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This application is a continuation of application Ser. No. 09/530,913, filed May 8, 2000, now abandoned which is a 371 of PCT/GB99/02974 filed Sep. 8, 1999.
FIELD OF INVENTION
The present invention relates to the manufacture of pigment granules, for example iron oxide and chromium oxide pigments.
BACKGROUND
Metal oxides, such as iron oxides or chromium oxides, are used in the pigmentation of, among other things, cement and concrete products (e.g. paving slabs and blocks), paints, plastics, toners and inks, chelants, catalysts, and also in a variety of magnetic, medical, and pharmaceutical applications. Such metal oxide pigments have traditionally been used in the form of a powder.
Powdered metal oxide pigments, such as iron oxide and chromium oxide pigments, are dusty, giving rise to health hazards and making storage and handling difficult. Also, the powders are not free flowing and so cannot readily be conveyed through pipes, which readily become blocked by the powder; furthermore the poor flowing properties of powders makes it hard to meter them using auger screws to ensure the correct proportion of pigment to base material (e.g. concrete).
Similar problems are known in other industries, e.g. in the animal feedstuff industry, and such problems have been solved to a substantial extent by granulating the product. It is readily apparent that such solutions can be applied to the field of pigments to solve the above problems. For example, it has been proposed in FR-A-2 450 273 to granulate carbon black pigment used in the pigmentation of paper and cement and concrete; here it should be understood that carbon black gives rise to an even greater dusting problem than iron oxides since the granule size of carbon black powders is much smaller than that of iron oxide powders but also carbon black suffers from an additional problem of floating on the base material, which makes incorporation into the base material difficult. According to FR-A-2 450 273, the twin problems of dusting and poor incorporation are solved by mixing carbon black with at least 30% water and optionally also a wetting or dispersing agent in an amount of 0.5 to 12% and preferably 5 to 10% (based on the amount of the carbon black) and subjecting the resulting mixture to compression forces in a pearlising machine to form pearls or granules. Depending on the nature and operation of the pearlising machine, the compression forces can be substantial.
In contrast to FR-A-2 450 273, EP-B-0 268 645 requires that no compression forces are applied to pigments during the formation of pigment granules for use in colouring of concrete and cement. This may be achieved by an agglomeration technique, e.g. by means of rotating pan or drum granulising machines, which merely bring individual pigment particles into contact with each other in the presence of water and a binder (e.g. lignin sulphonate), whereupon the particles adhere to each other, i.e. they coalesce, to form the required granules. Alternatively pigment granules may be formed by spray drying a mixture of the pigment, water and a binder and commercially it is the spray drying method that is used. Both methods, however, require the presence of a considerable amount of binders to ensure that the pigment particles adhere to one another. If made by pan or drum pelletising machines, it may be necessary to dry the granules to a commercially acceptable water content below 4.2% water.
In U.S. Pat. No. 4,277,288, it has been proposed to manufacture pigment granules by forming a fluidised bed of pigment powder and adding into the bed an organic liquid or wax as a binder to promote granulation. A surfactant is also added.
U.S. Pat. No. 5,484,481 discloses a process for the granulation of pigments for use in dyeing cement and concrete involving compacting pigment powders in the presence of a binder to form flakes, breaking up the flakes and pelletising the ground flakes using known techniques, e.g. using rotating pans or drums, which would involve the application of water and a binder to the ground flakes.
However, the granulation of pigments must meet another criterion not required in other industries where pelletisation is common, e.g. the animal feed stuff industry, namely the requirement that any pigment granules must be capable of being readily dispersed in the base material to colour it uniformly since if they did not readily disperse, they would give rise to streaks or pockets of colour, which detract from the appearance of the final product. Thus granules should be able to be dispersed in the base material while at the same time should be sufficiently coherent and robust that they do not break down into powder again during storage or handling.
The manufactures of coatings (whether liquid or dry) require that pigments contain as few unnecessary additives as possible and it would therefore be desirable to be able to produce pigments with substantially reduced amounts of binders and, if possible, even to eliminate such additives.
It has generally been thought indispensable commercially to use one or more binders (other than water or other material that is or can be removed after the formation of the granule) in the manufacture of pigment granules to give the granules strength to resist being broken up into powder during handling and storage and to promote the dispersion of these granules in their end use.
It is an object of the present invention to manufacture pigment granules that both readily disperse in the base medium and also are robust and have a reduced liability to dusting, i.e. to being broken down into powder. It is a further object of the present invention to provide a process of manufacturing robust and readily dispersible pigment granules without the use of substantial quantities of binder.
DISCLOSURE OF THE INVENTION
According to the present invention, there is provided a process for the preparation of low dusting, free flowing granules of at least one pigment, said at least one pigment being selected from the group consisting of iron oxides, chromium oxides, cobalt blues, mixed metal oxides, carbon blacks, titanium oxides, or mixtures thereof, which process comprises mixing said at least one pigment with water to form a mixture having a dough-like consistency, extruding the mixture through at least one die to form extruded granules, thereby also compacting the mixture, and drying the extruded granules, so that the final water content of the granules is less than substantially 5%.
The action of forcing the material through a die during the extrusion process exerts a substantial compaction on the individual pigment particles, thereby increasing the strength of the granules.
Surfactants and/or binders may be added to the extrusion dough, although any binder used is preferably of the type that also has some surfactant properties. Examples of suitable binders/dispersants are Borresperse NA, Ultrazine NA, Pexol 2000, Dresinate 214, Dispex N40, Narlex LD31, Suparex DP CC002. Surfactants (e.g. anti-flocculants or wetting agents), such as sodium alkylbenzene sulphonates, also make suitable additives, as they can provide some incidental binding action, as well as improving the dispersion properties in the end use.
The water content of the dough mixture is critical to:
forming a stable granule
preventing the extruded granules from fusing to one another
producing discrete granules rather than just a long ribbon.
but the optimum water content can readily be determined for any pigment composition by simple trial and error.
The damp mixture is fed to a compression device whereby the mixture is forced through holes in a die, which is preferably a perforated plate or screen. This can be achieved by the action of a screw pushing the mixture through the die or by the action of a moving blade or a roller (or similar pushing device) wiped over the die and thereby compressing the mixture through the die.
Typically the extruder holes would be between 0.3 mm and 4 mn in diameter, but could be smaller or larger.
The extruded granules are dried (e.g. in a tray drier, band dryer, fluidised bed dryer etc) and may then be screened to remove fines and/or oversized granules, which latter can arise either because they are too long or because individual granules have fused together. Both the fines and the oversize can be recycled, although the latter could be mechanically reduced in size and rescreened.
The shape of the granules can be further enhanced by rounding either before or after drying, which would give them a higher impact strength (and therefore a reduced liability to form dust) and a greater ability to flow.
The granules can be obtained in very high yields (e.g. in excess of 95%) and the process can easily be operated continuously and, if appropriate, automated.
The screened dried granules are relatively free of dust and fines, which is not the case with briquetted and spray dried granules. The extruded granules are low dusting, robust and exhibit good controllable flowability and handling properties.
The extruded granules of the present invention have greater impact strength than briquetted granules when made to have similar ability to be redispersed in the end use, e.g. in concrete. Looked at another way, the extruded granules having similar redispersion properties to briquetted granules have a greater impact strength. Thus, in general the redispersion properties and impact strength of the extruded granules are superior to spray dried granules.
The quantity of binder/surfactant used can be very low and indeed it is possible to dispense with such additives altogether, which is extremely advantageous for pigments used in wet or dry coatings industries (e.g. paints), where such additives are highly disadvantageous. This is a distinct advantage over spray dried and briquetted granules, where high levels of binders and/or surfactants are required.
The shear forces exerted and the mechanical energy input for the granule formation (and hence the compaction exerted on the pigment during granule formation) can be adjusted by:
changing the extrusion hole size (the larger the diameter, the lower the shear)
changing the extrusion speed, (e.g. the speed of the wiper blade/roller or the feed screw (the slower the speed, the lower the shear).
The compaction exerted on the pigment during granule formation brought about by the shear force and mechanical energy input during extrusion will determine the granules' redispersion and strength properties and hence by suitably setting these parameters during the manufacture of the extruded granules, the properties of the granules can be adjusted to match their intended end use. For example, in uses where redistribution is not a problem, high shear forces can be used during manufacture, which will mean that the granules will have high impact strengths and a low propensity to form dust during storage and handling. However, where easy redistribution properties are required, low shear forces should be used, but this will also make the granules less strong.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be illustrated by a number of non-limiting Examples. In the Examples, the percentages stated are by weight based on the weight of the pigment used.
In the present Examples, granules were subjected to various tests which were all conducted in the same manner:
Yield Test
The granules were screened and the percentage of granules produced having a diameter in the range 0.5-2.4 mm was measured together with the percentage of oversized granules having a diameter greater than 2.4 mm.
Flow Rate Test
The time taken for 100 g of granules to flow through a funnel having a 15 mm diameter aperture from a static start was measured.
Drop Strength
A sample of granules is sieved to remove fines (which are, except when specified otherwise, <0.5 mm) and the granules were then dropped from a height of 750 mm onto a steel plate tilted at an angle of 45 degrees. The dropped sample is then sieved again and the fines (<0.5 mm) generated by the drop are expressed as a percentage of the total sample weight. Hence the lower the fines generation figure, the higher the granule/granule impact strength.
Colour Shift (Delta E)
The colour shift displayed by a concrete brick made using the granular pigment as compared to a standard brick made using the original pigment powder was measured. The target Delta E should be less than 2.
Bulk Density
The bulk density of granules is measured by taking a known volume of granules in a bottle and weighing the bottle. The weight of the bottle is subtracted and the bulk density can then be calculated expressed as g/cc.
Dispersion Test
A weighed sample of material is stirred at a fixed rate in water for a fixed time, e.g. 3 grams in 225 cc of water, stirred for 5 mins using a 50 mm straight bladed turbine laboratory mixer at 1720 rpm (tip speed 4.5 m/s). The resulting slurry is then wet sieved through a 63 micron screen and the retained residue is dried, weighed and expressed as a percentage of the initial sample weight. The lower the residue figure, the more easily the material will disperse in the end use.
EXAMPLE 1
Manufacture of extruded granules of iron oxide pigments.
A test rig was set up using a perforated plate with 4 mm holes. Pigment paste was compressed through the holes using a hand roller with the extruded granules being collected in a tray beneath the perforated plate. These extruded granules were then dried in a laboratory oven.
The pigment paste was made by placing iron oxide pigment in a 0.5 litre tub and mixing it with soda ash to adjust the pH (0.8% soda ash was used for yellow and red iron oxides and 0.4% for black iron oxide). The yellow iron oxide pigment was YB3100, the red RB2500 and the black BK5500.
Ultrazine NA (sodium lignosulphonate) was dissolved in a small quantity of water as a binder and surfactant. Some dispersant, Dispex N40 was also added to this water, which was then mixed in with the pigment. Further water was added until a malleable pigment dough was formed, which was suitable for extrusion.
Yellow Iron Oxide
Run 1—Binder 2%; Dispersant 3%; Water 33%
The paste had a tendency to produce stringy granules but generally extruded well. The granules surface was too wet and extruded strings readily re-fused back together again as a mass. The dried granules appeared extremely hard with a very shiny surface.
Run 2—Binder 0.75%; Dispersant 1.5%; Water 36%
Paste still had a tendency to produce stringy granules and the extruded granules had a wet surface with some re-fusing occurring. Dried granules were hard.
Run 3—Binder 0.25%; Dispersant 0%; Water 40%
Paste no longer produced stringy granules and the surface of the extruded granules was fairly dry. The dried granules seemed very soft.
Run 4—Binder 0.75%; Dispersant 0.5%; Water 38% Good dough, which extruded well.
Dried granules looked stable and reasonably hard. Run 4 produced the most satisfactory result. The granules dispersed easily under the water tap.
Run 5—Binder 0%; Dispersant 0.5%; Water 46%. Good dough, which extruded well.
Dried granules surface very rough and fractured. Although the granules held their shape well, they disintegrated fairly easily and were deemed too soft at the time.
Black Iron Oxide
Binder 0.75%; Dispersant 0.5%; Water 23%
Granules looked very good.
Red Iron Oxide
Binder 0.75%; Dispersant 0.5%; Water 20.5%
Paste produced granules that were slightly stringy and the paste was difficult to compress through the extruder plate. Some surface wetness was evident on the granules. The granules looked hard, but they had a satin gloss finish.
The granules from the various runs were subjected to the following tests:
Yellow Granules
Drop Test (Fines<1.18 mm)
Run 4 2.1%—(showing good impact strength)
Run 5 5.8%
Dispersion Test
Run 1 41%
Run 2 30%
Run 3 30%
Run 4 30%
Run 5 6%
Black Granules
Dispersion Test 63%
Red Granules
Dispersion Test 67%
It appears to be a relatively straightforward process to produce extruded iron oxide granules, providing the level of additives (water, dispersant and binder) are optimised. The level of additives is low compared to granulation processes.
The level of water addition appears to be critical to achieve the right dough texture for extruding and hence obtain stable granules, minimise re-fusing of the extruded granules and provide discrete short granules rather than long strings but this can be optimised by simple trial and error.
EXAMPLE 2
Tests were conducted to produce extruded granules of iron oxide pigments of 2 mm diameter using a commercial basket extruder.
2.5 kgs each of yellow, red and black iron oxide (YB3100, RB2500 & BK5500 respectively) were mixed with soda ash for pH adjustment and then with water, Ultrazine NA (sodium lignosulphonate, as a binder) and Suparex DP CCOO2 (as a dispersant) in the amounts set out in Table 1. The resulting dough was extruded using a commercially available basket extruder obtainable form, e.g. Russell Finex Ltd to produce 2 mm diameter granules. Table 1 also sets out the results of the tests conducted on those granules:
TABLE 1
Yellow
Red
Black
Water addition
29%
17%
18%
Ultrazine NA
0.75 %
1.0 %
0.75 %
Suparex
0.5%
0.5%
0.5%
Bulk density g/cc
0.83
1.20
1.04
Flow Test
4.5 sec
3.5 sec
4 sec
Drop Test:
Fines <0.5 mm
1.2%
1.3%
1.5%
Fines <0.3 mm
0.6%
0.7%
0.8%
Dispersion Test
70%
70%
65%
Colour Shift Delta E
6.36
The 2 mm extruded iron oxide granules produced on the basket extruder displayed good strength and flow properties but gave poor dispersion test results of well over the 50% level. The latter problem was illustrated by a brick made with the red granules showing a large colour shift compared to the powder control brick with the Delta E well over the expected 2 limit; red spots were also visible in the brick.
EXAMPLE 3
A series of experiments were performed to optimise extruded granules of iron oxide pigments for their end use dispersion property.
The same test rig as used in Example 1 was set up but using a perforated plate with 3 mm holes. Pigment paste was compressed through the holes using a hand roller with the extruded granules being collected in a tray beneath the perforated plate. These extruded granules were then dried in a laboratory oven.
Iron oxide powder (Yellow iron oxide YB3100; Red iron oxide RB2500; Black iron oxide BK5500) were mixed with soda ash to adjust pH.
Water and the following dispersants and wetting agents were used to form the extrusion dough in amounts set out in Table 2:
Dispersants
Dispex N40 (Dis)
Suparex DP CCOO2 (Sup)
Narlex LD3 1 (Nar)
Wetting Agents
Ethylan BCP (Et1)
Surfinol 104-S (Sur)
Arylan SY30 (Ary)
Ethylan BCD 42 (Et2)
Lankropol K02 (Lan)
The granules were subjected to drop tests and dispersion tests and the results are given in Table 2, 3 and 4:
TABLE 2
YELLOW
Drop Test
Dispersion
Additives
Water
<1.18 mm
<0.3 mm
>0.63 mm
Nil
42%
7.8%
2.1%
18%
Dis 0.5%
39%
6.3%
1.6%
20%
Dis 0.75%
39%
5.3%
1.4%
24%
Dis 1%
36%
3.2%
0.8%
18%
Dis 1%
37%
3.8%
0.9%
18%
Dis 1.25%
37%
3.0%
0.8%
26%
Dis 1.5%
35%
1.5%
0.4%
47%
Nar 0.8%
39%
4.1%
1.1%
32%
Nar 1.25%
37%
2.8%
0.7%
45%
Sup 0.25%
41%
6.4%
1.6%
26%
Sup 0.5%
41%
4.0%
1.1%
21%
Sup 0.75%
39%
4.9%
1.2%
33%
Sup 1%
38%
4.8%
1.1%
37%
Sup 0.5% + Etl 0.025%
40%
6.3%
1.5%
30%
Sup 0.5% + Sur 0.025%
40%
4.3%
1.2%
20%
Sup 0.5% + Ary 0.025%
41%
3.9%
1.0%
11%
Sup 0.5% + Et2 0.025%
41%
3.4%
0.8%
16%
Sup 0.5% + Lan 0.025%
41%
4.9%
1.0%
17%
Ary 0.025%
43%
3.4%
0.8%
6%
TABLE 3
RED
Drop Test
Dispersion
Additives
Water
<1.18 mm
<0.3 mm
>0.63 mm
Nil
21%
10.6%
3.1%
40%
Nar 0.8%
19%
7.3%
1.9%
55%
Sup 0.5%
20%
6.3%
1.7%
42%
Sup 0.5% + Sur 0.025%
20%
7.7%
2.3%
41%
Sup 0.5% + Ary 0.025%
21%
5.3%
1.6%
40%
Sup 0.5% + Et2 0.025%
21%
5.2%
1.6%
47%
Sup 0.5% + Lan 0.025%
21%
5.3%
1.6%
48%
Ary 0.025%
21%
8.4%
2.4%
37%
TABLE 4
BLACK
Drop Test
Dispersion
Additives
Water
<1.18 mm
<0.3 mm
>0.63 mm
Nil
23%
5.8%
1.8%
48%
Nar 0.8%
21%
4.2%
1.2%
53%
Sup 0.5%
21%
3.8%
1.1%
49%
Sup 0.5% + Sur 0.025%
22%
4.4%
1.4%
37%
Sup 0.5% + Ary 0.025%
22%
5.3%
1.6%
35%
Sup 0.5% + Ary 0.025%
22%
3.2%
1.0%
32%
Sup 0.5% + Ary 0.075%
21%
5.5%
1.6%
44%
Sup 0.5% + Et2 0.025%
22%
3.0%
1.0%
42%
Sup 0.5% + Lan 0.025%
22%
4.1%
1.3%
50%
Ary 0.025%
23%
6.8%
2.1%
31%
Ary 0.250%
23%
6.0%
1.8%
42%
Yellow
The yellow granules show an increase in strength and less favourable dispersion as the dispersant addition increases. However at 1% for Dispex and 0.5% for Suparex, the dispersion property improves close to the virgin granule dispersion, but the granule strength is greater. A small addition of wetting agent can improve the dispersion further as with 0.5% Suparex plus 250 ppm Lankropol K02, Ethylan BCD 42 or Arylan SY30, the latter giving the best result;
250 ppm addition of Arylan SY30 alone was found to give the best all-round result for a 3 mm granule with good granule strength and very good redispersion.
Red
Less improvement achieved on the higher virgin dispersion result, although 0.5% Suparex plus 250 ppm Arylan SY30 produced the same dispersion with a stronger granule. 250 ppm Arylan SY30 alone provided some redispersion improvement, but at the cost of some granule strength.
Black 0.5% Suparex plus 250 ppm Arylan SY30 gave a definite improvement in redispersion with some improvement in granule strength, but increasing this Arylan level from 250 ppm to 750 ppm produced a less favourable dispersion result. There appears to be a definite optimum to the wetting agent addition level. Similarly 250 ppm Arylan alone gave a much improved dispersion result, which deteriorated at the 2500 ppm level.
EXAMPLE 4
Extruded granules of iron oxide pigments of 2 mm diameter were made using a commercial basket extruder and utilizing wetting agents to improve granule dispersion.
The same basket extruder was used as in Example 2.
2.5 kgs of yellow or 3.5 kgs of red or black iron oxide (YB3100, RB2500 & BK5500 respectively) were pre-mixed with soda ash for pH adjustment in a sigma blade mixer and water plus additives applied to give a compressible mixture suitable as a feed to the basket extruder. The extruded granules were dried in a fluidized bed dryer and bagged up for later analysis. The dispersant used was Suparex DP CCOO2 and the wetting agent was Arylan SY30. A second wetting agent Arylan 5BC25 was also examined on red and black granules. The results are given in Table 5:
TABLE 5
Drop Test
Dispersion
Flow Test
B.D.
Additives
Water
<0.3 mm
<0.63 mm
Sec
g/cc
YELLOW
0.5% Sup +
29%
0.8%
61%
3-3.5
0.84
0.025% ArSY30
0.5% Sup +
31%
0.4%
59%
3.5-4
0.92
0.025% ArSY30
0.025% Arylan
29%
0.5%
29%
4
0.91
SY30
RED
0.5% Sup +
18%
1.0%
61%
−3 sec
1.25
0.025% ArSY30
0.025% Arylan
18%
1.0%
50%
3 sec
1.27
SY30
0.025%
18%
2.2%
59%
+3 sec
1.22
ArylanSBC2S
BLACK
0.5% Sup +
20%
0.8%
48%
3.5 sec
1.27
0.025% ArSY30
0.025% Arylan
21%
0.5%
40%
3.5 sec
1.31
SY30
0.025%
20%
0.5%
45%
3 sec
1.30
ArylanSBC2S
Brick Delta E on the 0.025%
Arylan SY30 samples
Yellow
1.34
Red
1.29
Black
1.63
The 2 mm extruded iron oxide granules produced on the basket extruder using 250 ppm Arylan SY30 wetting agent displayed good strength and flow properties and showed a good improvement in their dispersion test results. This improvement was reflected in the brick colours which all exhibited a Delta E of less than 2 when compared to a powder control brick.
The basket extruder with 2 mm holes had exerted more shear on the material than the hand test rig with 3 mm holes (Example 3). Hence for the same additives and additive levels there had been a decrease in the dispersion property and an increase in the granule strength.
EXAMPLE 5
Various alternative wetting agents were investigated in laboratory-produced 3 mm extruded iron oxide granules with regard to end use dispersion.
The same test rig as in Example 3 was used having a perforated plate with 3 mm holes. Pigment paste was compressed through the holes using a hand roller with the extruded granules being collected in a tray beneath the perforated plate. The extruded granules were then dried in a laboratory oven.
Red or black iron oxide (RB2500 & BK5500 respectively) were mixed with soda ash for pH adjustment and water and wetting agents (in amounts set out in Table 6) applied to give a compressible mixture:
The wetting agents tried were:
Monolan PC
Ethylan GEO8
Ethylan CPG66O
Arylan SBC2S
Arylan SY30/Monolan PC mix (MaR)
The granules were tested for drop strength and dispersion and the results set out in Table 6:
TABLE 6
Drop Test
Dispersion
Additives
Water
<1.18 mm
<0.3 mm
>0.63 mm
BLACK
0.025% Monolan PC
24%
8.2%
2.9%
30%
0.1% Monolan PC
22%
6.6%
2.4%
45%
0.025% Ethylan GEO8
24%
9.2%
3.1%
36%
0.1% Ethylan GEO8
23%
5.6%
2.0%
51%
0.025% Ethylan
24%
5.7%
2.0%
37%
CPG66O
0.1% Ethylan CPG66O
5.2%
2.0%
44%
0.025% Arylan SBC2S
24%
6.6%
2.4%
35%
0.1% Arylan SBC2S
23%
6.0%
2.2%
58%
0.025% & 0.025% MaR
23%
5.2%
1.9%
34%
0.01% & 0.01% MaR
24%
5.5%
1.7%
33%
NIL
23%
5.8%
1.8%
48%
0.025% Arylan SY30
23%
6.8%
2.1%
31%
RED
0.025% Monolan PC
25%
11.9%
3.4%
34%
0.01% & 0.01% MaR
23%
12.7%
3.8%
35%
NIL
21%
10.6%
3.1%
40%
0.025% Arylan SY30
21%
8.4%
2.4%
37%)
Monolan PC (a glycerol based ethylene oxide—propylene oxide co-polymer) at 250 ppm provided a similar dispersion performance in black iron oxide extruded granules as Arylan SY30 (a sodium alkylbenzene sulphonate). At 1000 ppm the dispersion performance was less favourable.
The Monolan PC provided some improvement in the red iron oxide extruded granules compared to Arylan SY30, but at the expense of some granule strength.
Monolan PC is a non-ionic surfactant whilst Arylan SY30 is anionic.
EXAMPLE 6
Drop tests and dispersion tests were conducted to compare extruded granules of iron oxide pigments made by the present invention with commercially available spray-dried and briquetted granule products. The bulk density of the granules was also measured.
SD=spray dried granules
BR=briquetted granules
EG=extruded granules
Yellow Iron Oxide
Bulk
Granule
Dispersion
Drop fines
density
Type
residue
<0.3 mm
g/cc
Silo 49
SD
74%
6.3%
0.88
Bayer 920G
SD
33%
5.4%
0.62
Bayer 920C
BR
16%
2.9%
0.79
4 mm granules with 0.75%
EG
30%
UltrazNA + 0.5% DispX
4 mm granules with
EG
6%
0.5% DispX
3 mm granules with
EG
18%
2.1%
no additives
3 mm granules with 0.5%
EG
11%
1.0%
SupX + 250 ppm
ArylanSY3O
3 mm granules with 250 ppm
EG
6%
0.8%
ArylanSY3O
2 mm granules with 0.5%
EG
60%
0.6%
0.88
SupX + 250 ppm
ArylanSY3O
2 mm granules with 250 ppm
EG
29%
0.5%
0.91
ArylanSY3O
Red Iron Oxide
Bulk
Granule
Dispersion
Drop fines
density
Type
residue
<0.3 mm
g/cc
Silo 212
SD
53%-
7.1%
1.22
frothy
Bayer 110G
SD
87%
Bayer 130C
BR
31%-
v.frothy
Bayer 130C
BR
37%-
v.frothy
Bayer 110C
BR
38%-
2.7%
1.16
v.frothy
3 mm granules with no
EG
40%
3.1%
additives
3 mm granules with 0.5%
EG
40%
1.6%
SupX + 250 ppm
ArylanSY3O
3 mm granules with 250 ppm
EG
37%
2.4%
ArylanSY3O
3mm granules with 250 ppm
EG
34%
3.4%
Monolan PC
2 mm granules with 0.5%
EG
61%
1.0%
1.25
SupX + 250 ppm
Arylan SY3O
2 mm granules with 250 ppm
EG
50%
1.0%
1.27
Arylan SY3O
Black Iron Oxide
Bulk
Granule
Dispersion
Drop fines
density
Type
residue
<0.3 mm
g/cc
Silo 77
SD
91%
14.4%
1.20
Bayer 33OG
SD
72%
Bayer 33OC
BR
34%-
6.3%
1.23
v.frothy
3 mm granules with no
EG
48%
1.8%
additives
3 mm granules with 0.5%
EG
33%
1.3%
SupX + 250 ppm
Arylan SY3O
3 mm granules with 250 ppm
EG
31%
2.1%
Arylan SY3O
3mm granules with 250 ppm
EG
30%
2.9%
Monolan PC
2 mm granules with 0.5%
EG
48%
0.8%
1.27
SupX + 250 ppm
Arylan SY3O
2 mm granules with 250 ppm
EG
40%
0.5%
1.31
Arylan SY3O
Although throughout the description and in the specific examples only iron oxide and chromium oxide pigments are mentioned, the invention nevertheless encompasses the use of other pigments such as cobalt blues, mixed metal oxides, carbon blacks, and titanium oxides.
Furthermore, while specific examples refer to binders and/or surfactants with the active agent as described, other binders and surfactants may also be anticipated within the scope of the invention; put more generally, the invention encompasses the use of binders and/or surfactants comprising at least one material selected from the group consisting of stearates, acetates, alkyphenols, cellulosics, lignins, acrylics, epoxies, urethanes, sulphates, phosphates, formaldehyde condensates, silicates, silanes, siloxanes, and titanates.
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The present invention provides a method for the preparation of pigment granules that are readily dispersible, robust, and have a reduced liability to dusting, preferably without the use of substantial quantities of binder, if any at all. The method comprises mixing at least one pigment selected from the group consisting of iron oxides, chromium oxides, cobalt blues, mixed metal oxides, carbon blacks and titanium oxides, with water to form a mixture having a dough-like consistency. The mixture is then extruded through at least one die to form extruded granules, thereby also compacting the mixture, which increases the strength of the granules. The extruded granules are then dried so that the final water content of the granules is less than substantially 5%.
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RELATED APPLICATION
The present invention claims priority of India Patent Application No. 1060/Del/2004, filed Jun. 8, 2004, which is incorporated herein in its entirety by this reference.
FIELD OF THE INVENTION
The present invention relates to an input buffer in the field of integrated circuits. Specifically, the invention pertains to a high-voltage tolerant input buffer circuit.
BACKGROUND OF THE INVENTION
With the advent of sub-micron technology, the device dimensions are decreased so as to be suitable in low cost and low power applications. Also, circuit designing for standard protocols has become more challenging. Sub-micron technology devices cannot tolerate high-voltage because of reliability issues. The gate-oxide breakdown voltage and/or the punch-through between source and drain typically define the voltage of a particular technology. To meet the standard protocols' electrical specifications, interface circuits must work at high voltages (e.g. 5V, 3.3 V etc) with high reliability. One notable problem in interfacing low-voltage circuitry with high-voltage circuitry is that if the voltage applied to the low-voltage circuitry gets too high, some devices may experience temporary or even permanent damage. The gate-oxide stress causes threshold voltage to fluctuate because of tunneling effect—moreover, device lifetime deteriorate.
At the process level, the high-voltage tolerant transistors can be fabricated by increasing gate oxide and an extended drain scheme. These devices increase the fabrication cost because of extra masks required to make device level tune in the same CMOS baseline process. Another disadvantage is performance degradation.
FIG. 1 shows a schematic diagram of a conventional input buffer 100 with an input IN and output OUT, for 3.3 volt devices. VDDS=3.3 volt.
FIG. 2 is a schematic diagram of a 5V tolerant input buffer operating at 3.3V nominal voltage. VDDS=3.3 volt. All the devices are in 3.3V technology. IN is connected to the drain of MOSFET M 1 , which translates the input signal to a lower voltage at node 1 for safe operation of the buffer 200 . When IN goes as high as 5V, node is clamped to (VDDS−V t ), so all the devices are safe. Because the substrate bias effect V t of transistor M 1 is high, node 1 voltage is comparatively low. This may cause M 2 to be in weak inversion or in strong sub-threshold region. So, the conventional input buffer 200 will consume DC power, which is more serious in 0.13 μm technology because V t is less, when signal on pad is high. Moreover, this structure cannot be used when device is of 2.5V and is operating at 3.3V.
FIG. 3 is another schematic of 5V tolerant input buffer 300 in 3.3V technology. VDDS=3.3 volt. MOSFET 2 and an NMOS are used to clamp high voltage at the input. To avoid turn ON of M 2 (because of difference {VDDS−V 2 }>|VtM 2 |), a weak pull-up structure consisting of two series transistors 4 (PMOS) and 5 (NMOS) has been used. It will pull the node 120 to VDDS level provided node 110 is at (VDDS+Vt 5 ). It happens only when IN starts rising above VDDS. When IN reaches VDDS+|Vt 1 |, transistor 1 turns on and node 110 is charged to a voltage equal to IN. When IN rises to 5V, node 110 also gets charged to 5V. Transistor 3 remains OFF because the gate and source voltages are at the same level. Transistor 5 turns-on strongly and node 120 is pulled to VDDS (3.3V nominal). When the voltage at IN reaches ground level, node 110 discharges to (VDDS+|Vt 1 |) volt only through transistor 1 . Transistor 3 pulls node 110 to |Vt 3 | level so that transistor 5 (NMOS) is OFF.
The circuit in FIG. 3 cannot be used for 2.5V devices operating at 3.3V because the gates of 1 and 2 cannot be connected to VDDS (3.3 Volt) directly. Moreover, 5V cannot be directly applied to the gate of 2.5V devices because the gate-bulk voltage (Vgb) for NMOS ( 5 ) is significant (5.0V) to deteriorate the oxide.
The circuit in FIG. 4 is another 5V tolerant input buffer structure using 2.5V devices designed for 2.5V operation. VDDS=2.5 volt. This structure is able to tolerate input signal of 5V while operating safely. In normal mode LPN is connected to ground. Transistors M 1 and M 4 form a source follower structure where M 4 acts as a resistor. Node 1 never exceeds VDDS level. M 9 has been added to speed-up the buffer when IN makes transition from high to low, because the size of transistor M 4 is less (to reduce the dc power consumption in normal mode). Transistors M 6 and M 7 have been used to provide buffering at the output. This structure also works perfectly without stressing any device. But the buffer cannot be used for low power and 3.3 Volt operations. In normal mode it consumes dc current and an extra mode control signal is required.
U.S. Pat. Nos. 5,952,848 and 6,236,236 are referred to for additional reference.
Since for standard protocols, the voltage levels (usually 3.3V and 5V) are fixed, an input buffer is required which can tolerate signal of 5V at the receiver input and can be implemented with low-voltage technology.
It is therefore desirable to have an input buffer circuit, which is capable of receiving a high voltage without experiencing degradation of gate oxide lifetime. It would further be desirable if such input buffer does not increase the process complexity and is implemented in the recent technology while working at higher supply voltage (e.g. 3.3 volt nominal).
SUMMARY OF THE INVENTION
According to an embodiment of the present invention, structures and methods for a low-power input buffer enables low-voltage circuitry to be interfaced and operated with relatively high-voltage circuitry while minimizing the voltage across the gate oxide of transistors used in the input buffer. According to an embodiment of the present invention a stress-free circuit is achieved with fewer number of transistors while at the same time achieving large hysteresis (for better noise immunity) and providing high speed and low power. Device reliability is also improved.
An embodiment of the present invention provides a high-voltage tolerant input buffer circuit which includes a first NMOS transistor having its source terminal connected to the input pin, its gate terminal connected to a first reference voltage and its drain terminal connected to a first output terminal; a second NMOS transistor having its gate terminal connected to the first reference voltage and its source terminal connected to the first output terminal, a first PMOS transistor having its gate terminal connected to the drain terminal of the second NMOS transistor, its drain terminal connected to a second reference voltage which is lower than the first reference voltage and its source terminal connected to a second output terminal; a second PMOS transistor having its drain terminal connected to the drain terminal of the second NMOS transistor, its source terminal connected to the second output terminal; and its gate terminal connected to a control voltage, and a third PMOS transistor having its drain terminal connected to the second output terminal, its source terminal connected to a supply voltage, and its gate terminal connected to the control voltage.
The first output terminal is connected to the gate terminal of the lowermost NMOS transistor while said second output terminal is connected to the gate terminal of the topmost PMOS transistor and the control terminal is connected to the output of a complementary cascode structure which includes a plurality of transistors connected in series to provide feedback in order to improve speed of response.
A second complementary cascode structure having its input terminals connected in parallel with the input terminals of the first complementary cascode structure provides the output signal at a reduced voltage level, to the internal circuit.
The PMOS and NMOS transistors are small-sized transistors to speed up transition and reduce power dissipation.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned and other features and objects of the present invention and the manner of attaining them will become more apparent and the invention itself will be best understood by reference to the following description of a preferred embodiment taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of a conventional input buffer;
FIG. 2 is a schematic diagram of a conventional 5V tolerant input buffer;
FIGS. 3–4 are schematic diagrams of similar 5V tolerant input buffer;
FIGS. 5–7 are schematic diagrams of 5V tolerant input buffer with low-voltage device according to the present invention (VDDS=3.3 volt);
FIG. 8 shows internal node waveforms for low to high transition at IN;
FIG. 9 shows internal node waveforms for high to low transition at IN;
FIG. 10 shows delay plot for Schmitt-buffer at nominal case; and
FIG. 11 shows max frequency of operation vs load plot.
DETAILED DESCRIPTION
Two reference signals—one to protect PMOS and the other to protect NMOS—are used to avoid gate-oxide stress and V ds stress for oxide degradation and hot carrier effect respectively. Reference signals are necessary to be incorporated in the high-voltage designs with very short channel devices. So a single reference block can be used for the whole IO ring in the chip. Reference signals are shared among different IOs in the ring. For the sake of clear understanding of the new circuit, reference block has not been described.
In one embodiment ( FIG. 6 ), the input buffer circuit includes an n-channel field effect transistor and a feedback circuitry to provide a safe voltage range for the input inverter. This feedback circuitry structure includes series transistors and two-reference signal and is responsive to the voltage applied at the output node. It is also responsible for pulling-up the voltage at the gate of p-channel MOS transistor in the input inverter for low power consumption and to provide a high impedance input. This circuit does not consume dc current under steady state.
In another embodiment ( FIG. 5 ), the input buffer circuit includes a cascoded inverter. The cascading transistors are connected to the reference signals to avoid gate-oxide and junction stress while the inverter input is connected to the safe node, which receives the high-voltage pad signals after level translation. This structure speeds-up the circuit performance in terms of speed and hence reduces short-circuit current during transition.
The invention also includes the cascoded structure for the input inverter, which is similar to the second embodiment. The output of this inverter is fed to the low-voltage level-translator to provide a core level output signal.
The present invention is not dependent on the body effect of the field effect transistors. So it is not very sensitive to the process variations. Since very stable reference voltages have been used, a high-voltage supply can be input (max of 5 volt) and tolerated.
The input buffer of the present invention is particularly suitable to provide a level-shifted output voltage in response to a high-voltage input signal while working at a little higher voltage (3.3+/−10% in the present invention) while using the advantage of low-voltage technology (2.5 volt in the present invention).
A Schmitt version of the input buffer is also presented to receive a TTL level signal and translate it to the CMOS level signal. A 400 mV of hysteresis has been achieved in the worst case with a small modification in the main input buffer. Silicon result is also given for the hysteresis value.
In this invention such an input buffer in 2.5V technology has been presented and described in detail below:
A schematic diagram for new circuit is shown below in FIGS. 5–6 . FIG. 6 is an Schmitt version of new input buffer. It has been divided into three parts. Input block 3 is a normal Schmitt buffer with a level-shifter at the output, which converts 3.3-volt signal to the core level (1.2 V nominal) CMOS signal. Since an input buffer is normally used to drive core logic in the chip, level-shifter has been added to make it complete. Block 2 has been added to increase the speed of the Schmitt buffer (different threshold point for high and low transition of Schmitt buffer for input signal inherently makes it slow). Block 1 is responsible for the protection of input transistors in block 3 by level-shifting the input signal (which are propagated from pad).
Input buffer 3 consists of two parts, input inverter and a VDDS (nominal 3.3 volt) to VDD (core level with nominal voltage 1.2 volt) level-shifter. All the transistors are 2.5-volt capable in 0.13 μm technology except transistors 26 , 27 and inverter 30 which are 1.2-volt capable in 0.13 μm technology. Input inverter has two PMOS transistors 15 and 16 in series and two NMOS transistors 17 and 18 in series. Input inverter output E will swing from 0 to 3.3 volt (up to 3.6 volt in worst case) because it is directly connected to 3.3-volt power supply.
Inverter formed by transistors 24 and 25 also provides buffering to the signal at E. E and F are complementary signals of same level (3.3 volt) and are inputs of level-shifter. E is connected to the gate of NMOS 29 through pass-gate 5 and F to the gate of NMOS 28 through pass-gate 4 . The two complementary outputs of level-shifter are pull-down by NMOSs 28 and 29 . Only one of these outputs G has been used to drive the output inverter 30 to provide final CMOS level output. Transistors 4 and 5 have been used to level-translate the signal at F and E respectively so that signal levels at the gate of transistors 28 and 29 are 0−(VDDS−Vt|4|). Transistors 26 and 27 are 1.2-volt 0.13 um PMOS. This structure is faster than the two-inverter structure (First inverter of 3.3 V and second inverter of 1.2 V in 0.13 um) used for level shifting. Since low-voltage transistors 26 and 27 are faster (because of smaller channel length) than 28 and 29 , they can be made smaller. Again transistors size ratio of PMOS ( 15 or 16 ) to NMOS ( 17 or 18 ) will decide the input inverter's threshold point and hence the V il or V ih level. Size of transistors 23 and 18 is tuned to achieve V ih level for worst case (2.0 worst TTL level). V il level is set by the input inverters pull-up and pull-down ratio. An extra NMOS can also be used as feedback between nodes F and E (like PMOS transistor 23 ) to set V il level if necessary.
The gate of PMOS 16 is connected to VL reference signal and gate of NMOS 17 is connected to the VH reference signal. The typical value for VH and VL is 2.5 V and 0.7 V. When pull-down (NMOS structure of 17 and 18 ) is off and pull-up (PMOS structure of 15 and 16 ) is on, E will be at 3.3 volt for typical case. Because of cascading of 17 and 18 , V ds , (drain to source voltage) of these two transistors will be less than 2.5 volt and V dg (drain to gate voltage) of 17 is approximately 0.8 volt. In worst case it will be 1.1 volt when VDDS is 3.6 volt. When pull-down is on and pull-up is off, E is at 0 volt. Again transistors 15 and 16 are free from V ds stress. Gate to drain voltage of 16 is only 0.7 volt. In any case Vgb (gate to bulk voltage) of 16 and 17 are 2.6 volt and 2.5 volt respectively.
In fact, reference voltages VL and VH are dependent on supply voltage VDDS but the variation is small and it helps in making the junction and the gate-bulk voltages almost constant. For example, when VL is 0.7 volt for nominal case (3.3 volt), Vgb voltage for transistor 16 is 2.6 volt. When VDDS goes to 3.6 volt, VL increases to 0.8 volt to make Vgb 2.8 volt, which is acceptable for 2.5-volt device. Gate voltages of 15 and 18 are also limited by block 1 so that these devices are also safe from any kind of stress. For the sake of clarity, blocks 1 and 2 have been shown again in FIG. 7 .
Block 1 has been added to level-translate the input signal. NMOS 10 is directly connected to the input with gate connected to VH (2.5 volt nominal). Level-translated signal A is the input of the block 2 and block 3 (Schmitt buffer). Max value for logic high at A will be (VH−vt 10 ) which is less than VH so transistors 22 and 18 are also safe from stress. NMOS 11 is connected between nodes A and B with gate connection to VH. 11 will pass signal at A to B without level-translation. When logic high value at IN is 5.0 volts, V dg (drain to gate voltage) for 10 is approximately 2.5 volts and device 10 is not stressed. 10 and 11 will pass logic low (0 volt). When input IN is at logic high (3.0 to 5.0 volt, in case of TTL input worst value may be 2.0 volt), A and B will have values VH−vt 10 . It may be 2.0 volt if VH−vt 10 is greater than 2.0 volt. PMOS 12 will turn-off immediately because node C is at VL when IN was at logic low. When node A and B rises to VH−vt 10 , NMOSs 22 and 18 turn on, pulling node D and E towards zero. PMOSs 19 and 15 are still ON because transistors 14 and 13 are OFF and C is at VL. As soon as D drops below (VDDS−|vt 13 |), 13 turns on and starts charging node C rapidly which turns-off PMOSs 19 and 15 which further increases the speed of pulling-down of node D and E (block 2 ). Transistors 19 , 20 , 21 and 22 are small sized transistors, which have been added to speed-up the transition. Since node E is being pulled-up by PMOS 23 (in block 3 ), it takes long time to go to logic low as compared to that at node D. So addition of these four small size transistors have made the turn-off of PMOSs 19 and 15 very fast and hence reduced the crowbar current during transition because of short transition period to make circuit efficient for power and speed. Transistor 14 is required to turn-off transistor 12 to stop steady current from VDDS to VL because 12 will turn-on when C will rise to VDDS. As soon as D falls below VDDS−|vt 13 |, C starts rising and when difference [V(C)−V (D)] crosses |vt 14 |, also turns-on and starts charging node B to VDDS. So device 14 will not let transistor 12 turn-on. Transistor 11 will not pass VDDS at B to A because NMOS 11 gate is connected to VH. This will not let the devices 22 and 18 to get stressed. The transition of these nodes has been shown in FIG. 8 .
FIG. 8 shows internal node waveforms for low to high transition at IN. All the important internal nodes waveforms have been shown. Point C represents the point after which transition is very fast because of block 2 . It is clear that node D makes transition much faster than node E. It is also clear that when A has made transition to VH−vt 10 , node C and hence node B makes full transition. If feedback point was E instead of D, it would have taken long time for the node E to make transition.
In the second case when the input makes transition from high to low, A and B will be low and NMOSs 22 and 18 will turn off immediately. Transistor 12 will start discharging node C. Since PMOS 14 is on initially, node C will be discharged through PMOS 14 also. As soon as C drops below VDDS−|vt 19 |, transistors 19 and 15 turns ON and node D gets charged to VDDS rapidly. This fast charging stops current from VDDS to VL by turning 13 OFF. Transistors 14 will also turn-off and node C will discharge only to VL. If somehow node C goes up or down to VL, it will be discharged or charged to VL again by 12 because gate of 12 is at logic low (0 volt). So the steady state value of C is VL and it will not cause stress to transistors 19 and 15 . The internal nodes waveform has been shown in FIG. 9 for this case.
