obtains positional information from the positioning driver 140 or the positional information storage unit 126 on the basis of the result of the movement determination, notifies the positional information to the application 130 , and further, determines whether it has bee possible to estimate movement state of the mobile terminal apparatus 100 M or not (step S 203 ).
Here, if not determined that it has bee possible to estimate the movement state (No in step S 203 ), the movement-state estimation unit 127 terminates the sensor update processing without updating the sensors 112 to be used for the movement determination of the mobile terminal apparatus 100 M.
On the other hand, if determined that it has bee possible to estimate the movement state (Yes in step S 203 ), the movement-state estimation unit 127 obtains the walking-state probability and the in-vehicle state probability that are tied to the movement state as an estimation result (step S 204 ). In the present embodiment, it is assumed that in-vehicle state is estimated, and thus the walking-state probability is 0.1, and the in-vehicle state probability is 0.9.
Next, the sensor selection unit 123 calculates the total movement-determination failure rate on the basis of the walking-state probability and the in-vehicle state probability that are obtained by the movement-state estimation unit 127 using the above-described expression (3) (step S 205 ).
Next, the sensor selection unit 123 calculates the power-consumption evaluation value on the basis of the total movement-determination failure rate using the above-described expression (2) (step S 206 ).
Next, the sensor selection unit 123 determines whether a newly calculated power-consumption evaluation value is less than the power-consumption evaluation value calculated immediately before (most recently) or not (step S 207 ).
Here, if not determined that the newly calculated power-consumption evaluation value is less than the power-consumption evaluation value calculated immediately before (No in step S 207 ), the sensor selection unit 123 terminates the sensor update processing without updating the sensors 112 to be used for the movement determination of the mobile terminal apparatus 100 M.
On the other hand, if determined that the newly calculated power-consumption evaluation value is less than the power-consumption evaluation value calculated immediately before (Yes in step S 207 ), the sensor selection unit 123 updates the sensors 112 to be used for the movement determination to newly selected sensors 112 (step 208 ).
Specific Example 1 in the Case that Estimation of Movement State is not Possible
In the following, descriptions will be given of examples of calculation of the total movement-determination failure rate and the power-consumption evaluation value by the sensor selection unit 123 when the baseband and the WLAN are operating among the sensors 112 of the mobile terminal apparatus 100 M. Here, the movement-determination failure rates described in the movement-determination failure rate table Te in FIG. 9 are used. Also, it is assumed that the movement-determination failure threshold value is 0.1, and the positioning power is 40 [mW]. In the present specific example 1, it is assumed that estimation of movement state is not possible, and thus both of the movement state walking-state probability and the in-vehicle state probability are 0.5.
(D1) When the baseband and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.5×(0.8×0.5)+0.5×(0.2×0.1)=0.21
Power-consumption evaluation value=0.21×40+4=26
(D2) When the baseband, the pedometer, and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.5×(0.8×0.05×0.5)+0.5(0.2×0.8×0.1)=0.018
Power-consumption evaluation value=0.018×40+6=
As described above, in the case that estimation of movement state is not possible, when the combination of the baseband, the pedometer, and the WLAN is selected, it is understood that the movement-determination failure rate becomes lower than the threshold value of the movement-determination failure rate, and the power-consumption evaluation value becomes the minimum. Accordingly, if the baseband and the WLAN are operating, and estimation of movement state is not possible, the combination of the baseband, the pedometer, and the WLAN ought to be selected as use sensors.
Specific Example 2 in the Case that Estimation of Movement State was possible
In the following, descriptions will be given of examples of calculation of the total movement-determination failure rate and the power-consumption evaluation value by the sensor selection unit 123 when the baseband and the WLAN are operating among the sensors 112 of the mobile terminal apparatus 100 M. Here, the movement-determination failure rates described in the movement-determination failure rate table Te in FIG. 9 are used. Also, it is assumed that the movement-determination failure threshold value is 0.1, and the positioning power is 2000 [mWs]. In the present specific example 2, it is assumed that estimation of movement state has been possible, and thus the walking-state probability is 0.1, and the in-vehicle state probability is 0.9.
(E1) When the baseband and the WLAN are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.1×(0.8×0.5)+0.9×(0.2×0.1)=0.058
Power-consumption evaluation value=0.058×40+0=2.32
(E2) When the baseband and the pedometer are selected as a combination of the sensors 112 , the total movement-determination failure rate and the power-consumption evaluation value become as follows.
Total movement-determination failure rate=0.1×(0.8×0.05×0.5)+0.9(0.2×0.8×0.1)=0.0164
Power-consumption evaluation value=0.0164×40+6=8.98
As described above, in the case that estimation of movement state is possible, when the combination of the baseband, and the WLAN is selected, it is understood that the movement-determination failure rate becomes lower than the threshold value of the movement-determination failure rate, and the power-consumption evaluation value becomes the minimum. Accordingly, if the baseband and the WLAN are operating, and estimation of movement state is possible, the combination of the baseband and the WLAN ought to be selected as use sensors.
By the present embodiment, a combination of the sensors 112 to be used for movement determination is selected in consideration of the movement state of the mobile terminal apparatus 100 M. Accordingly, it is possible to carry out movement determination in accordance with the movement state of the mobile terminal apparatus 100 M. As a result, it is possible to suppress the occurrence of useless power consumption further.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
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A method of controlling a mobile terminal apparatus includes selecting, using a processor, a sensor from a plurality of sensors installed on the mobile terminal apparatus based on both of power consumption for determining whether the mobile terminal apparatus has moved based on an output of at least any one of the sensors and power consumption for identifying a position of the mobile terminal apparatus, determining whether the mobile terminal apparatus has moved based on an output of the sensor selected in the selecting, and identifying a position of the mobile terminal apparatus when it is determined that the mobile terminal apparatus has moved in the determining.
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This application is a Continuation-In-Part (CIP) of application Ser. No. 08/858,055, filed on May 16, 1997, now abandoned.
FIELD OF THE INVENTION
The present invention relates to air filters. More particularly, the present invention relates to a self-adhesive air filter for securable attachment to the air intake region of any device.
BACKGROUND OF THE INVENTION
A conventional air filter is typically mounted in a filter housing which, in turn, is typically mounted in a device which draws or pushes air through the air filter and filter housing. There are some devices, coming in various shapes and sizes, that require filtered air to protect internal components from abrasion and/or corrosion due to the intake of foreign particles. For example, computers, VCRs, stereos, and TVs require filtered air to protect internal components. There are other devices, also coming in various shapes and sizes, that can be used to provide filtered air by removing unwanted particles from the surrounding environment. For example, box fans, circular fans, air purifiers, and central heating air-conditioning systems can be used to provide filtered air in a home environment. As a result, there are a variety of air filters and air filter housings on the market that are custom made to be compatible with particular devices. For example, there are custom filters and filter housings which are compatible with air purifiers but are not compatible with computers. As can readily be appreciated, the purchase of custom made replacement filters and filter housings for each particular device can quickly become very expensive. Furthermore, it sometimes costs nearly as much to purchase the replacement filters and filter housings as it did to purchase the original device. Consequently, there is a continuing need for a universal air filter that is compatible with the various devices that require and/or provide filtered air.
Another drawback encountered with conventional air filters is the necessity of having air filter housings for supporting and properly positioning the air filters on a device. As can readily be appreciated, the mere presence of an air filter housing often increases the size of the overall device. This, in turn, increases the overall cost of the device. Furthermore, it is often difficult to manipulate the air filter housing to remove a spent air filter and replace it with a new air filter. Accordingly, users of devices that provide filtered air often fail to replace the spent air filters thereby thwarting the very reason for operating the air filtering devices. Additionally, users of devices that require filtered air often fail to replace the spent air filters thereby shortening the service life of the devices due to the corrosion or abrasion of the internal components within the devices. Furthermore, air filter housings often impede the flow of air through the air filters thereby reducing the effectiveness of the air filters. Consequently, there is a continuing need for a universal air filter that can be positioned in various air ingesting or expelling devices without using an air filter housing.
There is currently no self-adhesive air filter which is available that will secure itself to any dry surface that it is in contact with. It is oftentimes desirable to adhere a filter to such diverse surfaces as screens, grills and slotted air openings which not only present the challenge of having non-contiguous surfaces for filter application but also which may be of odd and unpredictable surface geometries.
As noted above, most commonly available filters are those which are confined within a casing made of material which is not intended to assist in the filtering function but simply intended to physically house and retain the filter in a given location. As such, casings made of, for example, cardboard and plastic limit the application of filter materials to unanticipated and geometrically complex surfaces. Even if a manufacturer was to offer a line of filters for every conceivable application, filter distributors would have to inventory an unrealistically large number of products to complete their filter line inventory.
Perhaps the closest design to the present invention, at least specifically, is shown in U.S. Pat. No. 5,490,336 to Smick et al. This Feb. 13, 1996 patent describes a filter design for appliances having electric motors such as hair dryers, power tools and drills. Smick et al. also discloses that their filter can be cut to fit onto the intake portion of such an appliance. However, the filter employs a foam material that has an asterisk shaped piece or pieces of plastic that are either pressed, compressed or molded into the foam filter material. This asterisk shaped add-on component retains adhesive. However, the plastic adhesive bearing strips, by their very nature, resists conforming to a complex geometric surface. In addition, when Smick et al. teaches cutting their filter to provide a cone-shaped object, some of the cutting inherently requires the removal of the asterisk-shaped plastic and related adhesive such that if the filter is cut as to remove the asterisk at a border of a cut region, there will be no adhesive at the margin of the filter to retain it onto the motor intake surface thus removing the effectiveness of the filter for all practical purposes. Finally, it should be appreciated that the plastic asterisk adhesive pattern does nothing but block portions of the filter resulting in a reduction in overall filter surface area.
While there are several prior art filters, each prior art filter suffers from the drawbacks discussed above. For example, U.S. Pat. No. 5,433,764 to Matschke, issued Jul. 18, 1995, describes a circular filter held by a retainer of porous material. A layer of adhesive is positioned on the retainer to hold it and the filter on a device. However, so much adhesive is used that it virtually blocks the porosity of the filter.
U.S. Pat. No. 5,331,748 to Miller, Jr., issued Jul. 26, 1994, describes a circular filter having three spaced strips of polyester on one side of the filter. The outer surfaces of the strips are coated with an adhesive for holding the filter on the intake portion of a blow dryer. Miller, Jr., like Smick et al., teaches using adhesive strips on a limited portion of the filter since the adhesive strips reduce the effectiveness of the filter by impeding the flow of air through the filter.
U.S. Pat. No. 5,370,721 to Carnahan, issued Dec. 6, 1994, describes a ceiling fan filter for filtering the air in a room having a ceiling fan. As can readily be appreciated upon reviewing Carnahan, the filter disclosed is custom made for a ceiling fan and is not compatible with other devices for filtering air.
It is an object of the present invention to provide a self-adhesive air filter which overcomes the drawbacks of the prior art.
It is another object of the present invention to provide a self-adhesive air filter which is universally compatible with devices that require filtered air.
It is yet another object of the present invention to provide a self-adhesive air filter which is universally compatible with devices that provide filtered air.
It is a further object of the present invention to provide a self-adhesive air filter which can be positioned in various air ingesting and/or expelling devices without using an air filter housing.
It is yet a further object of the present invention to provide a self-adhesive air filter which is self adhesive without reducing the effectiveness of the filter.
These and other objects of the present invention will become apparent to one skilled in the art in view of the figures and description of the figures given below.
SUMMARY OF THE INVENTION
Briefly stated, self-adhesive air filters are provided that are universally compatible with devices that require filtered air and devices that provide filtered air. The self-adhesive air filters are fabricated from a fibrous air filter blank that is coated with an air permeable non-drying adhesive. A template serves as a protective cover for the non-drying adhesive and enables a user to shape and/or size the blank to configurations that are compatible with the air intake regions of the devices on which the self-adhesive air filters are to be installed.
A feature of the invention includes a self-adhesive air filter for installing over the air intake region of a device, the self-adhesive air filter including a fibrous air filter member having at least one face, at least one layer of air-permeable adhesive coating the face in its entirety, and a protective layer lightly adhering to the layer of air-permeable adhesive to permit removal of the protective layer prior to installing the air filter member over the air intake region of the device.
Another feature of the invention includes a method of installing a self-adhesive air filter over the air intake region of a device, the method includes providing a rectangular blank of fibrous air filter material having an air-permeable adhesive on an upper surface thereof and having a template lightly adhering to the air-permeable adhesive, altering the rectangular blank into a shape that is compatible with the air intake region of the device by cutting the blank along one of a plurality of geometric patterns provided on the template, removing the template from the altered blank, placing the upper surface of the altered blank against the air intake region of the device such that the upper surface is aligned with the air intake region, and applying a pressure to a lower surface of the altered blank whereby the altered blank adheres to the air intake region of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a adhesive filter material blank and an associated template for cutting the blank to a size and/or shape to fit the blank to a particular device.
FIG. 2 is an exploded view showing a filter cut from the blank of FIG. 1 for installation on a circular fan.
FIG. 3 is an exploded view showing a filter cut from the blank of FIG. 1 for installation over an air intake vent of a lap top computer.
FIG. 4 is an exploded view showing a pair of filters cut from the blank of FIG. 1 for installation over the heat vents of a stereo system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a filter forming assembly 10 of the present invention is shown. The filter forming assembly 10 includes a square blank 12 of adhesive fibrous filter material and a template 14 for cutting the adhesive filter material. The template 14 is used to enable a user to shape and/or size the blank 12 to a configuration that is compatible with the air intake region of a device on which the self-adhesive air filter will be installed.
The fibrous blank 12 is an air filter material that has been treated with a non-drying adhesive. The preferred air filter material is composed of conventional fibrous polyester batting that can be treated with a non-drying adhesive. While the air filter material is preferably one quarter of an inch thick, the selection of the thickness would, of course, depend on the filter's intended use. However, a feature of this invention is to use a fibrous filter material that is flexible and easily conformable to complex geometric shapes--an attribute that is not shared by the filter of Smick et al. due to their use of plastic adhesive bearing strips.
The preferred adhesive is a non-drying adhesive such as Duro's All Purpose Spray Adhesive composed of n-hexane, dimethyl ether and acetone. However other non-drying adhesives can be used as long as the adhesive, once applied, would not be readily combustible. The adhesive offers minimal air flow resistance and releasably secures the air filter material on the air intake region of an underlying device. The adhesive also enhances the effectiveness of the air filter material by trapping minute particles not otherwise trapped by the air filter material. When the air filter material is spent the adhesive permits the air fiter material to be removed from the air intake region of an underlying device without excessive debris being left on the air intake region.
The template 14 is a flexible piece of material such as protective plastic, acetate film, or wax paper. Printed or otherwise provided on a first side 16 of the template 14 is a set of circles 18, a set of rectangular polygons 20, a set of arcuate lines 22, and a set of perpendicular lines 24. The sets of geometric FIGS. 18, 20, 22 and 24 are centered around a center 26 of the template 14. The sets of geometric FIGS. 18, 20, 22 and 24 enable a user to shape and/or size the blank 12 to a configuration that is compatible with the air intake region of the device on which the self-adhesive air filter will be installed.
During manufacturing of the filter forming assembly 10, a first uniform coating of the non-drying adhesive is preferably sprayed onto a surface 28 of the blank 12 and vacuumed into the fibers of the air filter material of the blank 12. A second coating of non-drying adhesive is then applied to the surface 28 of the blank 12. Additional coats of non-drying adhesive can be applied depending on the air filter's intended use. A second side 17 of the template 14 is then positioned on the adhesive surface 28 of the blank 12 so the template 14 covers and protects the adhesive surface 28 of the blank 12. It was found that the adhesive alone contributes approximately 10 to 15% or more of the actual filtering function of the present invention particularly noting that this invention contemplates the use of a uniform application of adhesive over the entire surface of the fibrous batting.
Referring now to FIG. 2, a self-adhesive air filter 30, cut from the filter-forming assembly 10 of FIG. 1, is shown. The self-adhesive air filter 30 is formed to fit a back side 32 of a circular fan 34. The air filter 30 is formed by first cutting the blank 12 and template 14 along two circles 34 and 36 provided in the set of circles 18 on the template 14. Then a slit 38 is cut along a portion of one line provided in the set of perpendicular lines 24 on the template 14 to give the self-adhesive air filter 30 a split annular configuration. Afterwards, the template 14 is peeled away from the self-adhesive air filter 30. The adhesive surface 28 of the self-adhesive air filter 30 is then mounted on the back side 32 of the circular fan 34 by spreading the self-adhesive air filter 30 apart at the slit 38, sliding the air filter 30 over the fan motor housing 40, rotating the air filter 30 until the slit 38 points radially upward away from the fan motor housing 40, and firmly pressing the filter 30 against the back side 32 of the circular fan 34.
Referring now to FIG. 3, another embodiment of a self-adhesive filter 42, cut from the filter forming assembly 10 of FIG. 1, is shown. The self-adhesive air filter 42 is formed to fit an air intake vent 44 of a lap top computer 46. The self-adhesive air filter 42 is formed by cutting the blank 12 and template 14 along a circle 48 provided in the set of circles 18 on the template 14. Afterwards, the template 14 is peeled away from the self-adhesive air filter 42. The self-adhesive air filter 42 is then mounted on the air intake vent 44 by placing the adhesive surface 28 of the self-adhesive air filter 42 against the air intake vent 44 and firmly pressing the self-adhesive air filter 42 against the air intake vent 44 of the lap top computer 46.
Referring now to FIG. 4, two more embodiments of self-adhesive air filters 48 and 49, cut from the filter forming assembly 10 of FIG. 1, are shown. The self-adhesive air filters 48 and 49 are formed to fit the heat vents 50 and 52 of a stereo system 54. The self-adhesive air filters 48 and 49 are formed by cutting the blank 12 and template 14 along two rectangles 56 and 58 provided in the set of rectangular polygons 20 on the template 14. Afterwards, the template 14 is peeled away from each self-adhesive air filter 48 and 49. The self-adhesive air filters 48 and 49 are then mounted on the heat vents 50 and 52 by placing the adhesive side 28 of each self-adhesive air-filter 48 and 49 on the respective heat vents 50 and 52 and firmly pressing each self-adhesive air filter 48 and 49 against the stereo system 54.
The present invention is remarkable in its simplicity, particularly as compared to the prior art. Superficially, Smick et al. in U.S. Pat. No. 5,490,336 seems to suggest an air filter similar to that proposed herein but the differences, as noted above, are remarkable. Smick et al.'s design is limited to a foam material employing plastic strips within the foam in order to adhere the foam to a receiving surface. Unlike the present invention in which adhesive is globally applied uniformly to a surface of fibrous batting, Smick et al. are unable to apply adhesive to their foam filter material for the adhesive would cause pores of the foam to clog and, in extreme cases, to melt. Smick et al. employ plastic strips to not only prevent this from occurring but because the adhesive-type caulking that Smick et al. employ would not adhere strongly enough to the foam filter material and, as a consequence, when removing the foam filter from its receiving surface, the adhesive would remain on the appliance causing an unsightly and generally unacceptable appearance.
The present invention is remarkable in its effectiveness and simplicity. A fibrous batting material such as a sheet of one-quarter inch polyester is sprayed uniformly with an adhesive which is vacuumed into the fibrous interstices of the filter material. A second light coating of adhesive is preferably then applied to the filter material and together, these adhesives not only act to removably retain the filter material onto a receiving surface but enhance the filtering characteristics of the fibrous batting to a point where the batting acts as a filter far superior to that demonstrated without the adhesive. In addition, the fibrous batting, being quite flexible, can readily adhere to any complex geometry while the filter can be cut to complex shapes with the reassurance that the filter material which remains after cutting continues to possess the necessary adhesive layer to ensure adhesion between the filter material and its receiving surface. By contrast, prior devices have resorted to the use of complex filtering materials, adhesive patterns and filter housings in an attempt to construct filters which simply don't compare to the filtering ability and flexibility of use enjoyed by the present invention.
A general description of the device and method of using the present invention, as well as the preferred embodiments of the present invention, has been set forth above. One skilled in the art will recognize and be able to practice many changes in many aspects of the device and method described above, including variations which fall within the teachings of the present invention. The spirit and scope of the invention should be limited only as set forth in the claims which follow.
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Self-adhesive fibrous air filters that are universally compatible with devices that require filtered air and devices that provide filtered air. The self-adhesive air filters are fabricated from a flexible fibrous air filter blank composed of, for example, polyester batting, that is coated with an air permeable non-drying adhesive that has been vacuumed into the interstices of the fibers. A template serves as a protective cover for the non-drying adhesive and enables a user to shape and/or size the blank to configurations that are compatible with the air intake regions of the devices on which the self-adhesive air filters are to be installed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a vehicle door structure that includes a slidable opening/closing type slide door and a swingable opening/closing type swing door.
[0003] 2. Related Background Art
[0004] For example, a vehicle door structure disclosed in Japanese Patent Application Laid-Open No. 2011-46271 is known as a vehicle door structure of the related art. The vehicle door structure disclosed in Japanese Patent Application Laid-Open No. 2011-46271 includes a slide door that opens and closes a front area of a rear door opening portion, a swing door that opens and closes a rear area of the rear door opening portion along with the slide door, an outer handle that is provided in an outer surface of the slide door and is used to open and close the slide door, an inner handle that is provided in an inner surface of the slide door and is used to open and close the slide door, and an opening and closing handle that is provided in a front edge of the swing door and is used to open and close the swing door. The slide door slides in the longitudinal direction of the vehicle body through a slide mechanism. The swing door rotates with respect to the vehicle body through a hinge mechanism while overlapping the slide door. Further, the vehicle door structure includes a swing door opening and closing regulation mechanism that connects (locks) the swing door and the vehicle body to each other when the swing door is fully closed.
[0005] However, the following problems exist in the related art. That is, there is a need to open the swing door by the operation of the opening and closing handle when the locking between the swing door and the vehicle body is released. Accordingly, there is a need to switch the outer handle or the inner handle to the opening and closing handle when the slide door is opened and then the swing door is opened, and hence the operation efficiency is degraded.
[0006] An object of the present invention is to provide a vehicle door structure capable of improving the efficiency of an operation of opening a slide door and then opening a swing door.
SUMMARY OF THE INVENTION
[0007] According to one embodiment of the present invention, there is provided a vehicle door structure equipped with a slide door that opens and closes a partial area of a door opening portion provided in a side portion or a rear portion of a vehicle body and a swing door that opens and closes the other partial area of the door opening portion along with the slide door, the vehicle door structure including: a slide door handle that is provided in the slide door so as to open and close the slide door; a lock unit that locks the swing door to the vehicle body when the swing door is fully closed; and a lock release unit that releases the locking of the swing door with respect to the vehicle body when the full opened state of the slide door is detected.
[0008] In this way, in the vehicle door structure according to one embodiment of the present invention, if the full opened state of the slide door is detected when the slide door is opened by the operation of the slide door handle in a state where the swing door is locked to the vehicle body, the swing door may be opened by releasing the locking of the swing door with respect to the vehicle body. Accordingly, since there is no need to switch the slide door handle when the slide door is opened and then the swing door is opened, the operation efficiency may be improved.
[0009] In one embodiment, the vehicle door structure may further include a slide door opening and closing regulation unit that regulates the operation of opening and closing the slide door before the slide door is fully opened. In this case, the position of the slide door may be maintained and fixed at the step before the slide door is fully opened. Accordingly, this configuration is effective in a case where only the slide door is opened and closed without opening and closing the swing door.
[0010] In one embodiment, the vehicle body may be provided with a first slide rail that extends in the slide door opening and closing direction, the swing door may be provided with a second slide rail that extends in the slide door opening and closing direction, the slide door may be provided with a first guide body guided by the first slide rail and a second guide body guided by the second slide rail, and the slide door opening and closing regulation unit may be configured as a plurality of protrusion portions that are provided in at least one of the first slide rail and the second slide rail and regulate a roller of at least one of the first guide body and the second guide body in the slide door opening and closing direction. In this case, the slide door opening and closing regulation unit may be realized by a simple configuration.