FIG. 9 shows internal node waveforms for high to low transition at IN. It is clear that transition of node E starts at point C. Block 1 introduces a small delay for high to low transition. This is the penalty, which will have to be paid for a stress free device operation higher voltage. After point C NMOS 22 turns-off and nodes A and B starts falling rapidly at the same time. Initially C starts falling fast because of two paths one through 14 and other through 12 . When 14 turns off node C discharges through 12 . Since transistor 12 is small (intentionally made) it delays the charging of node D and E. This is not a limitation of the design. If reference block has the capability to sink large current, then 12 can be made larger in size and speed can be improved further.
In this way block 1 protects the input transistors and along with block 2 it makes transition fast and reduces the crowbar current during transition.
Simulation Results:
Simulation results for the 5-volt tolerant Schmitt buffer in 0.13 um, 2.5 V CMOS process are provided below.
For performance, delay plot for the Schmitt buffer is shown in the FIG. 10 . Data has been obtained for the nominal case and 3.3 V over temp range −40 to 125 degrees Celsius for 32× (32 times of the cap of 1× drive inverter) load.
In FIG. 11 maximum frequency of operation of Schmitt buffer has been plotted against load. Input clock has been assumed to have rise and fall time (measured from 0% to 100% of supply) as 20% of the total period and on/off period as 30% of the total period. This characteristic of clock is good enough to emulate the real data signal for maximum number of transitions for a given frequency. For the output to be considered as real waveform, it has been assumed that output must reach at-least 90% of VDDS for logic high and must be below 10% of VDDS for logic low.
FIG. 10 shows a delay plot for Schmitt-buffer at nominal case.
FIG. 11 shows maximum frequency of operation vs load plot. The Y-axis is maximum frequency in MHz and X-axis is load in pf.
Hysteresis Data Results from Silicon:
TABLE 1
Hysteresis data for the Schmitt
LOT NO
VIL
VIH
VHYST
1
1.084
1.516
0.432
2
1.05
1.47
0.42
3
1.089
1.526
0.437
4
1.083
1.518
0.435
5
1.06
1.46
0.40
6
1.097
1.523
0.432
The data given above in the table is for ambient temperature and 3.3 volt. The worst values obtained for VIL and VIH are 0.903 V and 1.693 V respectively (not shown in the table). So it is clear that even for different lots, VIL and VIH values are according to the TTL specification with enough margins.
While there have been described above the principles of the present invention in conjunction with specific components, circuitry and bias techniques, it is to be clearly understood that the foregoing description is made only by way of example and not as a limitation to the scope of the invention. Particularly, it is recognized that the teachings of the foregoing disclosure will suggest other modifications to those persons skilled in the relevant art. Such modifications may involve other features which are already known per se and which may be used instead of or in addition to features already described herein. Although claims have been formulated in this application to particular combinations of features, it should be understood that the scope of the disclosure herein also includes any novel feature or any novel combination of features disclosed either explicitly or implicitly or any generalization or modification thereof which would be apparent to persons skilled in the relevant art, whether or not such relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as confronted by the present invention. The applicants hereby reserve the right to formulate new claims to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.
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The present invention provides a high-voltage tolerant input buffer circuit including a first NMOS transistor having its source terminal connected to the input pin, its gate terminal connected to a first reference voltage and its drain terminal connected to a first output terminal; a second NMOS transistor having its gate terminal connected to said first reference voltage and its source terminal connected to said first output terminal; a first PMOS transistor having its gate terminal connected to the drain terminal of said second NMOS transistor, its drain terminal connected to a second reference voltage lower than said first reference voltage and its source terminal connected to a second output terminal; a second PMOS transistor having its drain terminal connected to the drain terminal of said second NMOS transistor, its source terminal connected to said second output terminal, and its gate terminal connected to a control voltage; and a third PMOS transistor having its drain terminal connected to said second output terminal, its source terminal connected to a supply voltage, and its gate terminal connected to said control voltage.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Continuation-In-Part utility patent application claims priority benefit of and incorporates by reference the full and complete disclosure of the pending Nonprovisional Patent application Ser. No. 14/314,944, filed Jun. 25, 2014 which further having a priority date from Provisional Patent Application No. 61839357, originally filed on Jun. 25, 2013.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER LISTING APPENDIX
[0003] Not applicable.
COPYRIGHT NOTICE
[0004] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark office, patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
Field of the Invention
[0005] A neuro-muscular rehabilitation device for muscle tone development and improvement of neuro-muscular coordination of quadruped animals, specifically canines and equines.
Background
[0006] In the field of veterinary science, information on the topic of neuro-muscular development of equines at the cellular level is limited. Pierre A. Guertin, Central Pattern Generator for Locomotion: Anatomical, Physiological, and Pathophysiological Considerations, Front. Neurol., 3: 183 (2012). Much of the published information on the topic of muscular tone development and rehabilitation for equines focus on post-injury rehabilitation by way of physical therapy techniques, taking the approach of treating symptoms. A greater body of science relating to neuro-muscular function and development exists in the field of cellular biology and neuro-physiology. In these areas of study, a fundamental approach is taken with thorough comparative observations of neurophysiology among different species (human and cat) for causal understanding of muscular tone development. It would be in this area of study that greater insight can be gained over the cellular cause of poor postural symptoms observed among equines.
[0007] The Australian Journal of Physiotherapy published a very poignant article in 1983 entitled “The Neurophysiology of Tone: The Role of the Muscle Spindle and the Stretch Reflex” by Helen Cameron-Tucker regarding the cellular composition and development of muscle fiber in relation to external demands and intermuscular stimuli affecting muscle tone and function. Cameron-Tucker, Helen, The Neurophysiology of Tone: The Role of the Muscle Spindle and the Stretch Reflex, The Australian Journal of Physiotherapy, Vol. 29, No. 5, October 1983. This publication summarized the most current valid science of that time, which remains fundamental science today.
[0008] According to Cameron-Tucker and cited prior studies, muscular fibers comprise extended spindle features and core neurone features. The ends of each muscle spindle having neuro-synaptic sensitivity directly communicating with spinal grey matter and is individually sensitive as well as responsive to external stimuli. External stimuli in this context includes stimuli caused by intermuscular activity and usage, measured by locational quantity, quality and frequency of usage or demand. According to Cameron-Tucker in her discussion, the generation of muscle fiber tissue at an individual cellular level is in response to external stimulus and demand. Muscle spindle, having myogenetic capability (regenerating capability) is therefore dynamic and may adapt to new environmental demands as well as frequency of use by creating new muscle to suit external demand with either greater or lower ATP power. ATP power being positioned centrally within the muscle spindle. Muscle spindle positioning in fact, according to Eldred (1965) “is usually near an intramuscular nerve and artery . . . [t]his ‘in parallel’ arrangement means that the muscle spindle will be stretched at a similar rate and to a similar degree as the extrafusal fibers.” Cameron-Tucker, Helen, The Neurophysiology of Tone: The Role of the Muscle Spindle and the Stretch Reflex, The Australian Journal of Physiotherapy, Vol. 29, No. 5, p. 156, October 1983; Eldred, E., The dual sensory role of muscle spindles, Journal of the Americal Physical therapy Association, 45, 290-313 (1965). The strategic positioning of myogenic cells enables it to be sensitive to the realities of movement and external demand for timely muscle response, growth and tone development. Brodal (1962) “noted that muscle spindles are located in all the muscles of locomotion . . . muscles used in delicate movement such as the muscles of the hand have a greater density of muscle spindles than do muscles of the trunk . . . the muscle spindles of any of these muscles have a similar structure . . . ” Cameron-Tucker, Helen, The Neurophysiology of Tone: The Role of the Muscle Spindle and the Stretch Reflex, The Australian Journal of Physiotherapy, Vol. 29, No. 5, p. 156, October 1983; Brodal, A., Spasticity—Anatomical Aspects, Acta Neurologica Scandinavia, Supplement 3, 38, 9-40 (1962).
[0009] According to Matthews (1973) “Golgi tendon organs can be excited by single motor units and therefore may be excited by only the muscle fibres attaching to the tendon on which the organ lies and not by other fibres.” Cameron-Tucker, Helen, The Neurophysiology of Tone: The Role of the Muscle Spindle and the Stretch Reflex, The Australian Journal of Physiotherapy, Vol. 29, No. 5, p. 156, October 1983; Matthews P B C, The advances of the last decade of animal experimentation upon muscle spindles, in Desmedt J E ( ed ), New Developments in Electromygraphy and Clinical Neurophysiology, 3, 95-125, Karger, Basel (1973). The neuro-muscular sensitivity to isolated local stimuli is important to note, and may be a special condition to quadruped animals such as equines where the overlap of muscles between the fore-end and hind-end may be too distant, resulting in an area in the center of low intermuscular communication between the farther regions. As such, there is a likelihood that neuro-muscular communication would be regionally focused and local muscle interaction would create greater local stimuli, demand, and response for growth. In cases involving injured equines, avoidance of use over injured muscle regions may cause a communication blind spot with isolation and stagnation of muscle tone development around the injured area. Lack of use eventually resulting in muscles becoming deaf to the rest of its bodily activity. The lowered level of stimuli around the injured region may lead to decreased communication to muscle spindles around the injured area, resulting in eventual isolation, decreased muscle growth and disjointed posture and movement.
[0010] These scientific observations concur with current studies on proprioception among animals. Unlike other areas of animal physical therapy and training that focus on distinctive psychological or anatomical issues, the study of proprioception recognizes the interactive relationship between distinct senses in the horse's mind and body in relation to its external environment. It is distinguished from exteroception, by which one perceives the outside world, and interoception, by which one perceives the movement of internal organs such as sensing pain and hunger. “Proprioception” is an awareness of movement derived from muscular, tendon, and articular sources.
[0011] Proprioception is further distinguished from kinesthesia by the element of equilibrium or balance. The animal's proprioceptive awareness of its surrounding environment involves the combination of neurological senses that assist the body's various muscle and tendon groups to coordinate in a subconscious level to move in a proper fluid manner. Unlike kinesthesia which focuses on the body's motion or movement, proprioception focuses on the body's awareness of its own movement and behaviors. Poor proprioception may be due to a chronic imbalance in posture from prior injury or simply poor habit. In these circumstances, the chronic regions become isolated and less aware of the rest of the body.
[0012] Prior art devices relating to equine training and therapy fail to address neuro-muscular sensitivity and coordination at a cellular level. The method introduced by TTEAM company with its Tellington TTouch body wrap provides a loose length of fabric tied to the base of the horse's neck connected a second bandage connected around the rear of the horse's body. A quick release knot connecting the two bandages is located above the back of the animal, creating a sense of lift at the base of the horse's neck and the horse's lower hindquarter. This device takes a symptomatic approach to improving the animal's behavior in terms of its sense of secureness and confidence in relation to the rider by a swaddling effect. It would not have been easily understood by technicians in the field of equine physical rehabilitation the neuro-cellular interactions of skeletal muscle spindle cells as these are vastly different areas of expertise. As such, the TTEAM device and method is limited to treatment of the symptom rather than the cause of the problem.
[0013] Similarly, U.S. Pat. No. 6,612,265 does not facilitate regional muscular communication. Rather, the device functions as a training lead, restricting movement and causing further miscommunication between muscle regions.
[0014] U.S. Pat. No. 7,963,256 provides motion control for dog training. The device is self-restricting, wherein the animal becomes constricted when moving beyond the release of the straps. The device serves as a halter, creating unnatural external stimulus.
[0015] There remains a need in this field of art for a device and method that provides rehabilitative treatment muscle and postural issues among quadruped from a causal approach. Particularly, relating to neuro-physiology and skeletal muscle cell development, a means for improving neuro-communication between regional muscle groups to maintain continued intermuscular activity despite injury.
[0016] All patents and applications referred herein are incorporated by reference in their entirety. Furthermore, where a definition or use of a term in a reference, which is incorporated by reference herein, is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
SUMMARY OF INVENTION
[0017] The invention herein provides a conduit for communication between distant regions of muscle mass of a quadruped, specifically an equine. The device comprising an elastic band that is laterally positioned around the horizontal length of the quadruped, extending around the fore-end and hind-end through the midsection. The device having a width sufficient to contact various muscle groups of the front quarter, hindquarter and midsection along a lateral path, particularly contacting areas where muscle groups interconnect. The device comprising smooth soft nonviscous and breathable fabric like material with elasticity to cause compression against the body of the animal when worn. The device in general is preferably smooth in texture to avoid surface injury to the animal. The level of compression should be mild and comfortable, slightly compressing muscles against each other but not otherwise restrictive to movement or circulation. The intention of the compression affect in this case is to bring interconnected muscle groups closer together to improve contact between adjacent muscles among localized regions.
[0018] This helps drive muscle created stimuli among local muscle spindle cells for improved proportional tone development. The goal and purpose is to enhance inter-muscular stimulation reflective of the animal's own movement such that its cellular response would be in proportion to the animal's own force demand and synchronous with its own pattern of movement.
[0019] The path of communication for purposes of this invention should follow the neuro-synaptic pathway of the particular equine. In most cases, particularly canines and equines, the path is lateral where interconnected skeletal muscle groups coordinate between the fore-end and hind-end through the mid-section. This invention facilitates the natural path of neuro-muscular interaction by contact and compression among muscle groups along the length of the animal. It is important that the path of neuro-physiological communication be between areas of desired improvement or emphasis. If the device passes through areas not otherwise needing enhanced communication or stimulus, the misdirection may cause unnatural frequency of stimulation in those areas, leading to injury and chronic postural problems. The development of new skeletal muscle will be in proportion to received stimuli among spindle cells as discussed by Cameron-Tucker such that muscle development will be in proportion to the animal's own activity. The device of this invention should be constructed with minimal to no protrusions or such extra components that would otherwise cause artificial stimulation or extraneous stimulus noise substantially beyond the animal's own physiological demand. The device is preferably smooth in texture to avoid injury from extensive rubbing. The level of compression is preferably mild and not so tight as to cause pain or ache to the compressed areas.
[0020] The position of straps of this invention follows the lateral line of inter-muscular connection. The core feature of this device comprising a closed loop elastic band intended to be worn laterally along the length of the quadruped anima. At least one or more elastic band is positioned cross sectionally over the top of the closed loop band, primarily for the purpose of holding the closed loop band in place during use and movement. A first top elastic band is positioned rearward of the closed loop band near the hind-quarter of the quadruped while a second top elastic band is positioned above the front quarter. A bottom elastic band is connected to the bottom side of the closed loop elastic band in cross-sectional manner and optionally loops upward around the top side of the closed loop elastic band in full circle around the mid-section of the quadruped when worn. The device when worn, exerts a mild compression against the mid-section of the quadruped animal by said bottom elastic band, causing a lifting affect in relation to its natural movement. Enhanced stimuli is brought through the mid-section by way of the bottom elastic band to improve muscle awareness and tonal development relative to fore-quarter and hind-quarter movement.
[0021] Tension of this device against key muscle points on the animal's body helps to improve neurosynaptic communication and activity around the compressed area. The degree of pressure can be varied to adjust for proper level of communication to less receptive muscle regions. When the fore quarter moves in the forward direction, the front quarter muscle groups pushes against the closed loop elastic band of this invention, causing the band to pull against the hind quarter muscles and lift against the mid-section of the animal. The animal feels the coordinated push, pull and lift against targeted portions of the body in synchronous pattern and relative force to its own natural movement. The elastic material further pulls in lifting manner against the lower belly portion of the horse when the lateral portions are stretched, causing the horse to round and lift the arch of its back in response to overall active movement. The horse lowers its neck in response to a neutral position for improved alignment and posture. The fluctuating shift of force and neuro-muscular stimuli experienced by the quadruped over a period of use will help to generate proportional amount of new cell development and improved ton e to meet its ongoing activity demands. By the strict design requirements of this invention, not to include extraneous attachments or hard protrusions compressible against the animal's body and being non-viscous, the quadruped animal is able to sense almost purely its own movement and force demands. The quadruped animal thus adjusts to its own movement and does not develop unnatural dependencies to the device. As such, the device of this invention may be worn without the user present and preferably, may be worn either with or without the rider seated. Independence, confidence and improved posture and muscle tone are facilitated by this device.
[0022] A further object of this invention is to provide a device that can be quickly, easily and intuitively attached to the entire body of a horse by a single person. One embodiment of the invention may include a webbed device that is to be worn over the animal for the specific type of training or therapy sought to achieve. Another embodiment of the invention may comprise solid band of smooth soft nonviscous elastic fabric material. The device should be easily and intuitively worn over the animal's body with minimal connecting pieces to shorten the time for attaching device to the animal. The device preferably should avoid solid components such as plastic or metal connections or protruding portions such as knots or kinks to avoid hard rubbing against the horse's body, otherwise causing extraneous noise stimulus and injury to the contact area. The device should preferably not comprise linked chain material so as to avoid trapping and ripping of hair between the linking portions.
[0023] The preferred embodiment of the invention herein is intended for all quadrupeds, and specifically here for equines and canines. The device comprising a series of interconnected elastic bands in closed loop fashion. The material composition of each elastic band portion having a preferred range of tensity for purposes of creating mild compression against the animal's body. In the preferred embodiment herein, elongation is approximately 110% of the original gauge length, +/−10%. Each elastic band portion of this invention further comprising smooth soft non-viscous elastic fabric material that is breathable such as spandex, cotton, nylon or polyester or combinations thereof. Each elastic band portion should be wide enough to cover multiple local muscle groups of each region. Each elastic band being no less than 2 inches wide and preferably for purposes of use on equine, between 4 to 8 inches wide. The device should not comprise rope or chain or bands having such narrow width (less than 2 inches) because compression by a narrow band will cause acute stimulation to narrow muscle groups and eventual chronic harm and injury. The material may, but preferably does not contain latex material for reasons of skin sensitivity.
[0024] The band may be a simple single elastic band with only one point of connection. It may additionally comprise multiple elastic bands with multiple points of connection creating simple to complex webbing for the desired pattern of enhanced neuro-muscular communication. The various elastic bands preferably connecting by hook and loop means (i.e. Velcro) and without protrusions compressible onto or against the animal's body. The location of compression will define the targeted areas of the body for proprioception training and muscle stimulation enhancement. The pattern of interconnected points further aiding in targeted posture adjustment in tandem with muscle coordination training and resistance exercise.
[0025] The training device and method of use provided herein does not exist in the art at this time. Current products within the market lack the embodiment and capability to encourage the type of training and development that is achievable with this invention. Other features, advantages, and object of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1 A side perspective view of a preferred embodiment of the invention as provided herein.
[0027] FIG. 2 A front right perspective view of the preferred embodiment of the invention as provided herein.
[0028] FIG. 3 A front left perspective view of the preferred embodiment of the invention as provided herein.
[0029] FIG. 4 A rear side plan perspective view of the preferred embodiment of the invention as provided herein.
[0030] FIG. 5 A front side plan perspective view of the preferred embodiment of the invention as provided herein.
[0031] FIG. 6 A right side plan view of the preferred embodiment of the invention as provided herein.
[0032] FIG. 7 A left side plan view of the preferred embodiment of the invention as provided herein.
[0033] FIG. 8 A top forward plan view of the preferred embodiment of the invention as provided herein.
[0034] FIG. 9 A top rear plan view of the preferred embodiment of the invention as provided herein.
DETAILED DESCRIPTION
[0035] A preferred embodiment of the invention 100 herein being specifically geared for equine and canine use. In regards to equine use, the closed loop elastic band when worn should have an extended length ranging from 14.2 hands to 16.2 hands. The elements of this invention 100 being adjustable to achieve the same or similar effect for various sized animals, comprising a first closed loop elastic band 101 of a given length connected to create a closed loop elastic band, as provided in FIG. 1 , having a tensity of 110% beyond its original gauge length when worn. Said closed loop elastic band 101 is preferably 10 inches wide but no less than 2 inches wide. The circumference of said closed loop elastic band 101 should be such that when worn, it completely encircles the lateral length of the quadruped animal with 110% elongation from its original gauge length, give or take an additional difference of 10% from its original gauge length. The closed loop elastic band 101 intended to be wrapped along the lateral length of an equine 100 between a front end 102 immediately above the pectorals, below the neck, and encircling the mid body and encompassing the mid buttocks. The band has a minimal tension against the animal's body when worn with a mild compression against the area of contact. Gauge tension may be tightened or loosened at different location on this device to achieve the particular therapy objective. According to the embodiment of FIG. 1 , means for adjusting the overall circumference of the closed loop elastic band 103 may be located at either or both right 201 and left rear sides 202 of the device, but may be located anywhere along the length and circumference of the band. Said adjustment means 201 , 202 may comprising any known means that otherwise does not contain hard material or any protrusions otherwise compressible against the animal's body to cause chronic injury from localized rubbing. The closed loop elastic band may comprise any known smooth soft nonviscous elastic fabric material, preferably of a breathable fabric-like texture and composition. Ideally, the material should not catch on the animal's skin or hair to avoid injury from excessive rubbing. The material further having a preferred tensile strength for purposes of maintaining long term elastic strength from multiple reuse as well as to provide the desired level of resistance training. When in use, the closed loop elastic band 101 stretches between the animal's front portion 104 and hind portion 105 in a parallel horizontal or lateral manner relative to the animal's body. The elastic pressure laterally against the animal's body creates a heightened sense of awareness to the coordination of movement between these two more disparate sections of the body through its midsection.
[0036] A second elastic band 203 , 106 , also referred to as the bottom elastic band, is located in the vertical position at a cross section around the bottom side of said closed loop elastic band and optionally looping full circle around the midsection of the quadruped animal over the arch of its back. When worn, the bottom elastic band wraps around the bottom midsection 107 or abdomen of the quadruped animal. The bottom elastic band 203 , 106 is intended to encourage proper spinal posture and arch 109 in the equine animal by causing a lifting pressure against the abdominal area of the midsection. The bottom elastic band 203 , 106 is preferably six inches wide and should be no less than 2 inches wide. Said bottom elastic band 203 , 106 should be long enough to extend around the bottom girth of the quadruped animal 107 , 108 with 110% extension beyond its original gauge length when worn. The bottom elastic band 201 , 109 is attached to the closed loop elastic band 101 by a connection means located near the lower midsection area 108 of the animal's body. The fluctuating compression against the animal's body during movement between the forequarter, midsection, and hindquarter by the closed loop elastic band 101 and bottom elastic band 203 creates a synchronous pattern of stimulation during movement that helps to improve muscle tone, gate and posture. By causing a lift to the spine, space is increased in the vertebrae column, which helps alleviate central neurological symptoms. Spinal alignment further helps lower the neck to a more neutral balanced position.
[0037] An alternative embodiment having the same components as the preferred embodiment described above, further comprising a first 111 and second top elastic band 110 connected to the top side of said closed loop elastic band. When worn, said first and second top elastic bands being in contact with the upper front shoulder 104 (resting over the animal's lower neck region) and upper hindquarter 105 of the quadruped animal, as provided in FIG. 1 . The first and second top elastic bands 111 are detachably connectable to the closed loop elastic band 101 at either it's left or right sides or both sides. See FIG. 1 . Either first and second top elastic band 111 being no less than four inches in width but no less than 2 inches in width. Said first and second top elastic band having a length sufficient to wrap around the top side of the quadruped animal (at the respective front quarter and hind quarter 105 ) with 110% elongation from its original gauge length and with an additional 10% extension or compression length beyond the 110% stretch capability. The purpose of the first 111 and second 110 top elastic band is primarily to hold the closed loop elastic band and bottom elastic band in place on the horse's body during use. The respective lengths (or tensile) of each said first 111 and second 110 top elastic bands may be adjusted at their respective location of connection by their connection means. The connection means in this case also preferably a hook and loop device (i.e. Velcro), not containing hard material or protrusions otherwise compressible against the animal's body to cause chronic local injury. The first and second elastic band is comprised of the same type of material as that of the closed loop elastic band and the bottom elastic band.
[0038] The preferred embodiment of FIGS. 2, 3 6 , 7 , 8 and 9 provides for lateral adjustments to the rear on both sides of the device and attachment points for the vertical bands on the right side of the device, as worn by the animal. FIGS. 4 and 5 provide a plan view of the device from rear and front sides, respectively. Alternative methods of design accomplishing this same effect would be considered inherent to this invention. The device overall and in general should not have any protrusion or attachment that compresses into the skeletal muscle of the quadruped animal. The device is preferably flat in nature and attachable between its various parts by hook and loop means. The device should not create additional artificial pressure or stimulus upon the area of contact beyond the natural compression and force exerted by the quadruped animal's own movement upon and through the device worn. The device therefore should not contain hard material attachments that can protrude or compress onto the skeletal muscle of the quadruped animal.
[0039] The overall benefit and effect of this tool is multifaceted. Benefits include but are not limited to the following: 1) enhanced skeletal muscle and tone development in response to activity demands, 2) improved neuro-physiological awareness and communication between distal regions of the body, 3) improved inter-muscular coordination, 4) improved posture and gate, 5) improved independence and confidence, 5) means for diagnosing areas of weakness and muscle isolation.
[0040] Having fully described at least one embodiment of the present invention, other equivalent or alternative methods according to the present invention will be apparent to those skilled in the art. The invention has been described by way of summary, detailed description and illustration. The specific embodiments disclosed in the above drawings are not intended to be limiting. Implementations of the present invention with various different configurations are contemplated as within the scope of the present invention. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims.
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A neuro-muscular rehabilitation device for quadruped animal, specifically canine and equine animal. Said device comprising elastic compression bands to be worn laterally around the length of the quadruped animal and around its midsection. The device providing mild compression upon the contacted muscle groups to facilitate tension force transfer between moving parts of the animal.
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention pertains to earth boring and more particularly to drill directing apparatus.
2. Description of Prior Art
It is known to drill a hole in the earth with a rotating bit. In such drilling the bit may be loaded axially either by the weight of the drill stem to which the bit is connected or by application of fluid pressure to a piston or cylinder connected to the drill stem anywhere along its length between the bit and the mouth of the hole. The bit can be rotated by a motor connected to the drill stem anywhere between its inner end adjacent the bit and its other or outer end, which may be out of the hole at the earth's surface. It is known to guide the bit to cause the hole to be bored in any desired direction. For example, in U.S. Pat. Nos. 3,298,449 to Bachman et al; 3,326,305 to Garrett et al; and 3,460,639 to Garrett there is shown a bit deflection barrel around the drill stem and through which the drill stem moves axially as drilling proceeds, the drill stem being turned by an out of the hole motor. U.S. Pat. No. 2,637,527 to Andrews shows a deflection and force application barrel about a drill stem projectable into the hole as drilling proceeds and carrying an in-hole motor between the barrel and stem. See also U.S. Pat. No. 3,023,821, issued Mar. 6, 1962 to W. H. Etherington. Instead of fixing the barrel in the hole and drilling through it, it is also known to provide bit deflection means affixed to the bit or to the drill stem adjacent the bit, such deflection means moving axially in the hole as the bit proceeds.
To take the reaction force of an inhole bit loading device, an in-hole motor or a bit directing device, it is known to provide anchor means to engage the wall of the hole being drilled. This is shown, for example, in U.S. Pat. No. 556,718, to Semmer which also shows means for advancing an in-hole motor and bit loading device along the hole as it is drilled. Another example of such anchor means is the construction shown in U.S. Pat. No. 2,946,578, to DeSmaele. See also U.S. Pat. Nos. 3,088,532, 3,105,561, to Kellner; U.S. Pat. Nos. 3,180,436, 3,180,437, to Kellner et al; U.S. Pat. No. 3,225,844, to Roberts; and U.S. Pat. No. 3,561,549, to Garrison et al.
It is also known in the art to orient the pipe from outside the hole as in U.S. Pat. No. 3,561,549 to Garrison et al.
It is also known in the art to transmit electrical data from the hole to the surface, including the use of special pipe to transmit hydraulic fluid and electrical signals.
It is also known to mount two or three pipes concentrically with supports and including various types of expansion joints.
It is also known to centralize or prevent skewing by the drill bit in the hole. See U.S. Pat. No. 3,088.532, issued May 7, 1963, to J. M. Kellner and U.S. Pat. No. 3,561,549, issued Feb. 9, 1971, to E. P. Garrison et al.
SUMMARY OF THE INVENTION
According to the invention, a deflection barrel is disposed about and fixedly attached to the housing of an in-hole bit driving motor. The barrel is free to be turned within the hole to the desired azimuthal position about the center line of the hole. The barrel is connected to a string of pipe, connected at its outer end to an out-hole orientation and axial force application means for turning the barrel as desired relative to the hole and applying axial force to the bit, and supplying fluid to drive the motor and carry away the detritus. In-hole orientation responsive transmitter means and other hole characteristic responsive transmitters which provide means to give a remote indication of the barrel orientation and hole characteristics provide signals which are transmitted by electrical cable mounted within a hydraulic line inside the pipe string. A hydo electric triple swivel is connected mechanically to the outer end of the pipe string, provides means for connecting stationary out-hole fluid and electric conduits to the conduits in the pipe string independent of the orientation of the pipe string. The hydraulic and electric conduits are supported within the pipe string by shock mounts fixedly attached to the hydraulic conduit. Instruments out of the hole can be used to indicate the hole characteristics and barrel orientation. The hydraulic line supplies fluid to actuate wall engaging shoes in the deflection barrel. A sub between the motor shaft and bit carries means to limit rate of change of hole direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation largely in section, showing a drill bit connected to a rate of direction change limiter according to the invention;
FIGS. 2 through 5 together form a view partly in elevation and partly in section showing an apparatus embodying the invention;
FIGS. 6 through 8 are transverse sections taken through the apparatus shown in FIGS. 2 through 5 at the indicated planes,
FIGS. 9 and 10 are schematic views of a rig constituting the out hole force applicator and azimuthal orientation apparatus for turning the pipe string and applying axial force thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A. GENERAL
Referring now generally to FIGS. 1 through 5, there is shown a drill bit 21 connected by sub 63 to the shaft 23 of an in-hole motor 25. The motor is connected to an instrument package 27 supplied with electrical connections by electrical conduit 28. The motor and drill bit are suplied with fluid through fluid passage or conductor 29 provided by a string of pipe sections 32. Motor 25 is of the fluid turbine type including shaft 23 and housing 31. Fluid for operating the motor and carrying away the drill bit cuttings is supplied via tubular shaft 23 fed by conductor 29. Axial force to the motor housing 31 is supplied by the drilling rig (see also FIGS. 9-10) acting on the string of pipes 32 to which it is attached by connector 30. Rig 37 also takes the reaction torque of the in-hole motor 25. Devices supplying axial hole force are known in the art and a typical example thereof is disclosed in U.S. Pat. No. 3,463,252, issued Aug. 26, 1969, to C. E. Miller et al. The axial force on motor housing 31 is transmitted by thrust bearings (not shown) to motor shaft 23 and thus to bit 21.
To direct the drill bit a deflection barrel 41 is provided around the motor 25, the barrel 41 being provided with asymetrically disposed wall engaging means 81, 83 (shoes) to urge the motor and bit to one side of the hole. The wall engaging means 81, 83 are adapted to slide longitudinally along the hole as drilling proceeds. The barrel is rotatable with the motor housing to the desired position by means of connector 30 actuated by the drilling rig 37 through the rigid pipe connections 32.
The rate that deflection barrel 41 can change hole direction is limited by a rotating rate of change limiter 24 fixedly mounted on sub 63 which connects bit 21 to motor shaft 23.
It will be understood that the invention is designed for use in drilling more or less horizontal holes or holes having at least a horizontal component, so that devices such as gravity actuated mercury potentiometers, pendulums or other devices well known in the art may provide an indication of the azimuthal position of the barrel deflection means 81, 83 relative to the hole axis.
B. RATE OF CHANGE LIMITER
Referring now to FIGS. 1, 2 and 3, there is shown drill bit 21 having a pin 61 screwed into box 62 of sub 63. Box 62 has a rate of change limiter 24 comprising body 35 and fins 33 affixed thereto. The outer diameter of rate of change limiter 24 is less than the diameter of the bore 66 with the difference in diameters controlling the rate of change of the hole direction with bigger differences permitting faster changes in hole direction. Sub 63 has its other end 64 screwed onto the inner end 65 of motor shaft 23. Heavy, radial load, roller bearings 67 (see also FIG. 7) lie between outer end 64 and cuff 69 which is screwed to the inner end 71 of the deflection barrel 41.
C. DEFLECTION BARREL
Barrel 41 is sealed to motor housing 31 by annular elastomeric seal ring 73 disposed in an annular groove 75 in barrel end 71. Motor housing 31 is attached by shouldered screw connection 76 to deflection barrel 41. Referring also to FIG. 8, two windows 77, 79 in the barrel receive hole wall engaging blocks or pistons 81, 83. Between the pistons and the windows is disposed elastomeric mounting means 86 for sealingly mounting the pistons in the windows and which allows the pistons to be moved outwardly by pressure differential to engage the wall of hole or bore 66, as shown in dotted lines, and which retracts the pistons from wall engaging position, as shown in solid lines.
Fluid for pushing pistons 81, 83 outwardly is conveyed to the slight annular clearance between elastomeric sleeve 89, integral with means 86, and motor housing 31, by annular groove 93 in the sleeve. Fluid is supplied to groove 93 by longitudinal channel 95 cut into deflection barrel 41.
D. INSTRUMENT PACKAGE
Referring now to FIGS. 3 and 4, instrument package or tube 27 is connected by shouldered and threaded connection 94 to deflection barrel 41 and by similar connection 115 to pipe section 37. Tube 27 is provided with a tapered shoulder 30 facing the out-of-hole end of the package. An instrument container in the form of a hollow cylinder 116 is coaxially disposed inside tube 27. The in-hole end of cylinder 116 is closed by bulkhead 103, which is beveled at 96, and the bevel is provided with azimuthally spaced ribs 105 which rest against shoulder 30. The other end of cylinder 116 is closed by a screw plug 141 and sealed by seal ring 112. Screw plug 141 is provided with azimuthally spaced ribs 142. A threaded ring 144 secured to the outer ends of ribs 142 is screwed into the threaded box 98 of connection 115. Cylinder 116 is thus held in place within tube 28. The outer diameter of cylinder 116 is smaller than the inner diameter of tube 27 forming an annular fluid passage or channel 106 therebetween communicating through the flow passages formed between the ribs 105 and between the ribs 142 with the spaces inside tube 28 at the ends of the cylinder.
Axially extending through instrument container 116 is a tubular conduit 97 forming hydraulic channel 100. The conduit is sealed by seal rings 110 and 114 to inner bulkhead 103 and the outer bulkhead formed by plug 141. Conduit 97 is telescopically connected by tube or channel 104 to longitudinal channel 95 in barrel 41. Seal 101 keeps channels 100, 104 in fluid tight flow communication. Spider 102 connects longitudinal channel 104 to deflection barrel 41 and supports it to maintain proper alignment for telescopic connection. Spider 102 contains flow channels between its ribs to permit fluid flow between longitudinal drilling fluid channel 106 and flow channel 108. Flow channel 108 is formed at the entrance to motor shaft 23 to supply fluid from channel 105 via tubular pin 76 in motor stator 109 for powering motor 25 and for flowing through drill bit 21 to wash chips away for return through the annulus between the drill pipe and hole 66.
Instrument container 116 contains instruments (not shown) for determining tool position with relation to the edge of a coal or other mineral seam e.g. as shown in U.S. Pat. No. 3,823,787 to Haworth, so that the tool can be kept in the center of the seam, or for determining the direction and inclination of the hole, such as a three axis magnetometer or a compass and inclinometer known in the art of oil well surveying, whereby the hole can be kept straight or in other manner directed as desired. If desired, both types of hole responsive instruments can be used in the container. In any event the container will also include means for determining the azimuthal position of the deflection barrel, such as the mercury potentiometer described in co-pending U.S. application of Jackson M Kellner Ser. No. 584,736 filed June 9, 1975, entitled Drill Director.
E. INSTRUMENT PACKAGE CONNECTION TO PIPE SECTION
Referring now to FIG. 4, instrument package 27 is connected by threaded and shouldered connection 115 with pipe section 32 forming part of a string of pipe extending to out-of-hole drill rig 37. Section 32 is the same as all of the other pipe sections 32 of the pipe string so that only one need be described, as will be done in more detail hereinafter. As many pipe sections 32 are used as necessary to extend the pipe string from instrument package 27 to the mouth of the hole.
The instruments in instrument container 116 terminate in conductor means 118. Conductor means 118 includes a cable bundle of conductors 120 surrounded, insulated and sealed by rubber 124. Conductor means 118 extends radially through the side of tube 100 and into a position coaxial within hydraulic channel or tube 100 and is held concentrically therein by mount 119, leaving flow annulus 121 for flow of hydraulic fluid. Conductors 120 terminate in female banana connector 122. Female electrical connector 122 extends beyond the pin end 123 of tube 100 that extends out from screw plug 140 of the instrument container. Electric connector 122 and pin 123 of the hydralic tube are adapted to mate with correlation members on the adjacent one of pipe sections 32.
F. PIPE SECTION
Each pipe section 32 includes an outer tube 125 having a cylindrically threaded pin 126 at one end and a cylindrically threaded box 127 at the other end for making rotary shouldered connections with correlative members on adjacent pipe sections. For details of rotary shouldered connections see U.S. Pat. No. 3,754,609 to W. R. Garrett. Near its pin end the outer tube has an internal, tapered shoulder 128 facing toward its outer end. An other tube 129, providing a continuation of hydraulic fluid channel or tube 100, is disposed concentrically within outer tube 125 and is positioned centrally and axially by spiders 130 and 131. Spider 130 includes a disc 132 having a bevelled outer periphery 133 adapted to seat on shoulder 128. Disc 132 is provided with a plurality of fluid passages or ports 135. The inner periphery of disc 130 is secured to the outer periphery of tube 129 by a resilient sleeve 138. Sleeve 138 has a lower modulus of elasticity than that of tubes 125, 129, and disc 130, which typically are made of metal, usually steel. Preferably sleeve 138 has an elastic modulus of between 100,000 and 250,000 pounds per square inch. Sleeve 128 is preferably made of rubber or other elastomeric material having a durometer hardness of between 40 and 90 on the Shore A scale. Spider 131 at the out hole end of pipe section 32 includes threaded ring 145 rigidly mounted to hub 147 by azimuthally spaced ribs 149 leaving fluid passages between the ribs. Hub 147 fits snugly over a terminal portion 123 of the pipe section 32 and is welded thereto. Tube 129 is assembled within tube 125 by inserting it through box 127 until bevel 133 seats against shoulder 128, this being accomplished finally by rotation, to screw ring 195 into box 127. Alternatively ring 195 could be unthreaded, slipped into box 127, and welded thereto. Elastomeric sleeve 138 allows for relative rotation, turning or twisting, and elongation and contraction between outer tube 125 and the other tube 129. If this is insufficient, spider 131 can be constructed with an elastomeric portion the same as spider 132. Sleeve 138 provides also a damper for torsional and axial vibrations.
Within tube 129 is disposed an inner tube 151. Tube 151 has fins 153 secured to its outer periphery and to the inner periphery of intermediate tube 129, e.g. by epoxy cement. An annular fluid passage is thus formed between the intermediate and inner tubes, the space between the fins providing fluid passages from one side of the fins to the other. A box 155 on the in-hole end of the intermediate tube 129 telescopically receives pin 123 on the end of tube 100 in the instrument package or a like pin 123 on the end of tube 129 of another pipe section 32. A seal ring 157 received in a groove in box 155 seals with pin 123 while allowing relative rotation and relative axial motion, there being no shoulder or end engagement between the pin and box to prevent such axial motion, there being instead clearance at 159, 161 when connection 115 is made up tight.
Electric conduit or cable 28 extends axially through inner tube 129, being insulated therefrom by rubber sleeve 163, the same as cable 118 is insulated by rubber sleeve 124. The rubber sleeve fits tight enough in tube 129 to retain cable 118 therein. At the in-hole end of cable 28 there is a pin connector 165 adapted to connect with box connector 122 at the end of cable 118 or at the end of a like connector on the out hole end of another pipe section 32. An extension 167 of the rubber insulation around box 122 has an internal groove 169 adapted to snap over an annular rib 171 at the base of pin 165 to keep the electrical connection together. This snap together occurs as the threaded connection 115 on the outer tube is made up tight. A connection of this type is known as a bulkhead connection, one form of which is available from Vector Manufacturing Company, Houston, Texas.
It will be noted that inner tube 129 terminates short of the end of the rubber sleeve 163 at the out hole end of the sleeve, leaving the thickened end of the sleeve externally unsupported. This allows for rubber flow sufficient to permit twisting and axial motion of pin 165 relative to box 122.
G. SWIVEL
Pipe sections 32 may be strung for thousands of feet and terminate at interface section 150 (FIG. 5) whose out-hole end provides the outermost stem 152 of hydraulic pneumatic triple swivel 154. Swivel 154 includes a body 163 within which stem 152 is rotatably received. Swivel body 163 includes channel 156 in fluid tight flow communication with annular chamber 162, the latter being sealed by seals 158, 160. Port 164 in body 163 connects chamber 162 with a pipe 163 leading to drill fluid pump 166. A block 170 closing the end of stem 162 includes channel 168. Channel 168 permits fluid tight flow communication between socket 174, into which pin 172 on intermediate stem 175 of the swivel is screwed, and annular chamber 176 of swivel body 163. Chamber 176 is sealed by seals 160 and 178. It is connected by pipe 180 with hydraulic fluid source 182.
Block 170 has a smooth socket 183 receiving the out-hole end of inner stem 185 within which is disposed a continuation of electric cable 28. A radial passage 187 in block 170 receives electrical conductor riser 189, electrically coupling conductor cable 28 with electrical pick-offs 184 of swivel connector 154. Electrical pick-offs 184 are sealed by seals 178 and 186 and include springs 188 engaging pick-off wires 190 to annular slip ring terminals 194 of electrical conductor coupling riser 182. Wires 190 are terminated at electrical power and data transmission apparatus 196 which includes indicators and controls. Thrust bearings 198 permit terminating stem 152 to be rotatably engaged within body 163. The space surrounding bearings 198 is sealed by seals 158 and 200. Block 170 terminates at screw coupling 30 which connects to drill rig 37 to be rotated to position pistons 81, 83 azimuthally relative to the hole while leaving swivel body 163 in a fixed position.
Intermediate stem 175 is supported within outer stem 152 by spider 202 affixed to the intermediate stem and slipped into the outer stem, being otherwise similar to spider 31. The in-hole ends of the swivel stems terminate in threaded, telescopic, and bulkhead connections the same as on pipe sections 32, thereby to connect the swivel stems with the pipe sections. The annulus between the outer and inner stem provides a flow passage communicating with the flow passage between the outer and intermediate tubes of the pipe sections, the annulus between the intermediate and inner sleeve providing a flow passage communicates with the flow passage between the intermediate and inner tubes of the pipe sections, and the electric cable in the inner stem connecting to the electric cable in the inner tube of the pipe sections.
H. DRILL RIG
Referring now to FIGS. 9 and 10, there is shown the out-hole apparatus or rig 37 for turning the pipe string azimuthally about its axis as may be desired to position the deflection barrel and for advancing and retracting the pipe string axially in the hole as may be desired, e.g. for loading the drill bit axially or for withdrawing the drill string in whole or in part to change bits or add pipe sections or to commence or discontinue drilling. Rig 37 includes a frame 251 to be anchored to the earth or having sufficient weight to hold it in place. Mounted on the frame are tracks 253 having downwardly facing rack teeth 255. A movable chassis 257 has slides 259 resting on tracks 253. On the lower part of the chassis are mounted hydraulic motors 261 driving pinions 263. The pinion engage racks 253 so that when the motors are rotated the chassis 257 is driven forward or backwards along the tracks.
On top of the chassis 257 is disposed a gear box 265 driven by hydraulic motor 267. The output shaft 269 of the gear box is screwed to pin 30 on the out-hole end of the outermost stem 150 of the swival 154 (see also FIG. 5). The pin on the in-hole end of swivel stem 150 is connected to the box of the outer tube of the adjacent pipe section 32. When motor 267 drives the gear box, the string of pipe sections 32 is turned azimuthally about is axis.
I. OPERATION
During drilling motor 31 turns bit 21 to bore hole 66. Instruments in container 116 transmit signals out of the hole via cable to tell the operator if the hole is going in the desired direction. If not, the string of pipes 32 is turned by rig 37 through swivel stem 152 until deflection barrel 41 is in an azimuthal position that will redirect the bit in the proper direction. The azimuthal position of the barrel is known from electric signals transmitted out of the hole via cable 28. When the hole is going in the right direction, the deflection barrel may be deactivated by reducing the pressure therein, allowing the deflection pistons or shoes to retract.
J. MODIFICATIONS
Although the system as described above in detail is believed to be most satisfactory and preferred, different applications and many variations in its elements and the structure of its elements are possible. For example, an electric in-hole motor may be used. Moreover, out-hole torque detection means may be employed to detect the contacting of the rate of change limiter 24 with the hole which would indicate the desirability of letting off pressure on deflection pistons 81, 83.
The above are, of course, merely exemplary of the possible changes and variations.