[0011] In one embodiment, the lock unit may include a lock member that is provided in the swing door and an engagement portion that is provided in the vehicle body and engages with the lock member, and the lock release unit may include a detection component that is provided in the slide door, a rotation member that is rotatably provided in the swing door and engages with the detection component when the slide door is fully opened, and a connection member that connects the lock member to the rotation member. In such a configuration, if the detection component contacts the rotation member so as to rotate the rotation member when the slide door is opened, it is detected that the slide door is fully opened. At this time, when the lock member is separated from the engagement portion through the connection member by the rotation of the rotation member, the locking of the swing door with respect to the vehicle body is released.
[0012] In one embodiment, the swing door may be provided with a slide rail that extends in the slide door opening and closing direction, the slide door may be provided with a guide body that is guided by the slide rail, and the detection component may be the guide body. In this case, since the full opened state of the slide door is detected when the existing guide body contacts the rotation member so as to rotate the rotation member, the number of components does not increase.
[0013] In one embodiment, the slide door may be provided with a protrusion portion that protrudes toward the swing door, and the detection component may be the protrusion portion. In this case, when the protrusion portion contacts the rotation member so as to rotate the rotation member, the full opened state of the slide door is detected. At this time, the full opened state of the slide door may be detected with high precision by providing the protrusion portion at an appropriate position of the slide door.
[0014] In one embodiment, the lock unit may include a lock member that is provided in the swing door and an engagement portion that is provided in the vehicle body and engages with the lock member, and the lock release unit may include a sensor that detects whether the slide door is fully opened and a drive unit that moves the lock member so that the lock member is separated from the engagement portion when the sensor detects that the slide door is fully opened. When the sensor and the drive unit are used in this way, it is possible to electrically detect the full opened state of the slide door and release the locking of the swing door with respect to the vehicle body even when a complex structure is not particularly provided.
[0015] According to the present invention, it is possible to improve the efficiency of the operation of opening the slide door and then opening the swing door. Thus, the swing door handle is not needed, and hence the merchantability may be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a side view illustrating a vehicle that includes an embodiment of a vehicle door structure according to the present invention.
[0017] FIGS. 2A to 2C are perspective views illustrating a state where a slide door and a swing door illustrated in FIG. 1 are opened.
[0018] FIG. 3 is a schematic enlarged view illustrating a position that includes a lower slide rail and a guide body illustrated in FIGS. 2A to 2C .
[0019] FIG. 4 is a schematic enlarged view illustrating a position that includes a middle slide rail and a guide body illustrated in FIGS. 2A to 2C .
[0020] FIG. 5 is a schematic enlarged view illustrating a state where a perpendicular roller of the guide body is restrained by a protrusion portion of the lower slide rail illustrated in FIG. 3 .
[0021] FIG. 6 is a schematic enlarged view illustrating a state where the perpendicular roller of the guide body is restrained by a protrusion portion of the middle slide rail illustrated in FIG. 4 .
[0022] FIGS. 7A and 7B are views illustrating a swing door lock release mechanism along with the middle slide rail and the guide body illustrated in FIGS. 2A to 2C .
[0023] FIGS. 8A and 8B are views illustrating a part of the swing door lock release mechanism illustrated in FIGS. 7A and 7B along with a swing door lock mechanism.
[0024] FIG. 9 is a cross-sectional view taken along the line IX-IX of FIGS. 7A and 7B .
[0025] FIG. 10 is a view illustrating a swing door handle that is provided in the swing door as a comparative example.
[0026] FIG. 11 is a view illustrating a modified example of the swing door lock release mechanism illustrated in FIGS. 7A and 7B as another embodiment of the vehicle door structure according to the present invention.
[0027] FIG. 12 is a view illustrating another modified example of the swing door lock release mechanism illustrated in FIGS. 7A and 7B as still another embodiment of the vehicle door structure according to the present invention.
[0028] FIG. 13 is a view illustrating the arrangement position of the swing door lock release mechanism illustrated in FIG. 12 .
[0029] FIG. 14 is a view illustrating still another modified example of the swing door lock release mechanism illustrated in FIGS. 7A and 7B as still another embodiment of the vehicle door structure according to the present invention.
[0030] FIG. 15 is a view illustrating a part of the swing door lock release mechanism illustrated in FIG. 14 along with the swing door lock mechanism.
[0031] FIGS. 16A to 16C are views illustrating the structure of a lock member illustrated in FIG. 15 .
[0032] FIG. 17 is a view illustrating a modified example of the swing door lock release mechanism illustrated in FIGS. 8A and 8B as still another embodiment of the vehicle door structure according to the present invention along with the swing door lock mechanism.
[0033] FIG. 18 is a view illustrating the arrangement position of a proximity switch illustrated in FIG. 17 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Hereinafter, preferred embodiments of a vehicle door structure according to the present invention will be described in detail by referring to the drawings. Furthermore, in the drawings, the same reference numerals will be given to the identical or equivalent components, and the repetitive description thereof will not be repeated.
[0035] FIG. 1 is a side view illustrating a vehicle that includes an embodiment of the vehicle door structure according to the present invention. In the same drawing, a vehicle door structure 1 of this embodiment is applied to a side portion of a vehicle body 2 . The side portion of the vehicle body 2 is provided with a front door opening portion 3 that is located at the lateral side of a front seat and a rear door opening portion 4 that is located at the lateral side of a luggage compartment provided at the rear side of the front seat. The front door opening portion 3 is opened and closed by a front door 5 .
[0036] The rear door opening portion 4 is opened and closed by a slidable opening/closing type slide door 6 and a swingable opening/closing type swing door 7 . As illustrated in FIGS. 2A and 2B , the slide door 6 is adapted to open and close the front area of the rear door opening portion 4 while sliding in the longitudinal direction of the vehicle body 2 . In a state where the slide door 6 is fully opened, the slide door 6 is located at the outside of the swing door 7 so as to overlap the swing door 7 (see FIG. 2B ).
[0037] In a state where the slide door 6 is fully opened, the swing door 7 is adapted to open and close the rear area of the rear door opening portion 4 while rotating rotates with respect to the vehicle body 2 as illustrated in FIG. 2C along with the slide door 6 .
[0038] The outer surface of the slide door 6 is provided with an outer door opening and closing handle 8 , and the inner surface of the slide door 6 is provided with an inner door opening and closing handle 9 . The opening and closing handles 8 and 9 are slide door handles that are used to open and close the slide door 6 .
[0039] The vehicle door structure 1 includes slide support mechanisms 11 A to 11 C that slidably support the slide door 6 in the longitudinal direction of the vehicle body 2 and a rotation support mechanism 12 that rotatably supports the swing door 7 with respect to the vehicle body 2 .
[0040] The slide support mechanism 11 A includes an upper slide rail 13 that is provided in the upper portion of the vehicle body 2 so as to extend in the longitudinal direction of the vehicle body 2 (the opening and closing direction of the slide door 6 ) and a guide body 14 that is provided in the upper portion of the front end of the slide door 6 and is guided by the upper slide rail 13 when the slide door 6 is opened and closed.
[0041] The slide support mechanism 11 B includes a lower slide rail 15 that is provided in the lower portion of the vehicle body 2 so as to extend in the longitudinal direction of the vehicle body 2 and a guide body 16 that is provided in the lower portion of the front end of the slide door 6 and is guided by the lower slide rail 15 when the slide door 6 is opened and closed. As illustrated in FIG. 3 , the guide body 16 includes a horizontal roller 41 and a perpendicular roller 42 . The horizontal roller 41 and the perpendicular roller 42 are rotatably supported by a bracket 43 (see FIG. 2C ) attached to the slide door 6 . A latch 44 is attached to the bracket 43 . Furthermore, although not illustrated in the drawings, the guide body 14 also includes a horizontal roller 41 and a perpendicular roller 42 .
[0042] The slide support mechanism 11 C includes a middle slide rail 17 that is provided in the swing door 7 so as to extend in the longitudinal direction of the vehicle body 2 and a guide body 18 that is provided in the rear end of the slide door 6 and is guided by the middle slide rail 17 when the slide door 6 is opened and closed. As illustrated in FIG. 4 , the guide body 18 includes a pair of front and rear horizontal rollers 33 and a perpendicular roller 34 . The perpendicular roller 34 is disposed between the horizontal rollers 33 .
[0043] The rotation support mechanism 12 includes two upper and lower hinges 24 that rotatably connect the swing door 7 to a rear pillar 23 that is provided in the rear end of the vehicle body 2 .
[0044] Further, the vehicle door structure 1 further includes two upper and lower door lock mechanisms 25 that lock the slide door 6 and the swing door 7 when the slide door 6 is fully opened so that the slide door 6 overlaps the swing door 7 .
[0045] As illustrated in even FIG. 3 , the door lock mechanism 25 includes a latch 44 that is attached to each of the upper and lower portions of the front end of the slide door 6 and a striker 26 that is attached to each of the upper and lower portions of the front end of the swing door 7 so as to engage with the latch 44 .
[0046] When the slide door 6 is fully opened so that the latch 44 engages with the striker 26 , the slide door 6 is locked to the swing door 7 . Furthermore, the locking between the slide door 6 and the swing door 7 may be released when the slide door 6 is closed by the operation of the opening and closing handles 8 and 9 .
[0047] When the state where the slide door 6 and the swing door 7 are locked to each other is released, the upper and lower guide bodies 14 and 16 are separated from the rear ends of the upper slide rail 13 and the lower slide rail 15 . For this reason, the slide door 6 is supported only by the swing door 7 through the door lock mechanism 25 , the middle slide rail 17 , and the guide body 18 , and hence may be rotated along with the swing door 7 .
[0048] Further, the vehicle door structure 1 includes two upper and lower swing door lock mechanisms 27 that lock the swing door 7 to the vehicle body 2 when the swing door 7 is fully closed. The swing door lock mechanism 27 includes a bar-type lock member 28 that is attached to each of the upper and lower portions of the swing door 7 and a striker 29 (see FIG. 2C ) that is attached to each of the upper and lower portions of the vehicle body 2 so as to engage with the lock member 28 .
[0049] When the swing door 7 is fully closed, the lock member 28 protrudes from the swing door 7 toward the vehicle body 2 so as to engage with the striker 29 by a biasing force of a spring (not illustrated), so that the swing door 7 is locked to the vehicle body 2 (see FIG. 8A ).
[0050] Further, as illustrated in FIGS. 3 and 4 , the vehicle door structure 1 includes a slide door opening and closing regulation mechanism 50 that regulates the operation of opening and closing the slide door 6 immediately before the slide door 6 is fully opened. Furthermore, the slide door opening and closing regulation mechanism 50 is not illustrated in FIG. 1 . The slide door opening and closing regulation mechanism 50 includes a pair of front and rear protrusion portions 51 (see FIG. 3 ) that is provided in the lower portion of the lower slide rail 15 and restrains the perpendicular roller 42 of the guide body 16 in the longitudinal direction of the vehicle body 2 and a pair of front and rear protrusion portions 52 (see FIG. 4 ) that are provided in the lower portion of the middle slide rail 17 and restrains the perpendicular roller 34 of the guide body 18 in the longitudinal direction of the vehicle body 2 .
[0051] When the slide door 6 is opened, the perpendicular roller 42 is restrained by each protrusion portion 51 in the longitudinal direction of the vehicle body 2 as illustrated in FIG. 5 , and the perpendicular roller 34 is restrained by each protrusion portion 52 in the longitudinal direction of the vehicle body 2 as illustrated in FIG. 6 . Accordingly, the operation of opening and closing the slide door 6 is regulated so that the position of the slide door 6 is maintained and fixed before the slide door 6 is fully opened. Further, as illustrated in FIGS. 3 and 4 , when the slide door 6 is further opened so that the perpendicular roller 42 runs over each protrusion portion 51 and the perpendicular roller 34 runs over each protrusion portion 52 , the slide door 6 may be fully opened.
[0052] Further, as illustrated in FIGS. 7A to 8B , the vehicle door structure 1 includes a swing door lock release mechanism 60 that releases the locking of the swing door 7 with respect to the vehicle body 2 when detecting a state where the slide door 6 is fully opened so that the slide door 6 is locked to the swing door 7 . Furthermore, the swing door lock release mechanism 60 is not illustrated in FIG. 1 . A part of the swing door lock release mechanism 60 is formed by the guide body 18 provided in the slide door 6 .
[0053] As illustrated in FIGS. 7A to 9 , the guide body 18 is attached to a front end of an arm 32 that is substantially formed in an L-shape. The arm 32 is rotatably connected to the slide door 6 so as to extend toward the inside of the vehicle body 2 (toward the swing door 7 ). The guide body 18 includes the horizontal roller 33 and the perpendicular roller 34 . The horizontal roller 33 is rotatably supported by a shaft portion 35 attached to the upper side of the arm 32 . The perpendicular roller 34 is rotatably supported by a shaft portion 37 that is attached to the lower side of the arm 32 through a bracket 36 .
[0054] Further, as illustrated in FIGS. 7A to 9 , the swing door lock release mechanism 60 includes a rotation lever 38 that is swingably (rotatably) attached to the swing door 7 through a shaft portion 38 a and engages with a head portion 37 a of the shaft portion 37 of the guide body 18 and a cable 39 that connects the rotation lever 38 to the lock member 28 of each swing door lock mechanism 27 . The front end of the rotation lever 38 enters the middle slide rail 17 through a notch portion 17 a formed in the outer portion of the middle slide rail 17 . One end of the cable 39 is connected to the base end of the rotation lever 38 . Furthermore, as illustrated in FIG. 7A , the rotation lever 38 is generally maintained in a state where the rotation lever enters the middle slide rail 17 by a biasing force of a spring (not illustrated).
[0055] Here, when the slide door 6 is opened while being slid toward the rear side of the vehicle body 2 in a state where the swing door 7 is locked to the vehicle body 2 by the swing door lock mechanism 27 , it is detected that the slide door 6 is not fully opened and the slide door 6 and the swing door 7 are not locked to each other at the step before the shaft portion 37 of the guide body 18 contacts the rotation lever 38 as illustrated in FIG. 7A .
[0056] Then, when the slide door 6 is further opened so that the shaft portion 37 of the guide body 18 contacts the rotation lever 38 so as to press the rotation lever 38 inward as illustrated in FIG. 7B , it is detected that the slide door 6 is fully opened and the slide door 6 and the swing door 7 are locked to each other. At this time, the rotation lever 38 rotates so that the cable 39 is pulled toward the rotation lever 38 . For this reason, as illustrated in FIG. 8B , the lock member 28 is separated from the striker 29 against a biasing force of a spring (not illustrated) so as to be retracted into the swing door 7 , and hence the locking between the swing door 7 and the vehicle body 2 is released. Thus, the swing door 7 may be opened.
[0057] Incidentally, when the swing door 7 is opened, the swing door 7 is opened after the slide door 6 is fully opened as illustrated in FIGS. 2A to 2C . At this time, in a case where the swing door lock release mechanism 60 is not provided, when the slide door 6 is fully opened and a swing door handle 90 provided in the front end of the swing door 7 is operated as illustrated in FIG. 10 , the locking between the swing door 7 and the vehicle body 2 is released, so that the swing door 7 is opened. In this case, since the outer door opening and closing handle 8 or the inner door opening and closing handle 9 needs to be switched by the swing door handle 90 , a problem arises in that the workability is degraded.
[0058] On the contrary, in this embodiment, when it is detected that the slide door 6 is fully opened and the slide door 6 and the swing door 7 are locked to each other, the swing door 7 may be opened at the time point in which the slide door 6 is fully opened since the swing door lock release mechanism 60 is provided so as to release the locking of the swing door 7 with respect to the vehicle body 2 . For this reason, the swing door 7 may be opened by directly using the outer door opening and closing handle 8 or the inner door opening and closing handle 9 after the slide door 6 is fully opened by operating the outer door opening and closing handle 8 or the inner door opening and closing handle 9 . Thus, since there is no need to switch the outer door opening and closing handle 8 or the inner door opening and closing handle 9 at each time, the operation efficiency may be improved. Further, since the swing door handle 90 illustrated in FIG. 10 is not needed, the merchantability may be improved.
[0059] Further, since there is provided the slide door opening and closing regulation mechanism 50 that regulates the operation of opening and closing the slide door 6 immediately before the slide door 6 is fully opened, the position of the slide door 6 may maintained and fixed while the swing door 7 is locked to the vehicle body 2 and the slide door 6 is opened by a predetermined amount. Accordingly, in a case where a luggage is carried into or out of the luggage compartment by opening and closing only the slide door 6 while the swing door 7 is not opened and closed, there is no need to lock the slide door 6 and the swing door 7 at each time. Thus, the operation efficiency may be further improved.
[0060] FIG. 11 is a view illustrating a modified example of the swing door lock release mechanism 60 illustrated in FIGS. 7A and 7B as another embodiment of the vehicle door structure according to the present invention. In the same drawing, the swing door lock release mechanism 60 of this modified example includes a detection protrusion portion 61 that is fixed to the inner side surface of the slide door 6 . The protrusion portion 61 is formed so as to enter the middle slide rail 17 . Further, the protrusion portion 61 is disposed at the front side of the guide body 18 in the slide door 6 .
[0061] Further, the swing door lock release mechanism 60 includes the rotation lever 38 and the cable 39 as in the above-described embodiment. The rotation lever 38 is a rotation member that engages with the protrusion portion 61 .
[0062] In such a swing door lock release mechanism 60 , when the protrusion portion 61 contacts the rotation lever 38 so as to press the rotation lever 38 , the slide door 6 is fully opened and the slide door 6 and the swing door 7 are locked to each other. At this time, since the rotation lever 38 rotates so that the cable 39 is pulled toward the rotation lever 38 as in the above-described embodiment, the lock member 28 is separated from the striker 29 so that the locking between the swing door 7 and the vehicle body 2 is released.
[0063] FIG. 12 is a view illustrating another modified example of the swing door lock release mechanism 60 illustrated in FIGS. 7A and 7B as still another embodiment of the vehicle door structure according to the present invention. In the same drawing, the swing door lock release mechanism 60 of this modified example is provided in the upper portions of the front ends of the slide door 6 and the swing door 7 as illustrated in FIG. 13 . Furthermore, the swing door lock release mechanism 60 may be provided in the lower portions of the front ends of the slide door 6 and the swing door 7 .
[0064] The swing door lock release mechanism 60 includes a detection protrusion portion 65 that is fixed to the inner side surface of the upper portion of the front end of the slide door 6 . The rotation lever 38 is rotatably attached to the upper portion of the front end of the swing door 7 . The rotation lever 38 is a rotation member that engages with the protrusion portion 65 . Further, the swing door lock release mechanism 60 includes the cable 39 .
[0065] In such a swing door lock release mechanism 60 , when the protrusion portion 65 contacts the rotation lever 38 so as to press the rotation lever 38 , the slide door 6 is fully opened and the slide door 6 and the swing door 7 are locked to each other. At this time, since the rotation lever 38 rotates so that the cable 39 is pulled toward the rotation lever 38 as in the above-described embodiment, the lock member 28 is separated from the striker 29 so that the locking between the swing door 7 and the vehicle body 2 is released.
[0066] FIG. 14 is a view illustrating still another modified example of the swing door lock release mechanism 60 illustrated in FIGS. 7A and 7B as still another embodiment of the vehicle door structure according to the present invention. In the same drawing, the swing door lock release mechanism 60 of this modified example includes a rod 70 instead of the cable 39 . One end of the rod 70 is connected to the base end of the rotation lever 38 . As illustrated in FIG. 15 , the other end of the rod is branched into two parts. Further, the swing door lock release mechanism 60 includes a rotation type lock member 71 instead of the bar-type lock member 28 .
[0067] As illustrated in FIGS. 16A to 16C , the lock member 71 is accommodated inside a housing 75 attached to the swing door 7 . The lock member 71 includes a latch portion 72 and a rod receiving portion 73 that engages with the latch portion 72 . The housing 75 is provided with a striker introduction portion 75 a into which the striker 29 is introduced and a rod introduction portion 75 b into which the rod 70 is introduced. The latch portion 72 is rotatably supported by the swing door 7 through the shaft portion 72 a. The rod receiving portion 73 is rotatably supported by the swing door 7 through the shaft portion 73 a. The latch portion 72 is biased by a spring (not illustrated) in a counter-clockwise direction, and the rod receiving portion 73 is biased by a spring (not illustrated) in a clockwise direction.
[0068] In such a swing door lock release mechanism 60 , the rod 70 does not contact the rod receiving portion 73 as illustrated in FIG. 16A before the shaft portion 37 of the guide body 18 contacts the rotation lever 38 , that is, the slide door 6 is fully opened. In this state, when the rod receiving portion 73 engages with the latch portion 72 and the latch portion 72 engages with the striker 29 against a biasing force of a spring (not illustrated), the swing door 7 is locked to the vehicle body 2 .
[0069] As illustrated in FIG. 14 , the shaft portion 37 of the guide body 18 contacts the rotation lever 38 so as to press the rotation lever 38 and the slide door 6 is fully opened, the rod 70 is pulled toward the lock member 71 by the rotation of the rotation lever 38 . Then, as illustrated in FIG. 16B , since the rod 70 presses the rod receiving portion 73 , the rod receiving portion 73 rotates in a counter-clockwise direction (see the arrow A) against a biasing force of a spring (not illustrated) and the engagement between the rod receiving portion 73 and the latch portion 72 is released. As a result, as illustrated in FIG. 15 , the locking between the swing door 7 and the vehicle body 2 is released, so that the swing door 7 may be opened.
[0070] Then, as illustrated in FIG. 16C , when the swing door 7 is opened, the engagement between the latch portion 72 and the striker 29 is released by the movement of the swing door 7 , so that the latch portion 72 rotates in a counter-clockwise direction by a biasing force of a spring (not illustrated) (see the arrow B).
[0071] FIG. 17 is a view illustrating still another modified example of the swing door lock release mechanism 60 illustrated in FIGS. 8A and 8B as still another embodiment of the vehicle door structure according to the present invention along with the swing door lock mechanism 27 . In the same drawing, the swing door lock release mechanism 60 of this modified example includes a proximity switch 80 and two drive units 81 instead of the rotation lever 38 and the cable 39 .
[0072] As illustrated in FIG. 18 , the proximity switch 80 is disposed in the rear end of the swing door 7 . The proximity switch 80 is a switch that detects whether the slide door 6 is fully opened by detecting whether the guide body 18 approaches. When the guide body 18 does not approach the proximity switch 80 , that is, the slide door 6 is not fully opened, the proximity switch 80 becomes an off state. Meanwhile, when the guide body 18 approaches the proximity switch 80 , that is, the slide door 6 is fully opened, the proximity switch 80 becomes an on state.
[0073] Each drive unit 81 is configured as an electromagnetic solenoid connected to the proximity switch 80 . When the proximity switch 80 becomes an off state, the drive unit 81 causes the lock member 28 to engage with the striker 29 . Then, when the proximity switch 80 becomes an on state, the drive unit 81 moves the lock member 28 in a direction in which the lock member is separated from the striker 29 . Furthermore, the drive unit 81 may be configured by the combination of, for example, an electric motor and a gear or a ball screw.
[0074] In this way, in this embodiment, when it is detected that the slide door 6 is fully opened and the slide door 6 and the swing door 7 are locked to each other, the locking of the swing door 7 with respect to the vehicle body 2 is electrically released.
[0075] Furthermore, the present invention is not limited to the above-described embodiment. For example, in the embodiment illustrated in FIGS. 7A , 7 B, and 14 , the shaft portion 37 of the guide body 18 becomes a detection component that engages with the rotation lever 38 . However, for example, the detection protrusion portion that engages with the rotation lever 38 may be provided in the shaft portion 37 .
[0076] Further, in the above-described embodiment, the slide door opening and closing regulation mechanism 50 includes the pair of front and rear protrusion portions 51 provided in the lower portion of the lower slide rail 15 and the pair of front and rear protrusion portions 52 provided in the lower portion of the middle slide rail 17 , but may include any one of the protrusion portions 51 and 52 .
[0077] Further, in the above-described embodiment, the slide door 6 is adapted to open and close the front area of the rear door opening portion 4 , and the swing door 7 is adapted to open and close the rear area of the rear door opening portion 4 along with the slide door 6 . However, the vehicle door structure of the present invention may be applied to a vehicle in which the slide door 6 is adapted to open and close the rear area of the rear door opening portion 4 and the swing door 7 is adapted to open and close the front area of the rear door opening portion 4 along with the slide door 6 . Further, the vehicle door structure of the present invention may be applied to a vehicle that includes a slide door and a swing door that are used to open and close a door opening portion provided in the rear portion of the vehicle body 2 .
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A vehicle door structure equipped with a slide door that opens and closes a partial area of a door opening portion provided in a side portion or a rear portion of a vehicle body and a swing door that opens and closes the other partial area of the door opening portion along with the slide door, the vehicle door structure comprising: a slide door handle that is provided in the slide door so as to open and close the slide door; a swing door lock mechanism that locks the swing door to the vehicle body when the swing door is fully closed; and a swing door lock release mechanism that releases the locking of the swing door with respect to the vehicle body when the full opened state of the slide door is detected.
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BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to a system for preparing a wire harness production and, more particularly, to a system for preparing a production of a vehicle wire harness.
[0002] In preparation for production of a wire harness to be wired in a vehicle, inefficient interchanges of various information and repetitions of such interchanges occur between a design department and a production department, or between a carmaker and a parts maker. This causes a problem that such production preparation needs a very long preparation period. This problem is described below with reference to FIG. 10.
[0003] [0003]FIG. 10 is an explanatory diagram illustrating an example of an operation to be performed in a production preparation time in which preparation for production of a related vehicle wire harness is performed. At a design department shown in FIG. 10, during this time, for example, design, fabrication, and evaluation of a wire harness are performed for the production preparation. On the other hand, at a production department, for instance, manufacturing drawing, assembly-jig drawing and process study are performed. Incidentally, the design department and the production department may be present in the same company. However, alternatively, the design department and the production department may be provided so that the design department is provided in a carmaker, while the production department is provided in a parts maker commissioned by the carmaker to produce wire harnesses.
[0004] In this production preparation time, as described in step S 1 a shown in FIG. 10, first, the design department makes design department diagrams referred to as, for example, a wire-harness skeleton diagram, an intraconnector terminal wiring diagram, and a circuit information diagram according to circuit diagrams consisting of system wiring diagrams, which describe relevant electric circuits, path diagrams, which describe wiring paths of a wire harness, and specifications and associated data. Then, such design department diagrams are provided from the design department to the production department.
[0005] In the production department receiving this design department diagrams, the preparation, checking and review of various drawings, and the study of a wire harness process are performed in a production preparation process P 1 . At a stage of preparing various drawings, wire harness production drawings, subdrawings, and jig drawings are prepared according to the design department drawings received from the design department. Incidentally, a processing drawing and wire specifications are cited as the wire harness production drawings. A sub numbered sub-assembly drawing is cited as the subdrawing. A jig layout drawing, a jig production drawing and a component list are cited as the jig drawings. Further, product cost accounts are cited as other drawings.
[0006] Moreover, at a checking stage of the production preparation process P 1 , the preparation of a working drawing for an inspection table, operating instructions, and an important point drawing is performed by referring to the design department drawings. Furthermore, at a study stage, product study, workability verification, and evaluation, and production system study are performed. At the product study, study of dimensional setting of wire correction of protectors, study of the size and dimensions of a protective layer, and study of style of packing are performed. At the workability study, evaluation of wiring procedure and time, evaluation of working procedure and time, and evaluation of layout of the inspection table are performed. Further, at the production system study, pressure-welding and production facility study and manufacturing system study are performed. Furthermore, at the wire harness process study, wire harness process layout and contact study are performed. Particularly, line design, which concerns personnel assignment and work distribution, and facility evaluation, which concerns the number of facilities and also concerns production patterns, are performed.
[0007] Incidentally, irregular change requests issued from the design department are taken into consideration in the study and evaluation. Further, upon completion of such various studies and evaluations, the production department feeds back results thereof to the design department as demands.
[0008] In parallel with the production preparation process P 1 of the production department, in step S 1 b, the design department performs wire harness design, which includes study of wiring of a wire harness circuit and a path, and assembly and evaluation of an actual car. Then, each time when change processing to be performed occurs, the change request is issued to the production department. Further, the design department prepares design department drawings again in step S 2 a by referring to the demands fed back from the design department. Subsequently, the design department provides the prepared design department drawings to the production department.
[0009] Then, when receiving the design department drawings, the production department performs a production preparation process P 2 similar to the production preparation process P 1 again. Similarly, the design department performs the wire harness design and the assembly and evaluation of an actual car again in step S 2 b, and issues a change request to the production department again, if necessary. Such processes to be respectively performed at the design department and the production department, and interactions therebetween are repeatedly performed until a production preparation process P 3 based on the design department drawing prepared by the design department in step S 3 a and on the change request issued according to the wire harness design and to the assembly and evaluation of an actual car is finished so that the production department feeds back no demands to the design department.
[0010] When such processes, which relate to the preparation for production of a wire harness and are performed in the design department and the production department, and the interactions between both the departments are finished, the production department arranges provisions, such as necessary members and jigs, in step P 4 . Then, in step P 5 , the appointed production department performs practical production of a wire harness according to a predetermined manufacturing process. Furthermore, upon completion of production of a wire harness of a predetermined part of a predetermined type of vehicle, the production department makes shipment of the wire harness in step P 6 .
[0011] As described above, in the preparation of production of a wire harness, there are various processes, which are performed in the design department and the production department, and interactions to be performed therebetween. Further, it is frequent that similar processes and interactions are repeatedly performed. Thus, the production preparation is time-consuming and needs a large number of man-hours. Further, preparations of production of a wire harness, which respectively correspond to the types of vehicle, are performed separately from one another. Consequently, such production preparation does not effectively utilize a great number of similar databases. More particularly, the design department of such a related system has drawbacks in that it takes time to prepare the design department drawings, that a wire harness shown in a scheme drawing does not correspond with an actual one at the assembly and evaluation, and that a diameter of a wire harness, which is based on a path plan, often differs from that of an actual wire harness. Moreover, the production department of the related system has many drawbacks in that the production department cannot start a preparation process without the design department drawing, and that there are many hindrances to reduction in a preparation time, for example, many manual operations are caused and many iterative tasks are generated correspondingly to various kinds of inspections, studies and change requests.
SUMMARY OF THE INVENTION
[0012] It is therefore an object of the present invention to provide a system for preparing a wire harness production enabled to considerably reduce time needed for preparation for production of a wire harness by promoting the sharing and standardization of a database and by substantially reducing iterative tasks.
[0013] In order to achieve the above object, according to the present invention, there is provided the system for preparing a wire harness production comprising:
[0014] standard wire harness wiring pattern information related to a first pattern including parts, electric circuits, and wirings of a standard type vehicle;
[0015] a modified wiring pattern generator, which generates modified wire harness wiring pattern information related to at least one second pattern in which at least one of the parts, the electric circuits, and the wirings of the first pattern is altered;
[0016] a parts information storage, which stores parts specification information including specifications of the parts, the electric circuits and the wiring included in the second patterns;
[0017] a simulator, which simulates whether each of the second patterns is practical while referring to the parts specification information;
[0018] a sub wiring pattern modifier, which modifies at least one of first sub patterns constituting the first pattern to at least one of second sub patterns so as to constitute the second pattern judged as practical by the simulator;
[0019] wire harness path pattern information related to a plurality of wire harness path patterns of the standard type vehicle;
[0020] a jig arrangement pattern information generator, which generates jig arrangement pattern information related to jig arrangement patterns prepared by applying at least one sub jig arrangement pattern to each of the wire harness path patterns;
[0021] path decision information, which selects one wire harness path pattern among the plurality of wire harness path patterns;
[0022] alternation information which indicates at least one of alternation portions altered from the first pattern;
[0023] a jig arrangement pattern selector, which selects one jig arrangement pattern corresponding to the selected wire harness path pattern among the plurality of wire harness path patterns; and
[0024] a path plan generator, which generates a path plan by integrating the modified second sub pattern having the alternation portions which is indicated in the alternation information and the selected jig arrangement pattern.
[0025] In the above configuration, when the alternation information and the path decision information are received, suitable path plan is immediately provided. That is, this system can generate data, which is necessary for the production of the wire harness, by alternating only alternation portions relating thereto according to the preliminarily provided standard database. Therefore, the number of interchanges of data between departments and that of iterative tasks caused at each change in a process of preparation for production of a wire harness, which are very large in a related system, are reduced. Consequently, a preparation time and the number of man-hours are considerably reduced.
[0026] Preferably, the system further comprising a jig arrangement board plan generator, which generates a jig arrangement board plan in which a three dimensional extend elevation is based on the selected jig arrangement pattern.
[0027] Preferably, the sub wiring pattern modifier modifies the at least one of first sub patterns according to at least one of data concerning automatic machine conditions, special construction method verification, production requirements, and optimum circuit study.
[0028] In the above configuration, a more accurate path plan is provided.
[0029] Preferably, the system further comprising a wiring pattern information storage, which stores the standard wire harness wiring pattern information; and
[0030] a path pattern information storage, which stores the wire harness path pattern information.
[0031] In the above configuration, the production preparation time is more reduced by preliminarily generating or storing a plurality of standard subdrawings, standard parts information, and standard jig drawing board patterns.
[0032] Preferably, the alteration of the second pattern is at least one of a change to specifications, an addition, and a system change of the at least one of the parts, the electric circuits, and the wirings of the first pattern.
[0033] In the above configuration, the variations of the plurality of second pattern are generated by assuming a change to the specifications, an addition, and a system change, which are usually and frequently caused. Thus, accurate path plan is immediately provided.
[0034] Preferably, the wire harness is wired in a door portion of a vehicle, and wherein the simulator simulates a bending test of the wire harness wired in the door portion.
[0035] In the above configuration, the wire harness is wired in the door portion of the vehicle. Thus, the bending simulation relating to the wire harness of this door portion. Therefore, accurate life prediction of associated parts and a wire harness are enabled. Consequently, more accurate path plan drawing draft and jig drawing board draft can be provided.
[0036] Here, it is preferable that the wiring pattern information storage and the path pattern information storage are placed in a design department for designing the wire harness,
[0037] wherein the modified wiring pattern generator, the simulator, the sub wiring pattern modifier, the jig arrangement pattern information generator, the jig arrangement pattern selector, the path plan generator, and the parts information storage are placed in a production department, connected to the design department through a communicator,
[0038] wherein the path decision information and the alternation information are transmitted from the design department to the production department through the communicator, and
[0039] wherein the path plan are transmitted from the production department to the design department through the communicator.
[0040] In the above configuration, a production preparation time and the number of man-hours can be reduced still more.
[0041] Here, it is preferable that the design department belongs to a car maker, and
[0042] wherein the production department belongs to a parts maker for manufacturing the wire harness.
[0043] In the above configurations, efficient wire harness production preparation to be performed between the carmaker and the parts maker is enabled.
[0044] Preferably, the system further comprising a storage, which stores at least one of the modified wire harness wiring pattern information, a result simulated by the simulator, the at least one of first sub pattern, the jig arrangement pattern information, the selected jig arrangement pattern, and the path plan.
[0045] Preferably, the simulator simulates an electric characteristic and a durability of the second pattern.
[0046] According to the present invention, there is also provided a method of preparing a wire harness production, comprising the steps of:
[0047] providing standard wire harness wiring pattern information related to a first pattern including parts, electric circuits, and wirings of a standard type vehicle;
[0048] generating modified wire harness wiring pattern information related to at least one second pattern in which at least one of the parts, the electric circuits, and the wirings of the first pattern is altered;
[0049] providing parts specification information including specifications of the parts, the electric circuits and the wiring included in the second patterns;
[0050] simulating whether each of the second patterns is practical while referring to the parts specification information;
[0051] modifying at least one of first sub patterns constituting the first pattern to at least one of second sub patterns so as to constitute the second pattern judged as practical by the simulation step;
[0052] providing wire harness path pattern information related to a plurality of wire harness path patterns of the standard type vehicle;
[0053] generating jig arrangement pattern information related to jig arrangement patterns prepared by applying at least one sub jig arrangement pattern to each of the wire harness path patterns;
[0054] providing path decision information, which selects one wire harness path pattern among the plurality of wire harness path patterns;
[0055] providing alternation information, which indicates at least one of alternation portions altered from the first pattern;
[0056] selecting one jig arrangement pattern corresponding to the selected wire harness path pattern among the plurality of wire harness path patterns; and
[0057] generating a path plan by integrating the modified second sub pattern having the alternation portions which is indicated in the alternation information and the selected jig arrangement pattern.
[0058] Preferably, the at least one of first sub patterns are modified by at least one of data concerning automatic machine conditions, special construction method verification, production requirements, and optimum circuit study.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein:
[0060] [0060]FIG. 1 is a basic configuration diagram illustrating an embodiment of a system for preparing a wire harness production of the invention;
[0061] [0061]FIG. 2A is a diagram illustrating standard wire harness wiring diagrams according to this embodiment;
[0062] [0062]FIG. 2B is an explanatory diagram illustrating the standard wire harness wiring diagrams;
[0063] [0063]FIG. 3 is diagram illustrating path patterns according to this embodiment;
[0064] [0064]FIG. 4A is a diagram illustrating an example of a wire harness wiring diagram pattern according to this embodiment;
[0065] [0065]FIG. 4B is an explanatory diagram illustrating this example;
[0066] [0066]FIG. 5A is a diagram illustrating another example of a wire harness wiring diagram pattern according to this embodiment.
[0067] [0067]FIG. 5B is an explanatory diagram illustrating this example;
[0068] [0068]FIG. 6A is a diagram illustrating another example of a wire harness wiring diagram pattern according to this embodiment;
[0069] [0069]FIG. 6B is an explanatory diagram illustrating this example;
[0070] [0070]FIG. 7A is a diagram illustrating a standard subdrawing according to this embodiment. FIG. 7B is an explanatory diagram illustrating this standard subdrawing;
[0071] [0071]FIGS. 8A and 8B are explanatory diagrams illustrating examples of information compiled a database, which is obtained according to a simulation test in this embodiment;
[0072] [0072]FIG. 9A is an explanatory diagram illustrating a standard jig drawing board pattern according to this embodiment;
[0073] [0073]FIG. 9B is an explanatory diagram illustrating an example of jig information according to this embodiment; and
[0074] [0074]FIG. 10 is an explanatory diagram illustrating an example of an operation to be performed in a production preparation time in which preparation for production of a related vehicle wire harness is performed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0075] An embodiment of the invention is described below with reference to the accompanying drawings.
[0076] [0076]FIG. 1 is a basic configuration diagram illustrating an embodiment of a system for preparing a wire harness production of the invention. Hereunder, the system for preparing a wire harness production of the invention is described by taking a wire harness, which is wired in a rear door portion of a vehicle, as an example. Further, it is assumed that this embodiment is a system relating to an operation to be performed in a production preparation time before a production process of a wire harness starts. Further, FIGS. 2A to 9 B are explanatory diagrams schematically illustrating various kinds of data, information and drawings to be handled or caused in this system for preparing a wire harness production.
[0077] As illustrated in FIG. 1, a design department and a production department are connected through a communication unit 17 in this embodiment that is the system for preparing a wire harness production of the invention. Although the design department and the production department may be present in the same company, both these departments may be provided so that the design department is provided in a carmaker, while the production department is provided in a parts maker commissioned by the carmaker to produce wire harnesses.
[0078] The design department is configured in such a way as to include a standard wire harness wiring diagram storage unit 1 and a path pattern storage unit 2 . This standard wire harness wiring diagram storage unit 1 preliminarily stores a standard wire harness wiring diagram including information on parts, electric circuits, and wiring to be applied to a standard type vehicle. Further, the path pattern storage unit 2 preliminarily stores a plurality of path patterns of the wire harness, which respectively correspond to a plurality of variations derived by adding or altering the parts, electric circuits, and wiring to be applied to the standard type vehicle. Incidentally, the expression “standard type vehicle” indicates a normal type of vehicle among a plurality of types of vehicles. For example, what is called a standard specification car and what is called a standard grade car.
[0079] It is assumed that there are, for example, three kinds HA, HB, and HC of the standard wire harness wiring diagrams, which respectively correspond to a pattern A, a pattern B, and a pattern C, as illustrated in FIG. 2A. These patterns indicate examples of employing options one or all of options, for instance, an audio device (RAD), a door lock device (D/L), and a power window (P/W), as illustrated in FIG. 2A. That is, in the case of the pattern A, all the options RAD, D/L, and P/W. In the case of the pattern B, only the option PAN is employed. Further, in the case of the pattern C, only the option D/L is employed. Incidentally, a numeric value “10001” shown in FIG. 2B is a part number designating a specific part of a vehicle, more particularly, a rear door part in this case. The same holds true for each of the drawings (to be described later).
[0080] Further, as illustrated in FIG. 3, it is assumed that there are three kinds of the path patterns respectively correspond to the pattern A, the pattern B, and the pattern C shown in FIGS. 2A and 2B. For instance, the path pattern GA corresponding to the pattern A indicates that the wire harness 20 is connected to a speaker device 21 , a motor device 22 for D/L, and a motor device 23 for P/W, which are needed when the wire harness 20 employ RAD, D/L and P/W, and that leads are wired so that the path length is minimized. The path patterns GB, and GC respectively correspond to the pattern B and the patter C indicate wire-harness wiring patterns (not shown) established by taking parts for accommodating devices, which are respectively needed by the patterns, into consideration.
[0081] On the other hand, the production department is configured in such a way as to include a wire harness wiring diagram pattern generation unit 3 , a wire harness wiring diagram pattern storage unit 4 , a standard subdrawing generation unit 5 , a standard subdrawing storage unit 6 , a simulation unit 7 , a standard parts information storage unit 8 , a simulation result storage unit 9 , a new subdrawing generation unit 10 , a new subdrawing storage unit 11 , a standard jig drawing board pattern generation unit 12 , a standard jig drawing board pattern storage unit 13 , a jig drawing board pattern selection unit 14 , a jig drawing board draft generation unit 15 , and a path plan draft generation unit 16 . Further, the production department is connected to the design department through the communication unit 17 . In the case that the design department is included in a carmaker, and that the production department is included in a parts maker, the communication unit 17 includes leased lines and a transmitter-receiver device to be connected to the leased lines.
[0082] The wire harness wiring diagram pattern generation unit 3 generates a plurality of wire harness wiring diagram patterns respectively corresponding to a plurality of variations derived by addition or alteration of parts, electric circuits, and wires assumed from a standard wire harness wiring pattern, which is provided from the design department and includes information concerning parts, electric circuits, and wires applied to a standard type vehicle. The wire harness wiring diagram pattern storage unit 4 stores the plurality of wire harness wiring diagram patterns. Incidentally, when wire harness wiring diagram patterns are generated, the wire harness wiring diagram pattern generation unit 3 may refer to the path patterns stored in the path pattern storage unit 2 .
[0083] For example, FIGS. 4A, 5A, and 6 A illustrate the plurality of wire harness wiring diagram patterns respectively corresponding to the plurality of variations derived by the assumed addition or alteration.
[0084] A wire harness wiring diagram pattern PB 1 illustrated in FIG. 4A corresponds to a pattern obtained by adding D/L, which is designated by reference numeral 32 and is not employed in the pattern B initially, to the pattern B, as illustrated in FIG. 4B. Incidentally, in this case, it is assumed that there is no circuit change to be caused in D/L. In the wire harness wiring pattern PB 1 , the wire harness is changed in response to this addition, as indicated by reference numeral 31 in FIG. 4A.
[0085] A wire harness wiring diagram pattern PB 1 illustrated in FIG. 5A corresponds to a pattern obtained by newly adding an entry lamp (E/L), which is designated by reference numeral 34 , to the pattern A, as illustrated in FIG. 5B. To the wire harness wiring pattern PA 1 , a wire harness and associated parts are newly added in response to this addition, as indicated by reference numeral 33 in FIG. 5A. Incidentally, the differences between the example shown in FIGS. 5A and 5B and the example shown in FIGS. 4A and 4B is that the E/L, which is not employed in the pattern A, the pattern B, and the pattern C, is newly added to the example of FIGS. 5A and 5B, whereas the example of FIGS. 4A and 4B corresponds to what is called a change to the specification, according to which D/L originally employed in another pattern A is additionally employed in this wire harness wiring diagram pattern PB 1 .
[0086] A wire harness wiring diagram pattern PA 2 shown in FIG. 6A corresponds to a pattern obtained by performing system change on D/L, which is originally employed and designated by reference numeral 37 , to the pattern A, as illustrated in FIG. 6B. In response to this addition, the wire harness wiring pattern PA 2 is changed so that an original wire harness is deleted, as indicated by reference numeral 35 in FIG. 6A, whereas a new wire harness is newly added thereto, as indicated by reference numeral 36 .
[0087] Thus, the wire harness wiring diagram pattern generation unit 3 is adapted to generate variations of the plurality of standard wire harness wiring diagram by assuming changes to the specification, additions, and system changes, which may usually and frequently occur. Therefore, the wire harness wiring diagram pattern generation unit 3 contributes to immediate provision of a path plan draft as a practical one. Incidentally, in practical steps, a plurality of wire harness wiring diagram patterns corresponding to the assumed variations in addition to these three variations are generated and then stored by the wire harness wiring diagram pattern generation unit 3 .
[0088] The standard subdrawing generation unit 5 generates a plurality of standard subdrawings serving as constituent elements of the plurality of wire harness wiring diagram patterns, and causes the standard subdrawing storage unit 6 to store the generated standard subdrawings. Each of the wire harness wiring diagram patterns SA, SB, and SC is usually constituted by a combination of standard subdrawings, as illustrated in FIG. 7A. For instance, as illustrated in FIG. 7B, a wire harness wiring diagram SA corresponding to the pattern A is constituted by standard subdrawings a, c, and e. Similarly, a standard subdrawing SB corresponding to the pattern B is constituted by standard subdrawings a, b, c, d and e. A standard subdrawing SC corresponding to the pattern C is constituted by standard subdrawings a, c, and e.
[0089] The simulation unit 7 performs electric characteristic simulation tests and durability simulation tests on these circuits according to the plurality of wire harness wiring diagram patterns, and standard parts information preliminarily stored in the standard parts information storage unit 8 . Further, results of the simulation tests are stored in the simulation result storage unit 9 .
[0090] The standard parts information includes databased information obtained by preliminarily testing the relation between stress and durability at each temperature and the relation between occupancy and endurance of a wire harness in a grommet correspondingly to each wire kind and each wire diameter, as indicated by DB 1 , DB 2 , and DB 3 of FIG. 8A and DB 4 of FIG. 8B, in addition to inherent information concerning connectors and grommets.
[0091] According to such standard parts information, the simulation unit 7 performs life prediction in the case where the wire harness is free, and life prediction in the case where the wire harness is accommodated in a grommet. Especially, the accurate life prediction of a frequently bent part, such as a rear door portion, is enabled by utilizing a database illustrated in FIGS. 8A and 8B, and by performing simulation according to the wire kind, the wire diameter, the occupancy of the wire harness accommodated in the grommet. Further, a bending simulation using computer graphics, and tests for replicating a deflection characteristic and a jig characteristic may be performed.
[0092] Especially, accurate path plan draft and jig drawing board draft are enabled by performing the life prediction of the parts associated with a door portion and of the wire harness in the bending simulation.
[0093] Incidentally, in addition to the simulation test, the simulation unit 7 may assume a wire harness wired on an instrument panel and perform simulation tests of vibration characteristics, temperature characteristics and fuse characteristics. Further, the simulation unit 7 may assume a wire harness wired around an engine, and perform simulation test of vibration characteristics, temperature characteristics, fuse characteristics, waterproof characteristics, and soundproof characteristics.