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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The housing of an in-hole drill motor is provided with a deflection barrel to apply lateral force to the side of the housing directed along any desired radius. The barrel is fixedly attached to a pipe string and the motor is fixedly attached to the barrel inside the barrel. The barrel is oriented and axial force is applied to the motor housing through the pipe string from without the hole, using orientation and other signals transmitted from within the hole adjacent the motor. The signals are transmitted through an electrical conduit housed within a hydraulic conduit used to supply fluid to expand the deflection barrel shoes. The hydraulic and electric conduits are supported within the pipe string by shock mounts fixedly attached to the hydraulic conduit. The annulus between the hydraulic conduit and the pipe string provides means to transmit fluid for driving the motor and removing the detritus formed by a drill bit driven by the motor. The out-of-hole connections to the pipe string annulus and the hydraulic and electric conduits are made through a hydro-electric triple swivel. A rate of direction change limiting mechanism mounted between the bit and the barrel for rotation with the bit prevents the deflection barrel from changing hole direction too rapidly. Instruments out of the hole can be used to indicate the hole characteristics detected in the hole.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/526,264, filed Jan. 20, 2006, which is the national phase of PCT Application No. PCT/GB2003/003845, filed Sep. 5, 2003 and which claims priority from UK Application Serial No. 0220626.6, filed Sep. 5, 2002. Priority is hereby claimed to each of the above applications, and those applications are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to an underwater location device such as may be used for controlling the launch, positioning or recovery of a tidal turbine or other underwater equipment. It should be noted that the example of a tidal turbine is used herein but the invention is not limited to such uses.
BACKGROUND ART
[0003] Tidal currents offer a considerable source of sustainable energy at various sites throughout the world, usually within easy reach of land and in relatively shallow waters. Tidal currents are created by movement of the tides around the earth producing a varying sea level, dependent on the phases of the moon and sun. As the sea levels vary, so the waters attempt to maintain equilibrium subject to gravitational forces, thus inducing flow from one area of sea to another. This flow is modified by a number of factors such as, the Coriolis forces due to the earth rotation, earth/moon/sun alignment, local topography, atmospheric pressure and temperature and salinity gradients. The major advantage of tidal power generation is its regularity, which can be predicted for years in advance.
[0004] According to a study by the ETSU (Energy Technology Support Unit) the United Kingdom may obtain up to 20 percent of its total electricity by using these systems to collect energy from fast moving tidal currents that exist in channels and offshore areas. Similar resources have been noted to exist elsewhere such as in the Straits of Messina, between Sicily and mainland Italy.
[0005] The most powerful flows tend to occur in areas of restriction, either by width or depth, but for the same reasons are not suitable for widespread exploitation by large, fixed devices which require a minimum rotor area, and therefore water depth, to justify the costs of installation and maintenance. It is assumed from the outset that new tidal barrage systems are unlikely ever to be pursued due to their inherent properties of high cost, delayed financial return, and serious environmental consequences.
[0006] The considerable size of the available resource has attracted various proposals for its exploitation.
[0007] The following represents the existing systems within the field of tidal current energy extraction. It is assumed that power transmission problems will be equal for any system, and that all systems will require some form of non-toxic anti-fouling agent.
[0008] There also exist operational environmental impacts common to all methods of tidal power generation, such as, an inherent risk of collision damage to fish and marine mammals, redirection of currents and the sediments and food particles contained within them, and shipping, particularly fishing.
[0009] A first type of tidal current energy extraction system encountered on the market is the Monopile system. This technology is well known and understood by contractors familiar with the offshore oil industry. It consists of twin axial flow turbines, each turbine driving a generator via a gearbox, mounted on streamlined cantilevers either side of a circular section, vertical steel monopile. It is anticipated that a number of structures will be grouped together in ‘farms.’ The planning of such a tidal ‘farm’ would need to be accurately modelled for wake effects, as once installed, the monopile is expensive to re-site. In addition, operational depth is restricted to the 20 m-35 m range. Concerning the installation and maintenance, monopile systems require a hole to be drilled in suitable bedrock and the base of the turbine tower is secured within the socket so produced. Existing monopile support mechanisms for presenting a tidal turbine to the tidal currents are expensive, thus making only a few sites economically viable for power generation and requiring considerable sub sea engineering expertise.
[0010] The current monopile systems permit raising the turbines above water level for maintenance and repair, which is beneficial, but the long-term (i.e. 20 years) reliability and corrosion resistance of the necessary mechanism must be questionable. The protrusion of the piles above sea level would reduce the likelihood of impact with passing vessels.
[0011] Concerning the environmental and decommissioning issues, the impact of installation would be considerable, especially to the benthic flora and fauna, but subsequently the piles may become areas of shelter and therefore, populated. To minimize the danger to shipping and fishing, decommissioning would require complete removal of the piles, which would disturb the benthic population once again.
[0012] A second type of tidal current energy extraction system that exists in the prior art is the floating tether. This floating tether device is anchored to the seabed with a mooring cable and suspended clear of the seabed using a flotation buoy. The axial flow tidal current turbine is free to position itself into the direction of the tidal flow, which obviates the need for a yaw mechanism.
[0013] Several prototypes have already been developed including a 10-kilowatt device tested in Scotland in 1994. At present, the arrangement is unlikely to be suitable for large power output installations due to the relative sizes of anchor, turbine and float. On occasions of relatively high velocity tidal streams (e.g. spring tides), if the anchor holds, the turbine will be dragged lower in the water with the unwanted potential to collide with the seabed.
[0014] Concerning the installation of the floating tether system, it is relatively quick and inexpensive. However, visual inspection would need to be frequent as the structure is likely to be subject to storm damage and fatigue loading of the cable, leading to possible loss of the supporting float and subsequent sinking of the device, or loss of anchorage and subsequent drifting. Once sunk, the device would be open to damage by the oscillating tidal currents and could prove difficult to recover, whilst a drifting device would potentially cause damage to any other moored turbines in its path.
[0015] Due to the length of tether required and the random positioning of the device at any one time, this arrangement is not suitable for closely grouped tidal farms and a safe spread would fail to make economical use of the power available in a given area. For the same reasons, this type of arrangement would present a hazard to all forms of shipping, large and small. It would, however present a possible solution to a one-off, small scale installation in areas such as the mouth of a sea loch. Concerning the environmental impacts of installation and decommissioning of the floating tether systems, it will be minimal, leaving no footprint on removal.
[0016] A third type of tidal current energy extraction system that also exists in the prior art is the oscillating hydroplane system. In that system, a central post mounted on five legs supports a complex mechanism comprising two interconnected symmetrical hydrofoils. These hydrofoils are used to pump high-pressure oil, which drives an electrical generator via a hydraulic motor. At the end of each stroke, the hydrofoils are tilted to give the required angle of attack to produce the return stroke, thus creating an oscillating motion.
[0017] Concerning the installation and maintenance, at present, the oscillating hydroplane system does not yet possess a launch and recovery mechanism. As a result of the constant oscillations and considerable number of moving parts, it is probable that this device will be subject to high dynamic loading and subsequent fatigue stress. The upward stroke of the hydrofoils will tend to lift the device off the seabed and hence increase the possibility of it being washed away at high tidal stream velocities.
[0018] Concerning the environmental impacts of installation and decommissioning of the oscillating hydroplane systems, they are expected to be minimal, leaving no footprint on removal. However, this cannot be confirmed until a launch/recovery mechanism is proposed. Using high pressure oil as a means of power transmission does however introduce the possibility of pollution in the event of leakage.
[0019] Some ‘tidal’ energy extraction systems can also be used in freshwater applications such as rivers.
[0020] With these existing systems and designs, it is a problem that their instabilities during operations as well as during launch and recovery, if possible, might cause damage. In addition, since these systems are becoming larger and larger, the frequent installation and maintenance operations will become more and more difficult and expensive.
SUMMARY OF THE INVENTION
[0021] It is an object of the present invention to obviate or mitigate the problems of controlling underwater equipment in a flowstream.
[0022] In a first aspect, the invention described herein relates to an apparatus for controlling underwater equipment comprising: attachment means for attaching underwater equipment to the apparatus; and at least one member for generating positive or negative lift.
[0023] Preferably, the at least one member is adapted to create a negative lift due to fluid flow in a first direction and is adapted to create a negative lift due to fluid flow in a second, different, direction.
[0024] Preferably, the first and second directions are generally opposite to each other.
[0025] Preferably, the apparatus is adapted to anchor the underwater equipment to a sea- or river-bed.
[0026] Preferably, the attachment means is adapted to attach the underwater equipment in close proximity to the centre of gravity of the apparatus.
[0027] Preferably, the space frame is mounted on a number of feet equipped with slippage prevention means, which may be an arrangement of spikes or the like, to typically resist slipping by shear force rather than relying on friction alone such that, in use, the negative lift will preferably tend to force said slippage prevention means into a sea- or river-bed thus resisting the drag forces acting on the space frame tangentially to the seabed.
[0028] Preferably, the at least one member comprises at least one hydrofoil.
[0029] Typically, differences in pressure acting on opposing surfaces of each of the at least one member due to a predetermined angle of attack causes said at least one member to generate negative or positive lift.
[0030] Preferably, the apparatus is adapted to control the launch and/or recovery of the underwater equipment attached to it.
[0031] In a preferred embodiment, the at least one members are rotatable to any position and even more preferably in the region of 160° to 200° about a longitudinal axis of the respective member.
[0032] Preferably, the hydrofoils are symmetrical.
[0033] Said at least one members preferably comprise at least one hydrofoils which are more preferably self-rectifying static hydrofoils, which may be capable of passive rotation about an axis such that each hydrofoil maintains alignment with a periodically reciprocating rectilinear flow.
[0034] Moreover, the at least one members are preferably moveable between a first configuration in which they are capable of generating positive lift and a second configuration in which they are capable of generating negative lift.
[0035] Preferably, the at least one member has a variable actuating means to vary the positive or negative lift generated by the member.
[0036] Preferably, said actuating means comprises a motor which may be a hydraulic, pneumatic or electric actuated motor. Preferably, a shaft member is actuated when a change between first and second configurations is required, said actuation typically causing the shaft member to rotate through a predetermined angle, which may be in the region of 180°.
[0037] Preferably, said apparatus comprises a support framework which is typically composed of sub frameworks, where a number of shaft members are connected to the framework and on which said symmetrical hydrofoils are coupled. Preferably, the at least one hydrofoils are coupled to the support framework by a respective bearing member connected to the hydrofoil. The bearing member of the hydrofoil is typically coupled to the shaft member of the framework, the bearing member and shaft member combining to provide a rotation enabling portion and a rotation prevention portion. Preferably, the bearing member is substantially cylindrical. The rotation prevention portion typically comprises at least one stop members (which may be in the form of lugs mounted on the shaft member) and which are adapted to engage with at least one respective stop members (which may also be lugs) mounted on the respective bearing member of each hydrofoil. Typically, the bearing member comprises a pair of stop members which are spaced apart around its inner circumference, typically being spaced apart by approximately 180°.
[0038] Typically, the shaft member comprises a pair of stop members which are spaced apart around its outer circumference, typically being spaced apart by approximately 180°. Preferably, one of the bearing stop members is engageable with a respective shaft stop member to define the first negative configuration and the other of the bearing stop members is engageable with the other of the shaft stop members to define the second negative configuration.
[0039] Preferably, said apparatus is a multi-legged, self-leveling space frame equipped with a plurality of hydrofoils, typically at different heights.
[0040] In alternative embodiments, the at least one member is rigidly connected to a support framework and is unsymmetrical. Preferably, the at least one member comprises a disc shaped member which, in use, is adapted to produce positive or negative lift regardless of the direction of flow of fluid thereby. Preferably, the disc shaped member produces negative lift.
[0041] According to a second aspect of the invention, there is provided a method of controlling underwater equipment; the method comprising: providing an apparatus having at least one member for generating positive or negative lift; attaching the apparatus to underwater equipment; releasing the apparatus into a fluid; allowing fluid to flow past the at least one member to generate positive or negative lift.
[0042] Preferably, the method according to the second aspect of the invention is performed using the apparatus according to the first aspect of the invention.
[0043] Preferably, the apparatus is placed in a flow of water.
[0044] Preferably, the underwater equipment is a turbine.
[0045] According to a further aspect of the present invention, there is provided an apparatus for maintaining underwater equipment within a sea or river tidal current location, the apparatus comprising at least one moveable members capable of generating negative lift, where said at least one members are moveable between a first configuration in which they create a negative lift due to flow in a first direction, and a second configuration in which they create a negative lift due to flow in a second, different, direction.
[0046] The invention also provides energy extracting apparatus for extracting energy from fluid flow, said energy extracting apparatus comprising: a turbine; at least one member, which in use, generates positive or negative lift.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0048] FIG. 1 shows a side view of a space frame in accordance with the present invention, showing a tubular frame allowing the positioning of the hydrofoils at differing heights;
[0049] FIGS. 2 a to 2 d show the passive reversing of the hydrofoils in response to a change in flow direction whilst FIGS. 2 e to 2 h show the different movements of hydrofoils of FIG. 1 actuated by hydraulic motors to create positive and negative lifts during launch, recovery and transitional operations according to the present invention;
[0050] FIGS. 2 i to 2 m show the passive reversing of the hydrofoils in response to a change in flow direction;
[0051] FIG. 3 in its upper half shows a first side view, and in its lower half shows an opposite side view, illustrating the fundamental geometry of the passive reversing mechanism;
[0052] FIG. 3 a in its upper half shows a first side view, and in its lower half shows an opposite side view, illustrating the fundamental geometry of the passive reversing mechanism;
[0053] FIG. 3 b is a third side view showing the fundamental geometry of the passive reversing mechanism;
[0054] FIG. 4 shows in detail the assemblage of hydrofoils onto the space frame of FIG. 1 ;
[0055] FIG. 5 a is a side view of a second embodiment of an apparatus in accordance with the present invention and an attached canister;
[0056] FIG. 5 b is a front view of the FIG. 5 a apparatus with the attached canister;
[0057] FIG. 5 c is a plan view of the FIG. 5 a apparatus with the attached canister; and,
[0058] FIGS. 5 d - 5 f are a series of views of an attachment ring which forms part of the FIG. 5 a apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0059] According to the present invention, the apparatus for launching an underwater device from a vessel, securing the underwater device whilst in operation on the seabed and permitting recovery to a vessel, for maintenance and repair should be as simple as possible without involving any sophisticated and specialized equipment. A first embodiment of the invention is shown in FIG. 1 and utilizes passive, self-rectifying static hydrofoils, the central shaft (see FIG. 3 ) of which can be rotated through 180° to generate positive or negative lift as required.
[0060] As is shown in FIG. 1 , the apparatus 1 for controlling the launch, secure positioning and recovery of an underwater device comprises a space frame 10 for attaching to any desired underwater device such as power extraction equipment which may comprise a tidal turbine (not shown), a hydrofoil support frame to accommodate the self rectifying hydrofoil mechanisms 12 and hydraulically operated legs 11 for leveling of the apparatus 1 . The feet 14 are equipped with spikes or similar serrated attachments (not shown) to initiate grip on the sea or river bed.
[0061] The hydrofoils 12 are inclined in such a way as to generate a significant downforce as a result of the stream flow over their surfaces. This downforce will push the apparatus 1 into the seabed, and, since the actual applied force will be proportional to the square of the velocity of the fluid passing over them, the apparatus 1 will be more securely fixed as the streamflow velocity increases. By this means the apparatus can overcome overturning moments applied to the underwater device that it supports.
[0062] The space frame 10 is shown as arched tubing but is not restricted to shape since any frame configuration offering different levels of mounting point for the hydrofoils 12 will suffice. The apparatus 1 as shown has multiple hydrofoils 12 but any number of hydrofoils 12 will suffice. As is shown in FIGS. 2 a to 2 h, each hydrofoil 12 is mounted on a central shaft 48 such that it may rotate upwards from horizontal (or any angle of inclination above horizontal) through vertical to any angle above horizontal but now pointing in the opposite direction. The angle of attack of the hydrofoils 12 is governed by the relative size and positioning of lugs 46 attached to the central shaft 48 and the corresponding lobes 44 attached to an outer shaft (not shown) which is itself fixed to the hydrofoil 12 .
[0063] In a preferred embodiment, the apparatus 1 according to the present invention comprises a multi-legged, self-leveling space frame 10 equipped with a number of hydrofoils 12 at different heights with any underwater device, such as a tidal turbine, it supports, situated as close as practicable to the centre of gravity of the apparatus 1 .
[0064] It is anticipated that the space frame 10 will be mounted on a number of feet 14 equipped with spikes (not shown) to resist slipping of the apparatus 1 with respect to the river bed (not shown) by shear force rather than relying on friction alone. The number of feet 14 A, 14 B required will depend on the weight of the apparatus 1 ; however, the location and the shape of these supporting feet 14 A, 14 B aim at holding the apparatus 1 in the orientation shown in FIG. 1 upwards against the current and thus ensuring the stability of the space frame 10 . The negative lift (arrow A) will tend to force these spikes into the sea or river bed (not shown in FIG. 1 ) thus resisting the drag forces acting on the space frame 10 tangentially to the sea or river bed.
[0065] The drag forces acting on the underwater device (such as the tidal turbine) attached to the apparatus 1 will naturally tend to apply an overturning moment to the space frame 10 about its rearmost feet 14 B, with respect to the direction of flow (arrow F). These forces will however be overcome by positioning the hydrofoils 12 at stations such that the negative lift (arrow A), created by the foremost or upstream (those at the left hand side of the space frame 10 as shown in FIG. 1 ) hydrofoils 12 acting over the length of the space frame 10 , is arranged to exceed the overturning moment.
[0066] Thus, the space frame 10 is symmetrical about its midpoint M with the hydrofoils 12 being coupled to the space frame 10 in a manner, to be subsequently detailed in a discussion of FIGS. 2 a to 2 h, which allows them to passively reverse with stream flow F to maintain compressive forces in a downwards direction A and restraining moments regardless of tidal stream direction.
[0067] During operation of the apparatus 1 , the hydrofoils 12 are free to rotate (shown as clockwise in FIGS. 2 a to 2 d and 2 I to 2 m ) in response to the change in tidal stream flow F direction in a manner which is shown from left to right in FIGS. 2 a to 2 d to create a negative lift (arrow A) so as to push the apparatus 1 into the seabed.
[0068] When the apparatus 1 is to be installed on the seabed or is to be recovered from the seabed for e.g. maintenance of the apparatus 1 , as shown in the FIGS. 2 a to 2 d, hydraulic motors 30 , via a suitable gearing mechanism such as a worm and wheel arrangement 32 (as shown in FIG. 3 ) or chain type mechanism (not shown), are utilized to rotate (shown as anticlockwise in FIGS. 2 e to 2 h ) the longitudinal axes (i.e. the horizontal axes perpendicular to the stream flow 12 ) of the hydrofoils 12 through the required angle until the hydrofoils 12 have reached the configuration shown FIG. 2 h; for the configuration shown in FIGS. 2 e to 2 h, this angle is approximately 180°. It should be kept in mind that the hydraulic motors 30 can be replaced by pneumatic or electric motors. In other words, if the apparatus 1 is towed, e.g. by a boat or other vessel or installation at the surface, the hydrofoils 12 will produce positive lift (arrow B) as shown in FIGS. 2 e to 2 h. For launch and recovery, this positive lift can be utilized to raise or lower the space frame 10 within the tidal stream. If required, this action could be augmented by forming air tanks within the space frame 10 that can be ‘blown’ with compressed air to improve the buoyancy of the apparatus 1 . If the hydraulic motors 30 use the worm and wheel mechanism 32 form of drive, the hydrofoil 12 positions can be altered over a range of positions, thus permitting the apparatus 1 to be ‘flown’ in the water. Hydraulic connections (and pneumatic connections if required) can be affixed to a supporting marker buoy (not shown) for ease of access.
[0069] FIG. 3 shows the mechanism and assemblage of hydrofoils 12 , hydraulic motors 30 and worm and wheel drive shaft mechanisms 32 in more detail. The hydrofoils 12 are free to rotate about a central shaft 48 , through an included angle of say 160° which will maintain an angle of 10° to the horizontal. The 10° angle effectively becomes an angle of attack when the tidal stream flow F reverses. Thus as the tidal stream 10 reciprocates, the hydrofoils 12 will maintain an angle of 10°, creating a negative lift (arrow A), which will therefore push the spikes 16 into the seabed and immobilize the space frame 10 . As will be described subsequently, positioning lugs 46 mounted on a central shaft 48 provided a stop for locating lobes 44 of the hydrofoil 12 , such that the hydrofoil 12 cannot rotate further than the 160° shown in FIGS. 2 a to 2 d.
[0070] By rotating the central shaft 48 through slightly greater than 180° (say 200°), the negative lift becomes positive lift (arrow B) and the space frame 10 will rise through the water so that the tidal turbine 90 can be recovered on the vessel (not shown).
[0071] FIG. 4 shows in more detail the mechanical assemblage of hydrofoils 12 with space frame 10 . The hydraulic motor 30 for actuating the positioning gear is equipped with a drive shaft 32 that is utilized for rotating an indented positioning gear 42 or a toothed gear wheel. The positioning gear 42 is solidly attached to a central shaft 48 which passes through a bore provided in the larger end of each hydrofoil 12 , a section of which is show on FIG. 4 . The bore of the hydrofoil 12 is provided with a pair of diametrically opposed and inwardly projecting hydrofoil locating lobes 44 . The central shaft 48 has a pair of diametrically opposed and outwardly projecting positioning lugs 46 , each one of which selectively co-operates with one of the respective pair of diametrically opposed hydrofoil locating lobes 44 .
[0072] Thus, by rotating the drive shaft 32 , the hydraulic motor 30 actuates or rotates the position gear 42 which in turn rotates the central shaft 48 . The positioning lugs 46 will contact the locating lobes 44 and carry them 44 (and the hydrofoil 12 ) about the rotational axis of the central shaft 48 until the hydrofoil 12 is in the desired configuration, this being through an angle of approximately 160° until the hydrofoil 12 is in the configuration shown in FIG. 2 h. At this point, the motor 30 is de-actuated and the positioning lugs 46 will hold the hydrofoil 12 locked in this configuration. The rotation of 160° enables the hydrofoil 12 to maintain an angle of 10° to the horizontal in order to provide an angle of attack when the tidal stream F reverses.
[0073] Conversely, the rotation of the central shaft 48 by 180° drives the hydrofoils 12 to create a positive lift and in which case, the space frame 10 will rise through water. FIG. 3 a shows how the attitude of the hydrofoil 12 is changed by a simple 180° clockwise rotation of the central shaft 48 .
[0074] The apparatus according to the present invention, can be launched and recovered by a non-specialist vessel, using non-specialist equipment. Indeed if the vessel is large enough, a number of apparatus 1 may be launched or recovered in a day without the need to return to port. This will also permit easy access for maintenance and repair. Since apparatus 1 possesses few moving parts and no complex mechanisms, it should be inherently reliable.
[0075] A second embodiment of an apparatus in accordance with the present invention is shown in FIGS. 5 a - 5 d. The apparatus 100 comprises a tripod support frame 110 , a bottom ring or stand 126 , a disc-shaped hydrofoil 112 , support brackets 120 and an attachment ring 122 with bolts 123 . The apparatus 100 is attached to an ADCP canister 124 via the attachment ring 122 and bolts 123 . Other subsea equipment may also be attached to the apparatus 100 in place of the canister 124 .
[0076] The hydrofoil 112 is rigidly connected to the frame 110 via the support brackets 120 and its plane is generally parallel to the main plane defined by the bottom ring 126 such that the hydrofoil 122 will be generally parallel to the seabed in use. A central aperture 119 is provided within the hydrofoil 112 . A lower face 113 of the hydrofoil 112 faces the stand 126 and is of a generally flat surface, whereas its opposite, upper, face 115 faces away from the stand 126 and gradually curves upwards away from the main plane of the hydrofoil as it approaches the central aperture 119 to form a raised lip portion 117 . This can be achieved by the assembly of a plurality of smaller hydrofoils 112 s to produce a multi-faceted hydrofoil 112 . The hydrofoil 112 thus has rotational symmetry around a central axis 118 but is not symmetrical on either side of its main plane.
[0077] Thus when a flow of water passes over each face 113 , 115 of the hydrofoil 112 , the reaction force of the water on the raised lip 117 pushes the hydrofoil 112 along with the other components of the apparatus 100 and ADCP canister 124 in a downwards direction—that is “negative lift” results.
[0078] Thus in use, the hydrofoil helps to direct the apparatus 100 and attached equipment towards the seabed and once in position, the hydrofoil maintains the apparatus and equipment on the seabed.
[0079] The apparatus 100 may be attached to a line (not shown) and the line attached at its other end to a buoy. If the apparatus needs to be recovered, the apparatus may be pulled in by the line.
[0080] An advantage of certain embodiments of the present invention, such as the second embodiment, is that they continue to perform their function of providing negative lift regardless of the direction of flow of the water.
[0081] An advantage of the second embodiment of the invention is that it includes no moving parts and so is reliable and requires minimal maintenance.
[0082] The embodiments described herein may also be provided with an integral turbine or other underwater equipment rather than attaching such equipment to the apparatus before use.
[0083] Although reference is made to employing the apparatus 1 , 100 in a tidal current and in certain embodiments using a tidal turbine, it is to be understood that the apparatus 1 , 100 may be placed in any flow of liquid such as rivers and are not limited to their use tidal areas.
[0084] An advantage of certain embodiments of the present invention is that they permit the launch and recovery of underwater equipment to be carried out using a non-specialist but suitably equipped vessel.
[0085] Concerning the primary environmental impact of embodiments of apparatus 1 according to the present invention, it would have some impact upon the benthic flora and fauna, and, although the positioning and retrieval of apparatus 1 would be relatively frequent (at least once every year is anticipated), nothing more than temporary localized disturbance is anticipated. There exists some potential for hydraulic oil leakage, but the system contents are minimal so, even in the event of complete system evacuation, any oil contamination would be minor. Operational environmental hazards are in common with the other forms of tidal energy extraction and decommissioning would leave no footprint.
[0086] Improvements and modifications in terms of dimensions and locations of the different parts described above may be incorporated to the hereinbefore described apparatus for controlling the launch and recovery of a tidal turbine without departing from the scope of the present invention.
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The apparatus may include a space frame on which is mounted at least one hydrofoil for generating positive or negative lift. The frame is attachable to underwater equipment such as a turbine. The hydrofoils are adapted to produce negative lift when a flow of liquid passes over them and so in use cause the apparatus and attached equipment to sink to the seabed. The flow of water over the hydrofoils continue to produce negative life and so maintain the apparatus on the seabed. In certain embodiments, the hydrofoils can typically be set to a passive configuration in which they flip over when the current flow changes direction. Furthermore, the hydrofoils are selectively rotatable to provide an angle of attack such that they may be adapted to provide positive lift when it is necessary to remove the apparatus from the water.
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FIELD OF INVENTION
The present invention relates to analogue electronic timepieces and particularly to means for controlling the width of pulses supplied to the driving coil of a transducer in order to reduce power consumption and thereby increase the useful life of a battery which supplies power for the timepiece.
BACKGROUND OF THE INVENTION
Conventionally in an analogue electronic timepiece having a transducer driven by periodic pulses the pulse width has a fixed value of, for example, 15.6ms, 7.8ms or the like. In designing the circuitry the pulse width is determined by the performance characteristics of the transducer and by the load on the transducer so that the pulse width is sufficient for driving the transducer under all conditions.
SUMMARY OF THE INVENTION
It is an object of present invention to provide a circuit for adjusting the pulse width automatically according to the load of the transducer so as to reduce power consumption of an analogue electronic timepiece and thereby prolong the power cell life.
BRIEF DESCRIPTION OF DRAWINGS
The nature, objects and advantages of the invention will be more fully understood from the following description of a preferred embodiment of the invention shown by way of example in the accompanying drawings in which:
FIG. 1 is an enlarged schematic view showing the construction of a transducer
FIG. 2 is a curve showing the relation between the current flowing through the driving coil of the transducer and the rotor position
FIG. 3 is a circuit diagram of a preferred embodiment of the present invention
FIG. 4 is a curve showing the operating characteristics of a transistor in the pulse width control circuit and
FIG. 5 is a time chart illustrating the operation of the embodiment of the invention shown in FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 is a plan view of a transducer comprising a rotor 21, a stator 22 and a driving coil 6 on the stator. The rotor 21 is a bipolar magnet which assumes a predetermined stationary position when the current in the coil 6 is cut off.
FIG. 2 shows the relation between the current flowing through the coil 6 and the angle of rotation of the rotor 21. When the rotor 21 rotates, a counter voltage is induced in the coil 6 and the wave form of the current becomes uneven. When the current in the coil 6 is equal to I T , the rotor 21 is in a position opposite to the stationary position i.e. a position rotated 180 degrees from the stationary position. I T is a value which is the voltage of the power supply divided by the direct current resistance of the coil 6. In order to conserve power it is desired to cut off the electric current when the flow of current through the coil 6 reaches the value I T .
FIG. 3 is a circuit diagram of a preferred embodiment of the present invention providing means for controlling the pulse width according to the load of the transducer. Current is supplied to the transducer driving coil 6 by two transducer driving inverter 4 and 5 which are controlled by NAND circuits 2 and 3. The three inputs of NAND circuit 2 are connected respectively to a point A to which a clock pulse is applied (for example by the divided frequency of a quartz crystal oscillator, not shown) the Q terminal of a flip flop 14 and the Q terminal of a flip flop 1. The three input terminals of the NAND circuit 3 are connected respectively to point A, the Q terminal of flip flop 14 and the Q terminal of flip flop 1. The clock signal input A is also connected to the CL terminal of flip flop 1 and the R terminal of flip flop 14.
The width of pulses supplied to the driving coil 6 of the transducer is controlled by a circuit comprising an N channel MOS transistor 10 the gate of which is connected to a voltage divider comprising resistors 7 and 8 and an N channel MOS transistor 9. The source of the N-MOS transistor 10 is connected to the power supply V SS . The drain of the N-MOS transistor 10 is connected to the transducer driving inverters 4 and 5 and also to the gate of an N channel MOS transistor 12 of which a P channel transistor 11 is used as MOS resistance. The source of N-MOS transistor 12 is connected to the power supply line V SS while the drain is connected through an inverter 13 to the CL terminal of the flip flop 14.
The operation of the circuitry in accordance with the present invention will now be described with reference to FIGS. 3, 4 and 5. The voltage between the gate and the source of the N-MOS transistor 10 is set so that the saturation current becomes I T as shown in FIG. 4. Thus by way of example I T is 530μA when the voltage of the power source is 1.57V and the direct current resistance of the coil is 3KΩ. The saturation current I T of the transistor is represented by the following equation:
I.sub.T - K(V.sub.G - V.sub.T).sup.2
where K is the conductive coefficient of the transistor 10, V G is the voltage between the gate and source and V T is the threshold voltage. Therefore V T , V G and K of the transistor 10 are set so that I T becomes 530μA. The value of V G is set by the resistances 7 and 8 and the transistor 9.
When the I T current flows through the transistor 10, the voltage between the drain and the source increases. The current flow is detected by the transistor 12 which acts through the invertor 13 and flip flop 14 to cut off the driving pulse. A time chart illustrating the operation is shown in FIG. 5. The curves of FIG. 5 are designated by the same letters as the corresponding parts of the circuit in FIG. 3.
In the circuitry of FIG. 3 the transistor 9 compensates for dispersion due to the manufacturing process of the parameter characteristics of the N-MOS transistor 10. In the transistor 10 K and V T are determined so that; I D = K(V G - V T ) 2 = I T .
However when V T goes down to the designed value, I D increases so that I D > I T . In this case I D is made equal to I T by decreasing V G corresponding to variation of V T . The drain and the gate of the transistor 9 are connected so that the transistor operates in saturation state. Therefore, if K of the transistor becomes large, the voltage between the drain and the source of the transistor becomes V T .
Since the transistors 9 and 10 are made through the same process, V T of the two transistors are equal. Therefore the lower V T of the transistor 10 becomes, the lower V T of the transistor 9 also becomes. Then the voltage between the gate and the source of the transistor 10 decreases and an increase in I D caused by decrease in V T is revised.
According to FIG. 3 the source of the N channel transistor of the transducer driving invertor is common and the transistor is connected with the power source in series. However it is to be understood that the circuit operates as well if the source of the B channel transistor is common.
When the current which flows through the coil 6 reaches I T , the rotor has rotated through an arc of 180°. Actually however, the rotor rotates by inertia even if the pulse is cut off before hand. Therefore the power consumption can be decreased more if the saturation current is set less than I T .
It will thus be seen that according the the present invention power consumption of the transducer decreases and power cell life is prolonged. At the same time since the pulse width varies according to the load of the transducer, the transducer operates stably even though there is a variation of load.
While a preferred embodiment of the invention is illustrated in the drawings and is herein particularly described, it will be understood that modifications and variations may be made and that the invention is thus in no way limited to the illustrated embodiments.
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In an analogue electronic timepiece having a transducer comprising a rotor, a stator and a driving coil, means is provided for supplying to the driving coil, periodic pulses of a selected width to drive the rotor. The width of the pulses is automatically controlled according to the load of the transducer so as to reduce power consumption and accordingly to increase the useful life of the battery by which power is supplied.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to the field of golf. More particularly, the invention relates to sand bunkers and an improved water drain system for removing excess water.
[0002] The field of golf imposes unique design requirements on turf systems and sand bunkers disposed near greens. Bunkers are deliberately positioned to create artificial hazards to errant golf balls. The bunkers are typically constructed as depressions having a clay base with sloped sidewalls rising upward to turf. The bunkers have specific peripheral configurations, depth, and sloped sides. Sand overlays the clay base to provide the playing surface for golf balls. The sand is typically groomed daily by hand or with motorized equipment to present an even surface to the golfers. Rakes and other equipment “fluff” the top surface of the sand to present the desired surface.
[0003] In wet climates, rainwater compacts the sand and mixes the sand with the underlying clay base. Clay particles or “fines” discolor the overlying sand and also alter the playing qualities of the bunker. Various efforts have been made to reduce the commingling of sand and clay particles and to prevent other contamination of the sand. Cement is mixed with the clay base to harden and stabilize such base. However, mechanized equipment in the bunkers tends to crack the cement stabilized liner, leading to further deterioration. As shown in U.S. Pat. No. 5,746,546 to Hubbs et al. (1998), fiber strands and water absorbent particles such as psyllium are added to soil to improve the soil shear strength.
[0004] Other bunker systems use geotextile fabrics underlying the sand. Fabric liners do not easily retain the sand on the sloped sides and are subject to rupture and other failure. Such liners do not independently correct the problems associated with rainwater accumulation in the bunkers.
[0005] Because the bunkers comprise depressions in the soil, rainwater collects in the bunkers and must be drained to another location. Perforated pipe is installed in the bottom of bunkers to drain excess water to a water discharge line. Gravel is packed around the exterior surface of the perforated drain pipe to form a French drain. Such systems eventually fail in wet climates because the clay linings are susceptible to erosion. Clay particles and other contaminants such as grass clippings pack around the perforated pipe to lower the fluid transmissivity of the gravel, and such particles further enter the pipe interior. Over time the accumulated intrusion clogs the pipe, requiring reconstruction of the entire bunker. Such construction is not only expensive to accomplish but also disrupts the utility of the golf course during construction.
[0006] Drain systems have been developed for other applications such as large playing fields. For example, U.S. Pat. No. 5,848,856 to Bohnhoff (1998) disclosed a thermoplastic mat underlying the surface which facilitated capture of water within an inflatable container for redistribution to the turf surface. Bohnhoff further described conventional perforated pipe networks and the problems associated with poor drainage.
[0007] In bunkers having perforated pipe drains, clay fines inevitably pack off the pipe at the lowest point in the bunker. This occurrence causes excess water to pond at this position within the bunker, further accelerating deterioration of the bunker drain system. A need exists for an improved bunker drain system which facilitates water drainage from bunkers and facilitates maintenance operations.
SUMMARY OF THE INVENTION
[0008] The invention provides a system for draining water from a bunker having a surface covered with sand. The system comprises a receptacle having an interior space for collecting water and for discharging the water through an outlet in the receptacle, wherein the receptacle is capable of being positioned in the bunker surface at an elevation below the sand, an aperture in the receptacle for permitting water entry into the receptacle interior space, and a cover detachably engaged with the receptacle, wherein the cover resists entry of sand into the receptacle interior space, and wherein the cover is moveable to permit entry into the receptacle interior space.
[0009] In another embodiment of the invention, a perforated pipe connected to the receptacle collects water and directs the water toward the receptacle. The perforated pipe can be divided into two or more branches for covering a larger surface area of the bunker.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 illustrates an elevation view of a receptacle installed in a bunker.
[0011] [0011]FIG. 2 illustrates an elevation view of a pipe connected to a receptacle aperture.
[0012] [0012]FIG. 3 illustrates a screen in cooperation with an aperture for permitting entry of water while resisting sand entry into the receptacle interior space.
[0013] [0013]FIG. 4 illustrates a plan view of a perforated pipe collection system draining water to a single receptacle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The invention provides a unique method and apparatus for draining water from a bunker having a surface covered with sand. FIG. 1 illustrates receptacle 10 positioned within bunker 12 comprising soil 14 and sand 16 . Bunker 12 is irregularly shaped and is sloped toward one or more ends so that excess water collects toward the low end of bunker 12 . Soil 14 can comprises existing soil conditions, imported material such as clay, stabilized soil material, or other conventional bunker base material. Bunker 12 has steeply sloped sides terminating at ground elevation 18 so that bunker 12 forms a golf play hazard depressed below ground elevation 18 .
[0015] Receptacle 10 comprises a substantially hollow box having interior space 20 and is formed with a material resistant to degradation such as plastic, metal, composite, or cemetitious product. Cover 22 is engaged with receptacle 10 and is movable to permit entry into interior space 20 . Cover 22 resists entry of sand and other contaminants into interior space 20 and can be positioned on the upper portion of receptacle 10 as shown in FIG. 1 of on a side of receptacle 10 as shown in FIG. 2. One or more apertures 24 are located in receptacle 10 , in cover 22 , or both to permit water entry into interior space 20 . As shown in FIG. 1, one or more apertures 24 can be incorporated within cover 22 to permit water entry. As shown in FIG. 2, aperture 24 can be connected to pipe 26 for the purposes described below. Although apertures 24 are illustrated in the side of receptacle 10 , apertures 24 can be located in cover 22 as shown in FIG. 3.
[0016] In one embodiment of the invention, apertures 24 can be smaller than the particle size of sand 16 and other contaminants to resist entry into interior space 20 . In another embodiment, screen 28 can be integrated with one or more larger apertures to provide the function of resisting sand entry as shown in FIG. 3. Screen 28 can be formed with a rigid or flexible material resistant to degradation and can comprise expanded metal, plastic, composites, fibreglass, filter cloth, or other material. Screen 28 can be removable to facilitate damage repairs or to adjust the screen 28 mesh size. Screen 28 can be formed with a single material or a combination of materials.
[0017] In one embodiment of the invention as shown in FIG. 2, aperture 24 can be positioned in a side of receptacle 10 for connection with pipe 26 . Multiple pipes 26 can be connected with receptacle 10 instead of the single pipe shown. Pipe 26 can comprise a perforated pipe having one or multiple branches 30 for installation in different portions of bunker 12 . FIG. 4 illustrates a plan view of bunker 12 wherein multiple branches 30 of perforated pipe 26 are positioned in bunker 12 to resist surface movement of water and to facilitate water drainage from the bottom surface of bunker 12 . One or more branches 30 can connect directly to receptacle 10 or such branches can be combined into a single trunk branch 32 connected to receptacle 10 as shown. Depending upon the configuration and various elevations of bunker 12 , more than one receptacle 10 can be installed at various low points within bunker 12 , and such receptacles 10 can be connected together with pipe 16 or each can separately drain to an outside location. Although pipe 26 is not essential to the operation of the invention, pipe 26 removes water from the surface of bunker 12 at different locations and reduces the horizontal migration of water within bunker 12 . This feature reduces the impact of erosion on sand 16 during moderate rainfall. For events of heavy rain, excess water can flow along the surface of bunker 12 or through sand 16 and enter receptacle through one or more apertures 24 .
[0018] Referring to FIG. 2, receptacle 10 has one or more outlets 34 for discharging water from interior space 20 . Outlet 34 can be connected to conduit 36 for transporting water to another location by gravity fall or by a pump mechanism (not shown). Outlet 34 can be positioned flush with the bottom of interior space 20 or can be elevated above such bottom as illustrated to trap sediments within receptacle 10 for subsequent removal. If desired, filter 38 can be positioned proximate to outlet 34 to restrict sediment particles from outflow into conduit 36 .
[0019] As shown in FIG. 1, handle 40 can be attached to cover 22 to facilitate removal of cover 22 from engagement with receptacle 10 . Handle 40 can be attached to the top of cover 22 as shown or to the sides of cover 22 . In one embodiment of the invention, one or more hinges 42 can connect cover 22 to receptacle 22 . If cover 22 is located on the upper portion of receptacle 10 , cover 22 is preferable strong enough to withstand impacts from persons or equipment or other animate or inanimate object travelling over or stepping onto cover 22 . The size and configuration of apertures 24 located in cover 22 can be smaller than a person's foot to resist damage caused by overlying foot traffic.
[0020] By positioning sand on top of receptacle 10 or cover 22 , the presence and function of cover 22 is not readily apparent to golfers, leading to relatively uninterrupted golf play. This feature of the invention is particularly significant because a golf ball resting on top of receptacle 10 or cover 22 can be played from the overlying sand 16 surface, therefore providing uninterrupted play regardless of location.
[0021] The invention provides superior benefits regarding the installation cost, operability, and maintenance costs associated with sand bunkers on golf courses and other applications. Costly replacement of perforated drain pipe systems is essentially eliminated, since cover 22 provides access to interior space 20 within receptacle 10 to facilitate routine sediment removal. Sediment is easily removed from interior space 20 , from upstream pipe 26 , and from downstream conduit 36 . Pipe cleaning tools can be operated through cover 22 and moved upstream through pipe 26 (or downstream through conduit 36 ) to remove sediments intruding into pipe 26 without requiring upstream location of pipe 26 ends, and without requiring removal of pipe 26 from soil 14 or sand 16 . Underground maintenance can be performed through cover 22 and receptacle 10 without interfering with golf play, and without significantly disrupting the sand surface of bunker 12 . These features of the invention permit ongoing maintenance of golf bunkers without causing expensive cessation of golf play opportunities.
[0022] By providing cover 22 independent from receptacle 10 , the configuration of apertures 24 or the size and composition of screen 28 can be adjusted to adapt to field conditions or to permit change in the composition of materials such as a change in the bunker sand 16 . Screen 28 can comprise a single material or a composition of different materials or layers and can include screen and embedded strength components.
[0023] To enter interior space 20 , the position of receptacle 10 can be mapped regarding its location and sand 16 is removed from the relatively small region overlying cover 22 . After cover 22 is located, cover 22 can be completely detached from receptacle or otherwise moved relative to receptacle 10 to permit inspection or maintenance entry into interior space 20 . When finished, cover 22 is reinstalled relative to receptacle 10 and sand 16 is replaced over cover 22 to restore bunker 12 to the original playing surface.
[0024] Although the invention has been described in terms of certain preferred embodiments, it will become apparent to those of ordinary skill in the art that modifications and improvements can be made to the inventive concepts herein without departing from the scope of the invention. The embodiments shown herein are merely illustrative of the inventive concepts and should not be interpreted as limiting the scope of the invention.
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An improved system for draining bunkers on golf courses. A receptacle is positioned below the bunker surface and can have an aperture for receiving drain water and an outlet for discharging the water through a conduit. A perforated pipe water collection system can be attached to the receptacle to direct water to the receptacle interior space. A receptacle cover is removable to permit access to the receptacle interior space. The cover is sufficiently strong to support the overlying weight of people and equipment and can have apertures for permitting water entry while resisting sand entry into the receptacle interior space.
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This application is a continuation application of U.S. patent application Ser. No. 09/999,262, filed on Nov. 28, 2001, now U.S. Pat. No. 6,916,910, which is a continuation of U.S. patent application Ser. No. 08/959,272, filed on Oct. 28, 1997, now U.S. Pat. No. 6,337,389, which is a continuation-in-part of U.S. patent application Ser. No. 08/405,979, filed on Mar. 17, 1995, now U.S. Pat. No. 5,714,582.
FIELD OF THE INVENTION
This invention relates to the method and process for the production of collagen preparations from invertebrate marine animals including jellyfish and compositions of these preparations. These collagen preparations are useful in a variety of applications ranging from medical, pharmacological, and cosmetic. The composition is available as a mixture in a gel state, in a freeze-dried state, in a salt-reprecipitated state, and can be delivered as a mixture in a fluidized state, as a mixture in a gel state, and/or in association with surfactant/detergent combinations as an intact collagen molecule or as a hydrolyzed collagen product. The process for the production of collagen from invertebrate marine sources including jellyfish, takes advantage of the physical and chemical characteristics of jellyfish where the jellyfish is essentially a gelatinous state of collagen in water surrounding simple digestive systems and attached to other collagenous structures generally described as tentacles which are used in the capture of prey for the purpose of feeding.