[0094] The new subdrawing generation unit 10 generates new subdrawings according to data concerning automatic machine conditions, special construction method verification, production requirements, and optimum circuit study in addition to results of the simulation tests and a plurality of standard subdrawings. Then, the new subdrawing generation unit 10 causes the new subdrawing storage unit 11 to store the generated new subdrawings. The new subdrawing generation unit 10 generates new subdrawings by utilizing, for instance, predetermined production preparation tools and performing automatic machine condition verification, special construction method verification, production requirement study, and optimum circuit study. At that time, the new subdrawing generation unit 10 may be adapted to refer to results of simulation tests, which include wire kinds and wire diameters, and a plurality of standard subdrawings.
[0095] Thus, information, which is effective when the path plan drawing draft of an optimum wire harness is generated, can be provided by generating new subdrawings according to data concerning the automatic machine conditions, special construction method verification, production requirements, and optimum circuit study in addition to results of the simulation test, and a plurality of standard subdrawings.
[0096] On the other hand, the standard jig drawing board pattern generation unit 12 generates a plurality of standard jig drawing board patterns LA, LB, and LC respectively corresponding to path patterns GA, GB, and GC, as illustrated in FIG. 9A, according to a plurality of path patterns supplied from the design department and to jig information preliminarily stored in a jig information storage unit (not shown herein). The standard jig drawing board pattern generation unit 12 may be adapted to refer to the standard wire harness wiring diagrams stored in the standard wire harness wiring drawing storage unit 1 . Incidentally, jig information is databased in such a manner as to include items, such as a platform, a car model, a part, a steering wheel, a grommet, a protector, R/B, and a part number. The standard jig drawing board pattern generation unit 12 first receives the path patterns and retrieves the jig information and calls all the associated jig board patterns. Thereafter, standard jig drawing board pattern generation unit 12 generates a plurality of standard jig drawing board patterns and causes the standard jig drawing doard pattern storage unit 13 to store such generated standard jig drawing board patterns.
[0097] Such plural standard jig drawing board patterns are generated according to the jig information and a plurality of path patterns preliminarily stored in the jig information storage unit. Hence, very practical standard jig drawing board patterns are generated.
[0098] Further, the jig drawing board pattern selection unit 14 selects an optimum jig drawing board pattern from the plurality of standard jig drawing board patterns, which are stored in the standard jig drawing board pattern storage unit 13 , according to the circuit design information, which is provided from the design department, and path decision information, that is, information indicating which of the plurality of path patterns is employed.
[0099] The jig drawing board draft generation unit 15 generates a jig drawing board draft corresponding to the selected jig drawing board draft pattern. This jig drawing draft is, for instance, a 3D development drawing generated by using graphic tools, and transmitted to the design department together with data including the demand.
[0100] Further, when receiving diameter change information and addition/alteration information corresponding to the standard type vehicle, which are sent from the design department, the path plan draft generation unit 16 generates path plan drawing draft corresponding to the optimum wire harness according to the standard jig drawing board pattern information and the new subdrawing in addition to the results of the simulation tests and the plurality of standard subdrawing so that the optimum wire harness is determined in such a way as to reflect such information. At that time, the demands from the production department may be included therein. Further, Further, the generated path plan drawing draft is transmitted to the design department together with associated data.
[0101] The various units and the storage units provided in the production department are respectively implemented by software introduced into a personal computer (PC) and a storage apparatus, such as a hard disk, to be mounted on or connected to the PC.
[0102] In the above configuration, the wire harness wiring diagram pattern generation unit 3 generates a plurality of wire harness wiring diagram patterns corresponding to standard wire harness wiring diagrams, which include information concerning parts, electric circuits, and wirings applied to the standard type vehicle, and variations of a plurality of standard wire harness wiring diagrams, which are derived by addition/alteration of the parts, electric circuits, and wirings applied to the standard type vehicle. Further, the standard subdrawing generation unit 5 generates a plurality of standard subdrawings that are constituent elements of these wire harness wiring diagram patterns. The new subdrawing generation unit 10 generates new subdrawings. Furthermore, the simulation unit 7 performs simulation tests concerning electric characteristics and durability thereof according to a plurality of wire harness wiring diagram patterns, a plurality of path patterns of the plurality of wire harnesses corresponding to a standard type vehicle, and standard parts information. Furthermore, the data generated by these unit 3 , 5 , 7 and 10 are stored in the storage units 4 , 6 , 9 , and 11 . Moreover, the plurality of standard jig drawing board patterns respectively corresponding to a plurality of path patterns generated by the standard jig drawing board pattern storage unit 12 are stored in the standard jig drawing board pattern storage unit 13 .
[0103] Further, when receiving alternation information corresponding to the standard type vehicle, the path decision information indicating which of a plurality of path patterns is employed, and circuit design information concerning the employed path pattern, the path plan draft generation unit 16 generates the path plan draft corresponding to an optimum wire harness according to the results of the simulation tests, a plurality of standard subdrawings, and a plurality of standard jig drawing board patterns. Further, the jig drawing board draft generation unit 15 generates a optimum jig drawing draft according to the path decision information, the circuit design information, and the standard jig drawing board patterns. Thus, when receiving the alternation information, the path decision information, and the circuit design information, the path plan drawing draft corresponding to the suitable wire harness, and the jig drawing board draft can be immediately provided.
[0104] More specifically, units for storing the standard wire harness wiring diagrams and the wire harness wiring diagram patterns are placed in the design department. Units for generating wire harness wiring diagrams, pattern standard subdrawings, standard parts information, and standard jig drawing board patterns, and the path plan diagram draft and the jig drawing board draft, and simulation unit are disposed in the production department. Further, the design department and the production department are connected to each other through the communication unit 17 . Therefore, operations conforming to a job site of each of the departments can be efficiently performed. Moreover, when necessary, both the departments are enabled to communicate with each other. Furthermore, in the case that the design department belongs to a carmaker, and that the production department belongs to a parts maker, more efficient preparation for production of a wire harness can be performed. Consequently, a production preparation time and the number of man-hours can be reduced still more.
[0105] Thus, according to the embodiment, data needed for manufacturing a wire harness is generated by correcting only respects relating to the change according to a preliminarily prepared standard database. Therefore, the number of interchanges of data between the departments and that of iterative tasks caused at each change in a process of preparation for production of a wire harness, which are very large in a related system, are reduced. Consequently, a preparation time and the number of man-hours are considerably reduced. Furthermore, the production preparation time is more reduced by preliminarily generating or storing a plurality of standard subdrawings, standard parts information, and standard jig drawing board patterns.
[0106] Incidentally, it is assumed that a wire harness to be wired in the rear door portion is provided in the embodiment. A part, to which the invention is applied, is not limited to the rear door portion. Further, the drawings and data to be used in the system according to the invention are not limited to those exemplified in the foregoing description of the embodiment. Thus, such drawings and data may be changed in view of current conditions. Additionally, needless to say, various modifications made without departing from the technical idea of the invention are included in the scope of the invention.
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In a system for preparing a wire harness production, a modified wiring pattern generator generates modified wire harness wiring pattern information related to at least one second pattern in which at least one of parts, electric circuits, and wirings of a first pattern including the parts, the electric circuits, and the wirings of a standard type vehicle is altered. A parts information storage stores parts specification information including specifications of the parts, the electric circuits and the wiring included in the second patterns. A simulator simulates whether each of the second patterns is practical while referring to the parts specification information. A sub wiring pattern modifier modifies at least one of first sub patterns constituting the first pattern to at least one of second sub patterns so as to constitute the second pattern judged as practical by the simulator. A jig arrangement pattern information generator generates jig arrangement pattern information related to jig arrangement patterns prepared by applying at least one sub jig arrangement pattern to each of a plurality of wire harness path patterns of the standard type vehicle included in wire harness path pattern information. Path decision information selects one wire harness path pattern among the plurality of wire harness path patterns. Alternation information indicates at least one of alternation portions altered from the first pattern. A jig arrangement pattern selector selects one jig arrangement pattern corresponding to the selected wire harness path pattern among the plurality of wire harness path patterns. A path plan generator generates a path plan by integrating the modified second sub pattern having the alternation portions which is indicated in the alternation information and the selected jig arrangement pattern.
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BACKGROUND OF THE INVENTION
The invention relates to a device for shape-forming at least one recess in a film-type material, said device featuring a die with at least one opening, at least one shaping stem that can be introduced into the opening to create the recess by shape-forming and a clamping facility for holding the film-type material fast between the clamping facility and the die.
It is known to manufacture base parts of blister packs, also called push-through packs, or other packaging containers with recesses or cups to accommodate contents, by means of deep-drawing, stretch-drawing or thermo-forming methods. These types of packaging may be made from thermoplastics or film-type composites, or laminates such as aluminum foils laminated with plastic films, or extrusion-deposited layers of thermoplastics.
If the packaging is made from metal-containing laminates, the manufacturing process may be performed using tools comprising stems, dies and clamping facilities. During the shape forming operation, the laminate is clamped fast between the die and the clamping facility. In order to create the desired recess or cup, the laminate is pushed into the die opening by the stem, whereby the laminate is deformed by local elongation. The result is that a shaped part exhibiting one or more recesses is formed out of the originally flat laminate.
In order to be able to exploit the elongation properties of the material to be thus formed, and hence to achieve recesses with a good deepening ratio i.e. large depth and small diameter, it is known from EP-A-0779143 to carry out the cold-forming deepening of metal-containing laminates in two steps. Using a first stem with a shape-forming surface of high coefficient of friction, the metal-plastic composite is pre-formed and then formed into its final shape using a second stem with a shape-forming surface of low coefficient of friction. This procedure suffers the disadvantage that two different stems have to be employed one after the other and therefore calls for a high degree of precision with respect to the positioning of both stems. In another variant, a telescopic type of two part stem is employed instead of two different stems. These stems are however complicated in design and cannot be employed for forming all the standard kinds of laminate.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to provide a device of the kind mentioned above by means of which two-stage forming can be employed for deepening purposes, achieving a good deepening ratio in a simple manner.
That objective is achieved by way of the invention in that counter-stems which are displaceable at least within the die openings are situated in the die, whereby shape-forming regions of the forming stems and the counter-stems for clamping the film-shaped material can, at least in part, be superimposed on each other.
The arrangement of a shaping stem and a counter-stem according to the invention offers the significant advantage over the state-of-the-art that, in a simple manner, using two successive forming steps to create a recess or cup, first the potential for forming the base part and then the potential for forming the side walls, or vice versa, can be exploited.
In a preferred device according to the invention the counter-stems are positioned on a piston that can be displaced into the die along the forming axis.
The surface of the forming region of the shaping stem and/or the counter-stem may locally exhibit different coefficients of friction. Because of this the friction between the shaping stem or the counter-stem and the film to be shape-formed can be adjusted such that the sliding behavior of the film on the shaping surface of the shaping stem and the counter-stem can be influenced during the forming process.
The coefficient of friction of the shaping surface of the shaping stem and the counter-stem can be adjusted such that either stem is made of the appropriate material or features a corresponding coating.
A low coefficient of friction is obtained e.g. using materials such as polytetrafluorethylene, polyoxymethylene (polyacetal, POM), polyethylene or polyethylene-terephthalate, or mixtures thereof. Other materials than plastics may be considered e.g. metals such as aluminum or chrome steel, in particular also with polished surfaces. Further usable materials are e.g. ceramic layers or coatings containing graphite, boron nitride or molybdenum-sulphide.
Materials that may be employed to produce surfaces with high coefficients of friction are e.g. metals such as steel, or plastics such as polyacetal (POM), polyethylene, rubber, hard rubber or caoutchouc, including acrylic polymers. The metal surfaces may be given higher coefficients of friction e.g. by roughening.
The outer part of the forming and counter stems in the regions of the surfaces effecting the forming may be different in shape depending on the desired shape of recess or cup. In the simplest case the shaping and counter-stems are cylindrical in shape and exhibit flat bases; however, other three-dimensional shapes such as e.g. conical, pyramid, blunted cone, blunted pyramid, segments of spheres or a drum-shape are possible. At the same time, the counter-stem may also have a corresponding shape that fits to the shaping stem.
The shaping stem and/or the counter-stem may also be in two parts with a hollow cylindrical outer stem part and an inner stem part that can be slid in a telescopic manner out of the outer stem part.
In a preferred version of the device according to the invention, near a clamping area at the edges of the openings of the die and the clamping device, both the die and the clamping device exhibit a substrate of material of low coefficient of friction for guiding the film. This insures that the edge of the recess is uniformly formed and pore-free.
The device according to the invention is particularly suitable for producing recesses in a plastic-coated metal foil by means of cold forming, for example for manufacturing the bases for blister packs.
For the purposes of shape-forming with the device according to the invention, suitable metal-plastic composite films have e.g. a metal foil of 8 to 150 μm, preferably 20 to 80 μm. Suitable metals are e.g. steel, copper and aluminum. Preferred foils of aluminum are e.g. of 98% purity or higher, whereby in particular one may employ aluminum foils of alloys of the AlFeSi or AlFeSiMn type.
The plastics employed may be e.g. layers, films or laminate films of thermoplastics of the polyolefin, polyamide, polyester and polyvinylchloride series, whereby the films and film laminates may also be uniaxially or biaxially stretched. Typical examples of thermoplastics from the polyolefin series are polyethylenes, such as MDPE, HDPE, uniaxially and biaxially stretched polyethylenes, polypropylenes such as cast polypropylenes and uniaxially or biaxially stretched polypropylenes, or polyethylene-terephthalate from the polyester series. The thickness of the thermoplastic layer, in the form of a layer, film or film laminate, in the metal-plastic composite film may be e.g. 12 to 100 μm, preferably 20 to 60 μm.
The metal foils and the thermoplastics may e.g. be joined together by laminate bonding, colandering or extrusion bonding into composites. To join the layers, one may employ, from case to case, laminate bonding and bonding agents, and the surfaces to be joined may be modified by a plasma, corona or flame pre-treatment.
Examples of metal-plastic composite films that can be employed may have a first layer e.g. a film or laminate made up of the above mentioned thermoplastics, a second layer in the form of a metal foil and a third layer, e.g. a film or film laminate or an extruded layer made of the above mentioned thermoplastics. Further layers such as sealing layers may be fore-seen.
The metal-plastic composite films may exhibit on at least one of its outer facing sides or on both outer facing sides a sealing layer in the form of a sealable film or sealing lacquer. The sealing layer is situated, for reason of its function, in the outermost layer of the composite laminate. In particular, a sealing layer may be on the outside of the composite, whereby in the case of a blister pack this sealing layer should be facing the contents side in order to perform the sealing on of the lid film or the like.
Typical examples in practice of metal-plastic composite films that are formable using the device according to the invention are:
oPA25/Al45/PVC60
oPA25/Al45/oPA25
Al120/PP50
oPA25/Al60/PE50
oPA25/Al60/PP60
oPA25/Al45/PVC100
oPA25/Al60/PVC60
oPA25/Al45/PVC, PE-coated
oPA25/Al45/cPA25
oPA25/Al60/PVC100
oPA25/Al60/oPA25/EAA50
where oPA stands for oriented polyamide, cPA for cast polyamide, PVC for polyvinylchloride, PE for polyethylene, PP for polypropylene, EAA for ethyl-acrylic acid and Al for aluminum, and the numbers represent the thickness in μm of the layers or films.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention are revealed in the following description of preferred exemplified embodiments and with the aid of the accompanying drawings which show schematically:
FIG. 1 a cross-section through a shaping station with a die with an opening;
FIG. 2 a cross-section through a forming station with a die having a plurality of openings;
FIG. 3 a plan view of the die in FIG. 2, viewed in direction A;
FIG. 4 a plan view of the clamping facility in FIG. 2, viewed in direction B;
FIG. 5 a longitudinal section through a version of a shaping stem with counter-stem;
FIG. 6 a longitudinal section through a further version of a shaping stem with counter-stem
FIG. 7 a sequence of process steps for manufacturing blister packs.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 a shaping station 10 features a die 12 with an opening 14 and a clamping device 16 with clamp opening 18 . Situated in the die 12 is a piston 20 which is sealed off in a fluid-tight manner against the inner wall 22 of the die 12 by means of seals 22 and delimits with respect to the base 25 of the die 12 a cylindrical space 26 , which can be filled with hydraulic fluid 28 via pipeline 30 . The movement of the piston 20 along the direction of its z axis is controlled via a valve 32 situated in the pipeline 30 . Depending on its function, the piston 20 can be pressure-controlled and/or distance-controlled by way of the valve 32 . The distance control is symbolized in the drawing by a distance display 34 . Of course the piston movement may also be effected by means of other means e.g. mechanical means instead of hydraulic means.
A distance-controlled shaping stem 36 penetrates the clamp opening 18 and can be moved in and out of the die opening 14 along a displacement axis z which coincides with the axis of the piston 20 . The base 42 of a counter-stem 40 mounted above the piston 20 lies facing the base 38 of the shaping stem along the direction of displacement z and can be advanced into the clamp opening 18 . The base 42 of the counter-stem 40 is covered with a coating 44 e.g. made of rubber.
A metal-plastic composite film 46 is held under force in a clamping region 48 between the die 12 and the clamping device 16 . Next to the clamping region 48 facing the openings 14 and 18 is a ring-shaped, stepped recess 50 and 52 respectively in the periphery of the die 12 and that of the clamping device 16 . In the recesses 50 , 52 is a ring-shaped insert 54 and 56 respectively made of a low-friction material. The film 46 slides between the inserts 54 , 56 .
The formation of a recess or cup 58 by shape-forming the film 46 clamped between the die 12 and the clamping device 16 is readily understood from FIG. 1 . The film 46 , lying initially in a plane E in which it is clamped, is plastically deformed as it is pressed by the shaping stem 36 into the die opening 14 . In that process the recess 58 is formed with side wall 60 between shaping stem 36 and the inner wall 24 of the die and a base part 62 which corresponds to the base 38 and the shaping surface of the shaping stem 36 .
The shaping station shown in FIGS. 2 to 4 differ from that in FIG. 1 in that the die 12 and the clamping device 16 feature a plurality of openings 14 , 18 , in the present case 15 openings, and a pair of shaping stems 36 and counter-stems 40 facing each pair of openings 14 , 18 . The shaping stems 36 are mounted on a support plate 64 . Displacement of the support plate 64 in direction z leads to simultaneous displacement of all shaping stems 36 . In the same manner all counter-stems 40 are mounted on a common piston 20 with the result that, on displacing the piston in the direction z, the counter-stems 40 are also displaced simultaneously. This forming station enables therefore the simultaneous formation of a number of recesses or cups 58 in the metal-plastic composite, corresponding to the number of shaping stems 36 and counter-stems 40 .
The shaping stem 36 shown in FIG. 5 is made up of various parts 66 , 68 , 70 of materials of different friction coefficients. The surface 38 of the shaping stem 36 effecting the shape forming is comprised of the flat base 66 and the concentric, successively inclined side walls 68 , 70 . The surface 38 effecting the shaping extends over all of the parts 66 , 68 , 70 . The surface areas 66 , 68 , 70 , effecting the shaping may therefore have different coefficients of friction. For example, the parts 66 , 68 , 70 are of materials with increasing friction coefficients, whereby the base part 66 exhibits the lowest coefficient of friction.
The shape of the base 42 of the counter-stem 40 coated e.g. with a rubber liner 44 matches that of the shape-effecting surface 38 of the shaping stem 36 .
The version of shaping stem 36 shown in FIG. 6 is telescopic in structure and exhibits a first hollow-cylindrical stem 36 a with a first ring-shaped shape-effecting surface 38 a. Sliding in this first stem 36 a is a moveable second stem 36 b with a second shape-effecting surface 38 b. This two part shaping stem 36 permits shaping with the shaping stem 36 in two steps. As in FIG. 5, the base 42 of the counter-stem 40 matches the shape-effecting surface of the shaping stem 36 , whereby a ring-shaped base part 42 a faces the ring-shaped surface 38 a of the shaping stem 36 and a further base 42 b faces the shape-effecting surface 38 b of the inner stem 36 b.
In a process for manufacturing blister packs illustrated in FIG. 7 the metal-plastic composite 46 is unrolled from a roll 106 and fed discontinuously into through a shape forming station 100 . In a subsequent filling station 102 the recesses 58 are filed with contents 108 such as e.g. tablets. On advancing the shaped and filled film 46 further, a lid film 112 made e.g. of plastic-coated aluminum foil, unrolled from a storage roll 110 , is laid on top of the metal-plastic composite film 46 and sealed to it, producing the finished blister pack. The blister packs made in the form of an endless strip can then be cut into packs of the desired size.
In the following, using the example shown in FIG. 1, the manner in which the shaping stem 36 and counter-stem 40 operate is explained in terms of four examples of shape-forming.
Shape-forming Example 1
The film 46 is held, clamped between the die 12 and the clamping device 16 . The shaping stem 36 is advanced until it makes contact with the film 46 at the level of clamping E. On the opposite side, the counter-stem 40 is likewise advanced until it meets the unstretched film 46 . Via the piston 20 a preselected pressure is applied, clamping the film 46 between the base 38 of the shaping stem 36 and the base 42 or rubber cover 44 of the counter-stem 40 . The force of the shaping stem 36 is chosen to be greater than the force applied by the counter-stem 40 . As a result the shaping stem 36 penetrates the die opening 40 and at the same time pushes back the counter-stem 40 . In this first shaping step the film is stretched in a controlled manner in the side wall part 60 of the recess 58 being formed, until the forming potential of the film in the side wall part 60 is exhausted. After the elongation of the side wall part 60 , the piston 20 is drawn back along with the counter-stem 40 into its original position. In a second shaping step, the base part 62 of the recess 58 being formed is shaped by advancing the shaping stem 36 against the film 46 which up to then had been clamped against the base 42 of the counter-stem 40 .
Shape-forming Example 2
The film 46 is held, clamped between the die 12 and the clamping device 16 . The piston 20 along with the counter-stem 40 is thereby withdrawn to its starting position. The shaping stem 36 is advanced into the die opening 14 up to a pre-selected position in which the full shape-forming potential in the base part 62 of the recess 58 being formed is reached. In this first shape-forming step the film 46 is stretched mainly in the base part 62 . In a second step the piston 20 along with the counter-stem 40 is advanced with pre-selected pressure towards the shaping stem 36 and onto the film 46 resting on the base 38 of the shaping stem 36 . Thereby, that part of the film 46 which forms the base part 62 of the recess 58 being formed is held, clamped between the base 38 of the shaping stem 36 and the base 42 or the rubber cover 44 of the counter-stem. The force of the shaping stem 36 is now chosen to be greater than that of the counter-stem 40 . The shaping stem 36 and the counter-stem 40 move therefore with the clamped film 46 towards the base 25 of the die 12 , whereby the side wall part 60 of the recess 58 being formed is stretched until the shaping potential of the film in the side wall part 60 has been fully exploited. When the shaping potential of the film 46 has been fully exploited, the shaping stem 36 and the counter-stem 40 move back to their starting positions.
Shape-forming Example 3
The film 46 is held, clamped between the die 12 and the clamping facility 16 . The shaping stem 36 is moved back to its starting position. The counter-stem 40 moves to that position in the clamping device opening 18 at which the potential for shape forming the film in the base part 62 of the recess being formed has been fully exploited. Thereby, the base 42 of the counter-stem 40 exhibits a surface with a high coefficient of friction, with the result that the shape-forming potential of the film in the side wall part 60 of the recess 58 being formed is fully exploited in this first shape-forming step. After exhausting the shape-forming potential of the film in the side wall part 60 , the piston 20 is drawn back again to the starting position along with the counter-stem 40 . In a second shape-forming step the shape-forming stem 36 is moved into the die opening 14 until the shape-forming potential of the film in the base part 62 of the recess 58 being formed has been exhausted. To this end the surface of the base 38 of the shaping stem 36 exhibits a low coefficient of friction. In the first shaping step the film 46 may also be clamped between the shaping stem 36 and the counter-stem 40 .
Shape-forming Example 4
The film 46 is held, clamped between the die 12 and the clamping facility 16 . The shaping stem 36 is moved back to its starting position. The piston 20 with the counter-stem 40 is moved to a pre-selected position in the clamping device opening 18 at which the shape-forming potential of the film 46 in the base part 62 of the recess 58 being formed has been fully exploited. To that end the surface of the base 42 of the counter-stem 40 exhibits a low coefficient of friction. After this first shape-forming step the piston with the counter-stem 40 is moved back to its starting position. In a second shape-forming step the shaping stem 36 , the base 38 of which has a surface with a high coefficient of friction is moved to a pre-selected position in the die opening 14 until the shape-forming potential of the film in the side wall part 60 has been exhausted. In the second shape-forming step the film 46 may also be clamped between the shaping stem 36 and the counter-stem 40 .
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A device for shape-forming at least one recess in a film-type material features a die with at least one opening, at least one shaping stem that can be introduced into the opening to create the recess by shape-forming, and a clamping facility for holding the film-type material fast between the clamping facility and the die. Counter-stems which are displaceable at least within the die openings are situated in the die, whereby shape-forming regions of the shape forming stems and the counter-stems for clamping the film-shaped material are, at least in part, superimposed on each other.
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BACKGROUND OF THE INVENTION
This invention relates to a new class of chemical compounds which can be described generally as [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)]alkanoic acids, and the nontoxic pharmaceutically acceptable salts, esters and amides thereof. Further, this invention relates to methods for the preparation of such compounds, pharmaceutical compositions comprising such compounds and to methods of treatment comprising administering such compositions and compounds.
Pharmacological studies show that the instant compounds are effective diuretic and saluretic agents which can be used in the treatment of conditions associated with electrolyte and fluid retention. The instant compounds are also useful in the treatment of hypertension. In addition, these compounds are able to maintain the uric acid concentration in the body at pretreatment levels or to even effect a decrease in the uric acid concentration.
The compounds of this invention may be described more fully by the following general representation: ##SPC1##
Wherein A is oxygen or sulfur; X 1 is selected from hydrogen, halogen such as fluoro, bromo, chloro, iodo and the like, and methyl, X 2 is halogen, such as fluoro, chloro, bromo and iodo, methyl and trifluoromethyl, and taken together, the two X radicals may be joined to form a hydrocarbylene chain containing from 1 to 4 carbon atoms between their points of attachment, for example, trimethylene, tetramethylene, and 1,3-butadieneylene; Y is an alkylene or haloalkylene radical having a maximum of 4 carbon atoms as for example methylene, ethylene, propylidene, isopropylidene, isobutylidene, fluoromethylene and the like; R is hydrogen, or lower alkyl for example methyl, ethyl, propyl, isopropyl, butyl and the like; wherein the subscript t is either 1 or 0; and wherein Q represents a hydrocarbylene bridge containing, together with the carbon atoms of the indane nucleus to which they are attached, from 3 to 6 carbon atoms; and forming a hydrocarbylene ring which is either unsaturated, or saturated. The invention also includes the pharmaceutically acceptable salts, the lower alkyl ester, the amides and the derivatives where carboxy is replaced by 5-tetrazolyl.
For conceptual convenience the above described compounds of this invention may be considered as 2,3-hydrocarbylene derivatives of substituted 5-indanyloxyalkanoic acids.
When administered in therapeutic dosages, in conventional vehicles, the instant [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)] alkanoic acids effectively reduce the amount of sodium and chloride ions in the body, lower dangerous excesses of fluid levels and in general alleviate conditions usually associated with edema. In addition these compounds overcome a major problem associated with many of the presently available diuretics and saluretics. Many of the presently available diuretics and saluretics have a tendency upon administration to induce hyperuricemia which may precipitate uric acid or sodium urate or both in the body which may cause from mild to severe cases of gout. Thus the [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)]alkanoic acids of this invention provide an effective tool to treat those patients requiring diuretic and saluretic treatment without incurring the risk of inducing gout. Further the [1-oxo-2,5-hydrocarbylene-5-indanyloxy(and thio)]alkanoic acids of this invention are effective antihypertensive agents.
Thus it is an object of this invention to provide 2,3-hydrocarbylene indanes of the above description which offer diuretic, saluretic, uricosuric and antihypertensive activities.
It is also an object of this invention to provide processes for the preparation of such [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)]alkanoic acid indanes and to provide pharmaceutical compositions comprising a therapeutically effective amount of such compounds and to provide a method of treatment comprising administering such compounds and compositions.
SUMMARY OF THE INVENTION
In its product aspect this invention relates to [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)]alkanoic acids having diuretic, saluretic, uricosuric and antihypertensive pharmacological properties of the following formula along with the pharmaceutically acceptable salts thereof: ##SPC2##
wherein A is oxygen or sulfur; Y is an alkylene or halo alkylene radical having a maximum of 4 carbon atoms; X 1 is selected from hydrogen, halogen and methyl; X 2 is halogen or methyl and X 1 and X 2 may be joined to form a hydrocarbylene chain containing from 1 to 4 carbon atoms; R t is H or lower alkyl and the subscript t is either 0 or 1; Q represents a hydrocarbylene chain and contains, together with the carbon atoms of the indane nucleus, from 3 to 6 carbon atoms and is unsaturated, or saturated.
Pharmaceutical compositions comprising therapeutically effective amounts of such [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)alkanoic acids and methods of treatment comprising administering such compositions and compounds for the alleviation of edema, hyperuricemia and hypertension are described in detail below.
DETAILED DESCRIPTION OF THE INVENTION
Particularly preferred embodiments of the diuretic 2,3-hydrocarbylene indanes of this invention are those having the following structural formula: ##SPC3##
wherein X 2 is methyl or chloro; X 1 is hydrogen, methyl or chloro; R is H, or lower alkyl having from 1 to 4 carbon atoms and the subscript t is either 0 or 1; the hydrocarbylene group, Q is methylene, ethylene, trimethylene, tetramethylene or 1,4-butadienylene.
The [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)]alkanoic acids wherein the hydrocarbylene is methylene (III) may be prepared by the 1,1'-cyclo addition of a carbene or ylide to an appropriately substituted [1-oxoinden-5-yloxy(or thio)]alkanoic acid (II), according to the following reaction: ##SPC4##
wherein all substituents are as defined above. The (1-oxoindene-5-yloxy)alkanoic acids employed are described in U.S. Pat. No. 3,668,241.
The [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)]alkanoic acids and ester (I) wherein Y contains 1 or 3 linear carbon atoms may be prepared by an etherification method which comprises reacting a haloacetic acid or ester thereof of the formula: ##STR1## wherein R 1 is hydrogen or lower alkyl such as methyl, ethyl and the like and Z is halo such as bromo, chloro, iodo and the like with a suitable 2,3-hydrocarbylene-5-hydroxy(or mercapto)-1-indanone (IV, infra). The following equation illustrates this reaction: ##SPC5##
wherein X 1 , X 2 , R, R 1 , A, Q, Y, Z and t are as defined above; In general, the reaction is conducted in the presence of a base such as an alkali metal carbonate, hydroxide or alkoxide such as potassium carbonate, sodium carbonate, potassium hydroxide, sodium hydroxide, sodium ethoxide and the like. Any solvent which is inert or substantially inert to the reactants and in which the reagents are reasonably soluble may be employed. Acetone, ethanol and dimethylformamide, for example, have proved to be particularly advantageous solvents. The reaction may be conducted at a temperature in the range of from about 25°C. to the reflux temperature of the particular solvent employed. The reaction with the haloacetic acid or ester is generally complete in about 10 to 60 minutes. If the haloacetic acid ester is employed, the ester obtained may be hydrolyzed to the free acid by methods well known to those skilled in the art.
Those [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)]alkanoic acids (I) wherein the alkylene chain contains 2 linear carbon atoms between the carboxy and oxy (or thio) groups are prepared from their corresponding 2,3-hydrocarbylene-5-hydroxy-(or mercapto)-1-indanones (IV) by the reaction of the latter with propiolactone or with an appropriately substituted propiolactone, in the presence of a base such as aqueous solution of sodium hydroxide, preferably, while heating the solution at reflux temperatures; followed by the acidification of the carboxylate intermediate thus formed to the desired acid. The following equation illustrates the reaction: ##SPC6##
wherein A, Q, t, R, R 1 , X 1 and X 2 are as defined above and M is a cation derived from an alkali metal hydroxide or akali metal carbonate such as a sodium or potassium cation.
The 2,3-hydrocarbylene-5-hydroxy-(or mercapto)-1-indanones (IV, supra), which also exhibit diuretic and uricosuric activity, are prepared by treating the correspondingly substituted 2,3-hydrocarbylene-5-lower alkoxy (or lower alkylthio)-1-indanone with an ether cleaving reagent such as aluminum chloride, pyridine hydrochloride, sodium in liquid ammonia and the like. When aluminum chloride is employed, the solvent may be heptane, carbon disulfide, methyl chloride and the like and when pyridine hydrochloride is employed, it is not necessary to employ a solvent. The following equation illustrates this process: ##SPC7##
wherein A, Q, t, R, R 1 , X 1 and X 2 are as defined above, and R 2 is lower alkyl.
The 2-substituted-2,3-hydrocarbylene-5-lower-alkoxy-(or lower alkyl thio)-1-indanones (V, supra) which exhibit uricosuric activity are prepared by treating a 2,3-hydrocarbylene-5-lower alkoxy-(or lower alkyl thio)-1-indanone (VI, infra) with a suitable alkylating reagent of the formula: R Z wherein R and Z are as defined above. This reaction is conducted by first treating the 2,3-hydrocarbylene-5-lower alkoxy-1-indanone (VI) with a suitable base, for example, an alkali metal hydride such as sodium hydride and the like, or an alkali metal alkoxide, for example, potassium tertiary butoxide and the like. Other bases which may be employed include sodium amide, lithium amide and the like. This basified compound is then treated with the alkylating reagent, R Z. Any solvent which is inert or substantially inert to the reactants employed may be used. Suitable solvents include, for example, 1-2-dimethoxyethane, tertiary butanol, benzene, dimethylformamide and the like. The reaction may be conducted at a temperature in the range of from about 25° to about 150°C. In general, the reaction is conducted at a temperature in the range of from about 75° to about 90°C. The following equation illustrates this process: ##SPC8##
wherein A, R, Q, R 2 , X 1 , X 2 and Z are as defined above.
One method for preparing the 2,3-hydrocarbylene-5-lower alkoxy-(and lower alkyl thio)-1-indanones (VI, supra) comprises the cyclialkylation of a nuclear lower alkoxy (or lower alkyl thio) substituted cycloalkenoylbenzene (VII, infra) by treatment with an electron-acceptor acid, for example, a Lewis acid such as concentrated sulfuric acid, polyphosphoric acid, boron trifluoride and the like. The reaction may be conducted at a temperature in the range of from about 0° to about 60°C. In general, the reaction is conducted at ambient temperature. The following equation illustrates this process: ##SPC9##
wherein A, R 2 , Q, X 1 and X 2 are as defined above.
The nuclear lower alkoxy (and lower alkyl thio) cycloalkenoyl benzenes (VII, supra) employed above may be prepared by treating a nuclear lower alkoxy-(or lower alkyl thio)-substituted-2-halocycloakanoylbenzene (VIII, infra) with a dehydrohalogenating agent such as lithium bromide, lithium chloride and the like. Suitable solvents for this reaction include dimethylformamide and the like. This reaction is conveniently conducted at a temperature in the range of from about 50° to about 120°C. for a period of time of from about one hour to about six hours. The following equation illustrates this reaction: ##SPC10##
wherein A, Q, R 2 , X 1 and X 2 are as defined above.
The nuclear lower alkoxy (or lower alkyl thio) substituted (2-halocycloalkanoyl)benzenes (VIII, supra) are prepared by treating a nuclear lower alkoxy (or lower alkyl thio) substituted cycloalkanoyl benzene (IX, infra) with a halogenating agent such as bromine, chlorine, sulfuryl chloride and the like. Suitable solvents for this reaction include acetic acid, chloroform and the like. This reaction is conveniently conducted at temperatures from about 0°c. to the reflux temperature of the solvent employed for a period of time from about one-half to about two hours. The following equation illustrates this reaction: ##SPC11##
wherein A, Q, R 2 , X 1 , X 2 and Z are as described above.
The [4-nuclear lower alkoxy (and lower alkyl thio) substituted] cycloalkanoyl benzenes (IX) are either known compounds or may be prepared by the reaction of an cycloalkanoyl halide with a nuclear lower alkoxy (or lower alkyl thio) substituted benzene (X, infra) in the presence of a Friedel-Crafts catalyst such as aluminum chloride and the like. The reaction solvent and the temperature at which the reaction is conducted are not particularly critical aspects of this reaction inasmuch as any solvent which is inert to the acyl halide and nuclear lower alkoxy (or lower alkyl thio) substituted benzenes may be employed with good results. In this regard, it has been found that methylene chloride is a particularly suitable solvent. The following equation illustrates this reaction: ##SPC12##
wherein A, Q, R 2 , X 1 , X 2 and Z are as defined.
Also included within the scope of this invention are the ester and amide derivatives of the instant products which are prepared by conventional methods well known to those skilled in the art. Thus, for example, the ester derivative may be prepared by the reaction of the substituted [1-oxo-2,3-hydrocarbylene-5-indanyloxy(and thio)]alkanoic acids (I) of this invention as shown in compound (X) with an alcohol, for example, with a lower alkanol, R 10 OH. The amide derivatives (XII) may be prepared by converting compound (X) to its corresponding acid chloride (XI) by treatment with thionyl chloride followed by treating said acid chloride with ammonia, and appropriate monolower alkyl amide, di-lower alkyl amide, or a hetero amine, such as piperidine, morpholine and the like to produce the corresponding amide compound. These and other equivalent methods for the preparation of the ester and the amide derivatives of the [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)]alkanoic acids of this invention will be apparent to one having ordinary skill in the art and to the extent that said derivatives are both nontoxic and physiologically acceptable to the body system, said derivatives are the functional equivalent of the corresponding acids. ##SPC13##
wherein R 10 is lower alkyl; R 11 is hydrogen or lower alkyl; R 12 is hydrogen, lower alkyl, hydroxyalkyl, or amino alkyl; and R 11 and R 12 may be joined to form a cyclic structure with the nitrogen atom to which they are attached.
The invention, in addition to the [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)]alkanoic acids, salts, esters and amides includes those compounds wherein the carboxylic acid is replaced by a 5-tetrazolyl radical which are also functionally equivalent to the carboxylic acid. These tetrazole analogs are prepared as depicted in the following equation: ##SPC14##
wherein all substituents are as defined above.
The 5-hydroxy or mercapto precursors of the instant [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)] alkanoic acids (IV) is treated with a haloacetonitrile such as chloroacetonitrile, bromoacetonitrile, or iodoacetonitrile in the presence of a base such as potassium carbonate and the like in a suitable solvent such as acetone, dimethylformamide, dimethoxyethane and the like at a temperature in the range of from 25° to 100°C. to afford the corresponding nitrile (XIII) which, upon treatment with sodium azide and ammonium chloride in dimethylformamide at a temperature in the range of from 25° to 100°C., affords the 5-tetrazolyl analog of the [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)]acetic acid of this invention (XIV).
Many of the instant compounds (I) herein disclosed contain an assymetric carbon atom in the 2-position as illustrated: ##SPC15##
when this situation exists, the optical antipodes may be separated by methods described below. This invention embraces therefore, not only the racemic tricyclic indanes but also their optically active antipodes.
Separation of optical isomers of the racemic acids (I) may be accomplished by forming a salt of the racemic mixture with an optically active base such as (+) or (-) amphetamide, (-)-cinchonidine, dehydroabietylamine, (+) or (-)-α-methylbenzylamine, (+) or (-)-α-(1-naphthyl) ethylamine, brucine or strychnine and the like in the suitable solvents such as methanol, ethanol, 2-propanol benzene acetonitrile, nitromethane, acetone and the like. There is thus formed in the solution 2 diastereomeric salts one of which is usually more soluble as a solvent than the other. Repetitive recrystallizations of the crystalline salt generally afford a pure diastereomer. The optically pure [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)]alkanoic acid is obtained by acidification of the salt with a mineral acid, extraction into ether, evaporation of the solvent, recrystallization of the optically pure antipode.
The other optically pure antipode may generally be obtained by using a different base to form the diastereomeric salt. It is of an advantage to use the partially resolved acid from the filtrates of the purification of one diastereomeric salt and to further purify the substance through the use of another optically active base.
The Examples which follow illustrate the [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)]alkanoic acids of this invention and the methods by which they are prepared. However, the Examples are illustrative only and it would be apparent to those having ordinary skill in the art that all the products embraced by formula I may also be prepared in an analogous manner by substituting the appropriate starting materials for those set forth in the examples.
EXAMPLE 1
(1,2-Dichloro-5α-5,6,7,8,8α-hexahydro-9-oxofluoren-3-yloxy)acetic acid
Step A: Cyclohexyl (2,3-dichloro-4-methoxyphenyl) ketone
A stirred mixture of 2,3-dichloroanisole (88.5 g., 0.5 mole) and cyclohexanecarbonyl chloride (81 g., 0.55 mole) in methylene chloride (400 ml.) is cooled to 5°C. and treated with aluminum chloride (74 g., 0.55 mole) during a 1/2 hour period. the reaction is allowed to warm to 25°C. and after 16 hours is poured into ice-water (1 l.) and hydrochloric acid (200 ml.). The organic phase is washed with 10% sodium hydrochloride and saturated salt solution, and dried over magnesium sulfate. After evaporation of the solvent, the product is crystallized from hexane to give 42.3 g. of cyclohexyl (2,3-dichloro-4-methoxyphenyl) ketone which melts at 97°-98°C.
Elemental analysis for C 14 H 16 Cl 2 O 2 : Calc.: C, 58.55; H, 5.62; Found: C, 58.92; H, 5.64.
Step B: 1-Bromocyclohexyl (2,3-dichloro-4-methoxyphenyl) ketone
Bromine (22.4 g., 0.14 mole) in acetic acid (50 ml.) is added dropwise to a stirred solution of cyclohexyl(2,3-dichloro-4-methoxyphenyl)ketone (40 g., 0.14 mole) and 30% hydrobromic acid (0.5 ml.) in acetic acid (400 ml.) during a 11/2 hr. period at 25°C. The mixture is poured into water (1.5 l.) and sodium bisulfite (10 g.) The product which precipitates is crystallized from cyclohexane to give 47.3 g. of 1-bromocyclohexyl (2,3-dichloro-4-methoxyphenyl) ketone which melts at 94°-95°C.
Elemental analysis for C 14 H 15 BrCl 2 O 2 : Calc.: C, 45.93; H, 4.13; Found: C, 45.77; H, 4.11.
Step C: 1-Cyclohexenyl (2,3-dichloro-4-methoxyphenyl) ketone
1-Bromocyclohexyl (2,3-dichloro-4-methoxyphenyl) ketone (47.3 g., 0.13 mole), lithium chloride (16.5 g., 0.39 mole) and dimethylformamide (200 ml.) are heated at 90°C. for two hours, then poured into water (1 l.) to give 36.5 g. of 1-cyclohexenyl (2,3-dichloro-4 -methoxyphenyl) ketone which melts at 126°-129°C. after drying at 60°C. under vacuum for 16 hours.
Elemental analysis for C 14 H 14 Cl 2 O 2 : Calc.: C, 58.96; H, 4.95; Found: C, 58.87; H, 5.10.
Step D: 1α,1,2,3,4,4α-Hexahydro-6-methoxy-7,8-dichlorofluoren-9-one
A stirred mixture of 1-cyclohexenyl (2,3-dichloro-4-methoxyphenyl) ketone (34 g., 0.12 mole) and polyphosphoric acid (340 g.) is heated at 90°C. for 17 hours in a resin pot. Crushed ice (1 kg.) is added to precipitate the product which on crystallization from benzene:cyclohexane, 1:1, gives 18.4 g. of 1α,1,2,3,4,4α-hexahydro-6-methoxy-7,8-dichlorofluoren-9-one which melts at 169°-171°C.
Elemental analysis for C 14 H 14 Cl 2 O 2 : Calc: C, 58.96; H, 4.95; Found: C, 59.35; H, 5.43.
Step E: 1α,1,2,3,4,4α-Hexahydro-6-hydroxy-7,8-dichlorofluoren-9-one
A stirred mixture of 1α,1,2,3,4,4α-hexahydro-6-methoxy-7,8-dichlorofluoren-9-one (4.0 g., 0.014 mole) and pyridine hydrochloride (40 g.) is heated at 170°C. for 2 hours, then poured into water (800 ml.). The 1α,1,2,3,4,4α-hexahydro-6-hydroxy-7,8-dichlorofluoren-9-one which separates (3.75 g.) melts at 212°-219°C. after recrystallization from ethanol.
Elemental analysis for C 13 H 12 Cl 2 O 2 : Calc.: C, 57.58; H, 4.46; Found: C, 57.12; H, 4.53.
Step F: (1,2-Dichloro-5α,5,6,7,8,8α-hexahydro-9-oxo-fluoren-3-yloxy)acetic acid
A stirred mixture of 1α,1,2,3,4,4α-hexahydro-6-hydroxy-7,8-dichlorofluoren-9-one (3.55 g., 0.0131 mole), potassium carbonate (3.62 g., 0.0262 mole) and ethyl bromoacetate (4.37 g., 0.0262 mole) in dimethylformamide (30 ml.) is warmed at 55°-60°C. under nitrogen for three hours, then treated with potassium hydroxide (1.90 g., 0.0288 mole) in methanol (30 ml.) and heated on a steam bath for three hours. The reaction mixture is poured into water (500 ml.) and acidified with 12N hydrochloric acid to precipitate 2.00 g. to (1,2-dichloro-5α,5,6,7,8,8α-hexahydro-9-oxo-fluoren-3-yloxy)acetic acid which melts at 202°-206°C. after crystallization from acetic acid:water, 3:2.
Elemental analysis for C 15 H 14 Cl 2 O 4 : Calc.: C, 54.73; H, 4.29; Found: C, 54.84; H, 4.37.
EXAMPLE 2
Preparation of (1,2-dichloro-9-oxofluoren-3-yloxy)acetic acid
Step A: 1,2-Dichloro-3-methoxyfluoren-9-one
A stirred mixture of 1α,1,2,3,4,4α-hexahydro- 6-methoxy-7,8-dichlorofluoren-9-one (8.3 g., 0.029 mole), 2,3-dichloro-5,6-dicyano-1,4-benzoquinone (20.5 g., 0.091 mole), benzene (300 ml.) and acetic acid (10 ml.) is heated at reflux under nitrogen for 64 hours. The reaction mixture is dissolved in a large volume of ethyl acetate (3 l.), the organic solution treated with sodium bisulfite solution, washed with water, 5% sodium hydroxide solution and water, separated, dried over magnesium sulfate and concentrated to give 1,2-dichloro-3-methoxyfluoren-9-one which after sublimation and trituration with acetonitrile give 3.9 g. melting at 268°-270°C.
Elemental analysis for C 14 H 8 Cl 2 O 2 : Calc.: C, 60.24; H, 2.89; Found: C, 59.86; H, 3.10.
Step B: 1,2-Dichloro-3-hydroxyfluoren-9-one
A stirred mixture of 1,2-dichloro-3-methoxyfluoren-9-one (3.9 g., 0.014 mole) and pyridine hydrochloride (80 g.) is heated at 180°-190°C. (internal temperature) for 2 hours, then poured into water 1 l. The 1,2-dichloro-3-hydroxyfluoren-9-one which separates (3.25 g.) melts at 276°-284°C. and is used without further purification.
Step C: (1,2-Dichloro-9-oxo-fluoren-3-yloxy) acetic acid
A stirred mixture of 1,2-dichloro-3-hydroxyfluoren-9-one (3.0 g., 0.011 mole), potassium carbonate (3.04 g., 0.022 mole), and ethyl bromoacetate (3.68 g., 0.022 mole) in dimethylformamide (60 ml.) is warmed at 55°-60°C. for 3 hours, then treated with potassium hydroxide (1.62 g., 0.024 mole) dissolved in a minimum amount of water in methanol (60 ml.) and heated on a steam bath for 3 hours. The reaction mixture is poured into water (600 ml.) acidified with 6N hydrochloric acid and the gummy precipitate collected and crystallized from dimethylformamide:water, 3:2, to give 1.17 g. of (1,2-dichloro-9-oxo-fluoren-3-yloxy)acetic acid which melts at 305°-306°C.