BACKGROUND OF THE INVENTION
The term jellyfish refers to hundreds of species of primitive marine animals belonging to the class Scyphozoa, phylum Coelenterata. Coelenterata is a phylum name derived from the Greek words meaning “hollow gut.” It refers to important attributes of a group of invertebrate animals, called coelenterates, having a single internal cavity for digestion and excretion. Jellyfish often become abundant in coastal areas, particularly in late summer, and are regarded as a nuisance. Jellyfish sting swimmers, clog nuclear power plants, and fishing boat nets and, at times can cause severe damage to fishing nets owing to their huge volume and weight. In the water they are beautiful, colorful, and diaphanous creatures, yet most people only see them as a washed-up blob on the beach. Jellyfish can be found in both tropical and temperate waters of the world. The environmental factors affecting the occurrence of jellyfish are temperature, oxygen, salinity, and predation. Some species of jellyfish have great commercial potential. For example, the US coastal waters of the Florida Panhandle and all of the northern Gulf of Mexico provide an ideal environment for the seasonal proliferation of Stomolophus meleagris , which is commonly called the cannon-ball jellyfish. This species is found in abundance in certain areas of the world. For instance, it occurs from Southern New England, USA, to Venezuela and the Gulf of Mexico. One swarm observed at Port Arkansas, Tex., USA was estimated to have drifted through the channel at a rate of approximately 2 million per hour. Jellyfish occur world-wide, being caught in the Indian, Northwest Pacific and Western Central Pacific Oceans by Far Eastern countries including Thailand, Indonesia, Malaysia, the Philippines and China. In 1991, for example, the world harvest of jellyfish was 126,419 tons and Japanese buyers pay up to $25.00 per kilogram for large processed Grade “A” Rhopilema esculenta jellyfish.
Fresh jellyfish contain approximately 95 to 98% water by weight, depending on the particular species and approximately 2 to 3% salt by weight, which is in approximate osmotic equilibrium with salt water. The contents of solids other than salt is extremely low; not much higher than 1% by weight. Protein content is approximately 1.3%. The lipid content of jellyfish is very low. On a wet-weight basis, lipid contents in the range 0.0046 to 0.2% have been reported. The nonpolar lipids of lyophilized jellyfish comprised 31.1% of the total lipids and sterols may account for approximately 47.8% of the nonpolar lipids. The cholesterol content of four species of coelenterates was in the range of 72.2 to 88.8% of the sterol content. Calculated from the above values, the cholesterol content on a wet-weight basis would be less than 0.35 mg/100 gm.
Commercially available processed jellyfish contain approximately 5.5% protein, 25% salt and 68% water, however this type of jellyfish would be for consumption and would need to be desalted prior to consumption. As a food-stuff, the protein content of jellyfish in terms of protein level is similar to foods such as pasta and boiled rice.
Jellyfish proteins consist almost entirely of collagen. Analysis of the amino acid composition of mesogloea hydrolysate showed that glycine is the most abundant amino acid, and that hydroxyproline and hydroxylysine, which are characteristic of collagen, are present. Tryptophan is almost totally absent. Thus, mesogloea contain proteins belonging to the collagen group.
SUMMARY OF THE INVENTION
The present invention is concerned with the preparation of collagen compositions from invertebrate classes and species of marine animals constituting several hundreds of species of primitive marine animals, including species of jellyfish belonging to the class Scyphozoa, phylum Coelenterata. The present invention includes other classes of marine organisms and other species of invertebrates present in the marine environment where invertebrate type V collagen, the designation to be applied to collagens described by this present invention, possess similar physical and chemical characteristics. The present fibrous collagen products are unique and distinguished from previous collagen products formed from vertebrate animals species in that the marine invertebrate animals including jellyfish live and function in an environment different from that in which the vertebrate animal species live and function. For example, the marine jellyfish are found in salt-water environments hypertonic to vertebrate animals; are poikilothermal, i.e. have a body temperature that varies with the environmental temperature, and generally live and function at low temperatures compared to the body temperatures of most vertebrate species; live under variable pH conditions, but generally at pH values significantly less than “physiological” pH (pH 7.4) characteristic of vertebrate species; and lack significant tensile strength in their body structures. These attributes, i.e., pH, temperature, salt concentration, and tensile properties, represent important parameters used in the extraction and preparation of collagens from vertebrate species and thus, extraction and preparation of collagens from marine jellyfish would constitute a unique and novel process and the collagen preparation would have unique and novel properties even compared to type V collagen preparations from vertebrate species.
In the present invention, invertebrate marine animals including jellyfish of various genera, are subjected to mild mechanical disruption followed by mild acid solubilization of the disrupted tissue. Collagens are precipitated by salts with mild shearing and/or by continuous dialysis and are formed into aqueous, gelled, precipitated, and/or mat/sponge preparations. The fibrous collagen preparation(s), constitute primarily invertebrate type V telopeptide containing collagen, and are useful in a variety of medical, dental, nutritional applications, and/or as component(s) of cosmetics and other pharmacologicals depending on the purity of the collagen preparation and/or heterogeneity of jellyfish components allowed to remain in the preparations. The fibrous aggregates may be used directly for a variety of purposes or may be cross-linked to provide fibers having substantial structural integrity and macroscopic dimensions. Depending on the intended use of the fibrous materials, the fibers and/or other resident natural components may be treated in a variety of ways to prepare various articles of manufacture.
An object of the present invention is to provide substantially pure marine invertebrate type V telopeptide containing collagen.
A further object of the present invention is to provide a cosmetic composition containing marine invertebrate type V telopeptide containing collagen.
Another object of the present invention is to provide a cosmetic cream composition containing marine invertebrate type V telopeptide containing collagen.
An object of the present invention is to provide a cosmetic lotion composition containing marine invertebrate type V telopeptide containing collagen.
An additional object of the present invention is to provide a shampoo composition containing marine invertebrate type V telopeptide containing collagen.
An object of the present invention is to provide a hair conditioner composition containing marine invertebrate type V telopeptide containing collagen.
A further object of the present invention is to provide a makeup formulation containing marine invertebrate type V telopeptide containing collagen.
Another object of the present invention is to provide a colored cosmetic formulation containing marine invertebrate type V telopeptide containing collagen.
A further object of the present invention is to provide a cosmetic composition containing marine invertebrate type V telopeptide containing collagen in an amount of from 0.001 wt % to 30.000 wt %.
An object of the present invention is to provide a cosmetic composition containing marine invertebrate type V telopeptide containing collagen in an amount of from 0.1 wt % to 10.0 wt %.
An additional object of the present invention is to provide a cosmetic composition containing marine invertebrate type V telopeptide containing collagen in an amount of from 0.5 wt % to 5.0 wt %.
A further object of the present invention is to provide a process for preparing the present marine invertebrate type V telopeptide containing collagen by extracting, the collagen from a marine animal, in dilute acid; precipitating the extracted collagen, and washing the collagen precipitate.
An object of the present invention is to provide fibrillar marine invertebrate type V telopeptide containing collagen.
Another object of the present invention is to provide a cosmetic composition containing fibrillar marine invertebrate type V telopeptide containing collagen.
An additional object of the present invention is to provide marine invertebrate type V telopeptide containing collagen in the form of a gel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Definitions
In order to provide a clear and consistent understanding of the specification and claims, including the scope to be given such terms, the following definitions are provided.
Cosmetic Composition.
By the term “cosmetic composition” is intended for the purposes of the present invention any composition or agent for external application to human or animal skin, nails, or hair for the purpose of beautifying, coloring, conditioning, or protecting the body surface containing a cosmetically effective amount of marine invertebrate type V telopeptide containing collagen. A cosmetically effective amount of such collagen is that amount required to bring about the desired cosmetic effect, with from 0.001 wt % to 30.000 wt % being preferred, 0.1 wt % to 10.0 wt % more preferred, and 0.5 wt % to 5.0 wt % being most preferred. One of ordinary skill in the art to which the present invention pertains can readily determine what constitutes a “cosmetically effective amount” without undue experimentation. The present cosmetic composition can be in any form including for example: a gel, cream, lotion, makeup, colored cosmetic formulations, shampoo, hair conditioner, cleanser, toner, aftershave, fragrance, nail enamel, and nail treatment product.
Colored Cosmetic Formulation.
By the term “colored cosmetic formulation” is intended for the purposes of the present invention, those cosmetics containing pigment including for example eye shadow, lipsticks and glosses, lip and eye pencils, mascara, and blush.
Conditioning Agent.
By the term “conditioning agent” is intended any agent or composition which exerts a conditioning effect on the body including the skin, hair and/or nails upon external application and includes for example humectants; emollients; oils including for example mineral oil; proteins including the present collagen; and shine enhancers including for example dimethicone and cyclomethicone. The present conditioning agents may be included in any of the present pharmacological and/or cosmetic compositions.
Telopeptide Containing.
By the term “telopeptide containing” is intended, for the purposes of the present invention, a marine invertebrate type V collagen composition where the composition includes collagen molecules where the nonhelical terminal portions of the native collagen molecule, the telopeptides which extend as random coils from the amino and carboxyl ends of the collagen molecule, are retained.
Atelopeptide Containing.
By the term “atelopeptide containing” is intended, for the purposes of the present invention, a marine invertebrate type V collagen composition where the composition includes collagen molecules where the nonhelical terminal portions of the native collagen molecule, the telopeptides, have been removed for example by enzymatic cleavage.
Fibrillar Collagen.
By the term “fibrillar collagen” is intended for the purposes of the present invention, a natural polymeric form of collagen which is essentially insoluble in its aqueous environment yet forms a viscous gel-like matrix.
Invertebrate Marine Animal.
By the term “invertebrate marine animal” is intended, for the purposes of the present invention, invertebrate animals present in a salt-water or fresh-water marine environment and include for example members of the phylum Coelenterata, members of the class Scyphozoa and the phylum Coelenterata including for example jellyfish.
Pharmacological Compositions.
By the term “pharmacological compositions” is intended for the purposes of the present invention any composition or agent applied externally to the skin, hair, or nails of the human or a animal body for therapeutic purposes containing a pharmacologically effective amount of the present marine invertebrate type V telopeptide containing collagen. A “pharmacologically effective amount” is that amount required to bring about the desired therapeutic effect, with 0.001 wt % to 30.000 wt % being preferred, 0.1 wt % to 10.0 wt % more preferred, and 0.5 wt % to 5.0 wt % being most preferred. One of ordinary skill in the art to which the present invention pertains can readily determine what constitutes a “pharmacologically effective amount” without undue experimentation. Examples of pharmaceutical agents or compositions in accordance with the invention include ointments, creams, lotions, gels, solutions, and shampoos. More specific examples include for example, acne treatment preparations including creams, soaps, cleansers, moisturizers, ointments and lotions; anti-aging preparations including creams, cleansers, moisturizers and lotions; anti-dandruff preparations including shampoos and conditioners; antibiotic preparations; sunburn preparations; anti-itch preparations; and anti-fungal preparations.
The present non-cross-linked or cross-linked fibrillar telopeptide containing collagen may be used directly as a gel. As a gel, the fibrillar collagen can be used as a vitreous body or as dispersions/solutions for the preparation of cosmetic and pharmacological compositions. The fibrillar collagen can be cast into various forms at varying collagen fiber density and cross-linked to form mat or sponge-like structures which may be used in a variety of applications such as delivery of pharmaceutical agents to hair or skin, as artificial nails, as prosthetics, theatrical devices, etc. Articles of matter produced using marine invertebrate type V telopeptide containing fibrillar collagen are different from similar articles of matter produced using collagen preparations obtained from vertebrate species.
A method is provided for preparation of commercially useful amounts of essentially type V collagen from marine jellyfish which may be formed into a variety of formulations and/or products. The collagen is most conveniently prepared from the whole organism, but the hemispherical bell-shaped transparent umbrella may be separated from the numerous fine marginal tentacles and reproductive and/or digestive structures present in the umbrella may be removed and the partial umbrella used in the production of various collagen preparations. Depending on the intended use of the derived fibrous materials, the native collagen may be freed of extraneous matter such as lipids, saccharides, and noncollagenous proteins so as to leave an essentially purified preparation of type V collagen. Another approach includes using fibrous materials in the preparation of a “natural” cosmetic such as a hair or skin cleaning/conditioning preparation and in this application of the present invention, the native collagen may be less extensively purified such that the natural material components of the jellyfish are retained in the product(s).
The nonhelical terminal portions of the native collagen molecule, the telopeptides, extend as random coils from the amino and carboxyl ends of the molecules and may be retained or enzymatically removed in preparation of the final product(s). The telopeptides serve a number of functions in the formation of the native collagen fiber. The telopeptides serve as the primary sites for cross-linking intramolecularly (between the three constituent polypeptide chains in the native collagen molecule) and intermolecularly (between two or more native collagen molecules).
In a preferred embodiment of the present invention, native essentially type V marine invertebrate telopeptide containing collagen is produced essentially free of noncollagenous proteins and other substances naturally present in marine jellyfish. This collagen is soluble in dilute aqueous acid, e.g., 0.01 M acetic acid, and 0.001 N HCl, and any insoluble collagen, if present, may be removed by filtration, centrifugation, or other means.
In another preferred embodiment of the present invention, native essentially type V marine invertebrate telopeptide containing collagen is produced which retains appropriate noncollagenous proteins and/or polysaccharides naturally present in marine jellyfish. This collagen preparation is soluble in dilute aqueous acids and nonsoluble components and/or tissue structures may be removed by filtration, centrifugation, or other means.
Once the collagen solution is obtained, it may be employed for preparing fibrous aqueous solutions, fibrous aqueous gels, and dispersions/solutions of these products in surfactant solutions containing other ingredients suitable for the preparation of hair and skin treatments, and cosmetic and pharmacological compositions. The procedure for preparing the fibrous preparations involves a slow precipitation of the collagen from solution while subjecting the aqueous medium to mild shear (stirring). The conditions under which the precipitation of the collagen is achieved can vary. The temperatures employed are preferably in the range of from 0° C. to 42° C., more preferably from 10° C. to 30° C., and most preferably from 15° C. to 25° C. The pH is generally in the range of about 3 to 9, preferably in the range of 5 to 8, and more preferably between 6 and 7.5. A wide variety of salts may be used, usually alkali metal salts, both neutral and alkaline, more particularly sodium and potassium, with mono and polyvalent cation salts, particularly halides, e.g. chloride. The concentration of the salt may vary widely with the other conditions employed, e.g., temperature, and protein concentration, as well as the particular salt employed. Suitable concentrations are preferably in the range of from about 0.05 M to 4.0 M, more preferably from 1.0 M to 3.8 M, and most preferably between 2.5 M and 3.5 M. Suitable concentrations of polyvalent salts are in the range of from about 0.5 M to 4.0 M, more preferably from 1.0 M to 4.0 M and most preferred concentrations ranging from 2.5 M to 4.0 M. The concentration of collagen in the solutions being precipitated may range between 0.01 mg/ml and 10 mg/ml, preferably in the range of from 0.1 mg/ml to 5 mg/ml, and most preferably from 0.5 mg/ml and 4 mg/ml. Precipitation time varies from about 10 minutes to 5 hours, usually about 30 minutes to 2 hours, and preferably about 1 hour to 1.5 hours.
Various techniques may be used to obtain the desired rate of precipitation of collagen while applying the mild shearing. One technique is heat gelation, wherein a constant or slowly increasing temperature is employed to bring about precipitation of collagen in the presence of salt. Generally, the temperature range is from about 4° C. to 45° C., the temperature being slowly raised from about 4° C. to 10° C. to a temperature of about 20° C. to 37° C. Salt concentrations generally vary from about 1.0 M to 4.0 M. Alkali metal halides, e.g. sodium chloride, are preferably employed. The pH is generally from 4.0 to 8.0, preferably 5.0 to 6.0. Particularly preferred conditions are nonphysiological conditions for the jellyfish, namely 3.5 M NaCl, pH 5.0, with a final temperature of about 35° C.
A second technique is to provide a slow increase in ionic strength, pH, and temperature with the collagen in solution. This can be achieved by employing dialysis with a monovalent or polyvalent salt dialysate, thereby slowly raising the salt concentration (or ionic strength) while the acid in the collagen solution diffuses from the collagen solution into the dialysate. The change in pH can be either continual or incremental, typically by employing alkali salts in the dialysate. Usually the dialysate has a salt concentration of 1.0 M to 4.0 M, more usually to 2.5 M to3.8 M, particularly of disodium phosphate. The final pH of the medium is generally 3.0 to 8.5, more usually 4.0 to 6.5, and preferably 5.0 to 5.5.
Another procedure is that of continuous dialysis at moderately reduced to low temperatures while changing the dialysate from a dilute mildly acidic solution to (generally a mild mono or dicarboxylic organic acid or dilute mineral acid such as HCl) to a mildly basic salt solution, while increasing the ionic strength or salt concentration by using a dialysate of increasing salt concentration. With increasing ionic strength or salt concentration, the temperature of the solution may also be increased, until a fibrous mass of obtained. The fibrous mass is freed of any nonfibrous materials and may be treated in a variety of ways depending on the intended use.
Another use of the present collagen preparations includes the addition of the preparation into solutions of surfactants, detergents, soaps, and similar formulations for use with treatment of hair and skin as a cosmetic, a cosmetic ingredient, and/or pharmacological agent. The term “cosmetic ingredient” is the same as “cosmetic composition” and means a composition applied externally to skin, nails, or hair of the human or animal body, for purposes of beautifying, coloring, conditioning, cleansing, or protecting the bodily surface. Examples of cosmetic ingredients or cosmetic compositions in accordance with the invention include lotions, creams, moisturizers, gels, sun screens, makeup, cleansers, soaps, shampoos, hair conditioners, skin firming compositions, protein concentrates, after shaves, colored cosmetics including for example eye shadows and blushes, nail enamels, and so forth. Vertebrate animal collagen is known to have moisturizing and film forming properties, and is a popular additive to treatment cosmetics. The term “pharmacological agent” is the same as “pharmacological composition” and means a agent or composition applied externally to the skin, hair, or nails of the human or a animal body for therapeutic purposes. Examples of pharmaceutical agents or compositions in accordance with the invention include ointments, creams, lotions, gels, soaps, solutions, and shampoos.
Animal collagen protein is the main component of connective tissues and animal keratin is the main component of hair and fingernails. Collagen is responsible for most of skin structure. In the course of aging the polypeptide chains of collagen polymerize. The result is “cross-linking”, which causes wrinkling of the skin as well as reduction in skin elasticity. Keratin is responsible for the most of hair structure. In the course of hair growth, the keratins dry out and exhibit cracks in surface structure of hair. Collagens are natural film forming agents and aid in prevention of drying. The present collagen preparation can be added to a typical shampoo composition by weight, an example of which is set forth below:
Weight
Trade name
CTFA Name
Percent
Sulfotex UBL 100 acid
Dedecybenzene Sulfonic Acid
3.0
Triethanolamine
Triethanolamine
1.7
DI water
50
Invertebrate Type V Collagen
0.5
Panthenol
Panthenol
0.24
Sulfotex LMSE
Sodium Laureth Sulfate
15.0
Sulfotex WA
Sodium Lauryl Sulfate
10.0
Germaben II
Propylene Glycol
56.0
Diazolidinyl Urea
30.0
Methyl Paraben
11.0
Propyl Paraben
3.0
Ninol LL-50
Lauramide DEA
7.0
DC 929
Amodimethyl (and)
1.0
Nonoxynol-10 and
Tallowdimonium Chloride
D&C Yellow #5 Solution
0.04
Clindrol SEG
Glycol Stearate (optional)
2.0
In addition, the present material can be added to various formulations of skin care products generally described as lotions for application to human facial or body skin. These lotions generally contain from about 20-80% oil and 10-80% water in an emulsion form. In addition, the moisturizing lotion may contain humectants, emollients, surfactants, fragrances, preservatives, and so forth. About 5-10% humectant, about 5-20% emollient, and about 0.5-10% surfactant are suggested. Marine invertebrate Type V telopeptide containing collagen (at about 0.01 to 1.00 wt %) and hydrolyzed collagen (at about 0 1 to 2.0 wt %) products may be incorporated into moisturizing creams. Creams generally contain from about 20-70% water and about 30-70% oil. In addition, creams may contain a variety of humectants, emollients, surfactants, preservatives, and fragrances. About 5-10% humectant, about 5-20% emollient, and about 0.5-10% surfactant are suggested.
Marine invertebrate Type V telopeptide containing collagens (incorporated at about 0.01 to 5.0 wt %) and hydrolyzed collagen (incorporated at about 0.1 to 10.0 wt %) products may be incorporated into treatment makeups. Generally, makeup formulations comprising 5-70% oil, 10-95% water, and about 5-40% pigment, are suitable. In addition, the makeup as well as any of the present cosmetic or pharmacologic compositions may contain other components known and readily selected by those of ordinary skill in the art to which the present invention pertains. For makeup formulations such components may include for example surfactants, preservatives, silicone, humectants, emollients, and fragrances. Generally 0.5-10% surfactant, 0.1-30% silicone, 5-10% humectant, 0.1-30% emollient, and 0.1-5% preservative are included.
Marine invertebrate Type V telopeptide containing collagens (about 0.2 to 2.0 wt %) and hydrolyzed collagen (about 0.01 to 5.00 wt %) products may be incorporated into colored cosmetics such as eye shadow or blush. For example, a suitable eye shadow comprises 5-40% pigment, 1-50% oil, and 1-20% waxes. Additionally, the composition may contain one or more of 10-60% water, 0.5-30% surfactant, 1-10% humectants, 0.1-5% preservative, and 0.1-20% silicone.
Invertebrate Type V collagens (about 0.01 to 2.00 wt %) and hydrolyzed collagen (about 0.01 to 5.00 wt %) products may suitable for incorporation into shampoos and hair conditioners. Suitable shampoo formulations include 1-40% surfactant and 10-90% water Suitable hair condition formulations include 30-95% water, 0.5-30% conditioning ingredients including for example, emollients, proteins, and shine enhancers, and 1-40% surfactant. Hair conditioners and shampoos may also contain thickeners and silicone. About 0.05-5% silicone is suggested in shampoos and hair conditioners.
The invention includes cosmetic and pharmaceutical compositions containing a cosmetically or pharmaceutically effective amount of invertebrate type V telopeptide containing collagen protein. A cosmetically and/or pharmacologically effective amount of collagen protein in accordance with the invention is that amount required to bring about the desired cosmetic and/or therapeutic effect. Such amount can readily selected by one of ordinary skill in the art to which the present invention pertains based on the particular formulation and the desired effect, without undue experimentation. Preferably, about 0.001-30 wt %, more preferably 0.1-10 wt %, and most preferably 0.5-5 wt % is employed.
In describing the present invention, three stages will be considered. The first stage is the purification of native collagen and its transformation into collagen in solution. The second stage is the transformation of the collagen in solution into native fibrous polymers. The third stage is the use of the native collagen, collagen in solution, and fibrous polymers, for the fabrication of various articles or the formation of composites.
Suitable collagen sources include a wide variety of marine animals such as those of the phylum Coelenterata. Collagen dispersions or solutions obtained from the mantle, tentacles, and whole organism provide similar collagen dispersions or solutions. First the reproductive and digestive tissue structures and tentacles, are removed from the organism. The mantle portion of the jellyfish provides the most uniform materials for production of collagen dispersions or solutions with the least amount of noncollagenous protein material(s). For purposes of this invention, collagen dispersion or solutions are defined as aqueous compositions where the collagen does not settle away from the aqueous composition under normal conditions of preparation and storage.
To enhance the ease of purification and facilitate dispersion/solubilization of collagens, the material is subjected to various mechanical treatments such as dissection, grinding, high speed shearing, and the like. Depending on the particular treatment, the tissue may be wet or dry, frozen or cooled, high speed shearing is preferably carried out with frozen or cooled wet tissue, and grinding is preferably carried out with dry cooled tissue.
Coarsely divided tissues are swollen in aqueous acidic solutions under nondenaturing conditions. Further dispersion is achieved using high speed shearing in short bursts. Preferably dilute acid solutions at low temperatures are employed to minimize denaturation. Suitable acids include acetic, citric, malonic, or lactic acids, or other carboxylic acids having pK values from about 2 to 5 at room temperature. Dilute mineral acids such as HCl may also be used provided the pH of the dilute acid solution is approximately 2 to 5. Concentrations of the organic acid in the dispersion medium typically range from about 0.01 M to 1.0 M and the temperature may vary from 4° C. to about 25° C. Preferably, 0.5 M acetic or citric acid solubilization for 2-3 days yields a collagen dispersion which may be filtered through cheesecloth. The acid soluble extract may be dialyzed against sodium phosphate buffer and the formed precipitate redissolved in 0.5 M acetic or citric acid. Solid NaCl may be slowly added to the acid solubilized preparation to a final concentration of about 3.5 M to effect secondary precipitation. Precipitated collagen dispersion may be redissolved in dilute acid and freeze-dried.
Preparation of atelopeptide collagen dispersion may be accomplished by solubilizing collagen or dissolving the freeze-dried collagen preparation in dilute acid and digesting the materials with 4-10%, weight per weight, pepsin, ficin, collagenase, trypsin and pronase at 4° C. After 24 hours, the digest may be dialyzed against sodium phosphate and precipitated by addition of solid NaCl and/or the dialysate may be concentrated by freeze-drying. The formed precipitate may be redissolved in dilute acid and freeze-dried.
In the present invention, mantle from jellyfish is a preferable source of collagen, where the collagen-containing material is separated from adjacent tissues by dissection, soaked in dilute acid at room temperature and ground using short bursts of high speed shear (for example, using a blender). This technique provides a homogeneous dispersion of jellyfish which is readily available to subsequent treatment, so as to provide an efficient means for achieving collagen in solution.
The dispersion which is obtained by treatment with acid is a viscous dispersion containing native (telopeptide containing collagen) fibrillary collagen and a small amount of native collagen in solution.
The viscous product, i.e. dispersed swollen collagen, is marine invertebrate type V telopeptide containing collagen of the composition alpha1alpha2alpha3. Enzymatic treatment may be used at this point to remove telopeptides producing atelopeptide fibrillar collagen while leaving the major portion of the molecule intact. Illustrative enzymes include for example, pepsin, ficin, collagenase, trypsin, and pronase.
Depending on the particular enzyme employed, conditions for enzymatic cleavage of the telopeptides vary. With pepsin an acidic solution is employed, generally at a pH of about 2 to 4. The concentration of the enzyme varies from about 0.001 to 10 wt % based on the weight of collagen present. The collagen concentration generally varies from 0.5 g/l to 10 g/l, more usually from about 1 g/l to 5 g/l.
Preferably, the acidity is provided by an organic acid such as a carboxylic acid in a concentration of about 0.01 M to 1.0 M. If necessary, the pH can be adjusted by the addition of a mineral acid, e.g. hydrochloric.
The solution of soluble fibrillar collagen is then treated to separate the soluble fibrillary collagen from soluble noncollagenous materials. Primarily, the treatment involves separations, precipitations, and dialysis against various solutions of different ionic strength known to those of ordinary skill in the art, and readily selected and employed by those of ordinary skill in the art to which the present invention pertains without undue experimentation. Moderate temperatures are employed, normally between 0° C. and 20° C., and salt solutions of varying ionic strength and salt concentration, generally from about 0.01 M to 4.0 M. depending on the particular salt.
Neutral salt solutions, e.g. NaCl, of about 0.5 M to 4.0 M may be employed as a dialysate in a free-flow dialysis at a pH of at least 5 and not greater than about 9. Non-soluble contaminants which have been precipitated during preparation of soluble fibrillar collagen are filtered off to yield a filtrate which contains atelopeptide containing collagen in solution.
The collagen in dispersion/solution (telopeptide and/or atelopeptide) is precipitated as a part of a purification scheme, for example by adding a neutral salt to the solution to a concentration of about 1.0 M to 4.0 M, preferably 3.5 M. Various alkali metal halides, e.g. NaCl, may be used. The resulting precipitate is isolated, for example by centrifugation. Further treatment includes exchanging with a dilute carboxylic acid, e.g. acetic acid (0.05 M to 0.5 M) in the presence of aqueous NaCl (0.001 to 0.1 weight percent) with precipitation by addition of NaCl (1 to 4 M) and resolubilization to insure the purity of the collagen. Specifically, the procedure may involve an initial precipitation by use of a neutral salt (at least 10 to 30 wt %), isolation of the precipitate, redissolving in dilute acid, e.g. a carboxylic acid of about 0.05 M to 1.0 M, filtration, reprecipitation of the collagen with about 2 to 10 wt % aqueous salt solution, isolation, redissolution with a dilute carboxylic acid, with repetition of the purification process until the desired degree of purity. The collagen is then resuspended in dilute acid solution, generally a carboxylic acid such as acetic or citric acid at a concentration of about 0.01 M to 0.5 M. Activated charcoal can be added in particle tight containers or the collagen can be dialyzed to remove low molecular weight solutes which might present undesirable odors or fragrances.
Precipitation of the collagen can be achieved in a variety of ways, including for example, the addition of neutral salt, and decrease in pH in the presence of neutral salt. Preferably, mild conditions are employed to prevent denaturation and disruption of the natural fibrillar character of collagen. The collagen dispersion may then be concentrated, for example by dialysis, to a concentration of about 1 mg/ml to 20 mg/ml. The clear solution of collagen is relatively free of higher aggregates, is viscous, and consists essentially of marine invertebrate type V fibrillar collagen.
In the preparation of cosmetic or pharmaceutical products using the present invention, marine invertebrate type V collagen can be used in effective amounts of about 0.001 to 30 wt % of the collagen protein preparation, with 0.01 to 10 wt % preferred, and 0.5 to 5 wt % most preferred. The collagen proteins may be incorporated into suitable cosmetic or pharmaceutical vehicles such as lotions, creams, ointments, gels, shampoos, conditioners, or solutions. Suitable ointments are hydrophilic ointments (USP) or petrolatum and cosmetically effective amounts of collagen protein are incorporated into the ointment for topical application to skin or hair. Suitable lotions and creams are as mentioned previously for cosmetic compositions. Solutions are made by mixing solutions of collagen protein in deionized water for application to human or animal skin and hair. Gels are made by mixing 1-90% water with a suitable polymer.
Suitable humectants for use in the cosmetic compositions of the present invention include for example glycerin, propylene glycol, butylene glycol, urea, sorbitol, sodium PCA, gelatin, polyethylene glycols, sodium lactate, and hyaluronic acid.
Suitable emollients include for example glyceryl stearate, cetyl alcohol, stearyl alcohol, isopropyl stearate, stearyl alcohol, stearyl stearate, isopropyl stearate, stearic acid, isobutyl palmitate, isocetyl stearate, oleyl alcohol, sebacates, myristates, palmitates, squalenes, glyceryl monooleate, oleic acids, lanolin, acetylated lanolin alcohols, petrolatum, mineral oils, palmitic acids, and isostearyl neopentanoate.
A variety of surfactants can be used in the compositions of the invention including amphoteric, anionic, cationic, or nonionic surfactants. Suitable amphoteric surfactants include imidazolines, betaines, and amino acid salts. Suitable anionic surfactants include for example fatty acid soaps, salts of higher alkyl sulfates, n-acyl sarcosinates, salt or phosphates, sulfosuccinate salts, alkyl benzene sulfonates, salts of N-acyl glutamate, and polyoxyethylene alkyl ether carboxylic acids. Cationic surfactants include for example alkyl trimethyl ammonium salts, alkyl pyridinium salts, alkyl quaternary ammonium salts, and polyamine fatty acid derivatives. Nonionic surfactants include for example lipophilics such as sorbitan fatty acid esters, glycerol fatty acids, propylene glycol fatty acid esters; hydrophilics including for example polyoxyethylene sorbitan fatty acid esters, polyoxyethylene glycerol fatty acid esters, polyoxyethylene fatty acid esters, polyoxyethylene alkyl ethers, pluronics, polyoxyethylene alkyl phenyl ethers, and polyoxyethylene propylene glycol fatty acid esters.
Suitable pigments include for example organic and inorganic pigments such as talc, mica, titanium dioxide, titanated mica, iron oxides, ultramarines, chromium oxides, carmine, D&C, and FD&C colors and lakes, ferric and ferrous oxides.
Suitable waxes include for example beeswax, camuba, ceresin, microcrystalline, lanolin, candelilla, cetyl alcohol, cocoa butter, petrolatum, hydrogenated caster oil, spermaceti, bran wax, capok wax, and bayberry.
The present invention is directed to a method of moisturizing and forming a film on human and animal skin, nails, or hair by applying to the surface and effective amount of invertebrate type V telopeptide containing collagen protein. An effective amount of collagen protein is about 0.001-30 wt %. The collagen protein may be applied directly to the surface in a solution form, or it may be incorporated into cosmetic or pharmaceutical compositions mentioned herein. The collagen protein or protein containing composition may be applied to the surface once or twice a day or as necessary. For example, if the collagen protein is incorporated into a facial moisturizer, usually one to two applications of moisturizer per day will provide a beneficial effect. If the collagen proteins are incorporated into shampoos or hair conditioners, usually application once a day or every other day will be sufficient to provide a beneficial effect. When collagen proteins are incorporated into makeups, blushes, or eye shadows, they provide a treatment effect to the skin when applied once a day or whenever makeup is worn. If incorporated into nail treatment products or nail enamels, consistent usage in a nail care regimen (i.e. once or twice a week) will provide beneficial results.
The invention will be further described in connection with the following examples which are set forth for the purposes of illustration only.
EXAMPLES
Example 1
Preparation of Marine Invertebrate Type V Telopeptide Collagen Gel:
Cannon-ball jellyfish were dissected to separate the mantle from the tentacles and the reproductive and digestive organ was dissected from the mantle. The mantle was then cut into small pieces and placed into dilute (0.5 M) citric acid such that 10 mantles of average sized jellyfish (8-12 inches in diameter) were placed into 4 liters of citric acid solution. The container was covered to restrict evaporation and refrigerated at between 4° C. and 10° C. for three (3) days. The viscous collagen solution was filtered through 4 layers of cheese-cloth and the viscous materials precipitated by the addition of solid sodium chloride to a final concentration of 3.5 M. The sodium chloride was added in small increments and the precipitated materials removed as formed by the salt precipitation. Essentially all of the collagen was thus precipitated by the addition of sodium chloride and transferred to a separate container. The precipitated collagen was then gently and quickly washed with distilled water to remove associated salt crystals and then 1 liter of 0.5 M citric acid solution was added to resolubilize the precipitated collagen. This aqueous solution of invertebrate type V collagen was stored in a tight container, to prevent evaporation, under refrigeration until used. By sampling aliquots of this collagen preparation it was determined that the collagen content was 2.5% by weight. A particle tight container of activated charcoal was added to the collagen preparation during storage to reduce odors.
Example 2
Preparation of Marine Invertebrate Type V Telopeptide Collagen Solution:
In this example, cannon-ball jellyfish were dissected to separate the mantle from the tentacles and the reproductive and digestive organ was dissected from the mantle. The tentacles were then cut into small pieces and placed into dilute (0.5 M) citric acid such that tentacles from 10 average sized jellyfish (8-12 inches in diameter) were placed into 2 liters of citric acid solution. The container was covered to restrict evaporation and refrigerated at between 4° C. and 10° C. for three (3) days. The viscous collagen solution was filtered through 4 layers of cheese-cloth and the viscous materials precipitated by the addition of solid sodium chloride to a final concentration of 3.5 M. The sodium chloride was added in small increments and the precipitated materials removed as formed by the salt precipitation. Essentially all of the collagen was thus precipitated by the addition of sodium chloride and transferred to a separate container. The precipitated collagen was then gently and quickly washed with distilled water to remove associated salt crystals and then 1 liter of 0.5 M citric acid solution was added to resolubilize the precipitated collagen. This aqueous solution of invertebrate type V collagen was stored in a tight container, to prevent evaporation, under refrigeration until used. By sampling aliquots of this collagen preparation it was determined that the collagen content was 1.8% by weight.
Example 3
Preparation of Marine Invertebrate Type V Telopeptide Collagen Gelatin:
In this example, cannon-ball jellyfish were dissected to separate the mantle from the tentacles and the reproductive and digestive organ was dissected from the mantle. The mantle was then cut into small pieces and placed into dilute (0.5 M) citric acid such that 10 mantles of average sized jellyfish (8-12 inches in diameter) were placed into 4 liters of citric acid solution. The container was covered to restrict evaporation and heated to a temperature of 65° C. for 15 minutes (the solution appears to clear after approximately 10 minutes, however heating was continued until the solution temperature reached 70° C. at which time the collagen preparation was placed refrigerated at between 4° C. and 10° C. for three (3) days. The viscous gelatin solution was filtered through 4 layers of cheese-cloth and the viscous materials or aqueous solution of invertebrate type V gelatin was stored in a tight container, to prevent evaporation, under refrigeration until used. By sampling aliquots of this gelatin preparation it was determined that the collagen content was 2.8% by weight. A particle tight container of activated charcoal was added to the gelatin preparation during storage to reduce odors.
Example 4
Preparation of Marine Invertebrate Type V Telopeptide Collagen Solution:
In this example, cannon-ball jellyfish were dissected to separate the mantle from the tentacles and the reproductive and digestive organ was dissected from the mantle. The mantle and tentacles were then cut into small pieces and placed into dilute (1.0 M) acetic acid such that 10 mantles and associated tentacles of average sized jellyfish (8-12 inches in diameter) were placed into 2 liters of acetic acid solution. The container was covered to restrict evaporation and refrigerated at between 4° C. and 10° C. for three (3) days. The viscous collagen solution was filtered through 4 layers of cheese-cloth and the viscous materials precipitated by the addition of solid sodium chloride to a final concentration of 3.5 M. The sodium chloride was added in small increments and the precipitated materials removed as formed by the salt precipitation. Essentially all of the collagen was thus precipitated by the addition of sodium chloride and transferred to a separate container. The precipitated collagen was then gently and quickly washed with distilled water to remove associated salt crystals and then 1 liter of 0.5 M citric acid solution was added to resolubilize the precipitated collagen. This aqueous solution of invertebrate type V telopeptide containing collagen was stored in a tight container, to prevent evaporation, under refrigeration until used. By sampling aliquots of this collagen preparation it was determined that the collagen content was 3.2% by weight. A particle tight container of activated charcoal was added to the collagen preparation during storage to reduce odors.
Example 5
Preparation of Marine Invertebrate Type V Telopeptide Collagen-Freeze Dried:
In this example, cannon-ball jellyfish were dissected to separate the mantle from the tentacles and the reproductive and digestive organ was dissected from the mantle. The mantle and tentacles were then cut into small pieces and placed into dilute (1.0 M) acetic acid such that 10 mantles and associated tentacles of average sized jellyfish (8-12 inches in diameter) were placed into 2 liters of acetic acid solution. The container was covered to restrict evaporation and refrigerated at between 4° C. and 10° C. for three (3) days. The viscous collagen solution was filtered through 4 layers of cheese-cloth and the viscous materials precipitated by the addition of solid sodium chloride to a final concentration of 3.5 M. The sodium chloride was added in small increments and the precipitated materials removed as formed by the salt precipitation. Essentially all of the collagen was thus precipitated by the addition of sodium chloride and transferred to a separate container. The precipitated collagen was then gently and quickly washed with distilled water to remove associated salt crystals and then 1 liter of 0.5 M citric acid solution was added to resolubilize the precipitated collagen. This organic acid dispersion/solution of invertebrate type V collagen was then placed into dialysis bags and exhaustively dialyzed against deionized water at 0° C. (against crushed ice made with deionized water). This aqueous solution of invertebrate type V collagen was stored in a tight container, to prevent evaporation, under refrigeration until freeze-dried. By sampling aliquots of this collagen preparation it was determined that the collagen content was 3.2% by weight. A particle tight container of activated charcoal was added to the collagen preparation during storage to reduce odors. This deionized water dispersion of invertebrate type V collagen was carefully frozen in a freeze-drying vessel as to maximize the surface area to volume ratio, and freeze-dried. The freeze-dried collagen preparation was sealed under vacuum and stored at room temperature (for prolonged storage it is also possible to store this freeze-dried materials in a freezer at minus 20° C.). Prior to use in formulation of compositions containing this materials, the collagen was sheared in a Waring blender to achieve a fine powder and then reconstituted in 0.25 M citric acid.
Example 6
A collagen/gelatin containing oil in water moisturizing lotion was made as follows. Additive w/w % Glyceryl stearate 3.5 PPG-10 lanolin ether 0.5 Mineral oil 6.0 Lanolin alcohol 0.8 Oleic acid 2.8 Isocetyl stearate 10.0 Triethanolamine 1.3 Carbomer 941 0.1 Glycerin 9.0 Preservative 0.4 Collagen solution 5.0 Water qs 100.0. Marine invertebrate type V telopeptide containing collagen was used, preferably made according to example 1 or 2.
Example 7
An oil in water moisturizing cream was made as follows: Additive w/w % Glyceryl stearate 5.0 Cetyl alcohol 2.0 Stearyl alcohol 2.0 Isopropyl stearate 5.0 Mineral oil 13 Polysorbate 60 1.0 Glycerol 9.0 Zanthan gum 0.3 Preservative 0.5 Collagen solution 5.0 Hydrolyzed collagen solution 5.0 Water qs 100.0 Marine invertebrate type V telopeptide containing collagen was used.
Example 8
An oil/water cream makeup was made as follows: Additive w/w % Octyldodecyl stearyl stearate 4.0 Isocetylstearate 1.5 Glyceryl stearate 5.5 Isostearic acid 2.0 Ceteth 10 1.0 Cyclomethicone 12.0 Stearyl alcohol 1.2 Nonionic surfactant 1.0 Binders and Thickeners 1.8 Titanium dioxide 8.0 Iron oxide 1.0 Propylene glycol 2.5 Triethanolamine 1.5 Preservatives 0.6 Collagen Gelatin solution 1.5 Water qs 100.0
Marine invertebrate type V telopeptide containing collagen was used, made according to any one of examples 1-5, more preferably made according to example 3, 4, or 5.
Example 9
A protein shampoo was made as follows: Additive w/w % Ammonium lauryl sulfate 9.0 Sodium dodecyl sulfate 1.0 Cocamide diethanolamine 4.0 Cocamidopropyl betaine 4.0 Ammonium chloride 0.8 Collagen solution 2.0 Water qs 100.0
Marine invertebrate type V telopeptide containing collagen was used, made according to any one of examples 1-6.
Example 10
A creme rinse hair-conditioner was made as follows: Additive w/w % Stearalkonium chloride 2.0 Cetyl alcohol 1.0 Stearyl alcohol 0.5 Stearic acid 0.5 Ceteareth 20 2.0 Xanthan gum 0.5 Dimethicone 0.2 Collagen Gelatin solution 0.2 Water qs 100.0
Marine invertebrate type V telopeptide containing collagen was used, made according to any one of examples 1-6.
Example 11
Preparation of a Natural Collagen Dispersion:
Cannon-ball jellyfish were gently homogenized using a mechanical grinder similar to that used to grind hamburger meat. The group materials were collected into suitable containers (5 gallon plastic pails with locking lids are suitable as are 55 gallon tanks) and citric acid was added in dry powder form to a final concentration of 0.5 M with constant stirring to dissolve and disperse the citric acid. The container was closed and stored under refrigeration (4-10C.) for a minimum of 2 weeks. After two weeks, the containers were opened and the materials stirred using an electrically driven stirring device (an appropriate stirring device is one such as used to stir paint) to further homogenize the now viscous collagen preparation. The viscous collagen preparation was then filtered through fine screen wire to remove residual fragments of reproductive organs, and non-dispersed collagen/protein materials. The viscous clarified materials were returned to storage containers and stored under refrigeration until use. The produced natural collagen preparation is useful in formulations of a variety of products both hydrolyzed and non-hydrolyzed The natural collagen retains the natural salt and small molecular weight materials present in the source materials and can be preserved using chemical preservatives for storage without refrigeration, it can be diluted to provide less viscous collagen preparations, it can be heated to produce gelatin preparations. More specifically, this natural material is a base material which can be used with additional processing to produce the materials described in all other Examples.
Although the present invention has been described with reference to the presently preferred embodiments, the skilled artisan will appreciate the various modifications, substitutions, omissions, and changes may be made without departing from the spirit of the invention. Accordingly, it is intended that the scope of the present invention be limited only be the scope of the following claims, including equivalents thereof. All references cited herein are hereby incorporated by reference in their entirety.
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The present invention relates to a process for the production of marine invertebrate type V telopeptide containing collagen preparations from marine invertebrates, compositions containing preparations, and methods of using these preparations. The collagen preparation includes telopeptide containing and optionally invertebrate atelopeptide containing, type V fibrillar collagen. The present collagen preparations may be employed in a variety of products including for example, cosmetic, pharmacological, dental, and cell culture products.
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BACKGROUND OF THE INVENTION
This invention relates to clamping electrodes for use in a flashless D.C. butt welding method. According to the method, two ends to be butt welded are softened, by resistance heating, and plunged together. Two opposed clamping electrodes, according to the invention, are specially configured and find particular utility in the butt welding of aluminum and like metals.
Heretofore, continuous bands or hoops of aluminum alloy have been produced by a flash butt welding technique applied to the opposed ends of bar stock that has been rolled into a hoop shape. In this process, each end of a rolled piece of bar stock is clamped between a pair of clamping electrodes, the ends are positioned so that there is a small air gap between them, a charge is applied to one of the two pairs of clamping electrodes to cause an arc between the ends of the stock and the ends are plunged together to produce a weld from which a fair amount of stock metal is upset.
The opposed clamping electrodes used in the flash butt welding of aluminum alloy bar stock comprise flat major clamping surfaces adapted to engage opposed major surfaces of the stock. This process, referred to in U.S. Pat. No. 4,185,370, produces excellent welds, as evidenced by the fact that the welds stand up to the subsequent roll forming techniques described in the patent. Nonetheless, flashless welding techniques, generally, offer some advantages over flash butt welding techniques. Specifically, flashless welding consumes less metal and less electrical energy, per weld. Moreover, flashless welding is cleaner in that it produces virtually no smoke.