Elemental analysis for C 15 H 8 Cl 2 O 4 : Calc.: C, 55.75; H, 2.49; Found: C, 55.75; H, 2.60.
EXAMPLE 3
[1,1α-Dihydro-4,5-dichloro-6α-isopropyl-6-oxocycloprop[α] inden-3-yloxy]acetic acid
Step A: (1-Oxo-2-bromo-2-isopropyl-6,7-dichloro-5-indanyloxy)acetic acid
To a stirred suspension of (1-oxo-2-isopropyl-6,7-dichloro-5-indanyloxy)acetic acid (31.5 g., 0.10 mole) in acetic acid (500 ml.) is added 5 drops of 48% HBr and then a solution of bromine (7.5 ml.) in acetic acid (30 ml.) over a 30-minute period. The orange solution is stirred for one hour at 20°-25°C. and then poured into water (2.0 l.) containing 5 g. of sodium bisulfite. (1-Oxo-2-bromo-2-isopropyl-6,7-dichloro-5-indanyloxy)acetic acid (37.1 g., 93%), m.p. 150°-153°C., separates and is used directly in the next step.
Step B: (1-Oxo-2-isopropyl-6,7-dichloroinden-5-yloxy)acetic acid
(1-Oxo-2-bromo-2-isopropyl-6,7-dichloro-5-indanyloxy)acetic acid (17.3 g., 0.044 mole) is dissolved in dimethyl sulfoxide (DMSO, 100 ml.) stirred under nitrogen and 1,5-diazabicyclo[4.3.0]non-5-ene (DBN) (13 g.) is added dropwise. When the exothermic reaction ceases, the mixture is stored at 20°-25°C. for 1 1/2 hours and then poured into water (1.5 l.). The precipitate is recrystallized from acetic acid-water (1:1) to afford (1-oxo-2-isopropyl-6,7-dichloroinden-5-yloxy)acetic acid (9.6 g.), m.p. 175.5°-176°C.
Elemental analysis for C 14 H 12 Cl 2 O 4 : Calc.: C, 53.36; H, 3.84; Found: C, 53.55; H, 3.89.
Step C: [1,1α-Dihydro-4,5-dichloro-6α-isopropyl-6-oxocycloprop[α]-inden-3-yloxy]acetic acid
(1-Oxo-2-isopropyl-6,7-dichloroinden-5-yloxy)-acetic acid (6.3 g., 0.02 mole) is dissolved in DMF (300 ml.) and sodium hydride (1.7 g., 57% in mineral oil) is added to DMF (50 ml.) and then, with cooling, trimethylsulfoxonium iodide (8.6 g.). The solutions are combined, stored at 20°-30°C. for 31/2 hours, and poured into ice water (1.5 l.). The solution is extracted with hexane, acidified with 12N hydrochloric acid and extracted with ether. The ether extract is washed with water, dried (MgSO 4 ) and evaporated. A viscous yellow oil remains that on trituration with hexane forms a solid which is recrystallized from benzene-hexane (20:1) and butyl chloride to afford 2.0 g. of [1,1α-dihydro-4,5-dichloro-6α-isopropyl-6-oxocycloprop[α]-inden-3-yloxy] acetic acid, m.p. 133°-142°C.
Elemental analysis for C 15 H 14 Cl 2 O 4 : Calc. C, 54.73; H, 4.29; Found: C, 54.84; H, 4.27.
EXAMPLE 4
[1,1α-Dihydro-4,5-dichloro-6α-ethyl-6-oxocycloprop[α]inden-3-yloxy]acetic acid
A stirred solution of (1-oxo-2-ethyl-6,7-dichloro-inden-5-yloxy)acetic acid (3.1 g., 0.01 mole) in DMF (20 ml.) is cooled in an ice bath and treated with sodium hydride (0.42 g. of a 57% oil dispersion, 0.01 mole). The reaction is stirred at 25°C. for 11/2 hours, then treated with a solution prepared from sodium hydride (0.84 g. of a 57% oil dispersion, 0.02 mole) and trimethylsulfoxonium iodide (4.4 g., 0.02 mole) in DMF (20 ml.). After stirring for two hours, the reaction mixture is poured into water (100 ml.), extracted with hexane to remove the mineral oil, acidified with hydrochloric acid, extracted with ether which is washed with water, dried over magnesium sulfate and evaporated in vacuo affording 1.1 g. of [1,1α-dihydro-4,5-dichloro-6α-ethyl-6-oxocycloprop[α]inden-3-yloxy]acetic acid which melts at 167°C. after recrystallization from nitromethane.
Elemental analysis for C 14 H 12 Cl 2 O 4 : Calc.: C, 53.35; H, 3.84; Found: C, 53.02; H, 3.79.
EXAMPLE 5
(1,2-Dichloro-5α,5,6,7,8,8α-hexahydro-8α-methyl-9-oxofluoren-3-yloxy)acetic acid
Step A: 1α-Methyl-1α,1,2,3,4,4α-hexahydro-6-methoxy-7,8-dichloro-fluoren-9-one
Potassium tert.-butoxide (8.95 g., 0.080 mole) in tert-butanol (200 ml.) is added to a refluxing solution of 1α,1,2,3,4,4α-hexahydro-6-methoxy-7,8-dichlorofluoren-9-one (15.2 g., 0.053 mole) in dry benzene (200 ml.) and tert-butanol (25 ml.) under nitrogen. The solution is heated at reflux for one half hour, cooled, methyl iodide (17.0 ml., 0.27 mole) is added, and the mixture brought to reflux and then cooled. Water (50 ml.) is added and on concentrating the mixture to dryness, 12.4 g. of 1α-methyl-1α,1,2,3,4,4α-hexahydro-6-methoxy-7,8-dichlorofluoren-9-one is obtained which melts at 94°-95°C. on crystallization from acetic acid.
Elemental analysis for C 15 H 16 Cl 2 O 2 : Calc: C, 60.21; H, 5.39; found: C, 60.44; H 5.66.
Step B: 1α-Methyl-1α,1,2,3,4,4α-hexahydro-6-hydroxy-7,8-dichlorofluoren-9-one
A stirred mixture of 1α-methyl-1α,1,2,3,4,4α-hexahydro-6-methoxy-7,8-dichlorofluoren-9-one (12.2 g., 0.041 mole) and pyridine hydrochloride (120 g.) is heated at 170°C. for 3 hours, then poured into water (1 l.). The 1α-methyl-1α,1,2,3,4,4α-hexahydro-6-hydroxy-7,8-dichlorofluoren-9-one which separates (9.7 g.) melts at 217°-219.5°C. after recrystallization from ethanol.
Elemental analysis for C 14 H 14 Cl 2 O 2 : Calc.: C, 58.96; H, 4.95; Found: C, 59.59; H, 5.32.
Step C: (1,2-Dichloro-5α,5,6,7,8,8α-hexahydro-8α-methyl-9-oxo-fluoren-3-yloxy)acetic acid
A stirred mixture of 1α-methyl-1α,1,2,3,4,4α-hexahydro-6-hydroxy-7,8-dichlorofluoren-9-one (2.85 g., 0.01 mole), potassium carbonate (2.76 g., 0.02 mole) and ethylbromoacetate (3.34 g., 0.02 mole) in dimethylformamide (30 ml.) is warmed at 55°-60°C. for three hours, then treated with potassium hydroxide (1.45 g., 0.022 mole) dissolved in a minimum amount of water in methanol (30 ml.) and heated on a steam bath for three hours. The reaction mixture is poured into water (500 ml.), acidified with 12N hydrochloric acid to precipitate a gummy product. The product is taken up in ether, dried, concentrated, triturated with hexane, and crystallized from acetic acid:water, 3:2, to give 2.22 g. of (1,2-dichloro-5α,5,6,7,8,8α-hexahydro-8α-methyl-9-oxo-fluoren-3-yloxy)acetic acid which melts at 159°-161°C.
Elemental analysis for C 16 H 16 Cl 2 O 4 : Calc.: C, 55.99; H, 4.70; Found: C, 56.06; H, 4.74.
The novel compounds of this invention are diuretic and saluretic agents. In addition, these compounds are also able to maintain the uric acid concentration in the blood at pretreatment levels or even cause a decrease in uric acid concentration. The compounds of this invention can be administered in a wide variety of therapeutic dosages in conventional vehicles as, for example, by oral administration in the form of a tablet or by intravenous injection. Also, the daily dosage of the products may be varied over a wide range as, for example, in the form of scored tablets containing 5, 10, 25, 50, 100, 150, 250 and 500 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated. These dosages are well below the toxic or lethal dose of the products.
A suitable unit dosage form of the products of this invention can be administered by mixing 50 milligrams of a [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)] alkanoic acids, particularly the compounds of formula I or a suitable salt, ester or amide derivative thereof, with 149 mg. of lactose and 1 mg. of magnesium stearate and placing the 200 mg. mixture into a No. 1 gelatin capsule. Similarly, by employing more of the active ingredient and less lactose, other dosage forms can be put up in No. 1 gelatin capsules and, should it be necessary to mix more than 200 mg. of ingredients together, larger capsules may be employed. Compressed tablets, pills, or other desired unit dosages can be prepared to incorporate the compounds of this invention by conventional methods, and if desired, can be made up as elixirs or as injectable solutions by methods well known to pharmacists. An effective amount of the drug is ordinarily supplied at a dosage level of from about 1 mg. to about 50 mg./kg. of body weight. Preferably the range is from about 0.1 mg. to 7 mg./kg. of body weight.
It is also within the scope of this invention to combine two or more of the compounds of this invention in a unit dosage form or to combine one or more of the compounds of this invention with other known diuretics and saluretics or with other desired therapeutic and/or nutritive agents in dosage unit form.
The following example is included to illustrate the preparation of a representative dosage form
EXAMPLE 6
Dry-filled capsules containing 50 mg. of active ingredient per capsule
Per Capsule______________________________________(1,2-Dichloro-5α,5,6,7,8,8α-hexahydro-8α-methyl-9-oxo-fluoren-3-yloxy)acetic acid 50 mg.Lactose 149 mg.Magnesium Stearate 1 mg.Capsule (Size No. 1) 200 mg.______________________________________
The (1,2-dichloro-5α,5,6,7,8,8α-hexahydro-8α-methyl-9-oxofluoren-3-yloxy)acetic acid is reduced to a No. 60 powder and then lactose and magnesium stearate are passed through a No. 60 bolting cloth onto the powder and the combined ingredients admixed for 10 minutes and then filled into a No. 1 dry gelatin capsule.
Similar dry-filled capsules can be prepared by replacing the active ingredient of the above example by any of the other novel compounds of this invention.
It will be apparent from the foregoing description that the [1-oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)] alkanoic acids of this invention constitute a valuable class of compounds which have not been prepared heretofore. One skilled in the art will also appreciate that the processes disclosed in the above examples are merely illustrative and are capable of a wide variation and modification without departing from the spirit of this invention.
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[1-Oxo-2,3-hydrocarbylene-5-indanyloxy(or thio)] alkanoic acids, and the non-toxic pharmaceutically acceptable salts, esters and amides thereof are disclosed. The products display a polyfunctional pharmaceutical utility in that they exhibit diuretic, saluretic, uricosuric and antihypertensive activity. Also disclosed are processes for the preparation of such compounds, and methods of treatment comprising administering such compounds and compositions.
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FIELD OF THE INVENTION
[0001] The present invention relates to an installation provided with a device for ligning up pipes or pipe components, such as for example T-pieces and the like. The line up device ensures that one end of a pipe or component is positioned in such a manner with respect to a free end of a fixed pipe or component that these ends can then be connected to one another by means of a welded joint, a bolt connection or other mechanical connection, for example.
BACKGROUND OF THE INVENTION
[0002] Line up devices of the mentioned type are used in the construction of pipelines which are employed to transport petroleum or natural gas and for water injection.
[0003] A known application area is the laying of pipelines at sea from a vessel. Known methods for this purpose include the J-lay, S-lay and the Reel-lay methods, which are described in GB 2 335 722 A. The vessel is provided with an installation which comprises one or more connection stations, such as welding stations, for connecting various pipes or pipe components. The installation is also provided with a line up device in order to bring the pipes into line with one another.
[0004] A known line up device comprises two gripper means each having two movable clamping jaws which are arranged on a frame. These gripper means are positioned at a distance from one another in the axial direction of a pipe.
[0005] At the same time, the gripper means can be moved along a pipe receiving structure in the axial direction of the clamped pipe, in order to securely grip the pipe and to transport an end of this pipe to a short distance from the free end of a second, fixedly held pipe, so that a gap remains between the two ends or the ends touch one another.
[0006] In order then to line up the end of the fixedly held pipe and the first pipe with respect to one another, the clamped end of the first pipe can be moved in a plane which is perpendicular to the axial direction of the first pipe.
[0007] In a subsequent step, the clamped end of the first pipe is positioned against the end of the fixed pipe by moving the two gripper means simultaneously over a short distance in the axial direction towards the fixed pipe. Then, the two ends are welded together or are connected in some other way.
[0008] The installation which has been described is suitable for ligning up and connecting single-walled pipes and pipe components. In many cases, however, it is desirable to construct double-walled pipes, i.e. “pipe-in-pipe” pipes. The inner pipe of the double-walled pipe is in many cases in the offshore industry used to transport a liquid, such as oil, or a gas or a mixture thereof. The outer pipe serves as a protective pipe against external water pressure, inter alia. A thermal insulation means may be arranged between the inner pipe and the outer pipe, in order to ensure that the medium in the inner pipe is not cooled excessively by external conditions.
[0009] The object of the invention is to provide an installation as described in the preamble which is suitable for ligning up double walled pipes.
SUMMARY OF THE INVENTION
[0010] This object is achieved by at least one of the gripper means being designed to alternately securely grip an inner pipe and an outer pipe of a double-walled pipe.
[0011] In this way, the following method can be carried out. Firstly, the outer pipe of a first double-walled pipe is gripped by a first gripper means. Then, an end of the inner pipe of the first double-walled pipe which is projecting out of the outer pipe is gripped by a second gripper means. This second gripper means is then moved, bringing the inner pipe with it, in the axial direction towards the end of an inner pipe of a fixed, second double-walled pipe. In the process, the inner pipe and the outer pipe of the first double-walled pipe are displaced with respect to one another.
[0012] After the end of the inner pipe of the first double-walled pipe has been brought to a short distance from the end of the fixed inner pipe of the second double-walled pipe, the end of the inner pipe of the first double-walled pipe is ligned up by independent movement of at least one of the gripper means in a plane which is perpendicular to the axial direction of the pipes. When the inner pipes have been oriented in such a manner with respect to one another that they can be connected, the two gripper means are simultaneously moved in the axial direction, so that the inner pipes of the first and second double-walled pipes are positioned with their ends against each other. They are then connected to one another.
[0013] Next, the second gripper means releases the inner pipe of the first double-walled pipe and is displaced towards the first gripper means. If appropriate, an insulation means can then be arranged around the inner pipe.
[0014] Then, the outer pipe of the first double-walled pipe is gripped by the second gripper means and the first gripper means releases the outer pipe. The end of the outer pipe is then displaced, by means of the second gripper means, until it is close to the end of the fixed outer pipe of the second double-walled pipe.
[0015] Then, the outer pipe of the first double-walled pipe is in turn gripped by the first gripper means, after which the end of the outer pipe can be ligned up with the fixed outer pipe of the second pipe by moving the gripper means as described above. Next, the outer pipes are placed against one another as a result of the two gripper means being moved simultaneously towards second pipe by moving the gripper means as described above. Next, the outer pipes are placed against one another as a result of the two gripper means being moved simultaneously towards the second pipe, after which the ends of the outer pipes can be connected to one another.
[0016] The second gripper means is able to grip both an inner pipe and an outer pipe without it being necessary to adapt the second gripper means in order to enable pipes of different diameters to be gripped. This can be achieved by designing the gripper means as a clamp with a plurality of sets of shoes, it being possible to use one set of shoes to grip pipe diameters which lie between a specific minimum diameter and a specific maximum diameter.
[0017] In one embodiment, the gripper means may be arranged on a line up frame, in which case they can advance along the line up frame and the line up frame is attached to the main frame of the installation. The line up frame can be moved in the desired direction with respect to the main frame by means of actuators.
[0018] In another embodiment, the gripper means are arranged directly on the main frame and can move along it.
[0019] The present invention will be explained in more detail in the following detailed description of a preferred embodiment of an installation according to the invention and with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 shows a vessel for laying pipelines using the J-lay method;
[0021] [0021]FIG. 2 shows an installation for constructing pipelines on a vessel as shown in FIG. 1, a pipe being raised by means of a tilting device;
[0022] [0022]FIG. 3 illustrates one embodiment of a line up device;
[0023] [0023]FIG. 4 a diagrammatically depicts a first stage of a line up cycle;
[0024] [0024]FIG. 4 b diagrammatically depicts a second stage of a line up cycle;
[0025] [0025]FIG. 4 c diagrammatically depicts a third stage of a line up cycle;
[0026] [0026]FIG. 4 d diagrammatically depicts a fourth stage of a line up cycle;
[0027] [0027]FIG. 4 e diagrammatically depicts a fifth stage of a line up cycle;
[0028] [0028]FIG. 4 f diagrammatically depicts a sixth stage of a line up cycle;
[0029] [0029]FIG. 5 a shows a plan view of an embodiment of a second gripper means of the line up device in an open position;
[0030] [0030]FIG. 5 b shows a plan view of the gripper means shown in FIG. 5 a in a closed position, with a pipe being gripped by the gripper means;
[0031] [0031]FIG. 5 c shows a plan view of a second embodiment of a line up device;
[0032] [0032]FIG. 6 diagrammatically depicts another embodiment of a gripper means of the line up device;
[0033] [0033]FIGS. 7 and 8 respectively show a plan view and a side view of a first embodiment of a pipe stop; and
[0034] [0034]FIGS. 9 and 10 respectively show a plan view and a side view of a second embodiment of a pipe stop.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] [0035]FIG. 1 shows a vessel 1 which is laying a pipeline 2 on a seabed (not shown). The vessel 1 is provided with a pipe line up and connection installation 4 in which double-walled pipes 3 , 7 are connected to the double-walled pipeline 2 hanging from the vessel 1 . The installation 4 comprises a tilting device 5 and a pipe receiving strcture which is embodied here as a tower structure 6 of the J-lay type.
[0036] [0036]FIG. 2 illustrates how a double-walled pipe 7 which is fixed in supports 5 a is tilted off the deck of the vessel towards the J-lay tower 6 by means of the tilting device 5 and rests with its bottom end on a pipe stop 8 .
[0037] On the J-lay tower 6 there is a double-walled pipe 3 which is to be connected to the pipeline 2 . The pipeline 2 is being held by tensioners (not shown), so that the end of the pipeline 2 is held in a welding station 10 . Above the welding station 10 there is a line up device 11 which is provided with two gripper means or clamps 12 , 13 . Furthermore, the double-walled pipe 3 is resting in roller clamps 15 which are arranged on the J-lay tower 6 and through which the double-walled pipe 3 can be moved in the axial direction and rotated about the axial axis.
[0038] The way in which the line up device 11 operates will be explained with reference to a preferred embodiment which is shown in FIGS. 3, 5 a and 5 b and with reference to a diagrammatic illustration of various steps in a line up cycle as shown in FIGS. 4 a to 4 f . In this specific embodiment, the device 11 comprises first and second gripper means 12 , 13 which each have a separate frame 16 . The frame 16 is arranged directly on the main frame 17 of the J-lay tower 6 . At least second gripper means 13 can move with respect to the main frame 17 in the axial direction of the first pipe, by moving the frame 16 , by means of actuators (not shown), in the longitudinal direction of the main frame 17 along guides 20 . First gripper means 12 may be designed to be fixed on the main frame, but if appropriate may also be designed to be movable in the axial direction of the first pipe with respect to the main frame 17 . The gripper means 12 , 13 can be moved in translation in the lateral direction of the first pipe (as indicated by a double arrow in FIGS. 5 a and 5 b ) by means of linear actuators 50 . In this case, the gripper means 12 , 13 are moved along guides 51 (cf. FIG. 3). The gripper means 12 , 13 can be rotated about an axis which is parallel to the guides 51 by means of rotary actuators 52 which are securely attached to the actuators 50 by means of attachment brackets 53 .
[0039] A head 55 of each of the gripper means 12 , 13 can be moved in the lateral direction of the first double-walled pipe by means of actuators 54 .
[0040] The gripper means 12 , 13 each have one or more pairs of clamping jaws. The second gripper means 13 is equipped with a set of shoes (cf. FIGS. 5 a and 5 b ) comprising four shoes 21 , 22 which are suitable for gripping pipes of different diameters, with the result that the inner pipe 18 and the outer pipe 19 can be alternately gripped by the gripper means 13 , without the shoes having to be changed. The clamping jaws of the gripper means 12 , 13 can be moved between an open position (FIG. 5 a ) and a closed position (FIG. 5 b ) with the aid of actuators 56 and 57 . In the embodiment shown, an inner or outer pipe of a double-walled pipe which has been gripped by the gripper means 12 , 13 can rotate about the axial axis of this pipe 3 , as indicated by the circular double arrow in FIG. 5 b , since each of the shoes comprises a plurality of rollers 59 which can rotate freely about their axial axes.
[0041] The in the example shown gripper means 12 , 13 are each provided with one or more wheels 61 driven by a motor not shown. By means of the wheel 61 the pipe gripped by the gripper means 12 , 13 can be rotated via frictional contact. A specific angular position of the pipe can be fixed by blocking the wheel 61 . This is relevant if the pipe has a non circular cross-section.
[0042] In an alternative embodiment which is shown in FIG. 6, the gripper means 13 is equipped with three shoes 23 which are V-shaped. There may also be a different number of shoes, in which case a set of shoes comprises at least two shoes. The shape of the shoes may also differ from the embodiments shown here.
[0043] As illustrated by FIGS. 4 a - 4 f , a double-walled pipe 3 has been conveyed by the tilting device 5 to the tower 6 . The pipe 3 has an inner pipe 18 and an outer pipe 19 . The inner and outer pipes 18 , 19 are supported by a pipe stop 8 . Then, the following steps are carried out:
[0044] 1) the outer pipe 19 of a first pipe 3 is gripped securely by the first gripper means 12 ;
[0045] 2) the inner pipe 18 of the first pipe 3 is gripped securely by the second gripper means 13 , after which the tilting device 5 can be tilted away from the tower, resulting in the situation shown in FIG. 4 a;
[0046] 3) the second gripper means 13 with the inner pipe 18 clamped in it is displaced towards the connection station 10 , and the end of the inner pipe 18 is ligned up with the end of an inner pipe of the suspended pipeline 2 which is situated in the connection station 10 ;
[0047] 4) the ends of the inner pipes of the first pipe 3 and the pipeline 2 are connected to one another (cf. FIG. 4 b ), after which, if appropriate, an insulating layer can be arranged around the inner pipes around the area of the connection;
[0048] 5) the inner pipe 18 is released by the second gripper means 13 (cf. FIG. 4 c );
[0049] 6) the second gripper means 13 is displaced towards the first gripper means 12 (cf. FIG. 4 b );
[0050] 7) the outer pipe 19 is gripped securely by the second gripper means 13 ;
[0051] 8) the outer pipe 19 is released by the first gripper means 12 , resulting in the situation as shown in FIG. 4 e;
[0052] 9) the second gripper means 13 together with the outer pipe 19 is displaced towards the connection station 10 ;
[0053] 10) the outer pipe 19 is gripped securely by the first gripper means 12 , resulting in the situation shown in FIG. 4 f;
[0054] 11) the end of the outer pipe 19 is ligned up with the end of an outer pipe of the suspended pipeline 2 which is situated in the connection station 10 ;
[0055] 12) the ends of the outer pipes of the first pipe 3 and the suspended pipeline 2 are connected to one another.
[0056] In the embodiment shown (cf. FIG. 3), at least the second gripper means 13 can move along the main frame 17 via a guide 20 . However, in another embodiment (cf. FIG. 5 c ), it is also possible for the gripper means 12 , 13 to be arranged on a line up frame 17 a which is arranged on the main frame 17 of the tower 6 . On account of the view shown, only the second gripper means 13 can be seen in FIG. 5 c , but the first gripper means 12 is arranged in a similar way on the line up frame 17 a , axially above the second gripper means 13 . The line up frame 17 a can be moved with respect to the main frame 17 in the axial and transverse directions of the first pipe 3 by means of actuators 60 . At least the second gripper means 13 can be moved in the axial direction of the first pipe, along guides, with respect to the line up frame 17 a , in a similar manner to that illustrated in FIG. 3.
[0057] [0057]FIG. 7 and FIG. 8 show a pipe stop assembly 8 as shown in FIG. 2. It can be seen from these figures that the inner pipe 18 is supported on a stop 26 . The outer pipe 19 is resting on a stop which comprises two stop halves 24 , 25 which can be moved away from one another in order to allow the pipe stop assembly 8 to move away from the pipe when the gripper means 12 , 13 of the line up device have securely clamped the outer pipe 19 and the inner pipe 18 . The stop assembly 8 can be rotated away, about pivot point 27 , in a plane which is perpendicular to the axial direction of the pipe, after the pipe has been gripped securely by the gripper means 12 , 13 .
[0058] Another embodiment of a pipe stop assembly is shown in FIG. 9 and FIG. 10. The inner pipe 18 is supported by stop 28 . The outer pipe 19 is supported by a stop which is formed by two parallel limbs 29 , 30 . The stops 28 , 29 , 30 can be rotated away towards the axial direction of the pipe with the aid of piston-cylinder units 40 , 41 after the gripper means have gripped the pipe securely, as indicated in FIG. 10.
[0059] The line up device described above is suitable for ligning up double-walled pipes, but it will be clear that the device is also suitable for ligning up single pipes and pipe components.
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A line up and connection installation comrises an elongated pipe receiving structure, a line up device for ligning up double-walled pipes or pipe components and a connection station for connecting the lined up pipes or pipe components. The line up device has at least two gripper means. The gripper means are each movable in translation in a plane which lies substantially perpendicular to the axial direction of the pipe receiving structure. At least one of the gripper means is movable in the axial direction of the pipe receiving structure. The line up device positions a first pipe or component in such a manner with respect to a second pipe or component that they can be connected to one another at their ends in a connection station.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. §119 of German Patent Application No. 10 2010 052 713.0, filed on Nov. 26, 2010, the disclosure of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a drivable device for compacting a soil layer structure, having at least one vibration means or device, such as a vibration roller or a vibration plate, via which load pulses which compact the soil layer structure can be introduced into at least one load introduction area.
In addition, the present invention relates to a method for ascertaining a layer modulus of elasticity of an uppermost layer of a soil layer structure, in particular a roadway asphalt layer, during a compaction procedure.
BACKGROUND OF THE INVENTION
Such drivable devices for compacting a soil layer structure are known from the prior art. For example, there are machine driven rollers, and in particular road rollers, by which a soil layer structure, and in particular an asphalt road including its substrate, can be compacted. For this purpose, the drivable devices and also the above-mentioned road roller have a vibration means or device, via which load pulses which compact the soil layer structure can be introduced into the surface of the soil layer structure.
The drivable device moves in multiple work steps over the soil layer structure to be compacted, a further compaction up to a maximum compaction being achieved upon each passage. After achieving the maximum compaction, further compaction of the soil layer structure is no longer necessary or is even counterproductive, because it results in renewed loosening of the compacted soil layer structure and excess strain of the compaction device. For this reason, it is important to detect the degree of compaction of the soil layer structure continuously or at specific intervals.
However, it is problematic in this case that because of the structure of the soil composed of different layers, precise detection of the moduli of elasticity of the respective layers, i.e., the layer moduli of elasticity, is only imprecisely possible, since the moduli of elasticity of the individual layers, in particular unbound layers, mutually influence one another.
A method using the so-called “falling weight deflectometer” (FWD) is known from the prior art, in which a relatively precise detection of a layer modulus of elasticity is possible by ascertaining a depression trough caused by a load pulse via an established number of detection devices. In particular, in the case of the evaluation of the carrying capacity of existing asphalt roads, the carrying capacity studies using the FWD are increasingly gaining significance. Using the FWD, a load pulse is applied to the road surface using a falling mass, which serves to simulate a wheel rollover. The briefly occurring vertical deformation of the surface of the soil layer structure is recorded in the load center and remotely at eight predefined distances from the load center.
The stiffness of the entire road structure is ascertained via the measured depressions of the depression trough. The influence of the deeper layers on the measured depressions increases with increasing distance from the load introduction point. This means that the depression at the load introduction point is a function of the carrying capacity of the entire layer structure, while the depression at the most remote pickup is essentially determined by the carrying capacity of the substrate or deeper layers. The calculation of the stiffnesses or the layer moduli of elasticity is then performed based on the theory of the elastic half-space and a multilayer model (e.g., a 2-layer or 3-layer model) according to Boussinesq/Odemark.
The modulus of stiffness at the load introduction point results in the so-called equivalent modulus, i.e., the modulus of elasticity of the entire soil layer structure under the influence of all layers. At the far remote measuring point, the so-called bedding modulus, the modulus of elasticity of the substrate, is ascertained. The moduli of elasticity of the individual layers are then ascertained by means of back calculation from the measured depression troughs or moduli of elasticity of the roadway. The layer thicknesses of the bound and unbound carrier layers are incorporated in the calculation.
However, this method has the disadvantage that the ascertainment of the layer moduli of elasticity using the FWD is very time-consuming and no further work can be performed on the soil layer structures during the measurement. The values obtained by the FWD are also only available to a soil compaction device, and in particular a road roller, after a time delay, so that a compaction-controlled method or the compaction-controlled soil compaction is only possible with difficulty.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to specify a device for compacting a soil layer structure of the above-mentioned type, which allows the rapid and cost-effective detection or monitoring of a layer modulus of elasticity of the soil layer structure and in particular an uppermost layer.
This object is achieved according to one embodiment of the present invention by a drivable device for compacting a soil layer structure having at least one vibration means or device, such as a vibration roller or a vibration plate, via which load pulses, which compact the soil layer structure, can be introduced into at least one load introduction area, at least one first and one second detection means or devices being provided for detecting the modulus of elasticity of the soil layer structure, which are situated on the drivable device spaced apart from one another such that the first detection device allows a detection in the load introduction area and at least the second detection device allows a detection outside the load introduction area.
This object is achieved with respect to the method by a method for ascertaining a layer modulus of elasticity of a layer of a soil layer structure, in particular a roadway asphalt layer, having the following steps: introducing at least one load pulse into a load introduction area via a surface of the uppermost area of the soil layer structure; detecting a first value of a depression trough of the soil layer structure in the load introduction area by a first detection device, ascertaining the equivalent modulus of the soil layer structure from the detected first value of the depression trough; detecting at least one second value of the depression trough outside the load introduction area by at least one second detection device; ascertaining the bedding modulus and the layer modulus of elasticity of the uppermost layer of the soil layer structure from the detected values of the depression trough, the load pulses being introduced into the soil layer structure via a vibration means or device, such as a vibration roller or vibration plate, of a soil compaction machine.
An essential point is thus that, corresponding to the above-described FWD method, in the method according to the present invention or the drivable device according to the present invention, the vibration device provided for compacting soil layer structure, i.e., a vibration roller, a vibration plate, a vibration stamper, etc., is used as the load introduction means for initiating a defined load pulse.
In the scope of the present invention, a drivable device can be understood as any device which has operating means for soil compaction functioning as a vibration means or device and, in particular, which serves for mechanized planar soil compaction, in particular in construction operation. It is relevant that the drivable device is implemented so that the two detection means or devices for detecting the modulus of elasticity or for detecting a depression trough are situated spaced apart from one another so that the first detection device detects in the load introduction area while at least the second detection device detects outside this load introduction area. “Outside this load introduction area” is understood as any position in which the effect of the load pulse is detectable at a distance to a load introduction area.
As already described above, a deformation trough or a depression trough results through the load pulses introduced by the vibration means or device and, in particular, by a vibration roller in one embodiment.
Through the arrangement according to the present invention of the first and at least one second detection means, a conclusion about the individual layer moduli of elasticity and in particular a conclusion about the uppermost layer of the soil layer structure can be made via a targeted determination of the values of this depression trough.
The first detection device is preferably implemented in such a way that it allows a detection of a first value of a depression trough of the soil layer structure in the load introduction area, the second detection device preferably also being implemented in such a way that it allows a detection of at least one second value of the depression trough outside the load introduction area. A targeted determination of the respective layer modulus can then be performed via the values thus detected, as already described above.
The first detection means or device is preferably implemented and situated so that it allows a detection of a first value of the depression trough in the load introduction area. This first value allows the calculation of the equivalent modulus of the soil layer structure, i.e., the modulus of elasticity of the entire soil layer structure, since all deformations of the soil layer structure, from the uppermost layer to layers lying very far below it, influence it. In particular, it is possible to perform this detection during the soil compaction operation.
A further modulus of elasticity, namely the bedding modulus, can then be determined via at least the second detection means or device, which is situated outside the load introduction area or outside each load introduction area, so that it only detects effects of the load pulse of the compaction means. This ascertainment is also again performed via the detection of at least one value of the depression trough, namely at least the second value in the area of the second detection device. The bedding modulus can then be determined from at least this second value of the depression trough. The detection is also possible here during the soil compaction operation.
This bedding modulus is nearly independent of the substrate, since the deformation at this point is essentially only determined by the substrate and not by the uppermost layer, as already described. According to the theory of the multilayer model, the layer modulus of the uppermost layer and in particular the layer modulus of the asphalt layer is ascertained with the layer thicknesses of the individual layers of the soil layer structure. As an asphalt modulus which is corrected for the substrate influence, it represents the stiffness of the asphalt layer substantially more precisely than the equivalent modulus ascertained in the load introduction area.
By equipping a device for soil compaction with the detection means or device according to the present invention, monitoring of the compaction status, in particular a carrying capacity study of an asphalt road, can therefore also be performed during the compaction operation and in particular during the operation of a road roller or a comparable compaction means or device. The values thus ascertained can then directly influence the regulation procedures of the road construction machine, in order to achieve particularly effective control of the machine in accordance with demands.
The first and at least the second detection means or devices preferably have at least one geophone or similar deformation meter, via which reflected waves because of the introduced load pulses are detectable in particular in the soil layer structure. In this way, very precise detection of the respective values of the depression trough is possible.
The first and/or the second detection means or device preferably have a force sensor or a similar load cell, via which the introduced force pulses can be detected and/or relayed to a corresponding processing unit.
The detected force pulses are preferably stored in this processing unit. This is similarly true for the first and at least second values detected by the detection means, which are also preferably recorded, processed, and stored in a corresponding processing unit. The analysis of the detected values and the ascertainment of the respective moduli of elasticity are preferably possible in this analysis unit. It preferably also assumes the comparison of the ascertained equivalent and bedding moduli and the determination of the respective resulting layer modulus. Corresponding control and regulation programs as well as processing programs are preferably contained or storable for this purpose in the processing unit. The resulting results can then be displayed in a display unit and/or supplied to further program routines, such as the result-oriented regulation of the vibration means.
The first and at least second detection means or devices are preferably implemented so that they allow a precise detection of the deformations caused by the load introduction pulses in the respective areas. A detection can be performed using all methods and devices known from the prior art. It is thus also possible to perform a detection via the vibration means itself and by its settling movements during the vibration procedure. A very simple detection of the first and at least second values is possible, for example, by means of an electromechanical transducer implemented as a geophone, which converts the soil vibrations into analog voltage signals.
The detection means or devices are preferably situated so that a static coupling exists between the uppermost layer of the soil layer structure and the detection means.
In a particular embodiment, the first detection means or device is situated on the device in such a way that it allows a detection in the load center of the load introduction area. A maximum value can be ascertained as the first value of the depression trough in this way. The first detection device is preferably additionally situated coaxially to the load introduction axis of the vibration roller.
It is possible to situate the first detection means or device on the vibration roller or its bearing unit, in particular on a vibrating drum of the vibration roller. A precise detection of the first value in the load introduction area and in particular the load center of the load introduction area can be performed very simply in this way.
At least the second detection means or device is preferably situated on a static roller, in particular on the static drum thereof. A static roller is understood in the scope of the present invention as such a roller which does not have independent vibration means. Such a static roller can thus result in compaction of the soil solely because of its weight, for example, it can also only be used as the driving means for the drivable device according to the present invention. The term static roller thus also comprises rubber wheels or similar driving means in the scope of the present invention. The arrangement of the second detection means or device on a further non-vibrating, i.e., static suspension and in particular a static roller also allows the cost-effective and very precise detection of a second value of the depression trough. All methods for detecting the value in the depression trough known from the prior art can also be used here.
In an advantageous refinement, at least the second detection means or device is situated so it is displaceable, in particular via a support frame, in its position relative to the load introduction area of the vibration device. In this way, direct influence can be taken on the detection location of the second value of the depression trough. In addition, further detection means or devices for detecting further values of the depression trough outside the load introduction area can be situated on such a support frame. Moreover, of course, such further detection means or devices can also be situated on other components of the device, as long as they are spaced apart from the load introduction area.
The drivable device is preferably implemented as a compactor having a vibration roller and at least one static roller. A soil compaction with simultaneous carrying capacity study and in particular the detection of the carrying capacity status of the uppermost layer of the soil layer structure can then be performed very simply via a compactor equipped according to the present invention.
It is thus fundamentally possible by means of the drivable device according to the present invention and the method according to the present invention to perform a carrying capacity study, in particular of an uppermost layer of a soil layer structure, during a compaction process of a soil layer structure. A soil compaction machine, as is known from the prior art, is thus preferably equipped with the detection devices according to the present invention and further conversion and regulating units required for this purpose in order to perform a method similar to the method of the carrying capacity study using the “falling weight deflectometer”. It is also possible in this context to offer a drivable device which allows a soil compaction machine to be equipped later with the above detection means or means for detecting a layer modulus of elasticity of an uppermost layer of a layer structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described hereafter on the basis of an exemplary embodiment, which is explained in greater detail through the appended drawings. In the schematic figures:
FIG. 1 shows an illustration of a first embodiment of the drivable device for compacting a soil layer structure; and
FIG. 2 shows an illustration of the detection means or device arrangement of the embodiment from FIG. 1 .
The same reference numerals are used hereafter for comparable and identically acting components, apostrophes sometimes also being used for differentiation.
DETAILED DESCRIPTION
FIG. 1 shows an illustration of an embodiment of a drivable device 1 according to the present invention for compacting a soil layer structure. The device 1 is implemented here as a self-propelled road roller and in particular as a compactor 30 . It comprises a vibration means or device implemented as a vibration roller 6 , which is connected via a bearing unit 16 to a main body 34 of the compactor 30 . A static roller 24 is associated via a further bearing unit 26 , so that the compactor 30 is drivable via the two rollers 6 , 24 .
In contrast to the static roller 24 , in the case of which compaction of a soil structure 2 occurs exclusively because of its static weight, in the case of the vibration roller 6 , the soil layer structure 2 can be actively compacted via driven vibrating masses.
The vibration roller 6 relays load pulses P via a load introduction area 8 , which essentially corresponds to the contact area between the vibrating drum 18 of the vibration roller 6 and the surface 33 of the uppermost layer 32 of the soil layer structure 2 , into the substrate. These vibrations, which are caused by the load pulses P and induce settling, are shown by the concentric circles 15 in FIG. 1 .
Starting from a load center Z, settling in the soil layer structure 2 , which is schematically shown here by the depression trough 14 , occurs because of the introduced load pulses P and the resulting vibrations 15 . It is clear in this case that the settling or compaction caused by the load pulses P decreases with increasing distance A from the load center Z or a load introduction axis A P running vertically to the surface 33 .
A modulus of stiffness can be ascertained, as is known from the prior art, via the load pulses P introduced at the vibrating drum 18 or vibration roller 6 , which act as compaction or deformation force in the soil layer structure 2 . This modulus of stiffness corresponds to the equivalent modulus, i.e., a mean stiffness value over the entire measurement depth of the soil layer structure 2 . Both the layer modulus of elasticity of the uppermost layer 32 and also of the bedding layers 42 lying underneath thus have influence on this equivalent modulus.
The detection of the first value “w 1 ” of the depression trough 14 , required for ascertaining the equivalent modulus, is performed via a first detection means or device 10 , which is situated and statically coupled in this embodiment on the vibration roller 6 or its bearing unit 16 .
A second detection means or device 12 , via which a second detection value “w 2 ” of the depression trough 14 can be ascertained outside the load introduction area 8 , is situated on the static roller 24 or on its static drum 28 or its bearing unit 26 . As is shown in FIG. 1 , the second detection means 12 is spaced apart from the first detection means 10 and the load introduction area 8 in such a way that a detection of a modulus of elasticity of the layers situated below the uppermost layer 32 and in particular the bedding layer 42 is possible. Because of the distance A D between the first detection means or device 10 or the load introduction area 8 and the second detection means or device 12 , the deformations at the detection point of the second value “w 2 ” are essentially determined by the substrate and not by the asphalt layer itself. A value of 1 m to 2.6 m, in particular 1.8 m, has proven to be an advantageous distance value A D here.
According to the theory of the multilayer model known from the prior art, the layer modulus of elasticity of the asphalt layer 32 to be measured can then be ascertained using the layer thicknesses of the individual soil layers via the two ascertained first and second values “w 1 ” and “w 2 ” and the equivalent or bedding moduli obtained therefrom, the result being an asphalt modulus which is essentially corrected for the substrate influence, and which represents the stiffness of the asphalt layer 32 significantly more precisely than the equivalent modulus, which considers the entire soil structure 2 .
As a function of the components and detection means used, according to the present invention, a load introduction P can be performed at a frequency of 30 to 50 load introductions per second. A corresponding influence can be taken on the vibration means 4 or the vibration roller 6 here via corresponding control means. It is also possible to regulate the absolute value of the introduced load pulses via a corresponding regulation means in such a way that it corresponds to the required measuring conditions. For example, the load pulse P can be regulated to a value of 50 kN via the regulation means, which essentially corresponds to the wheel load of a truck and therefore allows an informative analysis of the carrying capacity of the soil layer structure 2 and in particular the upper layer 32 . It is thus possible in this regard to activate the device 1 according to the present invention or the compactor 30 in such a way that it allows a reliable and reproducible study of the soil layer structure 2 and in particular the uppermost soil layer 32 .
FIG. 2 shows a schematic illustration of the drivable device 1 according to FIG. 1 , showing the first and second detection devices 10 and 12 .
It is shown that a geophone 11 of the first detection means or device 10 is situated on the vibration roller 6 of the drivable device 1 so that it allows detection of the reflected waves which are caused by the load pulses P. Via the geophone 11 or the first detection means or device 10 , as is known from the prior art, the dynamic soil stiffness of the soil layer structure 2 located in the load introduction area 8 is thus detectable. Conclusions about the degree of compaction of the soil layer structure 2 may then be made in a known way via this dynamic soil stiffness.
A geophone 13 of the second detection means or device 12 , is also situated on the static roller 24 of the drivable device 1 . Since the static roller 24 does not introduce separate load pulses into the soil layer structure 2 , this geophone allows a detection of a stiffness value as a function of the load introduction in the load introduction area 8 , which, because of the distance A D between the two detection means or devices 10 and 12 or geophones 11 and 13 , is essentially only a function of the bedding layer 42 and not the upper layer 32 . Via the value “w 2 ” of the depression curve 14 detected by the geophone 13 or the second detection means or device 12 , the soil stiffness and in particular a bedding modulus may therefore be determined without influence of the upper layer 32 .
The first and second values “w 1 ”, “w 2 ” ascertained by the two geophones 11 , 13 are transmitted as measurement results to an analysis unit 36 , which compares the two detected first and second values “w 1 ” and “w 2 ” or ascertains equivalent and bedding moduli of a layer modulus of elasticity of the uppermost layer 32 which can be ascertained therefrom. The values thus obtained can then either be output to the operating personnel via a display unit 38 or can directly influence the machine controller of the drivable device 1 .
In addition, a calibration element 40 is shown in FIG. 2 , via which, for example, the load pulses P introduced into the soil layer structure are fixable at a fixed value and in particular, for example, at a value of 50 kN. The vibration speed and therefore the number of load pulses per second is also preferably settable to a value between 20 and 50 times per second via such a calibration element 40 .
A support frame 27 is also shown in FIG. 2 , via which the second detection means or device 12 is situated so it is displaceable in its position relative to the load introduction area 8 of the vibration means or device 4 or the vibration roller 6 (preferably essentially parallel to the soil surface 32 ). As a result, the distance A D between the two measuring points of the values “w 1 ” and “w 2 ” is therefore variable via the support frame 27 .
While the present invention has been illustrated by description of various embodiments and while those embodiments have been described in considerable detail, it is not the intention of Applicants to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. The present invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' invention.
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The present invention relates to a drivable device for compacting a soil layer structure, having at least one vibration means or device, such as a vibration roller or a vibration plate, via which load pulses (P), which compact the soil layer structure, can be introduced into at least one load introduction area. At least one first and one second detection means or devices for detecting the modulus of elasticity of the soil layer structure are provided, which are situated spaced apart from one another on the drivable device in such a way that the first detection means or device allows a detection in the load introduction area and at least the second detection means or devices allows a detection outside the load introduction area. The present invention also relates to a method for ascertaining a layer modulus of elasticity.
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This application claim the benefit of 60/229,818 filed Jun. 21, 2001.
FIELD OF THE INVENTION
The invention relates to the field of data processing, and more particularly to the field of data base performance tuning for improving workload performance.
BACKGROUND OF THE INVENTION
Deciding which materialized views (MVs) and indexes should be created that will likely result in good performance for a user's database workload is an exponentially complex problem with respect to the number of queries, the number of tables, the number of updates, and the number of columns on the tables. Having some automated method that analyzes the workload and uses information about the system configuration and the database characteristics will allow the user to answer the problem. If the method is efficient, the user will be able to derive a good set of materialized views and indexes with low cost.
SUMMARY OF THE INVENTION
The invention herein provides method and apparatus, including software for determining a set of materialized views or indices of the contents or a subset of the contents of a database in a data processing system to be created for one or more users of the database.
The method and apparatus provide method and means for evaluating a workload presented by a user to the database; evaluating the data processing system characteristics; evaluating the database characteristics; and, using the above evaluations for recommending a set of suitable materialized views or indices to the user.
Another aspect of the invention, which may be used for a workload presented by a user of a database in a data processing system, provides method and apparatus, including software for determining a set of materialized views or indices of the contents or a subset of the contents of the database, by:
generating a plurality of materialized view candidates from evaluation of the workload, data processing system characteristics and database characteristics;
estimating statistics for the materialized view candidates such as the number of rows, row size, and column statistics;
generating a plurality of potential index candidates by evaluating the workload, data processing system characteristics, database characteristics and the materialized view candidates; and,
from the materialized view candidates and index candidates selecting a set of suitable materialized views and/or indices for submission to the user.
DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
Deciding which materialized views (MVs) and indexes should be created that will likely result in good performance for a user's database workload is an exponentially complex problem with respect to the number of queries, the number of tables, the number of updates, and the number of columns on the tables. Having some automatic algorithm that analyzes the workload and uses information about the system configuration and the database characteristics will allow the user to answer the problem. If the algorithm is efficient, the user will be able to derive a good set of materialized views and indexes with low cost.
This invention describes such an automatic method. It should be noted that candidate MVs and indexes are chosen for base tables and existing MVs. Also, the candidates are all derived from the user's workload. A time constraint is used to limit how long the algorithm will take to produce a result so that the algorithm can determine MV and index recommendations before and during a database's use.
The invention also can use a multi-query optimization (MQO) process to compile workload queries together to find common query components among queries. These components are potential good MV candidates. This invention's algorithm saves these possible candidates as input to a selection method.
The index candidates are derived from a special optimization process [6], where virtual indexes are created when the optimizer determines they would be useful in query plans.