Flashless butt welding techniques have been successfully applied to opposed ends of steel bar stock that has been rolled into a hoop. In this process, two ends of steel bar stock are brought into contact, heated by resistance heating until they are softened, and plunged together. The clamping electrodes that have been employed in the flashless D.C. butt welding of steel correspond with the electrodes discussed above with reference to the flash butt welding of aluminum. These clamping electrodes, which are illustrated in the drawings hereof, have been found to produce unsatisfactory welds in the flashless D.C. butt welding of aluminum alloy. The difficulties which arise from attempts to employ these known electrodes in the flashless D.C. butt welding of aluminum are discussed herein.
SUMMARY OF THE INVENTION
The invention is based upon the discovery of new clamping electrodes for use in flashless D.C. butt welding of aluminum and the like. Each clamping electrode is provided with a clamping face for engaging opposed major surfaces of a work piece. According to the invention, the electrodes are configured so that, when opposed clamping electrodes are clamped around a workpiece having a pair of opposed major surfaces and a pair of opposed minor surfaces, the electrodes form opposed containment walls adjacent to the minor surfaces of said workpiece. The opposed clamping electrodes preferably include pinching surfaces adjacent to each of the containment walls and the clamping surfaces. According to a preferred embodiment, one clamping electrode is provided with a flat clamping surface and the opposed clamping electrode has a compound clamping surface including a flat clamping surface for engaging a major surface of a workpiece and two opposed containment surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a portion of a D.C. welder on which welding electrodes according to the present invention are mounted.
FIG 2 is a perspective view of first and second opposed welding electrodes according to the present invention.
FIG. 3 is a perspective view of the electrodes shown in FIG. 2 in a closed position clamping a work piece illustrated in phantom lines.
FIG. 4 is a side view of first and second pairs of opposed electrodes clamped on first and second ends of bar stock, just before they are plunged together.
FIG. 5 is a side view corresponding with FIG. 4 but showing the ends after they have been plunged together.
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 5.
FIG. 7 is a sectional view taken along the line 7--7 of FIG. 5.
FIG. 8 is an exploded perspective view of a pair of known clamping electrodes that are used to clamp aluminum bar stock in a flash butt welding process.
FIG 9 is a side view of first and second pairs of opposed electrodes of the type shown in FIG. 8, clamped on first and second ends of bar stock just before the ends are plunged together.
FIG 10 is a sectional view taken along the line 10--10 of FIG. 9.
FIG. 11 is a sectional view taken along the line 11--11 of FIG. 9
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a portion of a D.C. welder 20 including a lower stationary arm 22 and an upper stationary arm 24, both of which are fixed relative to a base (not shown). The welder 20 further comprises a lower ram arm 26 and an upper ram arm 28 which are supported, relative to the base for horizontal sliding movement away from and towards the stationary arms 22 and 24. A lower, fixed, stationary jaw 30 is securely fastened to a block 32 which is, in turn, anchored to the lower stationary arm 22. Opposite the jaw 30 is an upper, clamping stationary jaw 34 which is supported on the upper stationary arm 24 for clamping and unclamping movement towards and away from the jaw 30. Similarly, a lower, fixed, ram jaw 36 is securely fastened to a block 38 which is, in turn, anchored to the lower ram arm 26. Opposite the jaw 36 is an upper, clamping, ram jaw 40 which is supported on the upper ram arm 28 for clamping and unclamping movement towards and away from the jaw 36.
The welder 20 includes hydraulic clamping means (not shown) for actuating the upper jaws 34 and 40, as well as hydraulic ram means (not shown) for driving the ram arms 26 and 28 towards and away from the stationary arms 22 and 24. The welder 20 further includes circuitry associated with the lower, fixed, stationary jaw 30 and the lower, fixed ram jaw 36 for selectively creating a D.C. potential between them. As described thus far, the welder 20 corresponds with a 1000 KVa H-AUSH D/C Welder made by Hess. Its construction is well known to those skilled in the art of D.C. welding and further description of the welder 20, apart from its operation, is believed to be unnecessary to an understanding of the instant invention.
A stationary, clamping electrode 42 is anchored to the upper, clamping stationary jaw 34 by a plurality of bolts, one of which is shown in hidden lines at 44. Opposite the electrode 42 is a stationary, fixed electrode 46 which is anchored to the jaw 30 by a plurality of bolts, one of which is shown in hidden lines at 48. A ram clamping electrode 50 is anchored to the upper, clamping, ram jaw 40 by a plurality of bolts, one of which is shown in hidden lines at 52. Opposite the electrode 50 is a ram, fixed electrode 54 which is anchored to the jaw 36 by a plurality of bolts, one of which is shown in hidden lines at 56.
A workpiece W comprising an initially discontinuous band or hoop of rolled aluminum magnesium alloy bar stock, is illustrated in FIG. 1, at the completion of a welding sequence by which free ends of the workpiece W have been welded together. During the welding operation, some of the bar stock from each free end is upset out of the weld site and the upset metal is shown in phantom lines at 60. The workpiece W has two opposed major surfaces M and two opposed minor surfaces m, one of which is shown in FIG. 1.
Referring now to FIGS. 2 and 3, the stationary clamping electrode 42 and the stationary fixed electrode 46 are shown in more detail. The stationary electrodes 42 and 46 have the same configurations as the ram electrodes 50 and 54 (FIG. 1), respectively. References to the former pair as stationary and the latter pair as ram are based, not upon differences in the electrodes, but upon the fact that one pair is mounted on stationary arms 22 and 24 and the other pair is mounted on ram arms 26 and 28. Accordingly, the following detailed description of one pair of electrodes applies to both pairs of electrodes.
The electrode 42 comprises a front face 62 and a clamping face 64 positioned between two electrode shoulders which include a stop face 66. Between the clamping face 64 and each of the stop faces 66 of the electrode shoulders, there is a containment wall 68.
The electrode 46 comprises a front face 70 and a clamping face 72. When the electrodes 42 and 46 are brought together to a clamping position illustrated in FIG. 3, the stop faces 66 of the electrode 42 abut opposed regions of the clamping surface 72 of the electrode 46. With the electrodes 42 and 46 in the clamping position, the clamping faces 64 and 70 firmly engage opposed major surfaces M of a workpiece W illustrated in phantom lines in FIG. 3. To ensure a firm engagement of the workpiece W between the clamping faces 64 and 70, the height of each of the containment walls 68 is controlled so that, when the electrodes 42 and 46 are in the clamping position, the clamping surfaces 64 and 72 are separated by a distance which is slightly less than the nominal thickness of the workpiece W, between the major surfaces M. Generally, the distance between the clamping surfaces 64 and 72, when the electrodes 42 and 46 are in the clamping position should be close to but slightly less than 100% of the thickness of a given workpiece. In the case of an aluminum magnesium alloy bar stock having a nominal thickness of 0.235 inches, good results have been obtained where, with the electrodes 42 and 46 closed, there was a distance of 0.225 inches between the clamping faces 64 and 72 or approximately 96% of the nominal thickness of the workpiece. In any event, the clamping faces 64 and 72 need to firmly engage the major surfaces M of the workpiece when the electrodes are closed.
The containment walls 68 are oriented, relative to the clamping surface 64, so that they form an angle O. It is preferred that angle o be obtuse, i.e., greater than 90° and good results have been obtained where angle o was 97°. When the walls 68 are slightly tapered so that they are furthest apart immediately adjacent to the stop faces 66 of the electrode shoulders, this facilitates the step of positioning the electrode 42 in a clamping position relative to a workpiece W. It is preferred that the width of the clamping surface 64 of the electrode 42 be substantially equal to the width of a workpiece so that the containment walls 68, adjacent the stop faces 66 will be wider than the width of the workpiece.
Extending outwardly from the front faces 62 and 70 of the electrodes 42 and 46 are upset pinching shoulders. A shoulder including a pinching surface 74 is associated with the clamping surface 64. A pair of opposed pinching shoulders including pinching surfaces 76 are associated with the opposed containment walls 68. A shoulder including a pinching surface 78 is associated with the clamping surface 72 of the electrode 46. The pinching surface 78 forms an acute angle β with the clamping surface 72 of the electrode 46. Although the size of angle β is not critical, it is preferred that angle β be approximately 60°. Angle β has to be less than 90° in order to provide or define a space to receive the material 60 (FIG. 1) which is upset out of the weld site. Angles between the containment faces 68 and the pinching surfaces 76 as well as between the clamping face 64 and the pinching surface 74, are also preferably 60°, but, necessarily less than 90°.
The upset pinching shoulders terminate in edges 80, 82 and 84 defined, respectively, by the intersections between the clamping surface 64 and the pinching surface 74, the containment surfaces 68 and the pinching surfaces 76, and the clamping surface 72 and the pinching surface 78. The edges 80, 82 and 84 define a plane which preferably extends perpendicularly relative to opposed major surfaces M of the workpiece W. Thus, with the electrodes 42 and 46 in the closed position (FIG. 3), the workpiece W is circumscribed by the edges 80, 82 and 84.
A process for butt welding two ends of aluminum magnesium alloy bar stock will now be described with reference to FIG. 4. One end 86 of bar stock is clamped between electrodes 42 and 46. A portion of the bar stock extends beyond the edges 80, 82 and 84 a distance d. Preferably, distance d is slightly longer than the thickness of the bar stock. Good results have been obtained where d is approximately one and one quarter times the thickness of the bar stock.
Abutting the end 86 is an end 88 of bar stock which is clamped between ram electrodes 50 and 54. A like amount of the end 88 of the bar stock extends beyond the edges 80, 82 and 84 of the ram electrodes 50 and 54 which, as previously discussed, have the same configuration as the stationary electrodes 42 and 46. Accordingly, like reference numerals have been applied to corresponding elements of the electrodes 50 and 54.
With the ends 86 and 88 in contact, approximately 400 lbs. per square inch of hydraulic pressure is applied to a ram piston (not shown) in the welder 20, causing a ram force of about 7 tons to act through the ram arms 26 and 28 and through the ram jaws 36 and 40, urging the ends 88 and 86 together. Direct current is then passed through the weld site, between electrodes 46 and 54 causing resistance heating of the material adjacent the ends 86 and 88 of the bar stock. The current flow is maintained until the bar stock softens sufficiently to allow approximately 60 thousandths of an inch of movement of the ram electrodes under the applied force. Then, the current flow is stopped and the hydraulic pressure on the ram piston is increased to approximately 2000 lbs. per square inch, resulting in approximately 40 tons of ram force urging the ends 86 and 88 together. Under this force, the ram electrodes 50 and 54 are rapidly displaced to the left from the positions illustrated for them in FIG. 4 to the positions illustrated for them in FIG. 5. Although it is not clear from the detail shown in FIG. 5, displacement of the ram electrodes 50 and 54 is positively stopped when there is a slight gap between the edges 80 and 82 of the electrodes 42 and 50 as well as between the edges 84 of the electrodes 46 and 54. This gap is on the order of 10 to 20 thousandths of an inch.
The specific sequence of pressure and current is best carried out automatically and this can be accomplished with the addition of control equipment to the welder 20. Such control equipment can be obtained from Medar and programmed to carry out the described sequence. Variations in the sequence may be made to accommodate different bar stock material and sizes.
During displacement of the ram electrodes 50 and 54, a substantial amount of bar stock is upset out of the weld site. The amount of upset bar stock corresponds with the amount of bar stock which extended beyond the edges 80, 82 and 84 in FIG. 4, before the welding process began. The profile of the upset material, adjacent the opposed major surfaces M of the bar stock, is shown in phantom lines in FIG. 5 and is indicated by reference numeral 90. It can be seen from FIG. 5 that the upset material 90 extending from the major surfaces M of the welded bar stock has a profile which resembles a heart shape. Specifically, there are two hump areas 92 separated by a crease 94. The base of the heart shape has a thickness corresponding with the gap between the edges 80 and 82 of the electrodes 42 and 50 as well as between the edges 84 of the electrodes 46 and 54 at the completion of the welding operation, i.e., 10 to 20 thousandths of an inch. The upset material 90 can be scarfed or otherwise removed from the major surfaces M of the welded workpiece.
The crease 94 in the upset material 90 does not extend completely through the upset material 90, but terminates at some distance from the weld site and from the major surfaces M of the bar stock. Accordingly, when the upset material 90 is removed from the major surfaces M of the welded workpiece, the crease 94 is removed and there is no crack or crease in the weld site. Details regarding the condition of the upset material 90 adjacent the minor opposed surfaces of the bar stock are discussed below with reference to FIGS. 6 and 7.
The upset material 90 adjacent the minor surfaces m also has a profile which resembles a heart shape with two hump shaped regions 96 and a crease 98 which extends between the humps 96. The crease 98, in the vicinity of the minor surfaces m of the welded workpiece, does not extend through the upset material but terminates at some distance from the weld site and the minor surfaces m. Accordingly, the butt weld produced with electrodes according to the invention is one which is free from cracks, even in the vicinity of the minor surfaces m of the welded workpiece. This is not true of flashless butt welds of aluminum magnesium alloy bar stock made with known clamping electrodes. Such electrodes are described below with reference to FIG. 8.
A known clamping electrode 100 has a front face 102 and a clamping face 104. A pinching shoulder, defined by a pinching surface 106, extends outwardly from the front face 102. A known fixed electrode 108 has a front face 110 and a clamping face 112. The fixed electrode 108 includes a pinching shoulder defined by a pinching surface 114. The fixed electrode 108 corresponds with the fixed electrode 46, except for the size of acute angle a formed between the clamping surface 112 and the pinching surface 114. Angle a is 45°, as is the acute angle formed between the clamping surface 104 and the pinching surface 106. The smaller angle of 45 between the pinching surfaces and the clamping surfaces has been found to be operable in electrodes according to the invention. However, as stated above, an acute angle of 60° is preferred.
FIGS. 9, 10 and 11 show the results of an attempt to use an opposed pair of known clamping and fixed electrodes 100 and 108 in the flashless butt welding of aluminum magnesium alloy bar stock. During the welding process, corresponding with the process described above with reference to FIGS. 4 and 5, a substantial amount of bar stock is upset out of the weld site. The profile of the upset material, adjacent the major surfaces of the bar stock, is shown in phantom in FIG. 9, indicated generally at 116. In profile, the upset material 116 adjacent the major surfaces M is heart shaped including two humps 118 and a crease 120.
As shown in FIGS. 10 and 11, the upset material adjacent the minor surfaces m of the bar stock is not heart shaped. The upset material 116, however, does have two humps 122 with a crease 124 between the humps 122. It should be noted in FIG. 10 that the upset material adjacent the minor surfaces m has one profile on one side of the bar stock and a substantially different profile on the other side of the bar stock. Thus, it is shown that attempts to use known electrodes in flashless D.C. butt welding of aluminum magnesium alloy produces inconsistent results in the area adjacent the minor surfaces m of the bar stock.
FIGS. 10 and 11 highlight another problem that was encountered regularly with the attempted use of the prior art electrodes in the flashless D.C. butt welding of aluminum magnesium alloy. The creases 124 extend between the humps 122, inwardly to and past the plane of the minor surface m of the bar stock. Accordingly, after the upset material 116 is removed from the weld site, a portion of the crease 124 will be evident in the weld site, adjacent the minor surfaces m. Thus, in the flashless D.C. butt weld produced with the known electrodes, the crease 124, which is nothing more than a crack, will not be completely removed with the upset material 116. The presence of a crack in a weld site renders the weld unacceptable.
It should be noted that the illustrations of the upset material 116 in FIGS. 9, 10 and 11 and the upset material 90 in FIGS. 5, 6 and 7, are, necessarily, somewhat stylized. For example, generally, the humps 92, 96 and 118 tended to be less symmetrical than they are illustrated. Nonetheless, these illustrations are representative of the results obtained under the conditions described in connection with these FIGS. Accordingly, in a particular case, the upset material 116 and 90 would not have the exact configuration illustrated for it in the drawings. Indeed, there were variations in the exact profile of the upset material as between different welds, especially in connection with the use of the known electrodes as noted above with reference to FIG. 10. There were even variations in the profile of upset material at different locations on a specific weld. However, the illustrations accurately depict a problem with creases in butt welds produced using known electrodes, and the elimination of that problem in welds produced using electrodes according to the present invention.
A variety of materials are suitable for producing electrodes according to the present invention. In the case of clamping electrodes 42 and 50, a high temperature stainless steel is preferred, specifically, an #H-13 stainless steel hardened to Rockwell C-48 to C-50. For the fixed electrodes 46 and 54, a copper alloy is preferred, specifically, a Class 3 copper alloy. Copper is preferred for the fixed electrodes in this instance because, in the Hess welder 20, the fixed electrodes 46 and 54 are the hot electrodes through which current is applied to effect resistance heating of the workpiece. Accordingly, the good conductivity of copper is desired for the hot electrode, whether it is a clamping electrode or a fixed electrode.
It should be appreciated that the containment walls 48 can be provided on the fixed electrodes 46 and 54 instead of the clamping electrodes 42 and 50. If desired, one could provide one containment wall on a fixed electrode and an opposed containment wall on a clamping electrode. Alternatively, half height containment walls could be provided on all of the electrodes 42, 46, 50 and 54 so that, when they are clamped around a workpiece, the half height containment walls form full containment walls. Moreover, the clamping electrodes 42 and 50 could just as well be fixed electrodes in the sense that they could be mounted on arms that are not equipped with hydraulic clamping means. In that case, the fixed electrodes 46 and 54 could be mounted on arms that are equipped with hydraulic clamping means.
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A pair of clamping electrodes for use in flashless D.C. butt welding of aluminum and the like are disclosed. Each clamping electrode is provided with a clamping face for engaging opposed major surfaces of a work piece. The electrodes are configured so that, when a pair of opposed clamping electrodes are clamped around a workpiece having a pair of opposed major surfaces and a pair of opposed minor surfaces, the electrodes form opposed containment walls adjacent to the minor surfaces of said workpiece. The pair of opposed clamping electrodes preferably include pinching surfaces adjacent to each of the containment walls and the clamping surfaces. According to a preferred embodiment, a first clamping electrode is provided with a flat clamping surface and a second, opposed clamping electrode has a compound clamping surface including a flat clamping surface for engaging a major surface of a workpiece and two opposed containment walls adjacent the flat clamping surface. The containment walls are positioned to be adjacent to the minor surfaces of a workpiece when the clamping surface of the second electrode is engaged with a major surface of a workpiece.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to temporary support structures used in soft and environmentally sensitive areas to construct roads and pads to support heavy equipment and the like.
2. Information Disclosure Statement
Wooden mats and roads have been utilized for many years particularly in the oil and gas industry to provide temporary roads and pads for construction equipment and heavy trucks in areas that are environmentally sensitive or inaccessible due to poor soil conditions during the rainy part of the year. These roads and mats are typically constructed one piece at a time and are very time consuming and labor intensive to construct.
As pressure on labor markets increased and time constraints on construction tightened, some mat systems appeared on the market, and worked well to relieve the labor and time problems. However, when the wooden mats are laid piece by piece, the number of plys of lumber were determined by the soil conditions and the size of the loads to be hauled across them. The mat systems commonly used today are three ply systems. As a general rule, fewer plies of lumber are required to accomplish the same result as elevation increases above sea level. For example, a mat having four plys of lumber may be necessary to support typical oil industry equipment over a wet site close to sea level, while a mat having only two plys of lumber may be adequate to support the same equipment over a dryer site located well above sea level, etc.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for temporary matting for use on constructions sites to satisfy the aforementioned needs.
The mat of the present invention includes, in general, a bottom ply having a first end edge, a second end edge, a first side edge, a second side edge, and at least a first opening therethrough; and a top ply having a first end edge, a second end edge, a first side edge, a second side edge, at least a first slot extending into the first end edge of the top ply, at least a first tab aligned with the first slot in the first end edge of the top ply to and extending out of the second end edge of the top ply, and at least a first opening therethrough; the top and bottom plies are attached to one another with the first opening of the top ply positioned over the first opening of said bottom ply, with said first end edges of the top and bottom plies substantially aligned with one another so that the first slot of the top ply extends over a portion of the bottom ply, and with the second end edges of said top and bottom plies substantially aligned with one another so that the first tab of said top ply extends outward of the bottom ply.
It is an object of the present invention to provide a temporary support structure comprising a two ply, interlocking mat system that minimizes costs and maximizes the use of labor, equipment and material to provide temporary access to construction sites regardless of weather and soil conditions.
It is another object of the present invention to provide such a temporary support structure comprised of a plurality of two ply mats of rectangular configuration that interlock with slots or tabs on all sides of the mat.
It is another object of the present invention to provide such a temporary support structure in which the upper and lower layer of each mat are perpendicular and all boards on each layer are uniformly spaced to minimize cracks and maximize strength of the mat.
It is another object of the present invention to provide such a temporary support structure in which the slots and tabs on each mat are uniformly spaced and of sufficient length so that, when two or more mats are properly butted or joined together, every slot and tab is overlapped by at least it's width.
It is another object of the present invention to provide such a temporary support structure which provides a very stable working area when the mats are locked together using the slots and tabs on the side of the mats, because the slots and tabs of the surrounding mats hold each mat in place.
It is another object of the present invention to provide such a temporary support structure in which a temporary road or pad can be constructed by lifting the mats with forklifts, cranes or other suitable equipment
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the mat of the present invention.
FIG. 2 is a top plan view of the mat of FIG. 1 .
FIG. 3 is a top plan view of the bottom ply or layer of the mat of FIG. 1 .
FIG. 4 is a top plan view of the top play or layer of the mat of FIG. 1 .
FIG. 5 is a diagrammatic top plan view of several of the mats of FIG. 1 joined and being joined to one another to construct a road, including mats of different lengths.
FIG. 6 is a sectional view substantially as taken on line 6 — 6 of FIG. 5, on a somewhat enlarged scale.
FIG. 7 is a perspective view of a second embodiment of the mat of the present invention.
FIG. 8 is a top plan view of the mat of FIG. 7 .
FIG. 9 is a top plan view of the bottom ply or layer of the mat of FIG. 7 .
FIG. 10 is a top plan view of the top ply or layer of the mat of FIG. 7 .
FIG. 11 is a diagrammatic top plan view of several of the mats of FIG. 7 joined and being joined to one another to construct a pad.
FIG. 12 is a sectional view substantially as taken on line 12 — 12 of FIG. 11, rotated 90° and on a somewhat enlarged scale.
DETAILED DESCRIPTION OF THE INVENTION
First Embodiment
A first embodiment of the mat of the present invention is shown in FIGS. 1-6 and identified by the numeral 11 . The mat 11 is designed for use in combination with a plurality of similar mats to provide a temporary support structure used to construct roads and pads to support heavy equipment. The mat 11 is especially designed for the construction of temporary roads to support heavy construction equipment and trucks typically used in the oil and gas industry and in logging, etc.
The mat 11 includes a bottom ply or layer 13 and a top ply or layer 15 .
The bottom ply 13 may be constructed from a plurality of boards 17 of the same basic size. Thus, for a standard road, the bottom ply 13 is constructed from a plurality of 2 inches (5.08 centimeters) thick by 8 inches (20.32 centimeters) wide by 11.5 feet (3.5 meters) long lumber. Alternatively, the lumber could be 10 feet (3.05 meters) long. Each board 17 is arranged parallel and preferably spaced from one another an equal distance, e.g., 4 inches (10.16 centimeters). The number of boards 17 used to construct the bottom ply 13 can vary, depending on the length of mat 11 desired. Thus, for example, for a mat 11 that is 12 feet (3.7 meters) long, the bottom ply 13 preferably includes 12 boards 17 . Similarly, for a mat 11 that is 14 feet (4.3 meters) long, the bottom ply 13 preferably includes 14 boards 17 ; and for mat 11 that is 16 feet (4.9 meters) long, the bottom play 13 preferably includes 16 boards 17 .
While each of the boards 17 are preferably coextensive with one another, the middle portion of one or more of the boards 17 are preferably cut away to form a gap or opening 19 between the opposite ends of that board or boards 17 . Thus, with respect to the 12 foot mat 13 shown in the drawings, the middle portion of the third and fifth boards 17 from each end is cut away to form the gaps or openings 19 .
The top ply 15 may include a first track or runner 21 and a second track or runner 23 . The runners 21 , 23 support the wheels, etc., of heavy construction equipment and trucks typically used in the oil and gas industry and in logging, etc. In the preferred embodiment, each runner 21 , 23 of the top ply 15 is constructed from a plurality of boards 25 of the same basic size. Thus, for a standard road, each runner 21 , 23 is constructed from a plurality of 2 inches (5.08 centimeters) thick by 8 inches (20.32 centimeters) wide lumber. The length of each board 25 depends on the desired sized of the mat 11 . Thus, for a mat 11 that is 12 feet (3.7 meters) long, each board 25 is preferably 12 feet (3.7 meters) long. Similarly, for a mat 11 that is 14 feet (4.3 meters) long, each board 25 is preferably 14 feet (4.3 meters) long; and for mat 11 that is 16 feet (4.9 meters) long, each board 25 is preferably 16 feet (4.9 meters) long. Each board 25 is arranged parallel and preferably spaced from one another an equal distance, e.g., 1 inches (2.54 centimeters). While the number of boards 25 used to construct each runner 21 , 23 can vary, for a typical road each runner 21 , 23 preferably includes five boards 25 .
While each of the boards 25 are preferably the same length, the middle board or boards 25 of each runner 21 , 23 are offset with respect to the outside boards 25 of each runner 21 , 23 so that a slot 27 is formed at one end of each runner 21 , 23 and a tab 29 is formed at the other end of each runner 21 , 23 . With respect to the mat 11 shown in the drawings, the middle three boards 25 of each five board runner 21 , 23 is so offset.
The boards 25 of the top ply 15 are securely attached to the boards 17 of the bottom ply 13 , using bolts, nails, glue, etc., with the longitudinal axis of each board 25 substantially perpendicular to the longitudinal axis of each board 17 , and with the runners 21 , 23 substantially parallel to one another and centered between the opposite ends of each board 17 with a space therebetween to locate the centerline of each runner 21 , 23 the appropriate distance to support the wheels of heavy construction equipment and trucks typically used in the oil and gas industry and in logging, etc. Thus, the runners 21 , 23 are preferably spaced apart approximately 26 inches (66.04 centimeters).
In addition to the runners 21 , 23 , the top ply 15 preferably includes a plurality of reinforcing boards 31 attached to a plurality of the boards 17 of the bottom ply 13 in the space between the runners 21 , 23 . Thus, the top ply 15 may include three reinforcing boards 31 attached to the first two, last two and middle two boards 17 of the bottom ply 13 for strengthening the first two, last two and middle two boards 17 of the bottom ply 13 . The reinforcing boards 31 are preferably constructed from 2 inches (5.08 centimeters) thick by 8 inches (20.32 centimeters) wide by 20 inches (50.8 centimeters) long lumber, spaced apart from one another approximately 0.5 inches (1.27 centimeters). A set of reinforcing boards 31 are thus located adjacent each gap 19 , and coact with the gaps 19 and the portion of the boards 17 covered by the reinforcing boards 31 to form means for allowing the mat 11 to be easily grabbed with grapple of a knuckleboom, a crane, a forklift truck, etc., for pick up, moving, laying, etc. The reinforcing boards 31 strengthen the associated boards 17 to prevent damage to the mat 11 when those boards 17 are clamped by a grapple, etc.
Second Embodiment
A second embodiment of the mat of the present invention is shown in FIGS. 7-12 and identified by the numeral 2 . 11 . The mat 2 . 11 is also designed for use in combination with a plurality of similar mats to provide a temporary support structure used to construct roads and pads to support heavy equipment, but is especially designed for the construction of temporary pads to support heavy construction equipment and trucks typically used in the oil and gas industry and in logging, etc.
The mat 2 . 11 includes a bottom ply or layer 2 . 13 and a top ply or layer 2 . 15 .
The bottom ply 2 . 13 may be constructed from a plurality of boards 2 . 17 of the same basic size. Thus, for a standard pad, the bottom ply 2 . 13 may be constructed from a plurality of 2 inches (5.08 centimeters) thick by 8.25 inches (20.95 centimeters) wide by 8 feet (2.4 meters) long lumber. Each board 2 . 17 is arranged parallel and preferably spaced from one another an equal distance, e.g., 2.125 inches (5.3975 centimeters). The number of boards 2 . 17 used to construct the bottom ply 2 . 13 can vary, depending on the length of mat 2 . 11 desired. Thus, for example, for a mat 2 . 11 that is 12 feet (3.7 meters) long, the bottom ply 2 . 13 preferably includes 14 boards 2 . 17 . Similarly, for a mat 2 . 11 that is 10 feet (3.05 meters) long, the bottom play 2 . 13 preferably includes 12 boards 2 . 17 ; for a mat 2 . 11 that is 14 feet (4.3 meters) long, the bottom ply 2 . 13 preferably includes 16 boards 2 . 17 ; and for mat 2 . 11 that is 16 feet (4.9 meters) long, the bottom play 2 . 13 preferably includes 18 boards 2 . 17 .
While each of the boards 2 . 17 are preferably the same length, each adjacent board 2 . 17 is preferably offset or staggered with respect to one another so that, in combination with the top ply 2 . 15 , a slot 2 . 19 is formed at one end of each board 2 . 17 and a tab 2 . 21 is formed at the other end of each board 2 . 17 .
The top ply 2 . 15 may be constructed from a plurality of boards 2 . 23 of the same basic size. Thus, for a standard pad, the bottom ply 2 . 15 may be constructed from a plurality of 2 inches (5.08 centimeters) thick by 8.25 inches (20.95 centimeters) wide lumber. The length of each board 2 . 23 depends on the desired sized of the mat 2 . 11 . Thus, for a mat 2 . 11 that is 12 feet (3.7 meters) long, each board 2 . 23 is preferably 12 feet (3.7 meters) long. Similarly, for a mat 2 . 11 that is 10 feet (3.05 meters) long, each board 2 . 23 is preferably 10 feet (3.05 meters); for a mat 2 . 11 that is 14 feet (4.3 meters) long, each board 2 . 23 is preferably 14 feet (4.3 meters) long; and for mat 2 . 11 that is 16 feet (4.9 meters) long, each board 2 . 23 is preferably 16 feet (4.9 meters) long.
Each board 2 . 23 is arranged parallel and preferably spaced from one another an equal distance, e.g., 1 inches (2.54 centimeters). While the number of boards 2 . 23 used to construct the top ply 2 . 15 can vary, for a bottom ply 2 . 13 formed of boards 2 . 17 that are 8 feet (2.4 meters) long, the top ply 2 . 15 preferably includes ten boards 2 . 23 .
While each of the boards 2 . 23 are preferably the same length, each adjacent board 2 . 23 is preferably offset or staggered with respect to one another so that, in combination with the bottom ply 2 . 13 , a slot 2 . 25 is formed at one end of each board 2 . 23 and a tab 2 . 27 is formed at the other end of each board 2 . 23 .
The boards 2 . 23 of the top ply 2 . 15 are securely attached to the boards 2 . 17 of the bottom ply 2 . 13 , using bolts, nails, glue, etc., with the longitudinal axis of each board 2 . 23 substantially perpendicular to the longitudinal axis of each board 2 . 17 .
To form the slots and tabs 2 . 19 , 2 . 21 , 2 . 25 , 2 . 27 , and with reference to the layout of the mat 2 . 11 as shown in the drawings, the bottom and top plies 2 . 13 , 2 . 15 are attached to one another with the left most or first board 2 . 23 of the top ply 2 . 15 substantially aligned with the left most end of left most extending boards 2 . 17 of the bottom ply 2 . 13 , and the uppermost board 2 . 17 of the bottom ply 2 . 13 substantially aligned with the upper most end of the upper most extending board 2 . 23 of the top ply 2 . 15 , so that each slot 2 . 19 of the bottom ply 2 . 13 will be overlapped by a portion of the left most board 2 . 23 of the top ply 2 . 15 by a distance at least equal to its width, and so that each slot 2 . 25 of the top ply 2 . 15 will be overlapped by a portion of the upper most board 2 . 17 of the bottom ply 2 . 13 .
First Preferred Embodiment
The preferred embodiment of the bottom ply 13 includes a first board section 32 having a first end 33 and a second end 34 ; a second board section 35 extending parallel to the first board section 32 and having a first end 36 positioned conterminous with the first end 33 of the first board section 32 and a second end 37 positioned intermediate the first and second ends 33 , 34 of the first board section 32 ; a third board section 38 extending parallel to the first board section 32 and having a first end 39 positioned intermediate the first and second ends 33 , 34 of the first board section 32 and a second end 40 positioned conterminous with the second end 34 of the first board section 32 ; and a fourth board section 41 extending parallel to the first board section 32 and having a first end 42 positioned conterminous with the first end 33 of the first board section 32 and a second end 43 positioned conterminous with the second end 34 of the first board section 32 . The third board section 43 of the bottom ply 13 is aligned with the second board section 35 thereof, and the second and third board sections 35 , 38 are positioned intermediate the first and fourth board sections 32 , 41 of the bottom ply 13 . The bottom ply 13 has a bottom gap or opening 19 formed between the second end 37 of the second board section 35 and the first end 39 of the third board section 38 , and between the first and second board sections 32 , 41 .
The preferred embodiment of the top ply 15 includes a first board section 45 having a first end 46 and a second end 47 , and a second board section 48 having a first end 49 and a second end 51 . The first board section 45 of the top ply 15 is attached to and extends perpendicular to the first, second and fourth board sections 32 , 35 , 41 of the bottom ply 13 adjacent the first ends 33 , 36 , 42 of the first, second and fourth board sections 32 , 35 , 41 of the bottom ply 13 . The second board section 48 of the top ply 15 is attached to and extends perpendicular to the first, third and fourth board sections 32 , 38 , 41 of the bottom ply 13 adjacent the second ends 34 , 40 , 43 of the first, third and fourth board sections 32 , 38 , 41 of the bottom ply 13 . The first and second board sections 45 , 48 of the top ply 15 are spaced apart from one another with the space between the first and second board sections 45 , 48 generally overlying a bottom gap 19 .
The bottom ply 13 preferably includes a fifth board section 55 extending parallel to the first board section 32 thereof and having a first end 57 positioned conterminous with the first end 33 of the first board section 32 and a second end 59 positioned intermediate the first and second ends 33 , 34 of the first board section 32 ; a sixth board section 61 extending parallel to the first board section 32 thereof and having a first end positioned intermediate the first and second ends 33 , 34 of the first board section 32 and a second end 65 positioned conterminous with the second end 34 of the first board section 32 ; and a seventh board section 67 extending parallel to the first board section 32 and having a first end positioned 69 conterminous with the first end 33 of the first board section 32 and a second end 71 positioned conterminous with the second end 34 of the first board section 32 of the bottom ply 13 . The sixth board section 61 of the bottom ply 13 is aligned with the fifth board section 55 thereof, and the fifth and sixth board sections 55 , 61 are positioned intermediate the fourth and seventh board sections 41 , 67 of the bottom ply 13 . The bottom ply 13 preferably has another bottom opening or gap 19 formed between the second end 59 of the fifth board section 55 and the first end 63 of the sixth board section 61 thereof, and between the fourth and seventh board sections 41 , 67 thereof.
The bottom ply 13 preferably includes a eighth board section 75 extending parallel to the first board section 32 thereof and having a first end 77 positioned conterminous with the first end 33 of the first board section 32 and a second end 79 positioned intermediate the first and second ends 33 , 34 of the first board section 32 ; a ninth board section 81 extending parallel to the first board section 32 thereof and having a first end 83 positioned intermediate the first and second ends 33 , 34 of the first board section 32 and a second end 85 positioned conterminous with the second end of the first board section 32 of the bottom ply 13 ; and a tenth board section 87 extending parallel to the first board section 32 thereof and having a first end 89 positioned conterminous with the first end 33 of the first board section 32 and a second end 91 positioned conterminous with the second end 34 of the first board section 32 of the bottom ply 13 . The eighth and sixth ninth board sections 75 , 81 of the bottom ply 13 are positioned intermediate the seventh and tenth board sections 67 , 87 thereof and the ninth board section 81 is aligned with the eighth board section 75 thereof. The bottom ply 13 preferably has another bottom opening or gap 19 formed between the second end 79 of the eighth board section 75 and the first end 83 of the ninth board section 81 thereof, and between the seventh and tenth board sections 67 , 87 thereof.
The bottom ply 13 preferably includes an eleventh board section 95 extending parallel to the first board section 32 thereof and having a first end 97 positioned conterminous with the first end 33 of the first board section 32 and a second end 99 positioned intermediate the first and second ends 33 , 34 of the first board section 32 thereof; a twelfth board section 101 extending parallel to the first board section 32 of the bottom ply 13 and having a first end 103 positioned intermediate the first and second ends 33 , 34 of the first board section 32 and a second end 105 positioned conterminous with the second end 34 of the first board section 32 of the bottom ply 13 ; and a thirteenth board section 107 extending parallel to the first board section 32 thereof and having a first end 109 positioned conterminous with the first end 33 of the first board section 13 and a second end 111 positioned conterminous with the second end 34 of the first board section 32 of the bottom ply 13 . The eleventh and twelfth board sections 95 , 101 of the bottom ply 12 are positioned intermediate the tenth and thirteenth board sections 87 , 107 thereof, and the twelfth board section 101 is aligned with the eleventh board section 95 of the bottom ply 13 . The bottom ply 13 has another bottom opening or gap 19 formed between the second end 99 of the eleventh board section 95 and the first end 103 of the twelfth board section 101 of the bottom ply 13 .
The top ply 15 preferably includes a third board section 115 attached to and extending perpendicular to the first board section 32 of the bottom ply 13 between the first and second board sections 45 , 48 of the top ply 15 , and having a first end 117 and a second end 119 . The top ply 15 preferably includes a fourth board section 121 attached to and extending perpendicular to the seventh board section 67 of the bottom ply between the first and second board sections 45 , 48 of the top ply 15 , and having a first end 123 and a second end 125 . The top ply 15 preferably includes a fifth board section 127 attached to and extending perpendicular to the thirteenth board section 107 of the bottom ply 13 between the first and second board sections 45 , 48 of the top ply 13 , and having a first end 129 and a second end 131 . The space between the first and second board sections 45 , 48 of the top ply 13 is preferably divided into a first top space or gap 133 between the first and second board sections 45 , 48 and between the third and fourth board sections 115 , 121 for being aligned over one or more bottom gaps 19 with the intermediate portion of the fourth board section 41 of the bottom ply 13 extending thereacross; and a second top space or gap 135 between the first and second board sections 45 , 48 and between the fourth and fifth board sections 121 , 127 for being aligned over one or more bottom gaps 19 with the intermediate portion of the tenth board section 87 of the bottom ply 13 extending thereacross.
The mats 11 may be constructed in various manners and out of various materials, and in various sizes as will now be apparent to those skilled in the art. As hereinabove indicated, each of the board sections of the bottom and top plies 13 , 15 preferably include a plurality of parallel boards. Each individual board of each board section of the bottom ply 13 are preferably coextensive with each other individual board of that board section (i.e., each individual board of each board section is of equal length and the opposite ends are aligned with each other individual board of that board section). As indicated above, each runner 21 , 23 (i.e., each first and second board section 45 , 48 ) of the top ply 15 may be constructed from a plurality of individual parallel boards with the opposite ends of the middle individual parallel boards being offset from the opposite ends of the outer individual parallel boards an amount to form the interlocking slots and tabs 27 , 29 . The bottom and top plies 13 , 15 can be built out of standard hardwood lumber using a jig or the like to insure precise placement and squareness, with the individual boards of the bottom and top plies 13 , 15 fastened together by means of bolts, nails, glue, etc. The word “board” is used herein to define any generally long, rectangular, thin piece of lumber or other substantially rigid material, preferably having a shear stress substantially equal to or greater than that of typical hardwood lumber, etc. The phrase “board section” is used herein to define a board that is composed either from a single, unitary member or a plurality of individual members, or boards, joined together.
Second Preferred Embodiment
A second embodiment of the mat of the present invention is shown in FIGS. 7-12 and identified by the numeral 2 . 11 . The mat 2 . 11 is also designed for use in combination with a plurality of similar mats to provide a temporary support structure used to construct roads and pads to support heavy equipment. The mat 2 . 11 is especially designed for the construction of temporary pad to support heavy construction equipment typically used in the oil and gas industry and in logging, etc.
The mat 2 . 11 includes a bottom ply or layer 2 . 13 and a top ply or layer 2 . 15 .
The bottom ply 2 . 13 includes a first bottom ply board 2 . 28 having a first end 2 . 29 and a second end 2 . 30 , a second bottom ply board 2 . 31 having a first end 2 . 32 and a second end 2 . 33 positioned adjacent the first bottom ply board 2 . 28 , a third bottom ply board 2 . 34 positioned adjacent the second bottom ply boards 2 . 31 and having a first end 2 . 35 and a second end 2 . 36 , and a fourth bottom ply board 2 . 37 positioned adjacent the third bottom ply boards 2 . 34 and having a first end 2 . 38 and a second end 2 . 39 . Each of the bottom ply boards 2 . 28 , 2 . 31 , 2 . 34 , 2 . 37 are of equal length and are arranged parallel to one another and offset lengthwise from each adjacent bottom ply board 2 . 28 , 2 . 31 , 2 . 34 , 2 . 37 .
The top ply 2 . 15 includes a first top ply board 2 . 41 having a first end 2 . 43 and a second end 2 . 45 , a second top ply board 2 . 47 having a first end 2 . 49 and a second end 2 . 51 and positioned adjacent the first top ply board 2 . 41 , a third top ply board 2 . 59 positioned adjacent the second top ply board 2 . 47 and having a first end 2 . 55 and a second end 2 . 57 , and a fourth top ply board 2 . 59 positioned adjacent the third top ply board 2 . 59 and having a first end 2 . 61 and a second end 2 . 63 . Each the top ply boards 2 . 41 , 2 . 47 , 2 . 53 , 2 . 59 are of equal length and are arranged parallel to one another and offset lengthwise from each adjacent top ply board 2 . 41 , 2 . 47 , 2 . 53 , 2 . 59 .
The bottom and top plies 2 . 13 , 2 . 15 are attached to one another with each of the top ply boards 2 . 41 , 2 . 47 , 2 . 53 , 2 . 59 extending perpendicular to each of the bottom ply boards 2 . 28 , 2 . 31 , 2 . 34 , 2 . 37 , with the first end 2 . 43 of the first top ply board 2 . 41 positioned over the first end 2 . 29 of the first bottom ply board 2 . 28 , with the first end 2 . 49 of the second top ply board 2 . 47 positioned over the first end 2 . 32 of the second bottom ply board 2 . 31 , with the first end 2 . 55 of the third top ply board 2 . 53 positioned over the first bottom ply board 2 . 28 , with the first end 2 . 61 of the fourth top ply board 2 . 59 positioned over the second bottom ply board 2 . 31 , with the first end 2 . 35 of the third bottom ply board 2 . 34 positioned over the first top ply board 2 . 41 , and with the first end 2 . 38 of the fourth bottom ply board 2 . 37 positioned over the second top ply board 2 . 47 , thus forming the tabs and slots 2 . 19 , 2 . 25 on opposite ends of each top ply board and on the opposite ends of each bottom ply board.
While the number and size of boards 2 . 17 , 2 . 23 can vary depending on the size of the mat 2 . 11 desired, as hereinabove disclosed, for a mat 2 . 11 that is 12 feet (3.7 meters) long, the bottom ply 2 . 13 preferably includes a fifth bottom ply board 2 . 65 , a sixth bottom ply board 2 . 67 , a seventh bottom ply board 2 . 69 , an eight bottom ply board 2 . 71 , a ninth bottom ply board 2 . 73 , a tenth bottom ply board 2 . 75 , an eleventh bottom ply board 2 . 77 , a twelfth bottom ply board 2 . 79 , a thirteenth bottom ply board 2 . 81 , and a fourteenth bottom ply board 2 . 83 ; and the top ply 2 . 15 preferably includes a fifth top ply board 2 . 85 , a sixth top ply board 2 . 87 , a seventh top ply board 2 . 89 , an eight top ply board 2 . 91 , a ninth top ply board 2 . 93 , and a tenth top ply board 2 . 95 , with the ends of the additional top and bottom ply boards arranged in a manner like that disclosed hereinabove relative to the first four top and bottom ply boards to form the tabs and slots 2 . 19 , 2 . 25 on opposite ends of each additional top ply board and on the opposite ends of each additional bottom ply board.
Left and right side versions of the mat 2 . 11 can be constructed by merely reversing the layout of the boards 2 . 23 of the top ply 2 . 15 on the boards 2 . 17 of the bottom ply 2 . 13 . Thus, the mat 2 . 11 shown FIGS. 7 and 8 can be considered a right side mat. By merely moving the boards 2 . 23 of the top ply 2 . 15 to the right one board width so that the tenth top ply board 2 . 95 is positioned over the second ends of the second, fourth, sixth, eight, tenth, twelfth and fourteenth bottom ply boards 2 . 47 , 2 . 59 , 2 . 67 , 2 . 71 , 2 . 75 , 2 . 79 , 2 . 83 , etc., the mat 2 . 11 can be considered a left side mat.