The candidates are then input into a combinatorial selection algorithm that takes their performance benefits and space constraints into account, so that indexes and MVs are chosen together in the same algorithm. This invention extends the selection algorithm defined in [6] to obtain MV candidates using the MQO work in [5]. The selection algorithm includes an initial combinatorial algorithm (called the knapsack algorithm). Since the knapsack algorithm does not guarantee an optimal solution, the selection has an added random swapping phase that will iteratively trade MV's and indexes in a solution to ones not in the solution, but only if the swap results in a new solution with better performance that the original. This combined selection results in an algorithm that finds solutions for MV's beyond the solutions found by the algorithms defined in [2,4]. Also, the addition of indexes and MVs in this invention's selection is a differentiator with the work in [2,4].
The invention describes an algorithm for selecting either MVs only, indexes only, or both.
The benefits and differences of using the invention over existing MV algorithm inventions are as follows:
One aspect of the invention generates MV candidates using the multi-query optimization (MQO) work in [5]. Another technique in [4] attempts to find common subqueries, which has some similar goals to the MQO method. However, this other technique does not include the concept of matching similar subparts of queries and adding compensation in queries for using the subparts. The present invention identifies more common subexpressions and common subsumers, and thus it more MV candidates that directly relate to the workload. The MQO method also prunes useless MV candidates; other methods do not prune, and thus may lead to a lot of useless MVs being analyzed.
Another aspect of the present invention combines index and MV selection. The invention can use the index candidate generation described in [6]. Previous methods either do not consider index selection as being integrated with MV selection or disclose exponentially complex algorithms, e.g, [1,2,3,4,8]. Microsoft in [7] discloses a non-exponential algorithm that is different to this invention's. They determine single column indexes and single table MVs first and then build multi-table MVs and multi-column indexes one table and column (respectively) at a time using an iterative approach. A beneficial aspect of the MQO method of the present invention will directly find multicolumn MVs from one compilation of the workload.
Another aspect of the present invention also defines a cost/benefit metric to rank MVs and indexes together. The metric combines how much benefit candidates each give to the workload and how much space they use so that the selection algorithm can determine the set of candidates that would provide good workload performance with minimal storage used.
Another aspect of the present invention allows for different types of MVs. Refresh deferred MVs (that are updated manually by the user) and refresh immediate MVs (that update the MVs immediately when its base tables are changed) are included in these types. This invention also defines a cost/benefit metric to rank MVs and indexes together. The metric combines how much benefit candidates each give to the workload and how much space they use so that the selection algorithm can determine the set of candidates that would provide good workload performance with minimal storage used.
Another aspect of the present invention uses the constraints in [6] to permit the user to limit disk space used by new indexes and MVs and to limit the amount of time the selection algorithm will take to execute (which will be useful when DBAs have only a narrow batch window to run this tool). Other constraints could also be used in executing this algorithm. These include constraints such as limiting the total number of candidates chosen or limiting the number of candidates chosen per table. These constraints can be handled by having a counter for the number of candidates and/or the number per table. When a counter reaches its maximum, no more candidates are allowed to be selected in the solution for either all tables or a single table. A constraint to limit which tables can have candidate MVs and indexes defined on them is allowed as well. The algorithm would merely reject candidates defined on other tables.
Another aspect of the present invention deals with a large number of queries and execution memory constraints (limiting how much memory the algorithm's execution can use) by grouping workload queries and generating MV candidates for each group separately. Groups are constructed so that each group when compiled together using our MQO method will not exceed the execution memory constraint. This invention describes how to group similar queries together so that each group will provide meaningful candidates from the MQO method. Other existing methods, such as the one in [4], do not take execution memory constraints into account.
Another aspect of the present invention considers constructing materialized view candidates from other MV candidates, for example, by using the common subsumer work in [5], whereas other methods only consider MVs on base tables or existing views (e.g., [4])
Update, insert, and delete transactions are allowed in the workload to account for the penalty of adding too many MVs and indexes.
Statistics can be generated automatically (for example using an optimizer's cost model). However, it also allows the collection of statistics on candidate MVs to be done using sampling. Other methods just use estimated statistics. Sampling provides more accurate estimates with which to rank MVs.
A local DB catalog simulation can be used when executing the algorithm so that other users are unaffected by its execution. A simulation is described in [9].
The present invention can be used to determine replicas of a table (or replicas of a table's subset) in a multiprocessor system (MPP). This is allowed since a replica of a base table can be defined as a MV, which could be partitioned independently to the base table and/or other replicas of the base table.
The present invention can also be used to recommend index and MV candidates in a heterogeneous distributed DB system (HDDBS). Heterogeneous DB systems are systems in which different hardware architectures are connected by a network possibly running DB systems from different vendors. In the preferred embodiment, one of the DB systems is considered as the local DB system in which all the DB's in the HDDBS have their data structure objects logically defined in the local DB system's database. The local DB system can compile queries defined with DB data structure objects throughout the HDDBS. MVs and indexes can then be recommended on the local DB system using the invention, where these recommendations are for local and remote DB systems.
Before describing the invention, its required inputs are now described. There are three sets of inputs:
A set of workload queries. The invention makes recommendations based on a workload, which consists of a set of SQL statements and their individual frequencies of use. The preferred embodiment of the invention uses a default frequency is one. System information. This includes the number of nodes; the bandwidth of interconnect network; the latency, transfer rate, and seek times of the disk drives; and the estimated processing power of the processors. The Database (DB) characteristics. This information includes the relational schema, the cardinalities of tables, the column cardinalities, and possibly other physical DB design characteristics (such as indexes, partitioning, and already chosen views and materialized views). For example, in DB 2 , the system and DB information will come from the DB 2 configuration and catalog information.
Depending on the user's requirement, the invention allows for three types of output: the recommended MVs, the recommended indexes, or both.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a flow chart of a method of one embodiment of the invention.
FIG. 2 depicts a system, including a processor, a terminal, and memory, in which the method and article of the invention may be implemented.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 with workload 10 , system and database information 11 , as input, the invention generates a set of materialized view candidates, 1 , and then estimates statistics for the materialized views, 2 . Using the estimated statistics and the materialized view candidates along with workload, 10 , system and database information, 11 , the invention generates index candidates, 3 .
Referring to FIG. 2 , there is shown a system 21 including a processor 23 with a terminal 25 and external memory, as drives 27 A and 27 B for carrying database management system data files. The processor 23 includes one or more drives 29 for system software and application software, including database management system software.
The set of materialized new candidates and index candidates obtained above are consolidated by the invention into a consolidated set of materialized views and indices, 4 .
Next, the invention executes a selection algorithm, 5 , described below, to determine an intermediate set of data structure objects (indices and materialized views). The invention can generate more candidate data structure objects, 6 , for example, by constructing supersets or subsets of the current MVs. This new set would then be the new candidate set that is fed back, 9 , into the estimating statistics phase, 2 . The invention iterates until it either exceeds algorithm execution time constraint, 12 , or it cannot add any more new MVs without exceeding disk space constraint, 13 .
Since in the preferred embodiment, the invention executes on a local DB system to determine recommended MVs and/or indices, 14 , for a heterogeneous distributed DB system (HDDBS), a last “filtering” step, 7 , should be carried out on the remote DB systems to guarantee that the recommended MVs and indices will be used by the remote systems' compilers. If a recommended MV or index is not used at all to execute the workload at the remote DB system to which it is recommended for, the invention would eliminate the recommended object.
The invention can be executed in two ways. In the first way, the invention initially obtains the MV and index candidates and their estimated statistics in a phase called the CANDIDATE phase (steps 1 , 2 , 3 , 4 ). Candidates are stored in special ADVISE tables. In FIG. 1 , the steps in the CANDIDATE phase are the steps up to and including the Consolidating MVs and Indexes steps. The invention then executes the SEARCH phase (steps 5 , 6 , 7 , 9 ). This phase causes the combinatorial selection algorithm to be invoked using the candidates in the ADVISE tables. The SEARCH phase includes all steps under and including the combinatorial algorithm.
The other way to execute invention is to execute the CANDIDATE and SEARCH phases separately. The CANDIDATE phase is done initially. The invention then executes a REFINEMENT phase, 8 , in which a user can change, add, or drop MVs and indexes in the ADVISE tables. The user can change the statistics in the ADVISE tables either manually or through the use of sampling the real database. The REFINEMENT phase is shown in FIG. 1 with dotted lines for executions where the phases are to be run in two different invention invocations. When the user refinement phase is complete, the invention executes the SEARCH phase.
Note that if indexes are to be chosen alone, the Generate MV Candidate, Estimating Statistics (for MVs), and the Generate more MVs modules will not be executed. If only MVs are to be selected, the Generate Index Candidates module will not be executed. When selecting both indexes and MVs, all modules will be executed unless the user does not specify that REFINEMENT is required.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
3. Module Descriptions
3.1 Generate Materialized View Candidates
This module is used to generate MV candidates for the given workload of queries. These candidates will be the set of MVs used by some combinatorial selection algorithm as input to determine which subset gives the best performance benefits. The candidates are temporarily recorded in the ADVISE table.
Generating candidates can be done using various approaches, such as:
Use the queries supplied in the workload as candidates.
For each query, determine if it can be the query defining an MV and thus be an MV candidate. For example, the simplest case is to define the query itself as possible candidate:
CREATE SUMMARY TABLE <name> AS <query>
Use the views defined by the user as the candidate MVs. Utilize a MQO (Multi-Query Optimization) method to suggest candidates. We use the MQO method defined in [5].
Note that the multi-query optimization of all queries in a workload may cause MQO to use more space than is available. The invention handles this by adding information in the compiler that will tell us the memory space required to store the constructs of each query in the workload. MVs are grouped into sets such that the sum of each group's space is some factor (F) of the total execution memory space allowed for use by the MQO compiler phase. This execution memory constraint is given as part of the system information. Extra memory space is accounted for the space used by MQO to generate new MV candidates. Each group is compiled together using the MQO method. The grouping can be done in many ways, for example: 1) arbitrary grouping based only on the maximum space allowed per group (which is determined as a fraction F of the total space used for MQO) or 2) put MVs that are related (e.g., operate on similar tables/columns) somehow into the same groups. The invention describes a method below to handle #2, where the MVs will be grouped depending on the tables they access. This method is as follows:
a) Steps to create all queries as MVs in the workload:
i = 0 for each query in the workload { get the current time Obtain the tables used in the query for the query (e.g., using DB2 EXPLAIN) Obtain the space used to represent the query Determine the tables that the query used by doing the following Create a linked list structure struct tabname { CHAR* TABLE_SCHEMA, CHAR* TABLE_NAME , int tabnum, struct tabname *next} where each table is assigned a unique number by this algorithm. Also allocate an array of size equal to the number of queries where each element is the amount of space used for the query and a list of tablenums per query (call this array QUERYTAB) i++ }
Get the total memory space available for MQO
Determine the memory space per group of queries that can fit in that total space GROUPmax==TotalSPace*F
If the sum of the space used by all queries<=GROUPmax, then compile all queries as one group using MQO
OTHERWISE do the following:
{ In QUERYTAB, we mark each query as not being compiled in MQO yet (e.g., set a flag in QUERYTAB as REFRESHFLAG = false) Then do the following: num_refreshed_queries = 0 start = true while num_refreshed_queries < number of queries in the workload { If start == true then { Find the first uncompiled query in QUERYTAB, and set GROUPcount = space for the query from QUERYTAB Set the query's refreshflag = true start = false }
Go through QUERYTAB and find the query that has the greatest intersection in the tabnum lists to the query first (or all current queries) picked for the group (or possibly find a query that has the closet query structure to queries in the group). The preferred embodiment is to use the intersection of tables accessed between queries.
if( GROUPcount + size of new query > GROUPmax ) { /* Execution memory space for the current group and the current query exceed the execution memory constraints, so compile the current group only, and save the current query to create a new group. */ if we found >= 2 queries in the iteration then execute MQO with the current group (and set all queries with the refreshflag = true) Set start = true Continue grouping using the current query } Otherwise: set GROUPcount += space for new query and set the new query's refresh flag to TRUE Add one to the num_refreshed_queries } compile the last group if start = FALSE }
The preferred embodiment uses all the above methods to generate candidates.
3.2 Generate Index Candidates
The invention generates index candidates using the method described in [6]. When selecting indexes and MVs together, the candidate MVs from step 3.1 are set to appear as though they exist in the database before generating candidate indexes. Thus, indexes are recommended for base tables, existing MVs and candidate MVs.
In the preferred embodiment, after generating candidate MVs and indexes, as a sanity check, the invention compiles the queries with all candidate and real MVs and indexes to determine if any query in the workload would exploit each MV or index. If a MV or index is not used by any query, the invention removes it from the candidate list, as it will never be chosen. The remaining MVs and indexes will make up the candidate set for next module.
3.3 Simulated Catalogs
Since the MV and index candidates do not exist in the database, the compiler would not be aware it could use the candidates in compiling workload queries. Thus, the invention includes a method by which the candidates can be added to the existing DB information, which allows the compiler to compile queries with existing and candidate MVs and indexes. The preferred embodiment does not rely on creating the candidate data structure objects as real data structure objects in the database because this would allow concurrent access and modifications on these nonexistent candidates by other users. To handle this problem, the invention creates a simulation of the database seen only by the invention, which it modifies with the candidate information. This method is described in [9]. In this simulation, a candidate's DDL only affects the simulated catalog information.
3.4 Statistics Associated with MVs
There are many ways of obtaining estimated statistics for the candidates. The preferred embodiment of the invention uses two methods. One method is to use the statistics generated by the optimizer. For a MV, the statistics are generated from the optimizer for the query representing the MV. Example of statistics generated include the estimated MV cardinality, the npages (calculated by using the rowsize, cardinality, and pagesize), and the column cardinalities.
Another method is to use sampling. To estimate a candidate MV's statistics, the query defining a candidate MV could be encapsulated by another SQL statement to collect samples from the existing base tables and MVs. For example, if the query defining an MV is:
SELECT a as c 1 , count(b) as c 2 FROM R, S WHERE R.d=S.d GROUP BY a
then the encapsulated query could be:
SELECT count(*) as rowcount, count(distinct c 1 ) as c 1 count, count(distinct c 2 ) as c 2 count
FROM (SELECT a as c 1 , count(b) as c 2 FROM R, S WHERE R.d=S.d GROUP BY a) as Q
3.5 Calculate Weight for MVs and Indexes
As stated earlier, candidate data structure objects are ranked against each other to determine which candidates are more important than others. The ranking of a MV A in the invention is defined by the weight W(A) that is a measure of the MV's performance benefit (defined partly as B(w,A)) divided by disk space it will occupy (defined as D(A)). A high weight would suggest that the MV provides high performance benefit for little disk space cost. The weight of an index is defined similarly in [6]. Note that the overhead to updates will be reflected in the performance change and thus in the weight calculation. The MVs not used by any query would have weight 0.
The benefit B(w,A) of a MV A for a workload w is defined as:
B ( w,A )=Σ Fi ( P without A ( Qi )− P with A ( Qi ))/Σ Fi,
where Fi is the frequency of query or update i, (Pwithout A(Qi)−Pwith A(Qi)) is the performance increase of having MV A compared to not having A for query or update i. Basically, the benefit of an MV A is the average performance improvement of having an MV over not having it. A negative value denotes a MV that is harmful to performance.
The preferred embodiment is to use a query's or update's total estimated time as the performance measure.
The weight depends on what the MV type is. If the MV type is refresh immediate, the weight of MV A is:
W ( A )= B ( w,A )/ D ( A ).
If the type is refresh deferred, the weight of MV A is:
W ( A )=( B ( w,A )− g*C ( A ))/ D ( A ),
where C(A) is the cost to create the MV A and represents the cost to refresh the whole MV A from scratch. We assume that we have “g” refresh per time period that we are interested in, and g>0. The preferred embodiment assumes a MV must be refreshed once during the interval the invention is interested in, so it uses “g=1”.
3.6 Determine a Good Set of MVs for Materializing
In the invention, the selection algorithm sifts through the candidates suggested in the above modules. This algorithm's goal is to choose a subset of the candidates that lead to good workload performance while meeting certain constraints, e.g., disk space limitations. The core algorithm for this step is an algorithm that solves the Knapsack problem, which is to choose a set of items to fit within a fixed space such that the benefit of having the items you have chosen is optimized. Weightings defined in 3.5 are used to rank candidates in the knapsack algorithm.
The invention assumes the workload contains queries and updates. For index and MV selection, updates potentially perform more poorly when more MVs and indexes must be introduced. Queries perform better when more indexes and MVs are introduced. The calculation of costs of the updates and benefits of the queries when adding MVs is included as part of the search algorithm.
For MV selection only, the algorithm starts with the empty list of candidates, and, in each iteration, it adds the MV with the highest weight to the list until that MV causes the selected MVs to exceed the disk constraint. This algorithm is called the ADD_MV algorithm, and is given below.
/*
ADD_MV - selects a set of candidate MVs only
Input: A — a set of candidate MVs
space — the amount of space available for pre-computation
Output: S — the set of MVs to be materialized
*/
Algorithm ADD_MV
for each MV a, calculate its weight W(a)
re-order the MVs by weight in descending order and put in set A
S = { }
WHILE (space > 0 && A is not empty) DO
pick a from A such that a has the highest weight
IF W(a) <= 0 THEN
/* No more MVs should be picked since they have no performance benefit */
space = 0
ELSE IF (space − | a | ) >= 0) THEN
/* There is space for the next best MV a, so add it to the solution set S */
space = space − | a |
S = S ∪ a
A = A − a
END IF
END WHILE
RETURN S as the set of MVs picked by ADD_MV
The time complexity of ADD_MV is O(nlogn), where n is the number of candidate MVs. This complexity arises from the cost of sorting the candidate MVs by the weights calculated in section 3.5. Note that we continue to check when the time constraint is exceeded and stop the invention when it is. The best solution when the invention is stopped is picked as the recommended set.
The selection algorithm uses an added random swap method after the knapsack algorithm. This method exists to get around the selection of suboptimal solutions by the knapsack algorithm. The knapsack algorithm is used because it provides a good initial solution. There are three reasons the knapsack algorithm returns suboptimal results. First, the performance benefit for a query Q is assigned to all candidate indexes and MVs used by the query. This does not account for how much each candidate itself contributed to the performance improvement. As such, the benefit assigned to the candidates are optimistic. Second, the weighting of competing candidates is calculated independently. There is no concept of weighting an MV A, say, given that another MV B was not selected. Third, the ordering of some cost/benefit weightings to select a solution by the general knapsack algorithm provides a solution to a relaxed integral problem, but is known in the literature to not always lead to the optimal solution for the non-integral problem.
The random swap phase takes a random number of MVs from the current solution and replaces it with a random number of MVs not in the current solution. This causes a new solution to be generated. The invention executes this phase for either a user specified time limit or until the swapping cannot improve the workload performance (over a given number of consecutive swaps). This swapping phase is a useful amendment for the possibility of missing good MVs that we may have pruned off earlier.
To combine index and MV recommendations together, it should be noted that candidate indexes created on top of candidate MVs will have dependencies on the candidate MVs. The dependency has to be recorded before entering the selection algorithm.
The invention also includes an algorithm, ADD_COMBINE, for selecting a set of candidate data structure objects (MVs or indexes). This algorithm starts with the empty list of candidates. It repeats the following iteration until we exceed the disk constraint. On each iteration, it attempts to add the next object(s) with the highest weight(s) to the list. If the highest weighted object is an index that is dependent on a candidate MV and the MV has not been selected, the iteration must add both the index and MV to the list if they fit within the disk space. If they cannot fit, then the algorithm ignores the index and proceeds to the next highest weighted object.
/*
ADD_COMBINE - selects a set of candidate data structure objects (MVs or indexes)
Input: A — a set of candidate data structure objects (MVs or indexes)
space — the amount of space available for pre-computation
Output: S — the set of data structure objects to be recommended
*/
Algorithm ADD_COMBINE
for each object o (MV or index), calculate its weight W(o)
re-order the data structure objects by weight and put in set A
S = { }
WHILE (space > 0 && A is not empty) DO
pick object o from A S.T. o has the highest weight
IF W(o) <= 0 THEN
space = 0
ELSE
C = { o }
IF (o is an index on MV a in A) && (a ∉ S) THEN
/* Add in the MV a since it is not in the solution yet and has to be there for
the index to be chosen */
C = C ∪ a
END IF
IF (space − | C | ) >= 0) THEN
/* There is space for the data structure objects in C, so add
them to the solution. */
space = space − | C |
S = S ∪ C
A = A − C
END IF
END IF
END WHILE
RETURN S as the set of data structure objects picked by ADD_COMBINE
The random swap phase for this combined selection algorithm needs more considerations when we swap data structure objects. The data structure objects being swapped can be MVs and/or indexes. If an index is swapped into the solution, the swapping has to add in the candidate MV on which the index depends. For similar reasons, if a MV is swapped out of the solution, the indexes that depend on it have to be swapped out.
Here is an example of the random swap phase:
The RANDOM SWAP PHASE incorporates an adaptation of the Random-based bin-packing algorithm.
1. This phase is only required if some of the recommendations were discarded by the Knapsack selection, this would have happened because of negative benefits or missed constraints.
2. The set of recommendations discarded by the Knapsack selection is referred to as the “loser set”. The preserved recommendations are referred to as the “winner set”.
3. Randomly select a subset of the recommendations in the winner set, and randomly select a subset of the recommendations in the loser set.
4. Swap the two subsets so the losers become part of the winner set and vice-versa.
5. If the new solution set violates any of the user constraints, go back to step 1 and try again.
6. Using the optimizer, evaluate the new solution set.
If the new solution set is better than the best one so far with respect to estimated performance, keep it.
7. Go back to step 3 and try a new variation. The algorithm may choose to quit if certain criteria are met. For example, time has elapsed, or the best solution set has not been improved on over some time period.
REFERENCES
References on materialized view selection:
[1] Informix's materialized view selection. WO99/50762. (Title: Processing Precomputed Views, by Latha Colby et al.)
[2] Amit Shukla, Prasad M. Deshpande, Jeffrey F. Naughton, “Materialized view selection for multidimensional datasets”, VIDB 1998, New York.
[3] (Oracle Patent) “Summary table management in a computer system”, Andrew P. Osborn et al. (Appl # 962029, U.S. Pat. No. 6,023,695)
[4] Hoshi Mistry, Prasan Roy, S. Sudarshan, Krithi Ramamritham: Materialized View Selection and Maintenance Using Multi-Query Optimization. SIGMOD 2001
[5] (IBM) Roberta Cochrane et al, MQO in SIGMOD 2000)
[6] (IBM) Gary Valentin's and Guy Lohman's Index Invention U.S. Pat. No. 2,249,096
[7] Agrawal S., Chaudhuri, S., Narasayya V., “Automated Selection of Materialized Views and Indexes for SQL Databases” Proc. of the 26th VLDB Conference Cairo, Egypt, 2000
[8] Himanshu Gupta, Venky Harinarayan, Anand Rajaraman, Jeffrey D. Ullman: Index Selection for OLAP. ICDE 1997: 208–219
[9] (IBM) Walid Rjaibi's et al, Simulation Catalog patent application No. 2,283,052
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The invention herein provides method and apparatus, including software for determining a set of materialized views or indices of the contents or a subset of the contents of a database in a data processing system to be created for one or more users of the database. The method and apparatus provide method and means for evaluating a workload presented by a user to the database; evaluating the data processing system characteristics; evaluating the database characteristics; and, using the above evaluations for recommending a set of suitable materialized views or indices to the user. Another aspect of the invention, which may be used for a workload presented by a user of a database in a data processing system, provides method and apparatus, including software for determining a set of materialized views or indices of the contents or a subset of the contents of the database, by: generating a plurality of materialized view candidates from evaluation of the workload, data processing system characteristics and database characteristics; estimating statistics for the materialized view candidates such as the number of rows, row size, and column statistics; generating a plurality of potential index candidates by evaluating the workload, data processing system characteristics, database characteristics and the materialized view candidates; and, from the materialized view candidates and index candidates selecting a set of suitable materialized views and/or indices for submission to the user.
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