The mats 2 . 11 may be constructed in various manners and out of various materials, and in various sizes as will now be apparent to those skilled in the art. As hereinabove indicated, each of the board sections of the bottom and top plies 2 . 13 , 2 . 15 preferably include a plurality of parallel boards. Each individual board of the bottom and top plies 2 . 13 , 2 . 15 are preferably parallel to and the same length as all other individual boards of that ply 2 . 13 , 2 . 15 . However, each adjacent board of each ply 2 . 13 , 2 . 15 is offset from one another lengthwise to form the coacting, interlocking tabs 2 . 21 and slots 2 . 25 . The bottom and top plies 2 . 13 , 2 . 15 can be built out of standard hardwood lumber using a jig or the like to insure precise placement and squareness, with the individual boards of the bottom and top plies 2 . 13 , 2 . 15 fastened together by means of bolts, nails, glue, etc. The word “board” is used herein to define any generally long, rectangular, thin piece of wood or other substantially rigid material, composed either from a single, unitary member or a plurality of individual members, or boards, joined together, and preferably having a shear stress substantially equal to or greater than that of typical hardwood lumber, etc.
Description of Method of Use
A temporary structure such as a road or pad is constructed using a plurality of the mats of the present invention (either the mats 11 or the mats 2 . 11 ) by lifting a first mat with a forklift, crane, grapple, or other suitable equipment, and then moving that first mat into place, putting a tab end of the first mat at the starting point and putting a slotted end of the first mat in the direction of the end of the road or pad. A second mat is then lifted with the forklift, crane, grapple, or other suitable equipment, and then moved into place with the tabs of a tab end of the second mat extending into the slots of a slotted end of the first mat, with the top layer of boards being parallel or in line on both mats. This step is repeated until rows of mats of sufficient length and width are connected to build the desired road, pad, etc. If a two ply structure is not sufficient to carry the required loads on the particular ground, additional mats can be laid over the first layer of mats to reach the required mat strength (e.g., 4 ply, 6 ply, etc.). If a three ply structure is desired, a layer of loose lumber can be laid for the bottom layer of the structure and the mats can be laid over the loose lumber.
As thus constructed and used, the matting system of the present invention eliminates putting down layers of matting material for the sole use of connecting the mats together, and reduces cost through less trucking and handling of the mats by laborers and equipment. The upper and lower layers of each mat are perpendicular to one another and all boards on each layer are uniformly spaced to minimize cracks and maximize strength of the mat. The slots and tabs on each mat are also uniformly spaced and of sufficient length so that every board on the top and bottom layers of the mat is overlapped by at least the length of the board's width. When a plurality of the mats are locked together using the slots' and tabs, a very stable working area is provided because the slots and tabs of the surrounding mats hold each mat in place.
Although the present invention has been described and illustrated with respect to preferred embodiments and preferred uses therefor, it is not to be so limited since modifications and changes can be made therein which are within the full intended scope of the invention.
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A temporary support structure for use in soft and environmentally sensitive areas to construct roads and pads to support heavy equipment and the like on rough and normally impassable terrain. Roads and pads are constructed by interlocking a plurality of mats together to build a road or pad of the desired size. Each mat is comprised of two layers of boards made of a material with a shear stress equal to or greater than that of hardwood lumber. The top layer of boards are superimposed over the bottom layer and fastened by bolts, nails, glue, etc. Forklifts, cranes, etc., are used to handle individual mats and to position the mats and lock them together.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 09/088,712, filed Jun. 2, 1998, the contents of which are expressly incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to relay apparatuses that can be installed in Internet facsimile equipment which transmits/receives image information using E-mail over the Internet, and their relay method.
[0004] 2. Description of the Related Art
[0005] Facsimile apparatuses which transmit image information over the Internet using the same operations as in general facsimile equipment have been developed. Since these apparatuses use the Internet for the entire or part of their communication path, this type of facsimile apparatus is called “Internet facsimile”.
[0006] By placing the Internet facsimile at two Internet ends and using the relay function of the Internet facsimile, it is possible to achieve cost reduction taking advantage of the Internet independent of differences in distance. For example, E-mail data is sent to the nearest Internet facsimile of the G 3 FAX as the destination via the Internet and from the Internet facsimile it is transmitted to the destination G3FAX via a public line.
[0007] When using the Internet facsimile as such a relay apparatus, the owner of the relay apparatus pays the communication expenses up to the destination facsimile. Therefore, it is necessary to prevent the use of the Internet facsimile relay function without permission.
[0008] Unexamined Japanese Patent Publication No. 9-116728 is disclosed that the password corresponding to a relay apparatus will be searched from the relay apparatus list and encrypted and then E-mail with the encrypted password added will be sent, and the encrypted password added to the received E-mail is decrypted and if it matches the password that the owner registered beforehand, the relay will be permitted.
[0009] However, the above relay system requires all apparatuses using a relay apparatus to be equipped with a mechanism to search the password of the relay apparatus and a mechanism to encrypt the searched password. As apparatuses without the password search mechanism and encryption mechanism cannot use the relay apparatus, such a system has a demerit that this system is available to only a limited number of users.
SUMMARY OF THE INVENTION
[0010] The present invention has been implemented taking account of such circumstances. The objective of the present invention is to eliminate the necessity of providing special mechanisms for apparatuses on the transmitting side to prevent abuses of the relay apparatus by unauthorized users and provide a communication apparatus with a relay function and a relay method that allow only authorized users to use the relay apparatus by only inputting a secret relay mail address in the apparatus on the transmitting side.
[0011] The present invention provides a communication apparatus with a relay function comprising a recognition section that recognizes mail addresses from the received E-mail data, memory that stores two kinds of mail addresses for public use and relay use and control section that executes the relay processing only when said recognized mail address is a relay mail address.
[0012] According to the present invention, relay mail addresses are kept in secret to anybody other than the users who are authorized to use the communication apparatus as a relay apparatus, and thus even if a public mail address is disclosed as was previously, it can prevent unauthorized users from abusing them.
[0013] Furthermore, the password name is deleted from the mail address during the relay processing, and even when the header information including the mail address is added to the facsimile data and sent to the destination machine, it is possible to prevent the password from being displayed in a form of header information at the destination terminal.
[0014] The Internet facsimile converts received E-mail data to data in a format that renders it receivable by the facsimile apparatus and transmits it to the destination terminal according to a facsimile transmission procedure. Incorporating said communication apparatus on this Internet facsimile allows said communication apparatus with a relay function to be used as an Internet facsimile relay apparatus, converting E-mail to facsimile data and transmitting it to the facsimile apparatus via a telephone line.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a network configuration diagram of the Internet facsimile related to an embodiment of the present invention used as a relay apparatus for data communications;
[0016] [0016]FIG. 2 is a diagram that shows the basic configuration of the Internet facsimile in the embodiment;
[0017] [0017]FIG. 3 is a functional diagram of the Internet facsimile in the embodiment;
[0018] [0018]FIG. 4 is a configuration diagram of the mail address table in the embodiment;
[0019] [0019]FIG. 5 is a configuration diagram of the mail address in the embodiment;
[0020] [0020]FIG. 6 is a configuration diagram of the domain name table in the embodiment; and
[0021] [0021]FIG. 7 is a flowchart showing the relay procedure in the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] With reference now to the attached drawings, the embodiment of the present invention is explained in detail below:
[0023] As an operation example of the relay apparatus contained in the Internet facsimile related to the present embodiment, the following describes a case where the transmit data is converted from an E-mail format to a facsimile data format and transferred to the terminal facsimile apparatus.
[0024] [0024]FIG. 1 shows a network configuration diagram of the relay system using the Internet facsimile in the present embodiment as a relay apparatus. In FIG. 1, Internet facsimile 11 or personal computer 12 functions as a requesting terminal that uses Internet facsimile 14 as a relay apparatus and facsimile 15 functions as a destination terminal that receives data replayed by Internet facsimile 14 .
[0025] The data sent by E-mail from the requesting terminal (Internet facsimile 11 or personal computer 12 ) is stored in mail server 13 via the Internet. Internet facsimile 14 converts the E-mail collected from mail server 13 to data in a facsimile data format and transfers it to the destination terminal (facsimile 15 ) via a telephone line network (PSTN: Public Switched Telephone Network) according to a facsimile procedure.
[0026] [0026]FIG. 2 shows a schematic hardware configuration of Internet facsimile 14 provided with a relay function. Internet facsimile 14 comprises CPU 21 , ROM 22 , RAM 23 , LAN interface unit 24 , data storage section 25 , facsimile section 27 , modem 28 , network control unit 29 , and a scanner and printer, etc. which are not shown in the figure.
[0027] CPU 21 executes various functions which will be described later, operating according to a program stored in ROM 22 . RAM 23 stores data such as mail addresses and domain names required when it functions as a relay apparatus. LAN interface unit 24 executes the necessary procedure for transmitting/receiving E-mail to/from the network, and data storage section 25 is the memory that stores the received data temporarily. Facsimile section 27 transmits the data converted for facsimile and receives facsimile data and stores it in data storage section 25 . Modem 28 modulates/demodulates data transmitted/received to/from the telephone line, and network control unit 29 controls the telephone line.
[0028] [0028]FIG. 3 shows a functional section of the relay apparatus incorporated in Internet facsimile 14 . CPU 21 provides various functions which will be described later by executing the relay program stored in ROM 22 .
[0029] Mail address recognition section 211 recognizes a mail address from the E-mail data stored in data storage section 25 via LAN interface unit 24 . Mail address collation section 212 collates the mail address recognized by mail address recognition section 211 with the relay mail address registered in mail address table 231 in RAM 23 . If mail address collation section 212 proves that the mail address is a relay mail address, domain name recognition section 213 recognizes the domain name of the requesting node from the data stored in data storage section 25 . Domain name collation section 214 collates the domain name of the requesting node recognized by domain name recognition section 213 with the domain name whose relay stored in domain name table 232 in RAM 23 is permitted. When a relay permission signal is received from domain name collation section 214 , mail address edit section 215 extracts specific header information from the E-mail data stored in data storage section 25 and transmits it to format conversion section 26 . In the case of the present embodiment, the specific header information contains relay mail addresses without password names. When a relay permission signal is received from domain name collation section 214 , log information extraction section 216 extracts log information from the E-mail data stored in data storage section 25 and sends the log information to the administrator mail address destination registered in administrator mail address table 233 in RAM 23 . In the case of the present embodiment, the log information contains relay mail addresses and domain names of the requesting node.
[0030] The memory space of RAM 23 includes mail address table 231 , domain name table 232 and administrator mail address table 233 . As shown in FIG. 4, mail address table 231 registers two kinds of mail addresses, public mail address and relay mail address. A relay is permitted when the mail address of the received E-mail data matches the relay mail address registered in mail address table 231 .
[0031] As shown in FIG. 5A, a public mail address is made up of a password name from the start to @ (at mark) and a host name following @. As shown in FIG. 5B, a relay mail address is made up of a password name from the start to # (sharp), a destination telephone number from # (sharp) to @ (at mark) and a host name following @.
[0032] Thus, using the password name of the relay mail address different from the password name of the public mail address and making the relay mail address secret can prevent the relay mail address from being abused even if the public mail address is disclosed.
[0033] [0033]FIG. 6 shows the configuration of domain name table 233 . As shown in FIG. 6, domain name table 233 in RAM 203 contains domain names for which the relay processing is permitted. The relay processing is permitted as long as the same domain name of a requesting node in the received data is found in the registered domain names. This control allows the security of the Internet facsimile used as the relay apparatus to be maintained.
[0034] Then, the relay operation of the relay system containing the Internet facsimile configured as shown above is explained using FIG. 7. FIG. 7 shows the relay procedure when Internet facsimile 14 is used as the relay apparatus.
[0035] Here, two kinds of mail addresses (one for public and the other for relay), domain names for which the relay processing is permitted and mail address of the administrator are registered in each table in RAM 23 beforehand.
[0036] When the relay request source, Internet facsimile 11 or personal computer 12 , transmits E-mail whose relay mail address has been registered, the E-mail is stored in a mailbox of mail server 13 via the Internet.
[0037] Internet facsimile 14 collects the E-mail from mail server 13 installed on the LAN via LAN interface unit 28 (S 701 ). The received E-mail data collected from the network is stored in data storage section 25 in the same E-mail format (S 702 ).
[0038] Then, mail address recognition section 211 recognizes the destination mail address from the received E-mail data stored in data storage section 25 (S 703 ). The recognized mail address is handed over to mail address collation section 212 . Mail address collation section 212 judges whether the mail address of the received E-mail is a public mail address or relay mail address (S 704 ). Mail address collation section 212 performs this judgment by comparing the password name at the mail address registered in mail address table 231 and the password name registered at the mail address of the received E-mail. If the password name is a public mail address, normal reception processing is performed (S 705 ). That is since it is data that needs not be relayed to other apparatuses, it is printed out by a printer.
[0039] If the mail address is a relay mail address, domain name recognition section 213 recognizes the domain name of the requesting node from the received E-mail stored in data storage section 25 (S 706 ). The recognized domain name is handed over to domain name collation section 214 . Domain name collation section 214 checks whether the domain name handed over from domain name recognition section 213 is found in the domain names registered in domain name table 232 (S 707 ).
[0040] Since only domain names of terminals for which the relay is permitted are registered in domain name table 232 , the data from the requesting node with the domain name that does not match the domain name registered in domain name table 232 is not relayed, resulting in an error (S 708 ). This prevents the Internet facsimile from being abused as the relay apparatus without permission even in the case that the relay mail address is disclosed to users unauthorized to perform the relay processing. Furthermore, for reasons specific to relaying Internet facsimile 14 , if the number of domains available or domain name is to be restricted, arrangements can easily be made by only changing the domain name registered in domain name table 2322 .
[0041] On the other hand, if the same domain name of the requesting node has been registered in domain name table 232 , the subsequent processing is taken over by mail address edit section 215 . Mail address edit section 215 deletes the password name from the mail address the received E-mail data stored in data storage section 25 (S 709 ). Header information containing the mail address whose password name has been deleted is created (S 710 ). This header information is handed over to format conversion section 26 .
[0042] Then, format conversion section 26 collects the received E-mail data from data storage section 25 and replaces the mail header with the header information created by mail address edit section 215 and executes format conversion (S 711 ). Through format conversion, the received E-mail data is converted from an E-mail format to a facsimile data format. Even if the header information is output from the destination terminal (facsimile apparatus), this prevents the password name of the relay mail address from being displayed, making it possible to maintain the confidentiality of the relay mail address.
[0043] This facsimile data is buffered in transmission memory. Furthermore, the telephone number of the relay destination terminal (facsimile apparatus) inserted at the mail address of the received E-mail is stored in a prescribed area in RAM 23 .
[0044] When facsimile section 27 receives the relay permission signal from CPU 21 , it dials up the telephone number stored in the prescribed area in RAM 23 , connects the line with the relay destination terminal by controlling modem 28 and network control unit 29 and transmits the facsimile data to the connected terminal via a telephone line network (PSTN) (S 712 ).
[0045] Simultaneously with the creation of the header information, log information consisting of a mail address, requesting node domain name, etc. is created (S 713 ) and said log information is E-mailed to the mail address of the administrator (S 714 ).
[0046] This helps the Internet facsimile administrator control the situation, for example, investigate the frequency of use, improving the level of administrative convenience. It also allows the administrator to monitor the use of the apparatus as the relay apparatus every time the relay processing is performed and immediately discover any abuse or abnormal use of the apparatus by checking the transmission source/destination and quickly take the appropriate action, thus improving the security performance.
[0047] Through notification by E-mail each time, describing the transmission source mail address and destination telephone number, etc. according to the subject of the mail makes it possible to know the whole situation of relay processing clearly without opening the mail.
[0048] In the network configuration example shown in FIG. 1, the Internet facsimile and mail server are located in the LAN, but it is also possible to configure the system so that the Internet facsimile may have direct dial-up connections with the mail server located on the Internet.
[0049] In the explanation above, the relay mail address must always be described in the following format including a private password:
[0050] Password# transfer destination telephone number@domain name
[0051] On the other hand, the standardized relay mail address is described in the following format including a fixed form statement which indicates that it is a relay mail address. The fixed form portion specified by the IETF (Internet Engineering Task Force) is “FAX=” and since it follows a standardized procedure, everybody can know it.
[0052] Fixed form portion=transfer destination telephone number@domain name
[0053] When carrying out relay processing by recognizing the standardized relay mail address, the mail is transferred to the telephone number entered between “=” after the fixed form statement and “@”. No processing for restricting the users described in the above embodiment is performed.
[0054] The Internet facsimile is configured so that each user may select the relay (special relay) that restricts users by recognizing the relay mail addresses containing private passwords or relay (general relay) that does not restrict users by recognizing standardized relay mail addresses. The Internet facsimile is provided with both the function to perform the special relay and the function to perform the general relay described in said embodiment, and either one is enabled according to the user setting. This setting is implemented by adding it to the facsimile general setting items.
[0055] This Internet facsimile allows the relay apparatus side to select a desired relay method.
[0056] Furthermore, it can also be configured so that the mail address recognition section may recognize the type of the relay mail address and execute a special relay if it is a relay mail address for special relay and a general relay if it is a relay mail address for general relay.
[0057] Industrial Applicability
[0058] As described above, the facsimile data relay apparatus related to the present invention is effective in relaying E-mail received from the network by the Internet facsimile via a telephone line to a facsimile (G3FAX), which is suitable for enhancement of the mechanism and security on the transmitting side.
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A facsimile apparatus is connected to a telephone network and to an internet network. The facsimile apparatus is capable of receiving E-mail data via the internet network and transmitting facsimile data to a facsimile destination via the telephone network. A detector detects a password indicating an instruction to relay the received E-mail data to the facsimile destination, and a telephone number of the facsimile destination, in a mail address of the E-mail data. A generator, when the detector detects the password and the telephone number, deletes the password from the mail address, and generates header information including a mail address after deleting the password. A converter converts the E-mail data, including the header information, into facsimile data. A transmitter transmits the converted facsimile data with the header information, but without the password to the facsimile destination indicated by the telephone number.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a tubing grab assembly in order to grab, secure, lift and move a wide variety of tubing, pipes, tubulars or other cylindrical objects.
[0003] 2. Prior Art
[0004] There are a number of applications that utilize metal tubing, pipes or tubulars which are connected to each other end to end. One application would be a pipeline for transportation of liquids or gases which is assembled from multiple sections. In another application, various liquids or gases are distributed through networks of pipes. In yet another application, a plurality of tubing is connected end to end for subterranean downhole exploration drilling and production activities. When a drill is lowered, successive sections of tubing are connected to the drill bit and lowered into a well. When the drill bit requires changing, the entire process is reversed. The tubing sections are often stored near the drilling operations in the horizontal position on the ground or on racks.
[0005] The sections of tubing are connected in a number of way. For threaded tubing, one end of each tubing contains an external threaded end while the opposed end contains an enlarged end with internal threads. Other connections include flanged ends which arc bolted or fastened together.
[0006] Various existing types of mechanisms are utilized at present to grab or clamp and then lift the tubing. For example, scissor type devices of various sorts are known and utilized.
[0007] The present invention provides a light, compact and portable assembly to easily secure to tubing, pipes or tubulars in order to move the tubing from a horizontal to a vertical orientation and vice versa.
[0008] The present invention also provides a tubing grab assembly that may be lowered and automatically clamped onto a tubing, pipe or tubular.
[0009] The present invention also provides a tubing grab assembly requiring no other tools to operate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1 and 2 illustrate the sequential use or operation of a tubing grab assembly constructed in accordance with the present invention;
[0011] FIG. 3 illustrates a perspective view of a first preferred embodiment of the tubing grab assembly while FIG. 4 illustrates an exploded view of the tubing grab assembly shown in FIG. 3 ;
[0012] FIGS. 5A , 5 B, 5 C, 5 D, and 5 E illustrate sectional views taken along section line 5 - 5 of FIG. 3 showing a sequence in order to engage and retain a tubing; and
[0013] FIGS. 6A , 6 B, 6 C, 6 D, and 6 E illustrate sectional views of a second preferred embodiment of the tubing grab assembly showing a sequence to engage and retain a tubing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The embodiments discussed herein are merely illustrative of specific manners in which to make and use the invention and are not to be interpreted as limiting the scope of the instant invention.
[0015] While the invention has been described with a certain degree of particularity, it is to be noted that many modifications may be made in the details of the invention's construction and the arrangement of its components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification.
[0016] Referring to the drawings in detail, FIGS. 1 and 2 illustrate the use or operation of a tubing grab assembly 10 of the present invention. The tubing grab assembly 10 may be utilized to grab, secure, lift and move a wide variety of flanged tubing, tubulars, pipes or other cylindrical objects. As seen in FIGS. 1 and 2 , one type of flanged tubing 12 includes an end 14 with external threads and an opposed, enlarged end 16 . The enlarged end 16 has internal threads to mate with an adjacent tubing section and has an outside diameter larger than the diameter of the tubing. Accordingly, the transition between the tubing 12 and the enlarged flanged end 16 forms an interference or shoulder.
[0017] The tubing grab assembly 10 of the present invention is utilized to move the tubing 12 from a substantially horizontal position to a substantially vertical orientation. The tubing 12 is often stored or transported in a horizontal position. FIG. 1 illustrates the tubing 12 in a horizontal position on a rack 18 . As will be described in detail herein, the tubing grab assembly 10 is brought and secured to outer circumference of the tubing.
[0018] In order to move the tubing 12 from a horizontal position shown in FIG. 1 toward the vertical position shown in FIG. 2 , the tubing grab assembly 10 will be brought to and then installed around the tubing 12 as will be described herein. Either before the tubing grab assembly 10 is secured to the tubing or after, a hook or shackle 20 will be connected to the tubing grab assembly 10 . The shackle 20 will, in turn, be connected to a wire line, rope, or other hoisting device (not shown) in order to lift the tubing grab assembly 10 and the accompanying tubing 12 in the direction illustrated by arrow 22 .
[0019] As the tubing 12 is transitioned from horizontal to vertical, the enlarged end 16 acts as an interference to prevent the tubing grab assembly 10 from moving axially along the tubing and slipping off.
[0020] FIG. 2 shows the tubing grab assembly 10 with the tubing in a substantially vertical orientation.
[0021] FIG. 3 illustrates a perspective view of a first preferred embodiment of the tubing grab assembly 10 while FIG. 4 illustrates an exploded view of tubing grab assembly 10 shown in FIG. 3 .
[0022] The tubing grab assembly 10 includes a pair of opposed jaws 30 and 32 . In the first preferred embodiment shown in FIGS. 3 and 4 , one of the jaws 30 is integral with a housing 34 . Both jaws 30 and 32 have gripping edges 36 and 38 , respectively, which will mate with the outside surface of the tubing 12 (not shown in FIG. 3 or 4 ). The gripping edges 36 and 38 may be arcuate as shown, may have teeth (not shown), or may be angular (not shown).
[0023] At least one of the opposed jaws is permitted to rotate with respect to the housing 34 . The jaw 32 has a shaft 40 , bolt or pin which passes through a cavity 42 in the housing 34 and through an opening 44 in the jaw 32 . A nut 46 secures the bolt 40 in place. The bolt 40 acts as an axis around which the jaw 32 rotates. Other types of shaft mechanisms may be employed within the spirit or scope of the present invention.
[0024] The jaw 30 is stationary and the jaw 32 rotates between a normally closed position shown in FIG. 3 and an open position.
[0025] A coil jaw spring 50 is retained in a recess in the cavity 42 of the housing 34 . The coil spring may be compressed under force. The coil jaw spring 50 extends from the recess and engages the jaw 32 to force the jaw 32 toward the closed position.
[0026] The tubing grab assembly 10 also includes a connection mechanism such as an eye 24 or a pair of eyes extending from opposed sides of the housing 34 . The eye 24 would be utilized to connect to a shackle or hook.
[0027] The tubing grab assembly 10 also includes a spring trigger mechanism. The spring trigger mechanism includes a manually operated trigger 54 having a receptacle therein to receive a coil trigger spring 56 and a guide pin 58 . The spring 56 and the guide pin 58 are axially aligned with each other. The diameter of the receptacle is slightly larger than the spring or guide pin. The spring 56 is normally extended but may be compressed under force. The guide pin 58 may be retained in the housing 34 by a lock pin 60 (visible in FIG. 4 ).
[0028] FIGS. 5A , 5 B, 5 C, 5 D, and 5 E illustrate sectional views taken along section line 5 - 5 of FIG. 3 . FIG. 5A through 5E illustrate sequential views of the tubing grab assembly 10 brought adjacent to and engaged with a tubing 12 . In FIG. 5A , the jaws 30 and 32 are brought adjacent to the tubing 12 in a direction perpendicular to the axis of tubing 12 . The jaws 30 and 32 are locked with respect to each other in FIG. 5A .
[0029] As seen in FIG. 5B , the trigger 54 is then manually retracted so that the coil spring 56 is compressed in the receptacle and the trigger 54 is retracted from a void portion 52 of the jaw 32 . The void portion 52 of the jaw 32 together with the opposed jaw 30 forms a recess for the trigger 54 when it is extended.
[0030] When the trigger 54 has been manually retracted, the jaw 32 is no longer in the locked position. As seen in FIG. 5C , as the tubing 12 is brought into the jaws 30 and 32 or the assembly 10 is brought toward the tubing 12 , the jaw 32 will be free to rotate about the bolt 40 in order to move the opposed jaws to the open position. The force of the tubing moving into the jaws 30 and 32 overcomes the force of the jaw spring 50 .
[0031] As seen in FIG. 5D , once the tubing 12 is within the jaws 30 and 32 , the jaw 32 will rotate about the bolt back to the closed position by force of extension of the jaw coil spring 50 . Thereafter, the tubing grab assembly 10 may be placed in the locked position by releasing the trigger 54 . The force of the trigger coil spring 56 urges the trigger 54 into the recess formed by the void portion 52 in the jaw 32 and the jaw 30 .
[0032] Once in the position shown in FIG. 5E , the jaws 30 and 32 are locked and may not he moved. Accordingly, the grab assembly is locked to the tubing 12 . The foregoing sequence may be accomplished by lowering the tubing into the jaws of the assembly or lowering the jaws of the assembly on to the tubing 12 . The tubing grab assembly will be secured to the tubing adjacent the shoulder formed by the enlarged end. As the grab assembly 10 is lifted, the grab assembly 10 rests against and mates with the tubing.
[0033] FIGS. 6A , 6 B, 6 C, 6 D, and 6 E illustrate a second, alternate preferred embodiment 70 of the present invention shown in the sectional view.
[0034] The tubing grab assembly 70 includes a pair of opposed jaws 72 and 74 . Each of the jaws 72 and 74 has a gripping edge 76 and 78 , respectively, which mate with the outside surface of the tubing 12 . The gripping edges 76 and 78 may be arcuate, may have teeth, or may be angular.
[0035] Each of the jaws 72 and 74 has a shaft, pin or bolt, 80 and 82 , respectively, which passes through a cavity 84 in a housing 95 . The bolts 80 and 82 also pass through openings in the jaws 72 and 74 , respectively. A nut 86 and 88 secures each of the bolts 80 and 82 in place. Each bolt acts as an axis around which the jaw rotates.
[0036] Each of the jaws 72 and 74 rotates between a normally closed position and an open position. Coil jaw springs 90 and 92 are retained in recesses in a cavity 84 of the housing 95 . The coil jaw springs 90 and 92 engage the jaws 72 and 74 , respectively, to force them toward the closed position. The coil springs may be compressed under force.
[0037] The tubing grab assembly 70 also includes a connection mechanism, such as an eye 94 or a pair of eyes extending from opposed sides of the housing 95 . The eye 94 would be used to connect to a shackle or hook.
[0038] The tubing grab assembly 70 also includes a spring trigger mechanism. The spring trigger mechanism includes a manually operated trigger 96 having a receptacle therein to receive a coil trigger spring 98 and a guide pin 100 . The spring 98 and the guide pin 100 are axially aligned with each other. The diameter of the receptacle is slightly larger than the spring or guide pin. The guide pin 100 may be retained in the housing 95 by a lock pin 102 .
[0039] FIGS. 6A , 6 B, 6 C, 6 D, and 6 E illustrate sectional views and also illustrate a sequence to engage and lock a tubing. In FIG. 6A , the locked jaws 72 and 74 are brought adjacent to the tubing 12 . As seen in FIG. 6B , the trigger 96 is then manually retracted so that the coil spring 98 is compressed in the receptacle and the trigger 96 is retracted from void portions in the jaws 72 and 74 which form a recess for the trigger 96 .
[0040] When the trigger 96 is manually retracted, the jaws 72 and 74 are no longer in the locked position. As seen in FIG. 6C , the jaws 72 and 74 are free to rotate about the bolts 80 and 82 , respectively.
[0041] As seen in FIG. 6D , once the tubing is within the jaws 72 and 74 , the jaws 72 and 74 will rotate back to the closed position by force of extension of the coil springs 90 and 92 .
[0042] Thereafter, the tubing grab assembly 70 may be placed in the locked position by releasing the trigger 96 . The force of extension of the trigger coil spring urges the trigger 96 into the recesses formed by the void portions in the jaws 72 and 74 .
[0043] Once in the position shown in FIG. 6E , the jaws 72 and 74 are locked and may not he moved. Accordingly, the tubing 12 is locked in place.
[0044] Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.
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A tubing grab assembly to retain and lift tubing, pipes, tubulars or other cylindrical objects. The assembly includes a pair of opposed jaws and a housing having a cavity. A least one of the opposed jaws has a shaft therethrough to permit rotation of the jaw with respect to the housing between a closed position and an open position. A jaw spring forces the movable jaw toward the closed position. A retractable spring trigger mechanism locks the pair of opposed jaws in the closed position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a moveable platform facilitating access and inspection of vehicle chassis. Specifically, the platform comprises a main body and a series of removably attached wheel supports.
2. Background of the Invention
Inspection of a vehicle chassis is generally a two step process.
First, the space between the vehicle and the ground on which the vehicle stands must be increased, such that the vertical clearance is sufficient to allow a person to access the chassis from all angles. While through hydraulic or other means it is possible to lift the vehicle many feet off the ground, such high lifting requires specialized equipment and creates safety issues as well as other problems. For instance, while light passenger vehicles can be lifted with standard equipment, heavier passenger vehicles and commercial or industrial vehicles require complex and expensive lifting equipment in order to be raised sufficiently off the ground to allow personal inspection while standing.
An alternative is to jack up the vehicle by only a few feet, allowing inspection personnel to examine the car while lying on a moveable surface. The inspection of vehicle chassis while in the lying position has numerous benefits and has become the standard method of servicing vehicles. However, for safety and access reasons, the person checking the vehicle will not want to lie directly on the ground where the vehicle is parked. Instead, a support platform is employed. Such support platforms are termed vehicle creepers.
Support platforms must be highly mobile, contain as few elements as possible, and facilitate mobility while decreasing the amount of vertical space the creeper requires. Inasmuch as when the creeper takes more vertical space, less space is available for operating on the vehicle. A creeper that has a high vertical profile would require the car to be lifted higher. Once the car must be lifted more than a few feet, the same specialty lifting equipment must be used that would be required to lift the vehicle to the height of a standing person. As such, poorly designed creepers defeat the benefit on not requiring specialty jacking equipment.
Support platforms are therefore designed to be as low as possible. However, thin platform design approach results in little padding being placed on the user contact surface of the support platform. Given that some vehicle maintenance and inspection tasks require several hours, a thin platform results in considerable discomfort for the user of same. Alternatively, in order to increase the padding on the platform, some support platforms utilize wheels having minimal diameters. While this achieves a minimal vertical footprint, it results in support platforms that are difficult to maneuver over the smallest of obstacles, such as channels in concrete barriers. Small wheels also decrease mobility of the platform when a heavy load is placed thereupon. A support platform without sufficient mobility is self-defeating in most circumstances.
Finally, vehicle inspection support platforms are generally designed to take up as little space as possible while not in use. A narrow design is generally employed in order to minimize the amount of space required for the support platform. While this design limits the surface area of the platform, it has a detrimental effect on the stability of the platform and on the comfort of the user of same.
A need exists in the art for a support platform that features a sufficient amount of surface padding, that employs large casters without increasing the vertical clearance of the support platform, and that does not take up an excessive amount of space at times it is not used.
SUMMARY OF INVENTION
An object of the invention is to provide a device for providing access to a vehicle chassis that overcomes many of the disadvantages of the prior art.
Another object of the invention is to provide access to a vehicle chassis while the vehicle is lifted only a few feet off the ground. A feature of the invention is that it allows for comfortable access to the underside of the vehicle while providing support for the body of the vehicle inspector. An advantage of the invention is that the platform provides access to the vehicle chassis without requiring extensive upward lifting of same.
Still another object of the present invention is to provide a device to provide a padded surface to access a vehicle chassis. A feature of the invention is that it includes a padding layer featuring several area of reversibly deformable support. An advantage of the present invention is that the platform is used for extended periods of time without causing discomfort to the user. Another advantage of the present device is that the padding allows for comfortable use of the platform without adding separate cushions.
Yet another object of the current invention is to provide a platform wherein the padding on the platform will be optimized to not react with the surrounding environment. A feature of the instant invention is that in one embodiment the padding on the platform is removably attached to the platform and is selected to be nonreactive with the environment in which the platform is used. An advantage of the instant invention is that the padding will not be deteriorated by being used in a corrosive environment. A further advantage of the present system is that the padding is removed and cleaned as needed.
Yet another object is to provide a platform which features a minimal vertical profile. A feature of an embodiment of the presently invented system is that the wheels are removably attached to the sides of the platform. An advantage of the present system is that the wheels are positioned in such a way as to limit the heights of the platform.
A further object of the invention is to provide a support platform capable of rolling over irregular terrain. A feature of the invention is that the wheels attached to the sides of the platform extend above the horizontal plane of the platform frame. An advantage of the present invention is that the platform incorporates wheels that are sufficiently large so as to be able to roll over rough surfaces without raising the vertical profile of the platform.
Still another object of the present invention is to provide a large surface area to support a vehicle chassis mechanic and tools. A feature of the present invention is that, in one embodiment, the support platform frame includes a wide section. An advantage of the present system is that the platform is used comfortably for extended periods of time and is used to hold tools and other instruments.
Another object of the present invention is to provide a support platform that is stored while occupying a minimal amount of space. A feature of the present invention is that it incorporates a transverse fold line. An advantage of the present platform is that it allows storage of the support surface in a folded configuration resulting in a lessened physical profile for same.
A yet further object of the present invention is to provide a support platform wherein the wheels of same are replaced depending on the application of the platform. A feature of the invention is that the wheels are attached using removable attachment means. An advantage of the present invention is that different types of wheels are be attached to the platform depending on the application of the platform.
The invention comprises a vehicle chassis access platform, the platform comprising: a frame assembly comprising a first subportion, a second subportion, wherein the first subportion and the second subportion are removably joined together to form the frame assembly; at least three wheel assemblies wherein each wheel assembly comprises a wheel platform; a wheel; a wheel retention bracket; wherein each wheel is connected to a retention bracket and said retention bracket is removably connected to a corresponding wheel platform wherein each wheel assembly is removably attached to the frame; and a cushion layer removably attached to the frame assembly.
BRIEF DESCRIPTION OF DRAWING
The invention together with the above and other objects and advantages will be best understood from the following detailed description of the preferred embodiment of the invention shown in the accompanying drawings, wherein:
FIG. 1 depicts the schematic of an embodiment of the invention;
FIG. 2 depicts the wheel platform assembly of one embodiment of the invention;
FIGS. 3A-B depict the wheel assembly of one embodiment of the invention; and
FIG. 4 depicts the cushion of one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property.
The invention is a device and method of accessing a vehicle chassis while in the reclining position. As shown in FIG. 1 , one embodiment of the invention comprises a platform 10 which incorporates a first frame subportion 12 and a second frame subportion 14 . The first frame subportion 12 and second subportion 14 form a generally oval shape in the embodiment shown in FIG. 1 and are reversibly joined together to form an outer frame of the device 10 . In other embodiments, not shown, the outer frame defines a substantially rectangular shape.
In the embodiment shown in FIG. 1 , the device 10 incorporates two cross bars—a first cross bar 16 and a second cross bar 18 . In one embodiment of the invention, each cross bar is removably mounted to a corresponding subportion. Specifically, the first end 46 of the first cross bar 16 is received by the first subportion 12 while the second end 56 of the first cross bar 16 is received by the second subportion 14 . Further, the first end 48 of the second cross bar 18 is received by the first subportion 12 , while the second end 58 of the second cross bar 18 is received b the second subportion 14 .
In one embodiment of the invention, the cross bars 16 and 18 are removably mounted on the subportions through the use of mounting means such as a hook grip, threaded screw and nut assembly, clamp, gripping pressure, and other methods. In other embodiments, the cross bars are permanently attached to the corresponding subportions through permanent attachment means, such as welding. In other embodiments, the cross bars 16 and 18 are integrally molded to the corresponding subportions 12 and 14 .
The first subportion 12 and second subportion 14 meet at two connection points 32 and 34 . In the embodiment shown in FIG. 1 , the connection points 32 and 34 are found at opposing ends of the first subportion 12 and the second subportion 14 . In at least one embodiment, at the connection points 32 and 34 , the first subportion 12 and second subportion 14 are connected removably, through subportion connection means, such as a lock, or removable mechanical joints such as dovetail joints. In another embodiment, the first subportion 12 and second subportion 14 are in hingeable communication at connection points 32 and 34 . In this embodiment, connection points 32 and 34 incorporate hinges. In some embodiments the hinges are removably lockable through locking means such as a pin. In further embodiments, hinges at connection points 32 and 34 are allowed to move freely. However, the subportions are locked in place by the temporary placement of the first cross bar 16 and the second cross bar 18 .
A straight line running from the first connection point 32 to the second connection point 34 forms a transverse fold line 20 through the platform 10 . In the embodiment shown in FIG. 1 , the first frame subportion 12 is substantially identical to the second frame subportion 14 . As such, upon joining the first frame subportion 12 to the second frame subportion 14 at connection points 32 and 34 , the resulting frame features a shape wherein each point along the first subportion 12 having a distance x from the transverse fold line 20 , has a corresponding point along the second subportion 14 having the same distance x from the transverse fold line 20 .
While not shown in FIG. 1 , the frame 10 is folded along the transverse fold line 20 in some embodiments. In embodiments where the cross bars 16 , 18 are permanently attached the first subsection 12 and the second subsection 14 , the cross bars 16 , 18 also incorporate lockable hinges substantially at the location where the transverse fold line 20 crosses the cross bars 16 , 18 . In embodiments where the cross bars 16 , 18 are removably attached to the subsections 12 , 14 , the cross bars are unbending and continuous length of substantially inflexible material, such as steel or fortified aluminum. Such inflexible cross bars 16 , 18 are removed prior to the folding of the frame 10 .
In a folded configuration, the first subsection 12 and the second subsection 14 are angled together such that substantially each point on the first subsection 12 comes in contact with a corresponding point on the second subsection 14 . In one embodiment, the folding of the first subportion 12 is in the direction through the plane formed by the top surface of the first subportion 12 . In this embodiment, upon folding the top surface of the first subportion 12 meets the top surface of the second subportion 14 . In an alternative embodiment, the folding of the first subportion 12 is in the direction away from the plane formed by the top surface of the first subportion 12 . In this embodiment, upon folding the bottom surface of the first subportion 12 meets the bottom surface of the second subportion 14 .
In yet further embodiments, the connection points 32 and 34 do not incorporate hinges and the first subportion 12 is not in hingeable communication with the second subportion 14 . Instead, the connection points 32 and 34 include removable assembly means, such as combinations of apertures and insertion rods, pressure snaps, or other mechanisms. In this embodiment, the first subportion 12 and the second subportion 14 are removably assembled at connection 32 and 34 and so the frame is disassembled in lieu of being folded as is the case with embodiments featuring folding means.
As shown in FIG. 1 , the platform 10 incorporates a large area defined by the inner boundary 22 of the first subportion 12 and the inner boundary 24 of the second subportion 24 . The frame 10 is defined by the distance between the inner boundary 22 of the first subportion 12 and the outer boundary 26 of the first subportion 12 as removably combined with the material between the inner boundary 24 of the second subportion 14 and the outer boundary 28 of the second subportion 14 . The cross bars 16 and 18 add further bulk to the frame 10 , however, the predominant feature of the frame 10 is the absence of supporting material inside of the area defined by the inner boundaries 22 and 24 .
The first subportion 12 incorporates a series of first frame subportion apertures 30 . In the embodiment shown in FIG. 1 , the first frame subportion apertures 30 are substantially equally spaced from one another. Further, as is depicted in the embodiment shown in FIG. 1 , the second subportion 14 includes corresponding apertures in the area defined by the inner boundary 24 and the outer boundary 28 .
For both the first subportion 12 and the second subportion 14 the apertures 30 and 36 are added in such a manner as not to decrease the structural stability of the corresponding subportion. For instance, the subportion 12 remains sufficiently structurally sound, even at apertures 30 , such that it does not bend when a load is applied to the subportion 12 . Structural integrity for each subportion is assured by the careful selection of the size of each aperture 30 and 36 . The radius of each aperture is not larger than 30% of the length between a subportion inner boundary and subportion outer boundary.
Each aperture 30 , 36 receives a screw, peg, or similar structure to removably connect a wheel platform, one embodiment of which is shown in FIG. 2 . The wheel platform 60 consists of a main body 76 wherein the main body is defined by one substantially straight edge 72 and a curved edge 74 . As shown in the embodiment depicted in FIG. 2 , the shape of the wheel platform 60 is substantially triangular, with the substantially straight edge 72 defining the base of the triangle and the curved edge defining the remaining two triangle line segments. Consequently, in the embodiment shown in FIG. 2 , the curved edge 74 incorporates an turn of approximately 90 degrees in substantially the mid-section of the curved edge 74 . As shown in FIG. 2 , in one embodiment, the turn occurs at or near the point of height h of the creeper body 76 .
While a substantially triangular shape for the platform body 76 has been depicted in FIG. 2 , other shapes are envisioned. For example, while the curved edge 74 is shown to be a single curved segment in FIG. 2 , in another embodiment, the curved edge 74 comprises individual sub-segments forming a polygonal shape defined by straight line segments wherein the line segments join together at sharp corners.
Traversing at or near the midline h of the main body 76 are two apertures 62 , 64 . In one embodiment, the first aperture 62 is designated to receive the wheel assembly described in FIG. 3A . The second aperture 64 is designed to connect to the platform main body 10 shown in FIG. 1 . In the embodiment shown in FIG. 2 , the first aperture 62 and the second aperture 64 have substantially equivalent radii. Further, the frame receiving aperture 64 approximates the radius of the apertures 30 , 36 shown in FIG. 1 . Consequently, it is possible to use a joining member of a consistent radius to join the platform 60 to either subportion 12 , 14 of the main device frame 10 .
The wheel platform 60 incorporates additional apertures, such as the secondary apertures 66 found on the sides of the platform 60 . In the embodiment shown in FIG. 2 , the secondary apertures 66 feature the same radius as wheel assembly 62 receiving aperture, or the frame receiving aperture 64 . Consequently, it is possible to attach either the wheel assembly, or the frame to either one of the secondary apertures 66 . In one configuration, multiple wheel assemblies are attached to both the wheel assembly receiving aperture as well as the secondary apertures 66 .
Beyond the secondary apertures 66 , the wheel platform 60 incorporates tertiary apertures 68 and quandary apertures 70 . As compared with the secondary apertures 66 , each subsequent class of apertures incorporates a smaller radius. Consequently, the tertiary and quandary apertures cannot be used interchangeably with the secondary apertures 66 and the wheel assembly receiving apertures 62 and the frame receiving aperture 64 .
The wheel platform 60 incorporates the wheel assembly receiving apertures 62 . One embodiment of the wheel assembly is depicted in FIG. 3A . As shown therein, the wheel assembly 80 incorporates an outer wheel 82 . A wheel spinning pin 84 traverses the mid-point of the wheel 82 . The spinning pin 84 is in turn mounted on the wheel retension bracket 88 . The bracket 88 , in turn ends in a wheel assembly joining pin 86 .
In the embodiment shown in FIGS. 2 and 3A , the joining pin 86 is removably received in the wheel assembly receiving aperture 62 . While FIG. 3 a depicts the wheel as a caster, other wheels are be used in other embodiments. For example, rollers are retained by the retention bracket depicted in FIG. 3A in a different embodiment.
The type of wheel 82 that is used in the wheel assembly 80 is chosen in response to the environment in which the wheel 82 will be used. For example, in some environments, large casters made of hard rubber are employed. Such casters provide for insulation and prevent the buildup of static energy during the work on the vehicle. While desirable in some situations, such rubber wheels 82 are prone to deterioration in other environments. As such, wheels 82 are made from resilient metal or non-reactive polymers in other embodiments. Further, wheels are selected so as to be easiest to clean given the contaminants that are expected in a given work environment.
Given the modular nature of the wheel assembly 80 , for a given wheel platform 60 , multiple types and sizes of wheels are used and kept on an as-needed basis.
Finally, in other embodiments, not shown, the wheel assembly does not incorporate any wheel 82 . Instead, the wheel assembly 80 uses a support member in place of the wheel wherein the support member carries the weight of the assembled frame in place of the wheel. In order to facilitate movement, the support member includes a slick surface, or a gliding surface, such as skis.
In the embodiment shown in FIG. 3A , the retention bracket 88 does not encapsulate the wheel, but instead is designed to keep the spinning pin 84 in place. In other embodiments, not shown, the retention bracket covers a portion of the wheel, thereby protecting the wheel from drips and other contamination.
Further, while not shown in FIG. 3A , the retention bracket 88 includes a brake so as to interfere with the movement of the wheel 82 , keeping same in place when the operator of the device chooses to deploy same. In some embodiments of the invention, only one wheel assembly 80 deployed in conjunction with the creeper incorporates a braking mechanism.
In some embodiments of the invention, the wheel assembly joining pin 86 is adjustable in height.
A combination of a frame subportion, wheel platform, and wheel assembly is depicted in profile in FIG. 3B . As shown in FIG. 3B , a visible part of the first frame subportion 12 , incorporates an aperture 30 . While FIG. 3B shows a part of the first subportion 12 , the same arrangement would be used with the second subportion 14 .
Transversing the aperture 30 is a frame to wheel platform connection rod 90 . This connection rod 90 extends through the width of the first frame subportion 12 . Extending beyond the outer wall of the first frame subportion 12 , the connection rod 90 is capped by a first fastener 92 . The fastener 92 shown in FIG. 3B is a threaded cap. However, other fasteners are contemplated, such as a hex nut, wing nut, a locking pin or pins, and other possible fasteners.
While one end of the connection rod 90 is removably received by the fastener 92 , the opposing end of the connection rod 90 passes through the wheel platform 60 . The connection rod 90 extends through the width of the wheel platform 60 main body 76 at the wheel platform frame receiving aperture 64 . As was discussed in the description of FIG. 2 , the rod 90 is capable of being received by secondary apertures 66 inasmuch as the secondary apertures 66 have substantially the same diameter as the frame platform receiving aperture 64 .
The part of the rod 90 which extends beyond the horizontal plane formed by the wheel platform 60 main body 76 is removably locked in place by rod 90 second fastener 94 . This second fastener 94 is also depicted as a threaded cap received by the end of the rod 90 . Analogous to the first fastener 92 , the second fastener 94 comprises any possible type of fastener.
While in the embodiment shown in FIG. 3B , the connection rod 90 is removably connected to both the frame subportion 12 and the wheel platform 60 , the rod 90 are integrally molded with either element in other embodiments. For example, in one embodiment, the wheel platform 60 does not incorporate a frame receiving aperture 64 . Instead, in the place of the aperture 64 the wheel platform incorporates an integrally molded frame receiving rod 90 .
In the embodiment shown in FIG. 3B , the connection rod 90 has a substantially equal diameter throughout the length of the rod 90 . In other embodiments, the connection rod 90 features a variances in its diameter.
The wheel platform main body 76 is consequently removably attached to the frame subportion 12 through the combination of the rod 90 and the rod fasteners 92 , 94 . In turn, the wheel assembly 80 is removably attached to the wheel platform 60 by the removable placement of the joining pin 86 through the wheel assembly receiving aperture 62 . The joining pin 86 is kept in place through the removable fastening of wheel assembly fastener 96 . As was the case with the previously-described fasteners 92 , 94 , the wheel assembly fastener 96 may comprise any suitable fastener.
In alternative embodiments, the joining pin 86 is not fastened in place with a mechanical fastener. Instead, the joining pin 86 is kept in place by the force F which is applied to the surface of the first frame subportion 12 by a load placed on top of the device during use of the device. In other embodiments, in conjunction with this force, the locking pin 86 incorporates a magnetic joining means.
The wheel 82 is attached to the retension bracket 88 , and a joining pin 86 extends from the retention bracket 88 away from the wheel 82 towards the main body 76 of the wheel platform 60 . As such, the wheel 82 is attached to both the wheel platform 60 and in turn to the frame subportion 12 .
While only one wheel 82 is shown as attached in FIG. 3B , a complete device assembly would include at least four wheels attached to the first frame subportion and the second frame subportion so as to balance the device.
As shown in the profile view of FIG. 3B , the wheel 82 extends above the horizontal plane defined by the frame subportion 12 , consequently facilitating the use of large wheels without the necessity of lifting the frame subporiton 12 to the same height as the wheels.
Further, inasmuch as separate wheel assemblies are attached to the frame subportions, different wheels may be combined in a single creeper device. For example, in instances where the creeper is used on an uneven surface, one wheel may be larger than the remaining wheels so as to prevent the creeper from rolling around during use.
As shown in FIG. 4 , the assembled device 10 also incorporates a cushioning layer. The cushioning layer does not obscure any of the frame apertures.
In order to provide support for the user of the device, the cushioning layer is defined by two lateral cushions 110 . The lateral cushions, in turn comprise a padding material, such as reversibly deformable foam, and include an outer boundary 112 . The outer boundary is a sloping barrier thereby directing the user of the device away from the outer sides of the device.
Further, the cushioning layer shown in FIG. 4 includes a head cushion at one end of the device. In one embodiment of the invention, the head cushion is reversibly attached to the cushioning layer through means such as snaps or hook and pile layers. In other embodiments, the head cushion is integrally molded into the cushioning layer.
In the embodiment shown in FIG. 4 , the cushioning layer includes a transverse fold line 20 running through the middle of the cushioning layer. In embodiments where the head cushion 114 is integrally molded into the cushioning layer, the fold line 20 transverses the head cushion. In embodiments where the head cushion is not integrally molded into the cushioning layer, the head cushion 114 may be free of the fold line 20 .
The cushioning layer comprises a resilient material which does not absorb various vehicular fluids, but instead forces them to collect on the surface of the cushioning layer.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from tits scope. While the dimensions and types of materials described herein are intended to define the parameters of the invention, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure
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A vehicle chassis inspection platform, or creeper, comprising a frame, a cushion layer, and several wheel assemblies is disclosed. The creeper includes a wheel assembly designed to minimize vertical clearance of the creeper wherein the wheel assembly includes a wheel platform with multiple possible positions for joining of the wheel platform to the creeper.
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CROSS REFERENCE TO RELATED APPLICATION
Pursuant to 37 C.F.R. §1.78(a)(4), this application claims the benefit of and priority to prior filed co-pending Provisional Application Ser. No. 62/142,020, filed Apr. 2, 2015, which is expressly incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to semiconductor processing technology, and more particularly, to apparatus and methods for controlling properties of a processing system for treating a substrate.
BACKGROUND OF THE INVENTION
Patterning at 10 nm and sub-10 nm technology nodes is one of the key challenges for the semiconductor industry. Several patterning techniques are under investigation to enable the aggressive pitch requirements demanded by the logic technologies. Extreme ultraviolet (EUV) lithography based patterning is being considered as a serious candidate for the sub-10 nm nodes. One challenge of EUV technology is that EUV resists tend to have a lower etch selectivity and worse line edge roughness (LER) and line width roughness (LWR) than traditional 193 nm resists. Consequently, the characteristics of the dry etching process play an increasingly important role in defining the outcome of the patterning process.
Sub 30 nm node semiconductor manufacturing has imposed many challenges on the physical limits of traditional lithography techniques. There is a demand for alternative patterning strategies which involve augmentation of 193i lithography with LELE (Litho-Etch-Litho-Etch), SADP (Self Aligned Double Patterning) and SAQP (Self Aligned Quadruple Patterning). However, multiple patterning schemes bring additional challenges in the form of edge placement error, higher costs due to a larger number of passes through lithography and other processing steps, and the introduction of pitch walking at several processing steps.
SUMMARY OF THE INVENTION
Disclosed methods provide greater EUV photoresist etch selectivity and markedly reduced line edge roughness (LER) and line width roughness (LWR) in comparison with conventional approaches.
According to an embodiment, a method for etching an antireflective coating layer on a substrate is disclosed. The substrate comprises an organic layer, an antireflective coating layer disposed above the organic layer, and a photoresist layer disposed above the antireflective coating layer. The method includes patterning the photoresist layer to expose a non-masked portion of the antireflective coating layer and selectively depositing a carbon-containing layer on the non-masked portions of the antireflective coating layer and on non-sidewall portions of the patterned photoresist layer. The method further includes etching the film stack to remove the carbon-containing layer and to remove a partial thickness of the non-masked portions of the antireflective coating layer without reducing a thickness of the photoresist layer. The method further includes repeating the selective depositing and etching, at least until the complete thickness of the non-masked portions of the antireflective coating layer is removed, to expose the underlying organic layer.
According to an embodiment, a further method of etching a patterned substrate is disclosed. The method includes providing a patterned substrate that includes a patterned extreme ultraviolet (EUV) photoresist, a transfer layer (TL), and an organic planarizing layer (OPL). The method further includes repeatedly performing a deposition/etch process to selectively and incrementally etch through the TL and into the OPL, wherein the EUV photoresist and TL serve as a mask to transfer the pattern from the EUV photoresist to the OPL. The deposition/etch process includes the following two sub-processes in sequence. In a first sub-process ( 1 ), the method includes depositing a fluorocarbon layer on the patterned substrate, including deposition on the EUV photoresist and exposed portions of the TL or OPL. In a second sub-process ( 2 ), the method includes reactive ion etching to remove the fluorocarbon layer and an incremental portion of the TL or OPL selectively relative to the EUV photoresist. The method further includes repeatedly performing the deposition/etch sub-processes ( 1 ) and ( 2 ) to etch the TL and OPL with greater photoresist etch selectivity than is obtained by performing a reactive ion etch process alone.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention. Additionally, the left most digit(s) of a reference number identifies the drawing in which the reference number first appears.
FIG. 1A illustrates line edge roughness (LER), line width roughness (LWR), and contact edge roughness, resulting from conventional EUV lithography techniques.
FIG. 1B illustrates higher defectivity, resulting from conventional EUV lithography techniques, which may lead to chip failure during electrical testing.
FIG. 1C illustrates diminished etch resistance and low resist margin, resulting from conventional EUV lithography techniques, which demands a high selectivity transfer layer etch.
FIG. 2 is a schematic illustration 200 of a dual-frequency Capacitively Coupled Plasma (CCP) reactor used to etch EUV patterned substrates, according to an embodiment.
FIG. 3A illustrates top-down and cross sectional electron micrographs of line/space and contact/bar reference structures after lithography and after etch pattern transfer, according to an embodiment.
FIG. 3B is a schematic illustration of a typical material layer stack for EUV patterning, according to an embodiment.
FIG. 3C is a plot of normalized values of critical dimension, LER and LWR at each step of processing, according to an embodiment.
FIG. 4A is a schematic illustration of the process of Direct Current Superposition (DCS) resulting from application of a DC potential to a top electrode of a CCP chamber, according to an embodiment.
FIG. 4B illustrates top-down and cross section electron microscopy images showing the impact of DCS on organic selectivity during transfer layer etch, according to an embodiment.
FIG. 5A illustrates schematically an incoming stack for EUV patterning.
FIG. 5B illustrates cross section electron microscopy images showing the effects of DCS cure and etch process optimization on resist selectivity in an application of EUV lithography to trench patterning of the stack of FIG. 5A , according to an embodiment.
FIG. 6 is a schematic illustration of a repeated deposition/etch process, according to an embodiment.
FIG. 7 is a table illustrating the process conditions for an example deposition/etch process, according to an embodiment.
FIG. 8 illustrates cross section electron microscopy images showing the effects of the deposition/etch process in comparison with a conventional etch, according to an embodiment.
FIGS. 9A-9E illustrate evolution of LER and LWR during trench patterning using EUV lithography showing improvement of LER and LWR due to the use of the deposition/etch process, according to an embodiment.
FIGS. 10A-10E illustrate the effect aspect ratio has on pattern wiggling and distortion.
FIG. 11A illustrates the mechanical stability of the organic planarizer layer and resulting downstream pattern roughness, as obtained using conventional techniques.
FIG. 11B illustrates the effect of a DCS cure process on the mechanical stability of the organic planarizer layer and resulting downstream pattern roughness, according to an embodiment, as compared to the process without a DCS cure, as illustrated in FIG. 11A .
FIGS. 12A-12B illustrate top-down cross section electron microscopy images of scummed contact hole and bridged contact hole defects, respectively.
FIG. 13 illustrates results of a conventional approach to reducing defects in a contact hole array based on tuning of PR selectivity.
FIG. 14 illustrates results of an approach to reducing defects in a contact hole array based on techniques including the performance of the repeated deposition/etch process, according to an embodiment.
FIG. 15 shows cross section electron microscopy images showing at three stages of TL open etch, according to an embodiment.
DETAILED DESCRIPTION
The following Detailed Description refers to accompanying drawings to illustrate exemplary embodiments consistent with the disclosure. References in the Detailed Description to “one embodiment,” “an embodiment,” “an exemplary embodiment,” etc., indicate that the exemplary embodiment described can include a particular feature, structure, or characteristic, but every exemplary embodiment does not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is within the knowledge of those skilled in the relevant art(s) to affect such feature, structure, or characteristic in connection with other exemplary embodiments whether or not explicitly described.
The exemplary embodiments described herein are provided for illustrative purposes, and are not limiting. Other embodiments are possible, and modifications can be made to exemplary embodiments within the scope of the disclosure. Therefore, the Detailed Description is not meant to limit the disclosure. Rather, the scope of the disclosure is defined only in accordance with the following claims and their equivalents.
The following Detailed Description of the exemplary embodiments will so fully reveal the general nature of the disclosure that others can, by applying knowledge of those skilled in the relevant art(s), readily modify and/or adapt for various applications such exemplary embodiments, without undue experimentation, without departing from the scope of the disclosure. Therefore, such adaptations and modifications are intended to be within the meaning and plurality of equivalents of the exemplary embodiments based upon the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not limitation, such that the terminology or phraseology of the instant specification is to be interpreted by those skilled in relevant art(s) in light of the teachings herein.
Sub 30 nm node semiconductor manufacturing has imposed many challenges on the physical limits of traditional lithography techniques. EUV lithography is a promising approach to confront the challenges of patterning at 10 nm and sub-10 nm technology nodes. EUV lithography, however, also suffers from a number of significant challenges as illustrated, for example, in FIGS. 1A-1C .
FIG. 1A illustrates line edge roughness, line width roughness, and contact edge roughness, resulting from conventional EUV lithography techniques. In another example, FIG. 1B illustrates higher defectivity, resulting from conventional EUV lithography techniques, which may lead to chip failure during electrical testing. In a further example, FIG. 1C illustrates diminished etch resistance and low resist margin, resulting from conventional EUV lithography techniques, which demands a high selectivity transfer layer etch.
The photoresist budget has been constantly shrinking with each technology node. The capability of performing lithography at smaller pitches comes with a tradeoff in PR thickness. The typical thickness of PR for sub-30 nm technology nodes ranges between 60-20 nm, with smaller technology nodes having thinner incoming resist available for dry etch. Additionally, etch resistance of EUV resist is much less than 193/193i lithography resist, posing further demands on etch process development to provide higher selectivity processes. Efforts to overcome these challenges include EUV source optimization and development of new EUV resist materials.
This disclosure presents lithography techniques based on Capacitively Coupled Plasma (CCP) dry etching methodologies to meet EUV patterning challenges. The disclosed systems and methods use dual-frequency CCP in a patterning process that includes a repeated deposition/etch process. As described below, the disclosed embodiments show improvements in LER/LWR, resist selectivity, and critical dimension (CD) tunability for holes and line patterns. Results obtained using the disclosed embodiments are compared to results obtained using traditional plasma curing methods. Data from a systematic study, which shows the role of various plasma etch parameters that influence the key patterning metrics of CD, resist selectivity, and LER/LWR, is presented.
According to an embodiment, one technique for improving LER and LWR, involves superimposing a negative DC voltage in a radio-frequency (RF) plasma at one of the electrodes of a plasma reactor. The resulting emission of ballistic electrons, in concert with the plasma chemistry, has shown to improve LER and LWR, as described in further detail below.
FIG. 2 is a schematic illustration 200 of a dual-frequency CCP reactor used to etch EUV patterned substrates, according to an embodiment. A wafer 202 to be patterned is mounted to an electrostatic chuck (ESC) 204 . According to an embodiment, a bias RF voltage 206 may be applied to the ESC to fix the voltage of the wafer 202 . The reactor may include an upper electrode (EL) 208 to which a high frequency (HF) voltage 210 may be applied. In addition to the HF voltage 210 , a negative DC voltage 212 may also be applied to the upper EL 208 . A DC anode EL 214 may also be provided, according to an embodiment. According to an embodiment, a 1 kV DC bias 215 may be applied between the upper EL 208 and the DC anode EL 214 .
According to an embodiment, an ionized plasma is generated in the reactor of FIG. 2 through the introduction of process gasses and the application of bias voltages 206 to the ESC 204 , the upper EL 208 and the anode EL 214 . According to an embodiment, the process gasses may include Ar, N 2 H 2 , and various fluorocarbons (CF x ). Application of a DC potential to the upper EL 208 creates a plasma having a lower region 216 and an upper region 218 . The upper region 218 is a sheath having higher plasma density, and more uniform radial distribution of plasma, than the lower region 216 . The process of generating a plasma using the above-described DC potential is called Direct Current Superposition (DCS), or DCS cure, as described in further detail below (with reference to FIGS. 4A-4B and related discussion).
Initial etch feasibility studies utilizing EUV based photoresists were executed on relaxed pitch samples to gauge the impact of resist material change on CD bias control and pattern fidelity. For this work, the patterning was done using an IBM EUV lithography tool set.
FIGS. 3A-3C illustrate the results of initial etch feasibility studies, according to an embodiment. FIG. 3A illustrates top-down and cross sectional electron micrographs of line/space and contact/bar reference structures after lithography and after etch pattern transfer, according to an embodiment. FIG. 3B is a schematic illustration of a typical material layer stack for EUV patterning, according to an embodiment. A trilayer patterning scheme was used: a photoresist (PR) 302 , a transfer layer (TL) 304 , and an organic planarizer layer (OPL) 306 . The TL 304 was chosen for its high degree of plasma etch selectivity to both the PR 302 and OPL 306 , while the OPL 306 , as its name suggests, has the benefit to planarize any existing topography. According to an embodiment, the trilayer stack may be generated on top of a dielectric stack 308 .
Four reactive ion etch (RIE) process conditions, referred to as RIE 1 -RIE 4 , were developed for the transfer layer open, showing CD bias control from 0 to 50% of incoming develop CD as shown, for example, in FIG. 3A . In RIE 1 - 4 , variations were made in one or more of time, pressure, electrode frequencies, DC potential, gas flow rates, or substrate temperature. The PR budget was initially thought to be insufficient to prevent LER degradation and bridging in the leaner ‘ 0 etch bias’ case. However, no LER degradation and bridging was observed, proving this suspicion incorrect. Furthermore, all etch cases exhibit a dramatic improvement of LWR of approximately 63% relative to incoming (i.e., relative to the incoming patterned resist), independent of etch condition. LER degraded slightly as a function of CD bias, and may be an indication that fluorocarbon (CFx) passivation used in the transfer layer open is greater than desired and contributes to LER generation as illustrated, for example, in FIG. 3C . FIG. 3C is a plot of normalized values of critical dimension, LER and LWR at each step of processing, according to an embodiment.
Aggressive pitch scaling for line-space applications leads to a high aspect ratio in the photoresist, thereby inducing pattern collapse marginality. Concurrent with EUV resist height scaling, it is desirable to reduce TL thickness to reduce the etch selectivity requirement. Lower limits on TL thickness are in part dictated by hermeticity to resist solvent and developer solutions. One of the challenges associated with EUV resists is the selectivity when transferring the pattern to the TL. Therefore, in order to enable good pattern transfer with reduced LER and LWR, it is desirable to have good resist selectivity. To achieve reasonable pattern transfer fidelity, it is estimated that etch selectivity should be TL: EUV PR>5:1, according to an embodiment.
The above-described results are typical of conventional EUV lithography techniques. According to an embodiment, improved results can be obtained through the use of DCS technology, as discussed in the following.
FIG. 4A is a schematic illustration of the process of DCS resulting from application of a DC potential to a top electrode of a CCP chamber, according to an embodiment. In this process, application of a DC potential to the upper EL 402 creates a thicker top sheath 404 , changing the radial distribution of the plasma and increasing plasma density relative to plasmas generated without the application of a DC bias.
Additionally, according to an embodiment, the DC potential accelerates positive ions 406 toward the upper electrode. The impact of positive ions on the upper electrode generates secondary electron emission 408 that is accelerated by the DC potential toward the wafer surface 410 . The electrons are of sufficient energy to penetrate a bottom sheath 412 and affect processes at the wafer surface 410 , including charge cancellation and cross-linking of organic films comprising the resist 414 . This electron beam induced cross-linking/hardening may improve etch selectivity to organic photoresists and organic planarizers.
FIG. 4B illustrates top-down and cross section electron microscopy images showing the impact of DCS on organic selectivity during transfer layer etch, according to an embodiment. Clearly, more resist is consumed 416 using the process without DCS in comparison with the result 418 obtained with the use of DCS. Further, an improved CD bias 420 is obtained using DCS than the bias 422 obtained when DCS is not used. Further comparisons of results obtained with and without DCS are presented in the following.
FIG. 5A schematically depicts a stack for EUV patterning and FIG. 5B illustrates cross section electron microscopy images of the stack showing the effects of DCS cure and etch process optimization on resist selectivity in an application of EUV lithography to trench patterning, according to an embodiment. In this example, as shown schematically in FIG. 5A , a stack for EUV patterning 502 comprises an EUV patterned PR 504 , a TL 506 , and an organic planarizing layer (OPL) 508 , constructed on top of a dielectric stack 510 . The PR 504 was patterned having features 512 exhibiting a pitch of less than 40 nm.
The first panel 514 of FIG. 5B is a cross section electron microscopy image of the incoming patterned substrate before etching. The second panel 516 of FIG. 5B shows the results of a conventional Transfer Layer open applied to trenches. It has low resist selectivity (i.e., 1.3:1) to EUV resist and most of the resist is consumed during the TL open, resulting in poor pattern transfer. In the third panel 518 , a DC voltage based treatment was employed prior to the Transfer Layer open process. Ballistic electrons generated by the DC voltage applied to the upper electrode may be collected at the wafer level and may result in the modification and hardening or curing of the resist. For this EUV resist, the DC voltage-based pre-treatment also showed a resist selectivity increase to 2.2:1.
The fourth panel 520 of FIG. 5B shows an increase in resist selectivity resulting from a reduction in the ion energy. In this example, a reduction of the ion energy in the Transfer Layer open step enhanced the resist selectivity to 3.6:1. Reduction in ion energy also improved the EUV resist profile enabling maintenance of a straighter profile with less resist corner “erosion.”
According to an embodiment, the results of FIG. 5B illustrate that the selectivity to the EUV resist can be incrementally increased for a conventional TL open process. To dramatically improve the resist selectivity, a repeated deposition/etch process was developed, as described in greater detail below. Results obtained using the repeated deposition/etch process are shown in the fifth panel 522 of FIG. 5B . This result shows a dramatic improvement, from 3.6:1 to 7.8:1, in resist etch selectivity using the deposition/etch process of an embodiment of the invention.
FIG. 6 is a schematic illustration of the above-mentioned repeated deposition/etch process, according to an embodiment. This approach is based on a process sequence consisting of a deposition process followed by an etch process. In this example, an incoming substrate 600 comprises a PR 602 , a TL 604 , and an organic layer 606 , such as an OPL. According to an embodiment, the PR 602 is an organic photoresist, for example, an EUV photoresist. Also, according to an embodiment, the TL 604 may be a silicon anti-reflection coating (SiARC). The PR 602 is patterned, such that the PR 602 masks a portion of the underlying TL 604 , while exposing non-masked portions of the TL 604 .
In a first step or stage, a deposition process 608 is performed. According to an embodiment, a carbon-containing layer 609 , such as a fluorocarbon (CF x ) polymer, may be deposited on the substrate during the deposition process 608 . Advantageously, the CF x polymer deposits on the exposed non-masked portions of the TL 604 and on non-sidewall portions of the PR 602 . Ion fluxes and the flux of CF x radicals may be controlled through the application of a DC voltage to the upper EL (e.g., 402 in FIG. 4 ). According to an embodiment, the ion flux may have relatively low energy (e.g., <100 eV). In the deposition step 608 , the gas flow of the fluorocarbon gas controls the CF x radical flux therefore controlling the deposition. According to an embodiment, the CF x polymer deposits preferentially on the resist patterns. In other words, the CF x polymer deposits to a greater thickness on the non-sidewall portions of the PR 602 than on the non-masked portions of the TL 604 .
According to an embodiment, in a second step or stage, a reactive ion etch 610 is performed. In the reactive ion etch 610 , a portion of the TL 604 may be preferentially etched while the PR 602 largely remains. To state another way, a partial thickness of the TL 604 is etched without reducing the thickness of the PR 602 to any appreciable extent. In one embodiment, DCS is used during the etch 610 which hardens (cures) the PR 602 as the TL 604 is etched, thereby facilitating the preferential etch.
In a further step or stage, as indicated by arrow 612 , the sequential process of deposition 608 then etching 610 is repeated. As the repeated process progresses, the TL 604 is etched through followed by etching of the underlying OPL to transfer the pattern into the OPL 606 . According to an embodiment, this repeated process results in a structure 614 in which the TL 604 and planarizing layer are etched through while the PR is left reasonably intact. The number of times the sequential deposition 608 /etch 610 process must be repeated is determined by the initial thickness of the TL 604 and organic layer 606 thickness and the partial thickness etched in each iteration.
FIG. 7 is a table 700 illustrating the process conditions for an example deposition/etch, according to an embodiment. In this example, during the first deposition process 702 fluorocarbons CH 3 F 704 and CF 4 706 are introduced into the plasma reactor along with H 2 708 at gas flow rates of 40 sccm, 50 sccm, and 330 sccm, respectively. During the first etch/cure process 710 , the flow of fluorocarbons 704 and 706 is stopped and H 2 708 and N 2 712 are introduced into the plasma reactor, each at a gas flow rate of 450 sccm. The alternating deposition/etch (cure) is then repeated for a predetermined number of iterations.
In this example, the combined deposition/etch (cure) process is repeated three times. In other embodiments, the deposition/etch (cure) process may be repeated any number of predetermined times as needed. Other process parameters provided in table 700 include the gas pressure 714 , the power 716 supplied to the upper EL 208 (see FIG. 2 ) at high frequency (HF), the power 718 supplied to the ESC 204 (see FIG. 2 ), and the DC voltage 720 applied to the upper EL 208 (see FIG. 2 ).
FIG. 8 illustrates cross section electron microscopy images 800 showing the effects of the deposition/etch process in comparison with a conventional etch, according to an embodiment. The first image 802 shows the incoming substrate having a patterned PR 804 , a SiARC transfer layer 806 , and an OPL 808 . The second image 810 clearly shows that with a conventional process the PR 804 is consumed during the SiARC etching process. The third image 812 shows the results of the deposition/etch (cure) process, of an embodiment of the invention, after the SiARC 806 has been etched and the OPL 808 has been partially etched. In this example, the PR 814 remains intact and the height of the PR 814 has not decreased.
FIGS. 9A-9E illustrate evolution of LER and LWR during trench patterning using EUV lithography showing improvement of LER and LWR due to the use of one cycle of the deposition/etch process, according to an embodiment. The DC voltage-based plasma condition facilitates a good control of the CF x radical flux at relatively low ion energy, which helps to maintain the resist budget and the resist profile.
FIG. 9A is a schematic cross-sectional view of the incoming substrate 900 . The incoming substrate 900 includes a patterned resist 902 , a transfer layer 904 , and a planarizer 906 . According to an embodiment, the substrate 900 may also include a hard mask (HM) stack 908 . The HM stack 908 may be provided on top of a dielectric stack 910 and may be used to pattern the dielectric stack 910 .
FIG. 9B includes top-down electron microscopy images 912 , 914 , 916 , and 918 , illustrating the features of the etched substrate at different stages of the etching process. Image 912 shows the substrate after EUV lithography. Image 914 shows the substrate after the TL etch (“TL open”) process. Image 916 shows the substrate after the HM stack open process. Image 918 shows the substrate after the trench and dielectric etch process. The results for LER evolution are shown in the graph 920 of FIG. 9C . The results for LWR evolution are shown in graph 922 of FIG. 9D . These results show a good CD uniformity, measured after TL layer open, is achieved. These results also show a reduction of about 25-30% of the measured LER and LWR, as summarized in table 924 of FIG. 9E .
FIGS. 10A-10E illustrate the effect aspect ratio has on pattern wiggling and distortion using one cycle of the deposition/etch process, according to an embodiment. Unlike multiple patterning schemes, EUV lithography allows the complete line-space pattern to be exposed in a single pass. As the line-space pitch is decreased, the high aspect ratio of the soft mask results in a reduction in its relative mechanical stability. This leads to aspect ratio dependent pattern distortion and wiggling.
In FIG. 10A , a top-down electron micrograph image 1002 illustrates good results for patterning a substrate having an aspect ratio of approximately 4.1. In FIG. 10B , a similar top-down electron micrograph image 1004 illustrates good results for patterning a substrate having an aspect ratio of approximately 4.25. However, distortion in the resulting patterned substrate is observed for substrates having aspect ratios larger than approximately 4.5. For example, in FIG. 10C , a top-down electron micrograph image 1006 illustrates pattern distortions (i.e., LER and LWR) for patterning a substrate having an aspect ratio of approximately 4.6. A pronounced wiggling distortion is observed for a substrate having an aspect ratio of approximately 6.1, as shown in FIG. 10D in top-down electron micrograph image 1008 . The results of FIGS. 10A-10D are graphically depicted in FIG. 10E , where normalized CD is shown as a function of aspect ratio.
According to an embodiment, keeping the aspect ratio of the soft mask under 4.5 allows good pattern transfer to the hard mask to be achieved, even at a small pitch size, as shown in FIGS. 10A, 10B, and 10E . At an aspect ratio above 6.0, the soft mask is no longer able to maintain the pattern, and wiggling is induced, as shown in image 1008 in FIG. 10D and in FIG. 10E . Between the aspect ratios 4.5 and 6.0, a small amount of pattern distortion is observed, as shown in FIGS. 10C and 10E .
The aspect ratio of the soft mask is dictated by the pitch dimension required by integration and the planarizer material performance. A thinner planarizing layer reduces the aspect ratio, but the process of producing such a layer reliably can be challenging and constrains the design of the stack. In addition, there is consequently a thinner soft mask during the ensuing steps, requiring additional high selectivity processes. The onset of pattern distortion may also depend on the etch chemistry used to etch the planarizing layer. The utilization of new etch chemistries and conditions may lend added rigidity to the soft mask and enable a wiggle-free process at higher aspect ratios.
Top-down inspection through a partition of the etch sequence, as shown in FIGS. 9A-9E , for example, provides some additional insight into the mechanism inducing line wiggle. Although edge roughness is apparent after TL strip, mask CD growth and significant line wiggle degradation after oxide etch is observed. It is possible that either CF x deposition or swelling of the soft mask from plasma chemistry exposure induces a compressive stress that is relieved through the line wiggle. This non-ideality may be transferred directly to the dielectric as shown in the post-ash image (discussed further below with reference to FIGS. 11A-11B ). Application of a DCS cure prior to, or during, TL open may eliminate this wiggling phenomenon. At aggressive <40 nm pitch, where the wiggling is most apparent, the effect is dramatic and readily apparent by visual inspection, as shown in FIGS. 11A-11B , and described in further detail below.
FIGS. 11A-11B illustrate the effect of a DCS cure process on the mechanical stability of the organic planarizer layer and resulting downstream pattern roughness, according to an embodiment. Process 1102 of FIG. 11A illustrates the results obtained for etching a high aspect ratio substrate without application of a DCS cure process. An aspect ratio of about 5:1 was used in this example, but other aspect ratios are contemplated. Process 1104 of FIG. 11B illustrates improved results obtained for etching a high aspect ratio substrate with application of a DCS cure process. Panel 1106 schematically illustrates the incoming substrate. Panel 1108 schematically illustrates the substrate after the TL open operation has been applied. The third panel 1110 includes a top-down electron microscopy image 1112 showing significant wiggling after the organic mask opening/TL strip process. The fourth panel 1114 includes a top-down electron microscopy image 1116 showing enhanced wiggling after the oxide etch process. Panel 1118 includes a top-down electron microscopy image 1120 showing significant wiggling of the final etched dielectric.
Effects of performing a DCS cure process are illustrated in process 1104 of FIG. 11B . Panel 1122 schematically illustrates the incoming substrate, which is identical to the incoming substrate in process 1102 . Panel 1124 schematically illustrates the substrate after the TL open operation has been applied, wherein the TL open operation includes application of a DCS cure process. Panel 1126 schematically illustrates the organic mask open/TL strip operation and panel 1128 schematically illustrates the oxide etch process. Panel 1130 includes a top-down electron microscopy image 1132 of the final etched dielectric. Image 1132 clearly shows improved LER and LWR characteristics, resulting from the DCS cure process of panel 1124 , in contrast to image 1120 resulting from the etch process that is performed without the DCS cure process.
FIGS. 11A-11B show the result of two processes with equal post-etch CD and thus planarizer aspect ratio. Without DCS cure in the TL open, the LWR is improved by 34% from incoming ( FIG. 11A ). Inclusion of a DCS cure prior to TL open ( FIG. 11B ) provides additional improvement, to a 52% reduction from incoming. Significant improvement of LER and LWR was also observed for substrates having relaxed pitch where the planarizer aspect ratio is well below the 4.5:1 threshold previously identified (results not shown here).
The improved results obtained using the DCS cure process, shown in FIG. 11B , may be due to the interaction of ballistic electrons with the planarizer stack. With scaled resist, TL and planarizer thicknesses, the ballistic electrons may penetrate well into the planarizer stack to provide enhanced mechanical resistance to the stress-induced deformation previously observed during the oxide etch.
Another pattern fidelity challenge observed for this evaluation is a tradeoff between missing and bridged contacts for a dense 1×1 contact hole array, as shown in FIGS. 12A-12B , which illustrate top-down cross section electron microscopy images of “scummed” contact hole and bridged contact hole defects, respectively. Close inspection of the incoming pattern reveals concurrent scummed contacts 1202 , where resist material is incompletely developed from an intended hole, and partially bridged contacts 1204 where the resist height between neighboring contacts is much less than intended.
While conventional etch processes can solve either problem (i.e., scummed contacts 1202 or bridged contacts 1204 ) independently, there is inadequate PR budget to insert a de-scum process (to cure a scummed defect) prior to TL open. Further, there is insufficient margin for simply tuning PR selectivity of the TL open.
FIG. 13 represents a conventional approach to reducing defects in a contact hole array based on tuning of PR selectivity. In this example, FIG. 13 shows three arrays 1302 , 1304 , 1306 with application of low, medium, and high PR selectivity TL open recipes, respectively. The three arrays 1302 , 1304 , 1306 were each a 1×1 contact hole array with 2200 contacts. For each case, the contacts were inspected for missing or bridged contacts. Although this sampling rate of 2200 contacts is very low for manufacturing level yield analysis, it provides adequate resolution to observe the trade-off between the competing defectivity modes as a function of resist selectivity.
The results of FIG. 13 clearly indicate that there is a tradeoff between bridged contact and scummed contacts as a function of tuning the PR selectivity. For example, at low PR selectivity in array 1302 , bridged contacts 1310 form preferentially rather than scummed contacts. However, as PR selectivity is increased to mid PR selectivity in array 1304 , and to high PR selectivity in array 1306 , scummed contacts 1312 , 1316 are formed preferentially over bridged contacts. For example, when a low PR selectivity recipe was used, there were no detected scummed contacts in the array 1302 of 2200 contact holes, while 4 bridged contacts 1310 were observed. When a mid PR selectivity recipe was used, 5 scummed contacts 1312 were observed in the array 1304 of 2200 contact holes, while there were no bridged contacts observed. Lastly, when a high PR selectivity recipe was used, 20 scummed contacts 1316 were observed in the array 1306 of 2200 contact holes, while no bridged contacts were observed.
FIG. 14 illustrates results of an approach to reducing defects in a contact hole array based on techniques including the performance of the repeated deposition/etch process (described above and illustrated in FIGS. 5A, 5B, 6, 7, and 8 ), according to an embodiment. FIG. 14 shows that for the array 1402 of 2200 contact holes there were no scummed defects and no bridge contacts observed. These results show a significant improvement over the conventional approach illustrated in FIG. 13 . A possible explanation for these improved results is provided as follows.
Further characterization of the component steps of the high selectivity (7.8:1 as shown in panel 522 in FIG. 5B ) deposition/etch process, described above, provided insight into a possible explanation of the improved results of FIG. 14 . The results of this investigation are presented in FIG. 15 , as follows.
FIG. 15 shows cross section electron microscopy images taken at three stages of TL open etch, according to an embodiment. Application of a standard TL open recipe results in a trapezoidal mask shape with monotonic taper, as shown in image 1502 . Application of the DCS-enhanced deposition process preferentially deposits CFx polymer on the resist, resulting in a more vertical profile, as shown in image 1504 . Doubling the deposition time produces an aspect ratio dependent deposition, evidenced by the rounding of the top of the structure and formation of polymer overhang, as shown in image 1506 . This preferential deposition of CFx on the resist in low aspect ratio structures provides a mechanism by which the weak spots of partially bridged contact holes can be passivated without significant deposition on the scumming/remaining resist at the bottom of the higher aspect ratio hole. Cycling this new deposition process with an organic etch/descum was applied prior to TL open, resulting in an apparent elimination of both defect modes (i.e., scummed and bridged contacts) for the 2200 contact holes sampled, as illustrated in FIG. 14 .
The disclosed methods, including repetition of a deposition/etch sequence, have successfully demonstrated CCP plasma based etch solutions enabling EUV lithography for trench and contact hole patterning applications. Application of EUV reduces the reticle count, cycle times, integration complexity and intra-level overlay variation for sub 40 nm pitch applications. These methods show promise for meeting the challenge of reducing incoming organic mask thickness to avoid pattern collapse.
The disclosed methods further show the application of DCS in the deposition/etch sequence to be advantageous for improving organic rigidity and etch resistance. DCS also aids in mitigating pattern distortion occurring during the planarizer layer open process, in turn, reducing the downstream pattern roughness. A plasma etch method for providing high resist selectivity during trench patterning and improving defectivity for contact hole patterning applications by selective passivation on resist patterns, was also disclosed.
It is to be appreciated that the Detailed Description section, and not the Abstract section, is intended to be used to interpret the claims. The Abstract section can set forth one or more, but not all exemplary embodiments, of the disclosure, and thus, is not intended to limit the disclosure and the appended claims in any way.
While the disclosed invention has been illustrated by the description of one or more embodiments thereof, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those of ordinary skill in art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept.
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A method for etching an antireflective coating on a substrate is disclosed. The substrate comprises an organic layer, an antireflective coating layer disposed above the organic layer, and a photoresist layer disposed above the antireflective coating layer. The method includes patterning the photoresist layer to expose a non-masked portion of the antireflective coating layer and selectively depositing a carbon-containing layer on the non-masked portions of the antireflective coating layer and on non-sidewall portions of the patterned photoresist layer. The method further includes etching the film stack to remove the carbon-containing layer and to remove a partial thickness of the non-masked portions of the antireflective coating layer without reducing a thickness of the photoresist layer. The method further includes repeating the selective depositing and etching, at least until the complete thickness of the non-masked portions of the antireflective coating layer is removed, to expose the underlying organic layer.
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FIELD OF THE INVENTION
The field of the invention is actuators for subterranean tools and more particularly those that are initially in pressure balance to tubing pressure through spaced ports leading to opposed pistons and more specifically where the access ports to tubing pressure can be sequentially exposed for unlocking, setting and releasing the tool such as a liner hanger.
BACKGROUND OF THE INVENTION
Hydraulic actuators in the past have been made insensitive to tubing pressure using opposed pistons that create opposing forces to any tubing pressure so that the net result is no movement of the actuator mechanism so that the tool is not set even if there are pressure surges in the tubing. To insure that there is no premature setting the sleeve to be moved to set the tool can be held with a shear pin that breaks under a predetermined net force. Tool actuation involves isolating an upper inlet to one of the pistons from a lower inlet to an opposing piston, such as with an object dropped on a seat in the tubing. This is followed with elevating the pressure to one of the pistons that has access to tubing pressure above the seated object so that one piston creates a net force in the setting direction for setting the tool. A retainer for the setting sleeve can be broken in the setting process as the tool is set with the actuator. This design is shown in schematic terms in U.S. Pat. No. 7,766,088. While this reference mentions in passing an application for unsetting a tool, the details provided focus on how to set and no details are provided as to how to unset with the described actuation tool.
U.S. Pat. No. 7,686,090 shows the use of a floating piston in a liner hanger actuation tool with a balance piston referenced to the annulus. US Publication 2010/0319927 shows the use of a ball seat that can be displaced with a seated ball on it into a larger diameter for release of the ball.
The present invention goes a step further by initial isolation of one actuating piston to set a tool such as a liner hanger and then isolation of an opposing piston to tubing pressure to reverse the movement of an actuation mechanism for release of the tool such as a liner hanger. Those skilled in the art will more readily appreciate various aspects of the invention from a review of the description of the preferred embodiment and the associated drawings while recognizing that the full scope of the invention is to be determined by the appended claims.
SUMMARY OF THE INVENTION
An actuator for a subterranean tool is releasably retained by a collet. The actuation system features opposing actuation pistons with ports communicating to the tubing. The spaced ports are sequentially straddled for initial setting and a subsequent release using a predetermined applied pressure. The applied pressure overcomes the retaining force of the collet and actuates a one of two opposed pistons to set the tool, which is preferably a liner hanger. Upon shifting the actuation tool to communication to another port leading to an actuating piston pushing in another direction with applied pressure releases the tool and re-latches a retaining collet. The tool can be set, released and repositioned for another cycle in the same trip in the hole.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the actuator tool in the run in position;
FIG. 2 shows an upper port in the actuator tool isolated with an internal straddle device so that pressure applied to the isolated port will set the downhole tool that is operably connected to the actuator tool;
FIG. 3 is the view of FIG. 2 with the straddle device shifted to straddle another isolated port so that applied pressure will cause the downhole tool to release;
FIG. 4 shows the released downhole tool in position for being pulled out of the hole or relocated for another setting; and
FIG. 5 is an enlarged view of the detail in the circle of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the actuation tool 10 that has a mandrel 12 that defines a tubing passage 14 that extends to a well surface through a tubular string that is not shown. An actuating sleeve 16 is connected at an upper end 18 to a schematically represented tool 20 which preferably is a liner hanger but it can be a variety of other tools. The sleeve 16 is moved axially in opposed directions to set and release the tool 20 .
For running in with ports 22 and 24 accessible in passage 14 there will be no movement of sleeve 16 because the piston area in chamber 26 defined by seals 28 and 30 is equal to the piston area in chamber 32 defined by seals 34 and 36 and opposing in direction. The volume in chambers 26 and 32 varies as the sleeve 16 is forced to move axially. Before any axial movement of sleeve 16 can occur, to set the tool 20 , enough pressure has to be applied to port 22 to make collet 38 jump out of groove 40 . Groove 40 is retained to mandrel 12 with ring 42 . Collet 38 is secured at thread 44 to the sleeve 16 . The purpose of the collet 38 being in groove 40 is to allow a predetermined force to build up through ports 22 before there is sleeve 16 movement. Additionally, during run in, if the sleeve 16 is bumped on a surrounding tubular or connection in the wellbore then the collet 38 in groove 40 will resist sliding movement and pre-setting of tool 20 due to the engagement of collets 38 in groove 40 .
FIG. 2 shows a running and actuation tool that is associated with the mandrel 12 and the string that is not shown and attached to the lower end 46 . The running and actuation tool has several features that are schematically illustrated. There is a gripping device shown schematically as 48 that grabs the mandrel 12 and selectively releases when the mandrel 12 becomes independently supported to the surrounding tubular 50 or some other way supported in the wellbore. At the same time the gripping device 48 allows for run in and release of the mandrel 12 when there is support such as by actuation of a tool 20 that in the preferred embodiment is a liner hanger. When running in, spaced seals 52 and 54 can be located in a straddle about openings 22 and 24 or both ports 22 and 24 can be open to the passage 14 . Seals 52 and 54 are an isolation assembly and can be a variety of designs that are either run in with a sealing position or that need to be actuated when in the proper location. These seals can be cup seals, inflatable, ball seats S that accept balls or other styles that allow selective straddling of the ports 22 or 24 . Application of pressure through passage 56 goes into ports 22 but that same pressure is isolated from ports 24 due to seal 54 . As pressure is applied the collets 38 jump out of groove 40 when a predetermined pressure is applied in chamber 26 which then starts to increase in volume as the collets 38 jump groove 40 . If the tool 20 is a liner hanger, then movement of sleeve 16 in the direction of arrow 58 will set the liner hanger and support the mandrel 12 . The running tool gripping device 48 is released from the mandrel 12 in conjunction with the shifting of the sleeve 16 . At this point the running and straddle tool assembly can be moved relative to the mandrel 12 to assume the FIG. 3 position from which it is possible to urge the sleeve 16 in the direction of arrow 60 to release the tool 20 or to reverse its previous motion, depending on the nature of the tool. Such reverse movement will bring collets 38 back to groove 40 and release the slips of the liner hanger (not shown) so that the mandrel 12 can be moved within the borehole or pulled out of the hole. Such movement in the direction of arrow 60 must also be preceded with regaining a grip on the mandrel 12 as the tool 20 such as a hanger is released. In FIG. 3 the openings 24 are straddled so that pressure applied to chamber 32 moves the sleeve 16 in the direction of arrow 60 .
In FIG. 4 the mandrel 12 is supported by the grip 48 up above so that the liner supported by mandrel 12 will not drop if the liner hanger or other tool 20 is released. In essence, after releasing the hanger 20 while gripping the mandrel 12 with the seals straddling ports 24 the gripper 48 is engaged to the mandrel 12 . If the mandrel 12 is to be pulled out of the hole then an upward force is applied to the running tool that now supports the mandrel 12 in the FIG. 3 position and the string and mandrel 12 with the tool 20 come out of the hole as an assembly.
On the other hand if after a release of tool 20 in FIG. 3 it is desired to reposition the mandrel 12 with the tool 20 in another well location without coming out of the hole then there needs to be an ability to retain support for mandrel 12 while repositioning seals 52 and 54 to again straddle ports 22 so that the tool 20 can be reset again before the gripper 48 releases the mandrel 12 . This repositioning of the seals 52 and 54 can be done with a telescoping member responsive to fluid pressure or any other method that can then draw up the seals 52 and 54 to the FIG. 4 position and the process can be repeated.
Seal 54 can be a packer that can be set mechanically, hydraulically or by inflation to name a few options. Alternatively, seal 54 can be a ball seat that permits circulation or reverse circulation as long as there is no seated ball. To set the tool a ball can be dropped to the ball seat and pressure built in the FIG. 2 position for setting the tool 20 . The ball can then be extruded through the seat such that a bigger ball can land on the same seat when the position of FIG. 3 is obtained so that the tool 20 can be released in the manner previously described. The same ball seat can accept many balls of increasing size, or can be a stack of different size ball seats, to allow the pressure cycling to be repeated several times for subsequent setting and releases of the tool 20 in different wellbore locations in the same trip. Such a design is well known in the art.
The present invention allows setting and releasing a tool multiple times in a single rip with a feature of making the setting sleeve 16 insensitive to tubing pressure or mechanical shocks from a surrounding tubular when running in. The grip and straddle tool allows setting a tool such as a liner hanger while releasing the grip of the mandrel. The mandrel can be gripped again when it is desired to release a tool such as a liner hanger by straddling different ports to reverse the movement of the actuating sleeve while at the same time gripping the mandrel so as to retain a liner string once the hanger releases. At this point the hanger and liner attached to it can be pulled out of the hole. Alternatively, while retaining the grip obtained, to initiate the release, the straddle seals can be repositioned by use of a telescoping member, among other techniques, to locate the seals 52 and 54 back over ports 22 and repeat the cycle without coming out of the hole.
The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below:
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An actuator for a subterranean tool is releasably retained by a collet. The actuation system features opposing actuation pistons with ports communicating to the tubing. The spaced ports are sequentially straddled for initial setting and a subsequent release using a predetermined applied pressure. The applied pressure overcomes the retaining force of the collet and actuates a one of two opposed pistons to set the tool, which is preferably a liner hanger. Upon shifting the actuation tool to communication to another port leading to an actuating piston pushing in another direction with applied pressure releases the tool and re-latches a retaining collet. The tool can be set, released and repositioned for another cycle in the same trip in the hole.
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FIELD OF THE INVENTION
[0001] The invention is generally related to the field of damping cylinders. More particularly, the present invention is an improvement to damping cylinders previously having both internal floating pistons and shafts.
BACKGROUND OF THE INVENTION
[0002] The use of internal floating pistons,—also known as and will be referred to herein as IFPs—in damping cylinders to compensate for volume changes due to the displacement of damping fluid within the damping cylinder and thermal expansion of the damping fluid, is well known. For example, the following Fox Racing Shox (Fox Factory, Inc.) patents depict the use of an IFP: U.S. Pat. No. 6,135,434; U.S. Pat. No. 6,296,092; U.S. Pat. No. 6,311,962; U.S. Pat. No. 6,360,857; U.S. Pat. No. 6,415,895; and U.S. Pat. No. 6,604,751 and are incorporated by reference herein as are all the patents and published patent applications referred to within this patent application.
[0003] Furthermore, it is often common to have shafts extending the longitudinal length of the damping cylinder. The shaft may comprise a piston rod, a valve control rod, or a combination of both. For example, in FOX U.S. Pat. No. 6,360,857, we depict the use of a shaft extending the length of the damping cylinder wherein the shaft comprises a piston shaft and a control shaft. In another FOX patent, the shaft passes through the IFP. See U.S. Pat. No. 6,415,895 ( FIG. 7 ).
[0004] The present invention is an extremely simple to implement improvement and innovation in damping cylinders, and especially those damping cylinders that may have originally been designed to have both IFPs and shafts or in any other damping cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a simplified schematic depicting a prior art damping cylinder having an IFP and a shaft.
[0006] FIG. 2 is a cross section along line 2 - 2 of FIG. 1 .
[0007] FIG. 3 is a simplified schematic of a damping cylinder according to a first exemplary embodiment of the invention.
[0008] FIG. 4 is a cross section along line 4 - 4 of FIG. 3 .
[0009] FIG. 5 is a detailed cross-section of a lower portion a damping cylinder according to an exemplary embodiment of the invention.
[0010] FIG. 6 is a simplified schematic of a damping cylinder according to a second exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] FIG. 1 is a simplified schematic depicting a prior art damping cylinder having an IFP and a shaft. FIG. 2 is a cross section along line 2 - 2 of FIG. 1 . Damping cylinders such as these have widespread application in many diverse devices, including but not limited to, shock absorbers and forks for two-wheeled vehicles. Damping cylinder 100 generally comprises a cylinder body 110 having an inner wall 110 a and that is divided into fluid chamber 103 and fluid chamber 115 by a partition 117 . Partition 117 may comprise a wall (as shown) or a piston (not shown) sealed against inner wall 110 a . Fluid will be able to flow into (arrow A) and out of (arrow B) fluid chamber 115 via conventional fluid flow control valves such as check valves, spring-biased valves or deflectable disc valves (shown schematically and collectively in black-box form by valve V). In other situations, such as will be described with respect to FIG. 6 , fluid chamber 115 will contain an axially movable shaft 120 and piston ( 195 ) that are used to impart a force onto and displace the damping fluid within fluid chamber 115 . Fluid chamber 115 generally comprises a single open volume defined by inner walls 110 a of cylinder body 110 . Furthermore, extending a substantial length of cylinder body 110 is a shaft 120 having a shaft surface 120 a . As previously mentioned, the shaft 120 may comprise a piston rod, a valve control rod, or a combination of both. For example, as shown in FIG. 1 , by turning knob K on the end of shaft 120 , through a mechanism passing through shaft 120 , it is possible to control one or more flow characteristics of valve V. While in no way critical to this invention, valve V may control, for example, rebound damping, low and/or high speed compression damping, lockout, bleed, or blowoff threshold.
[0012] Cylinder body 110 will also contain an IFP 150 that divides fluid chamber 115 into first and second fluid chambers 115 a , 115 b , respectively. While in FIG. 1 , IFP 150 is backed by a pressurized and compressible fluid, typically in the form of a gas G contained within second fluid chamber 115 b , in other situations the IFP may be backed by a coil spring (not shown). The amount of gas G within second fluid chamber 115 b can either be at ambient pressure when the damping cylinder is at fluid extension or may optionally be varied using optional pressurization valve 170 , which can be a Schrader Valve. To prevent pressurized gas G within second fluid chamber 115 b or damping fluid within first fluid chamber 1115 a from intermingling, seals, typically in the form of o-rings 160 a , 160 b , will be used to seal the IFP 150 against the inner wall 110 a of cylinder body 110 and the outer surface 120 a of shaft 120 (see also e.g. Fox U.S. Pat. No. 6,415,897 ( FIG. 7 )).
[0013] As is known, IFP 150 will be able to move longitudinally within cylinder body 110 , as shown by arrows C dependent upon the flow direction of the damping fluid within first fluid chamber 115 a . However, due to the seals running against the inner walls of cylinder body 110 a and the outer surface of shaft 120 a , friction is created. In many damper applications, the effects of friction are undesirable. Finally, for there to be a good seal between the seals and the inner walls 110 a of cylinder body 110 and the outer surface 120 a of shaft 120 , typically the inner walls 110 a of cylinder 110 and the outer surface 120 a of shaft 120 must be properly prepared with a smooth high-quality surface finish and toleranced/dimensioned, adding cost to the overall damping cylinder.
[0014] Having described the prior art, a damping cylinder according to multiple exemplary embodiments of the invention will now be described.
[0015] FIG. 3 is a simplified schematic of a damping cylinder according to a first exemplary embodiment of the invention. FIG. 4 is a cross section along line 4 - 4 of FIG. 3 . When referring to FIGS. 3 and 4 , where similar elements are found in FIGS. 1 and 2 , the same reference numerals are used.
[0016] According to an exemplary embodiment of the invention, IFP 150 is simply replaced with a properly and securely mounted annular bladder 200 (see FIG. 5 ). Annular bladder 200 will typically comprise a unitary body having outer and inner annular walls 200 a , 200 c , respectively that are substantially parallel to shaft 120 and connected to each other by a third wall 200 b that closes off an end of annular bladder 200 so as to define a bladder fluid chamber 210 within bladder 200 . Bladder 200 has no structural connection with the bulk of the damping cylinder 100 , except in the area of base 175 . Cf. U.S. Pat. No. 4,700,815 (edge of bag 44 is fixed around the inner end of the tubular extension 30 of the cap 22 by means of a spring ring 48 ). The gas G is contained within the bladder fluid chamber 210 defined by annular bladder 200 . As shown in FIG. 4 , annular bladder 200 will surround shaft 120 without there being any intermediate structures and with their being a space 205 between shaft 120 and bladder 200 for fluid to be able to fill. The annular bladder 200 may completely surround shaft 120 as shown in the present FIGS, or may at least partially surround the shaft 120 and have, for example, a “c”-shape (not shown). Shaft 120 will extend through space 205 defined by inner annular wall 200 b . Furthermore, bladder 200 will also not necessarily come into contact with (and therefore have a clearance from) the inner walls 110 a of cylinder body 110 . Bladder 200 will typically be constructed from an elastomeric material, capable of withstanding typical damping fluids and elevated temperatures, for example, a high-grade rubber.
[0017] FIG. 5 depicts an exemplary method for attaching bladder 200 to cylinder base 175 . The open end of bladder 200 will have mounting beads 201 and inner 207 and outer sealing beads 203 formed thereon. Mounting beads 201 will be securely press-fit into grooves 176 of cylinder base 175 . Inner sealing beads 207 will be pressed against shoulder 128 of shaft 120 to create a fluid seal for space 205 as well as provide additional structural support for inner bladder wall 200 b . Outer sealing beads 203 will be pressed against inner walls 110 a of cylinder body 110 to create another fluid seal for space 205 as well as provide additional structural support for outer bladder wall 200 a.
[0018] It should be noted that there is a clearance 204 between the outer walls 200 a of bladder 200 and the inner walls 110 a of cylinder body 110 . This clearance, as well as space 205 allow for the purging of excess air and oil from cylinder body 110 during the manufacture of damping cylinder 100 . In particular, damping cylinder 110 is manufactured generally as follows:
[0019] 1) Damping cylinder 100 is inverted from the orientation shown in FIGS. 3-6 ;
[0020] 2) Oil is filled into fluid chamber 115 in the same way as if one were filling a cup;
[0021] 3) Bladder 200 is inserted into the oil-filled chamber 115 ;
[0022] 4) Excess oil flows out clearance 204 and space 205 ;
[0023] 5) Cylinder base 175 is used to seal off damping cylinder 100 .
[0024] Finally, as can be seen in FIG. 5 , shaft 120 actually may comprise a stationary outer shaft 125 and an inner control rod 127 . Inner control rod 127 may be connected to knob K and used to control valve V, as mentioned above. In some instances, it is possible for there to be multiple control rods associated with multiple valves and/or knobs.
[0025] The use of bladders, in general, is known in the art of damping cylinders. Furthermore, annular bladders have also been used. For example, annular bladders were described in U.S. Pat. No. 2,571,279 and U.S. Pat. No. 4,700,815. However, in these patents, the bladder and the shaft are not designed to be immediately adjacent each other without any intermediate structures, as they are in the current exemplary embodiments of the invention.
[0026] Therefore, bladders separating a single fluid chamber into two fluid chambers and having a shaft passing there through have not been implemented. It is assumed that they were not used in such situations because it was not readily evident how to effectively maintain the fluid seal between the shaft 120 and the hole that would be needed in the bladder for the shaft to pass through (cf. Fox U.S. Pat. No. 6,415,895 (o-rings between piston and rod)). Note that in U.S. Pat. No. 2,708,112, a metallic member is used to define a reservoir and surrounds a shaft, but it is intended in that patent that fluid can pass from inside the reservoir to outside the reservoir. However, in the present invention, damping fluid is completely retained on one side of the bladder in the bladder fluid chamber and we have found a way to implement a bladder around a shaft without having to worry about any sealing losses due to, for example, degradation of o-rings.
[0027] Thus, according to this exemplary embodiment of the invention, as fluid either enters cylinder body 110 via valve V or is moved due to shaft 120 and piston 195 ( FIG. 6 ), the increasing volume of fluid within chamber 115 will result in the partial compression of bladder 200 in the direction of arrows F against the internal pressure of gas G. Then, as fluid either leaves the cylinder body 110 via valve V or has more volume to fill due to the retraction of shaft 120 and piston 195 , the internal pressure of gas G will result in the expansion of the bladder 200 against the fluid to prevent, for example, the creation of a vacuum within cylinder body 110 or the cavitation of the fluid within cylinder body 110 . While as the bladder 200 expands and contracts it may come into contact with the inner wall 110 a of the cylinder body 110 and/or the outer surface 120 a of shaft 120 , friction is negligible and much lower than would result from an IFP application. Furthermore, as opposed to applications in which the “bladder” may be fixed at both its ends (e.g. U.S. Pat. No. 4,700,815), the presently described bladder is much more easily and flexibly compressed.
[0028] While the invention has been disclosed with reference to certain exemplary features, the scope of the invention shall only be defined by the appended claims.
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An improvement to damping cylinders in which the damping fluid needs to be separated from a gas is disclosed. In particular, an annular bladder is used. An annular bladder allows for a control shaft to extend at least at least a portion of the length of the damping cylinder. This configuration effectively and simply reduces most issues that result from when an IFP is used for the same purpose.
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REFERENCE TO RELATED APPLICATIONS
This application claims one or more inventions which were disclosed in Provisional Application No. 61/232,521, filed Aug. 10, 2009, entitled “Christmas Tree Game”. The benefit under 35 USC §119(e) of the United States provisional application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention generally relates to a board game, and more specifically relates to a Christmas-themed board game that may be enjoyed by people celebrating Christmas around the world.
SUMMARY OF THE INVENTION
In one aspect of the present invention, a game comprises a game board; a tree trunk for each player playing the game, the tree truck attachable to the game board; a plurality of branches for the each player playing the game, the plurality of branches attachable to the tree trunk; a tree topper; and a pair of dice; wherein players in turn roll the pair of dice and build a tree from the tree trunk and the plurality of branches based on rolls of the pair of dice.
In another aspect of the present invention, a method for playing a game, comprises opening a game board; rolling a pair of six-sided dice within a center area of the game board; taking an action in response to the rolling of the pair of six-sided dice; and continuing to roll the dice and to take the action until a tree topper is placed atop a tree trunk.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a view of the components of a Christmas tree game in accordance with an embodiment of the present invention;
FIG. 2 shows an overhead view of the game board and dice of the Christmas tree game shown in FIG. 1 ;
FIG. 3 shows a side view of the components of the Christmas tree game shown in FIG. 1 ; and
FIG. 4 shows a flowchart of a method for playing the Christmas tree game of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
Various inventive features are described below that can each be used independently of one another or in combination with other features.
Broadly, embodiments of the present invention generally provide a Christmas tree game that combines the joy of Christmas with a fun and challenging board game.
FIG. 1 shows a view of the components of a Christmas tree game in accordance with an embodiment of the present invention. FIG. 2 shows an overhead view of the game board and dice of the Christmas tree game shown in FIG. 1 . FIG. 3 shows a side view of the components of the Christmas tree game shown in FIG. 1 .
In accordance with an embodiment of the present invention, the Christmas tree game may comprise a game board 101 , Christmas tree trunks 103 , branches 104 , colored dice 107 , and a tree topper 108 , such as a star.
The game board 101 may be a foldable board on which the Christmas tree game may be played. The game board 101 may be approximately 18-inches square and may have rounded corners. The game board 101 may comprise, for example, four pre-fastened bases 102 near each corner of the game board 101 that may accept the Christmas tree trunks 103 so that the Christmas tree trunks 103 may be held straight and firmly in place on the game board 101 . The bases 102 may also be situated in an offset position so that the game board 101 may fold up flat. A center area 111 of the game board 101 may comprise a cone 106 at the center point 109 of the game board 101 and a containment fence 105 that forms a circle around the center area 111 of the game board 101 . The cone 106 may protrude from the game board 101 and may scatter the dice 107 when the dice 107 are dropped over the cone 106 . The containment fence 105 may help keep the dice 107 contained within the center area 111 of the game board 101 when the dice 107 are dropped on and scattered by the cone 106 . The containment fence 105 may also be fixed in an offset position to allow the game board 101 to fold flat.
The Christmas tree trunks 103 may be affixed to the game board 101 by inserting the Christmas tree trunks 103 into the pre-fastened bases 102 on the game board 101 . The trunks 103 may be straight rods having square holes 110 up and around its body that may accept the branches 104 of the Christmas tree in order to attach the branches 104 to the Christmas tree trunk 103 .
The branches 104 of the Christmas tree may be inserted into the holes 110 of the Christmas tree trunks 103 to attach to the Christmas tree trunk 103 . The branches 104 may be constructed in one piece, and, as can be seen in the drawing, are of differing size such that the branches gradually reduce in length as the tree grows up to the top end for a natural appearance when the tree is constructed, with the lowest level having the longest flared-out branches and the longest square ended stems and the highest level having the shortest branches and stems. The branches may have impressions of needles and/or secondary branches pressed into the branches 104 . The branches 104 may also have decorative ornaments fixed or painted on to them to create a more colorful tree.
The tree topper 108 may be placed atop the Christmas tree created by a Christmas tree trunk 103 and branches 104 of the winning player. The tree topper 108 may light up, play a Christmas tune, and/or ring a bell when it is place on top of a Christmas tree.
The colored dice 107 may comprise a pair of dice 107 having the same color pattern. Each of the colored dice 107 may be a 6-sided dice having two opposite sides that may be red and the other four sides that may be green.
In an exemplary embodiment of the present invention, one to four players may play the Christmas tree game. The game board may be unfolded flat on a flat surface with the cone and the containment fence rising from the game board. Each player may have a Christmas tree trunk and branches to complete his Christmas tree.
FIG. 4 shows a flowchart of a method for playing the Christmas tree game in accordance with an embodiment of the present invention.
The object of the Christmas tree game may be to be the first player to finish constructing his Christmas tree including placing a tree topper atop the Christmas tree. To play the Christmas tree game in accordance with an embodiment of the present invention, each player of the game may be given game pieces for constructing a Christmas tree, including a tree trunk, branches, and a tree topper, and may take turns tossing the pair of dice within the area of the game board contained by the containment fence.
If the value of the pair of tossed dice is two red sides, the rules may instruct the player to remove one part of his Christmas tree. For example, the player may remove a branch from his Christmas tree trunk, remove the Christmas tree trunk from the game board if the player's Christmas tree trunk does not have any branches attached to it, or do nothing if he has not yet had the opportunity to attach his Christmas tree trunk to the game board.
If the value of the pair of tossed dice is two green sides, the rules may instruct the player to add a part to his Christmas tree. The player may attach his Christmas tree trunk to the game board via one of the pre-fastened bases on the game board if he has not yet had the opportunity to do so, attach a branch to his Christmas tree trunk if his Christmas tree trunk has already been attached to the game board and if his Christmas tree trunk is not completely full of attached branches, or place a tree topper on top of his Christmas tree if his Christmas tree trunk is completely full of attached branches, thus signifying that the player has won the game.
If the value of the pair of tossed dice is one green side and one red site, the dice may signify that the player should take no action and that his turn has ended.
The players of the Christmas tree game should take turn rolling dice and taking actions in accordance with the dice rolled, until one player wins by placing the tree topper atop his Christmas tree. After a player has placed the tree topper atop his Christmas tree, the game may be ended, or the remaining players may continue playing the game until they each are able to place a tree topper atop their respective Christmas trees.
In accordance with alternate embodiments of the present invention, the Christmas tree game may be implemented as a computer game, wherein the elements of the games and rules may be implemented using software, hardware, or a combination of software and/or software.
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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A game comprises: a game board; a tree trunk for each player playing the game, the tree truck attachable to the game board; a plurality of branches for the each player playing the game, the plurality of branches attachable to the tree trunk; a tree topper; and a pair of dice; wherein players in turn roll the pair of dice and build a tree from the tree trunk and the plurality of branches based on rolls of the pair of dice.
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This application is a continuation-in-part of U.S. application Ser. No. 733,428 filed May 13, 1985, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a process for preparing piperidylidene dihydro-dibenzo[a,d]cycloheptenes or aza-derivatives thereof and intermediates and individual steps in such process.
Various process for preparing 1, 2, 3 or 4-aza-5-(4-piperidylidene)-10,11-dihydro-dihenzo[a,d]cycloheptene derivatives are disclosed in U.S. Pat. Nos. 3,326,924 and 3,717,647 and Villani et al., Journal of Medicinal Chemistry, 1972, Vol. 15, No. 7, pp. 750-754. For example, one such scheme is as follows: ##STR1## This type scheme has certain disadvantages in that the ring closure steps to the aza-ketone intermediate of formula XVI give relatively poor yields and are labor intensive steps. Also, the reaction of the Grignard reagent with the aza-ketone intermediate of formula XVI can proceed via an undesired 1,6 addition reducing the yield of the desired end product.
U.S. Pat. No. 3,326,924 also discloses other processes proceeding via, for example, 5,6-dihydro-11H-benzo[5,6]cyclohepta[1,2-b]oyridin-11-one as an azaketone intermediate in the preparation of, e.g., azatadine. In one such process, ethyl nicotinate is condensed with phenylacetonitrile to form a keto nitrile. Conversion to the ketone is effected by heating the keto nitrile with a strong mineral acid. Reduction of the so produced 3-pyridyl ketone to a 3-phenethyl pyridine may be carried out by the well-known Wolff-Kishner reaction. The phenethyl pyridine is transformed into its N-oxide by means of a peroxy acid. The N-oxide is then reacted with dimethyl sulfate and then aqueous sodium cyanide to produce a 3-phenethyl-2-pyridylnitrile. The nitrile is cyclized directly to the 5,6-dihydro-11H-benzo-[5,6]cyclohepta[1,2-b]pyridin-11-one. Althouch this prior art process operates successfully, it would be desirable to use a process which is more economical to provide the aza-ketone intermediate.
SUMMARY OF THE INVENTION
A process for preparing piperidylidene-dihydrodibenzo[a,d]cycloheptenes or aza-derivatives thereof of formula I ##STR2## has now been found which results in a higher effective yield of the desired end products in comparison to the processes described above. One aspect of the new process eliminates the labor intensive step of ring closure to a ketone intermediate (e.g., an aza-ketone), can eliminate the poor yielding Grignard reaction with the ketone intermediate, and reduces the total number of steps in the synthesis from six to five. Thus, a first process aspect of the invention involves a new process for preparing a compound of formula I comprising the steps of reacting a compound of formula II ##STR3## with a compound of formula III ##STR4## in the presence of base to produce a compound of formula IV ##STR5## reacting the compound of formula IV with a dehydrating agent to produce a compound of formula V ##STR6## reacting the compound of formula V with a compound of formula VI ##STR7## and hydrolyzing the product thereof to produce a compound of formula VII ##STR8## and reacting the compound of formula VII with a super acid having a Hammett acidity function of less than minus 12 to produce the compound of formula I, wherein:
a, b, c, and d represent CH or one of a, b, c and d represents N and the others represent CH;
R 1 , R 2 , R 3 and R 4 may be the same or different and each independently represents hydrogen, alkyl having from 1 to 6 carbon atoms, halo (i.e., fluoro, chloro, bromo or iodo), nitro, alkoxy having from 1 to 6 carbon atoms or trifluoromethyl;
R 5 represents an N-protecting group which does not prevent formation of the Griqnard reagent of formula VI;
R 6 represents a protecting group that will protect the N of the group CONHR 6 in formula II from reaction with an alkylating agent such as a compound of formula III; and
Z represents chloro, bromo or iodo. The compounds of formula I can be converted to the corresponding 1-substituted-4-piperidylidene and 4-piperidylidene derivatives, i.e., where the substituent on the piperidinyl nitrogen atom is COOR 8 wherein R 8 is as defined below or H.
A second process aspect of the invention includes a process which comprises reacting a compound of formula VIIa ##STR9## with a super acid having a Hammett acidity function value of less than minus 12 to produce a compound of formula Ia ##STR10## wherein a, b, c, d, R 1 , R 2 , R 3 , and R 4 are as defined above and R 7 is an N-protecting group, --H or --COOR 8 , wherein R 8 represents C 1 to C 12 alkyl, substituted C 1 to C 12 alkyl, C 2 to C 12 alkenyl, substituted C 2 to C 12 alkenyl, phenyl, substituted phenyl, C 7 to C 10 phenylalkyl or C 7 to C 10 phenylalkyl wherein the phenyl moiety is substituted, or R 8 is 2-, 3-, or 4-piperidyl or N-substituted piperidyl, wherein the substitutents on said substituted C 1 to C 12 alkyl and on said substituted C 2 to C 12 alkenyl are selected from amino or substituted amino and the substituents on said substituted amino are selected from C 1 to C 6 alkyl, the substituents on said substituted phenyl and on said substituted phenyl moiety of the C 7 to C 10 phenylalkyl are selected from C 1 to C 4 alkyl and halo, and the substituent on said N-substituted piperidyl is C 1 to C 4 alkyl.
A third process aspect of the invention involves a process for preparing an intermediate of formula XIII ##STR11## by reacting a compound of formula II ##STR12## with a compound of formula III ##STR13## in the presence of base to produce a compound of formula IV ##STR14## and converting the compound of formula IV to a compound of formula XIII, wherein a, b, c, d, R 1 R 2 , R 3 , R 4 , R 6 and Z are as defined above.
Still other aspects of the present invention comprise an intermediate of the formula IV ##STR15## wherein a, b, c, d, R 1 , R 2 , R 3 , R 4 and R 6 are as defined above, and an intermediate of the formula XV ##STR16## or a pharmaceutically accentable salt thereof, preferably the hydrochloride salt.
The intermediates of formula IV are particularly useful in the preparation of the compounds of formula XIII, e.g., these intermediates provide improved yields of the comoounds of formula XIII in the third process aspect of the invention above. The intermediates of formula IV also can be used to conveniently prepare the cyano compounds of formula V in the first process aspect of the invention as described above. The intermediate of formula XV has been found to provide particular advantage in the first and second process aspects of the invention in that such an intermediate allows easy separation from the reactants leading thereto and provides a hiqh degree of purity. Thus, the ring closure step in these first and second process aspects can start with clean material, thus a purer ring-closed product.
The above described processes are preferably performed with compounds in which R 2 and R 3 are independently hydrogen or halo (such as chloro or fluoro); R 1 and R 4 are hydrogen; d is N; and a, b and c are CH. A preferred N-protecting R 5 group is methyl and a preferred R 6 group is tertiary butyl.
When utilized herein, the terms below have the following scope:
N-protecting group (R 5 or R 7 )--represents any group which will allow reaction of magnesium with the 4-halo substituent of a 4-halo-substituted piperidinyl compound without reacting with other portions of the compound and which can later be removed.
a protecting group (R 6 )--represents any group which will protect the N of the group CONHR 6 in the compound of formula II from reaction with an alkylating agent, e.g., an aralkyl halide such as a compound of formula III.
aryl (including the aryl portions of aralkyl)--represents a carbocyclic group containing from 6 to 15 carbon atoms and having at least one benzene ring. Preferably, aryl is phenyl or substituted phenyl (with the proviso that the substituent is not halo in the case of R 5 ). Suitable substituents may include alkoxy, alkyl, alkoxyalky, etc. Suitable aryl groups include phenyl, naphthyl, indenyl, indanyl, etc., with all appropriate points of attachment being intended.
alkyl (including the alkyl portions of alkoxy, aralkyl, etc.)--represents a straight or branched carbon chain containing from 1 to 6 carbon atoms.
DETAILED DESCRIPTION OF THE INVENTION
An appropriate starting material for the process of the invention is an appropriately substituted cyano-toluene or cyano-methyl pyridine (such as 2-cyanotoluene, 2-cyano-3-methyl-pyridine, 3-cyano-4-methylpyridine, 3-methyl-4-cyano-pyridine or 2-methyl-3-cyanopyridine). The cyano compound can be converted into the corresponding carboxylic acid, e.c, 3-methyl-2-pyridine carboxylic acid or activated esters thereof, e.g., a succinimide or hydroxysuccinimide ester, by reactions conventional in the art. The carboxylic acid or activated ester thereof can then be reacted with the appropriate amino compound of formula NH 2 R 6 to formulate a compound of formula II ##STR17##
R 6 is preferably a tertiary butyl group. A compound having such an R 6 tertiary butyl group can be obtained, for example, by a Ritter reaction in which a tertiary butyl compound is reacted with a cyano-toluene or cyano-methyl-pyridine compound to produce a compound of formula XVII ##STR18## This reaction is generally performed in an acid such as concentrated sulfuric acid or concentrated sulfuric acid in glacial acetic acid. Suitable tertiary butyl compounds include, but are not limited to, t-butyl alcohol, t-butyl chloride, t-butyl bromide, t-butyl iodide, isobutylene or any other compound which under hydrolytic conditions forms t-butyl carboxamides with cyano compounds. The temperature of the reaction will vary depending on the reactants, but generally is conducted in the range of from about 50° to about 100° C. with t-butyl alcohol. The reaction may be performed with inert solvents but is usually run neat.
The compound formula II is reacted with an appropriate benzyl halide of formula III in the presence of a base to form the compound of formula IV above. Examples of appropriate benzyl halides include, but are not limited to, benzyl chloride, 3-chloro-benzyl chloride, 3-fluoro-benzyl chloride, 3,4-dichlorobenzylchloride, 4-fluoro-benzyl chloride, 3-nitro-benzyl chloride, 3-methyl-benzyl chloride, etc. Any suitable base can be employed, e.g., an alkyl lithium compound such as n-butyl lithium in tetrahydrofuran (THF). Preferably the base has a pK a of greater than 20 and more preferably greater than 30. This reaction can be conducted at any suitable temperature, e.g., temperatures of from about -78° C. to about 30° C., preferably from about -40° C. to about -30° C. The reaction can be performed in any suitable inert solvent such as THF, diethyl ether, etc.
The amide of formula IV is converted to the cyano compound of formula V by the use of a suitable dehydrating agent such as POCl 3 , SOCl 2 , P 2 O 5 , toluene sulfonyl chloride in pyridine, oxalyl chloride in pyridine, etc. This reaction can be performed in the absence of or with an inert co-solvent such as xylene. The dehydrating agent such as POCl 3 is employed in equivalent amounts or greater and preferably in amounts of from about 2 to about 15 equivalents. Any suitable temperature and time can be employed for performing the reaction, but generally heat is added to speed up the reaction. Preferably, the reaction is performed at or near reflux.
The cyano compound of formula V is reacted with a Grignard reagent (formula VI) prepared from the appropriate 1-(N-protected)-4-halopiperidine. Any suitable N-protecting group known in the art to protect the piperidinyl nitrogen atom from reaction during formation of the Grignard reagent of formula VI can be employed. Suitable N-protecting groups include alkyl (e.g, methyl), aryl (e.g. phenyl or substituted phenyl), alkyloxyalkyl (e.g., methoxymethyl), benzyloxyalkyl (e.g., benzyloxymethyl), substituted benzyloxyalkyl (e.g., (di-p-methoxyphenyl)methyl), triphenylmethyl, tetrahydropyranyl, diphenyl phosphinyl, benzene sulfenyl, etc. The N-protecting group can be later removed by conventional means once the Grignard reagent has been reacted with the compound of formula V.
The reaction between compounds of formulae V and VI is generally performed in an inert solvent such as an ether, toluene or tetrahydrofuran. This reaction is performed under the general conditions for a Grignard reaction, e.g., at temperatures of from about 0° C. to about 75° C. The resulting intermediate of formula XVIII ##STR19##
is hydrolyzed, e.g., with aqueous acid such as aqueous HCl, to prepare the corresponding ketone of formula VII.
The compound of formula VII can be ring-closed to form the desired cycloheptene ring system by treating the compound VII with a super acid having a Hammett acidity function of less than about minus 12, e.g., minus 13, minus 14, etc. This measure of acidity is defined in Hammett, Louis P., and Deyrup, Alden J., Journal of the American Chemical Society, Vol. 54, 1932, p. 2721. Suitable super acids for this purpose include, for example, HF/BF 3 , CF 3 SO 3 H, CH 3 SO 3 H/BF 3 , etc. The reaction can be performed in the absence of or with a suitable inert co-solvent such as CH 2 Cl 2 . The temperature and time of the reaction vary with the acid employed. For example, with HF/BF 3 as the super acid system the temperature may be controlled so as to minimize side reactions, such as HF addition to the double bond of the rings. For this purpose, the temperature is generally in the range of from about +5° to -50° C., preferably from about -30° to -35° C. With CF 3 SO 3 H as the super acid system, the reaction may be run at elevated temperatures, e.g., from about 25° to about 150° C. and at lower temperatures but the reaction then takes longer to complete.
Generally the super acid is employed in excess, preferably in amount of from about 1.5 to about 30 equivalents. For example, with HF/BF 3 as the super acid system the volume/weight ratio of HF to the compound of formula VIII in the reaction mixture is preferably from about 30 to about 1.5, more preferably 2.5 to 1.5. In such system, the weight/weight ratio of BF 3 to the compound of formula VIII in the reaction mixture is preferably from about 15 to about 0.75, more preferably from about 1 to about 0.75.
If it is desired to proceed via a ketone intermediate of formula XIII ##STR20## a compound of formula IV can be converted directly to a compound of formula XIII by reaction with any of the conventional acidic compounds used for such purpose, e.g., polyphosphoric acid. Alternatively, the compound of formula IV can first be hydrolyzed to the acid form ##STR21## e.g., with sulfuric acid. This acid form can then be cyclized, for example, by use of anhydrous HCl gas, oxalyl chloride or thionyl chloride and aluminum chloride. In this latter alternative method, preferably no more than two of R 1 , R 2 , R 3 and R 4 represent a halo, nitro, alkoxy or trifluoromethyl group and more preferably no more than one of R 1 , R 2 , R 3 and R 4 is such a group. Preferably, R 1 , R 2 , R 3 and R 4 are hydrogen in these reactions leading to the compound of formula XIII.
The intermediate of formula XIII above can be reacted with a Grignard reagent to replace the carbonyl group with a piperidylidine or an N-substituted piperidylidene group by processes conventional in the art. Suitable methods are disclosed in U.S. Pat. Nos. 3,326,924, 3,717,647, 4,282,233 and 4,072,756, the disclosures of which are incorporated herein by reference.
The compounds of formula Ia or VIIa wherein R 7 is an N-protecting group can be converted to the corresponding 4-piperidylidene (i.e., R 7 =--H) or 4-(COOR 8 )-piperidylidene (i.e., R 7 =COOR 8 ) compounds. For example, prior to ring closure of a compound of formula VIIa by reaction with the super acid, e.g. HF/BF 3 , the R 7 N-protecting group can be converted to --H or --COOR8 by any method conventional in the art for such groups. Alternatively, the conversion can take place after ring closure to the compound of formula I. For example, an R 7 methoxymethyl group may be converted to --H by treatment with boron trifluoride etherate, acetic anhydride and LiBr, while an R 7 benzyloxymethyl group can be converted to --H by catalytic reduction followed by basic hydrolysis. The resulting compounds wherein R 7 is --H can be converted to compounds wherein R 7 is --COOR 8 by reaction with a compound of the formula ZCOOR 8 (X) wherein Z is chloro, bromo or iodo. Further, when R.sup. 7 is an allyl group, such compounds may be directly converted to compounds wherein R 7 is --COOR 8 by reaction with a compound ZCOOR 8 (X) as described above. Examples of the latter two processes are disclosed in U.S. Pat. No. 4,282,233.
Compounds of formula XII ##STR22## can be prepared from the compounds of formula I or the compounds of formula XI ##STR23## Thus, with the compounds of formula XI the COOR 8 group can be removed simply by treatment with base. Alternatively, the compounds of formula XII can be prepared by dealkylation of the compounds of formula I wherein R 5 is alkyl (preferably methyl), e.g., by reaction with cyanogen bromide and subsequent hydrolysis of the N-cyano product with, for example, aqueous acid solution.
The compounds of formulas I (wherein R 5 is alkyl), XI and XII possess desirable pharmacological properties, e.g., antihistaminic and anti-allergy properties and are therefore the desired end products of the process of the invention. Preferred are the compounds wherein d is N; a, b and c are CH; R 2 and R 3 are each independently selected from hydrogen or halo; and R 1 and R 4 are hydrogen. In formula I, a preferred R 5 N-protecting group is alkyl, preferably methyl, and in formula XI R 8 is preferably ethyl. Particularly preferred are the compounds of the formula XIX ##STR24## wherein R 2 =Cl, R 3 =H and R 9 =H, CH 3 or COOC 2 H 5 ; R 2 =F, R 3 =H and R 9 =H, CH 3 or COOC 2 H 5 ; R 2 =H, R 3 =F and R 9 =H, CH 3 or COOC 2 H 5 ; R 2 =R 3 =F or Cl, and R 9 =H, CH 3 or COOC 2 H 5 ; and R 2 and R 3 =H, and R 9 =CH 3 .
The following examples are intended to illustrate, but not to limit, the processes and intermediates of the invention.
EXAMPLE 1
Step A: N-(1,1-dimethylethyl)-3-methyl-2-pyridine carboxamide
2-cyano-3-methyl pyridine (400 g) is suspended in t-BuOH (800 mL) and the mixture heated to 70° C. Concentrated sulphuric acid (400 mL) is added dropwise over 45 minutes. The reaction is complete after a further 30 minutes at 75° C. The mixture is then diluted with water (400 mL), charged with toluene (600 mL) and brought to pH 10 with concentrated aqueous ammonia. The temperature is kept at 50°-55° C. during the work up. The toluene phase is separated, the aqueous layer reextracted and the combined toluene phases are washed with water. Removal of the toluene yields an oil, N-(1,1-dimethylethyl)-3-methyl-2-pyridine carboxamide, from which solid product may crystallize. Product yield of 97% is determined by internal standard assay on gas chromatograph.
Step B: 3-[2-(3-fluoro-phenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide
Tetrahydrofuran (125 mL), and N-(1,1-dimethylethyl)-3-methyl-2-pyridine carboxamide (1 equivalent), are charged and cooled to -40° C. under nitrogen. Two equivalents of n-butyllithium are then added over 40 minutes. When half the n-butyllithium is added the mixture turns purple. Sodium bromide (1.3 g) is added and 3-fluoro-benzyl chloride (1.05 equivalents) is added dropwise (1:1 solution in tetrahydrofuran) over 40-50 minutes while the temperature is maintained at -40° C. After 30 minutes at -40° C., the mixture is diluted with water (250 mL) and the organic phase separated. This phase is dried over sodium sulphate and the solvent removed yielding an oil from which solid product, 3-[2-( 3-fluoro-phenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide, may crystallize.
Step C: 3-[2-(3-fluorophenyl)ethyl]-2-pyridinecarbonitrile
A solution of 3-[2-(3-fluorophenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide (36.4 g, 0.121 mole) in 123 mL (202.3 g, 1.32 mole) of phosphorous oxychloride is heated at 110° C. for 3.5 hours and stirred at ambient temperature an additional 15 hours. The reaction is quenched with ice and water and the pH of the solution is brought to 8 by the addition of a saturated aqueous solution of potassium carbonate. The product is extracted into ethyl acetate and the solution is concentrated to a residue. Following purification by silica gel chromatography and trituration with pentane, 16.2 g (0.072 mole) of product is obtained in 60% yield.
Step D: (1-methyl-4-piperidinyl)[3-[2-(3-fluorophenyl)ethyl]-2-pyridinyl]methanone
To a solution of 3-[2-(3-fluorophenyl)ethyl]-2-pyridine carbonitrile (28.0 g, 0.123 mole) in 150 mL of dry THF is added 92 mL (1.48 moles/liter, 0.136 mole) of N-methylpiperidyl magnesium chloride over 10 minutes maintaining the temperature at 45-50° C. The reaction is maintained at 40° C. to 50° C. for another 10 minutes and at ambient temperature for 45 minutes. The reaction is quenched to below pH 2 with aqueous hydrochloric acid and the resulting solution is stirred at 25° C. for 1 hour. The pH of the solution is adjusted to about 8, the product is extracted with ethyl acetate, and the solution is concentrated to a residue. Following purification by silica gel chromatography, 38.3 g of product is obtained as a brown oil.
Step E: 6,11-dihydro-8-fluoro-11-(1-methyl-4-piperidylidene)-5H-benzo[5,6]cyclohepta[1,2-b]-pyridine
A solution of (1-methyl-4-piperidinyl)[3-[2-(3-fluorophenyl)ethyl]-2-piperidinyl]methanone (15.0 g, 0.046 mole) in 74 mL (125.5 g, 0.837 mole) of trifluoromethanesulfonic acid is stirred at ambient temperature for 18 hours. The reaction is quenched with ice-water and the solution made basic with potassium hydroxide. The product is extracted into ethyl acetate. The ethyl acetate solution is filtered to remove insolubles and the filtrate is concentrated to a residue. Following purification by silica gel chromatography, 5.4 g (0.0175 mole) of product is obtained in 38% yield.
By analogous procedures employing the appropriate substituted benzyl chloride, the corresponding 8-bromo, 9-fluoro, 8,9-dichloro and 9-bromo analogs may be prepared.
EXAMPLE 2
Step B: 3-[2-(3-chlorophenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide
31.5 g of N-(1,1-dimethylethyl)-3-methyl-2-pyridine carboxamide is dissolved in 600 mL of dry tetrahydrofuran and the resulting solution is cooled to -40° C. Two equivalents of n-butyllithium in hexane are added while the temperature is maintained at -40° C. The solution turned deep purple-red. 1.6 g of sodium bromide is added and the mixture is stirred. A solution of 26.5 g (0.174 mole) m-chlorobenzylchloride in 125 mL of tetrahydrofuran is added while the temperature is maintained at -40° C. The reaction mixture is stirred until the reaction is complete as determined by thin layer chromatography. Water is added to the reaction until the color is dissipated. The reaction mixture is extracted with ethyl acetate, washed with water, and concentrated to a residue. A yield of 92% for the product is shown by chromatography.
Step C: 3-[2-(3-chlorophenyl)ethyl]-2-pyridine-carbonitrile
A solution of 3-[2-(3-chlorophenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide (175 g, 0.544 mole), in 525 mL (863 g, 5.63 mole) of phosphorous oxychloride is heated at reflux for 3 hours. Completion of the reaction is determined by thin layer chromatography. Excess phosphorous oxychloride is removed by distillation at reduced pressure and the residue is quenched into a mixture of water and isopropanol. The pH is brought to 5-7 by addition of 50% aqueous sodium hydroxide solution while maintaining the temperature below 30° C. The crystalline slurry of crude product is filtered and washed with water. Crude product is purified by slurrying the wet cake in hot isopropanol followed by cooling at 0-5° C. The product is filtered, washed with hexane and dried at below 50° C. Yield: 118 g (HPLC purity 95.7%), m.p. 72°-73° C., 89.4% of theory.
Step D: (1-methyl-4-piperidinyl)[3-[2-( 3-chlorophenyl)ethyl]-2-pyridinyl]methanone hydrochloride
To a solution of product of Step C above (118 g, 0.487 mole) in 1.2 L of dry tetrahydrofuran is added 395 mL (2.48 mole/liter, 0.585 mole, 1.2 eg.) of N-methyl-piperidyl magnesium chloride over about 15 minutes maintaining the temperature at 45° C.-50° C. by cooling with water as necessary. The reaction is maintained at 40° C. to 50° C. for about another 30 minutes. Completion of the reaction is determined by thin-layer chromatography. The reaction is quenched to pH below 2 with 2N hydrochloric acid and the resulting solution is stirred at about 25° C. for 1 hour. The bulk of the tetrahydrofuran is removed by distillation and the resulting solution is adjusted to pH 3.5 by the addition of aqueous sodium hydroxide. After cooling to 0° to 5° C., the crystalline hydrochloride salt product is filtered off, washed with ice cold water and dried to constant weight at 60° C. Yield: 168.2 g (HALC purity 94%), m.p. 183° -185° C., 89% of theory.
Step E: 8-chloro-6,11-dihydro-11-(1-methyl-piperidylidene)-5H-benzo[5,6]cyclohepta[1,2-b]pyridine
To a solution of a product of Step D above (59 g, 0.15 mole) in 120 mL (120 g, 6.0 mole) of hydrofluoric acid at -35° C. is added boron trifluoridine (44.3 g, 0.66 mole) over 1 hour. Completeness of the reaction is determined by thin-layer chromatography. The reaction is quenched using ice, water and potassium hydroxide to a final pH of 10. The product is extracted into toulene and the toluene solution is washed with water and brine. The toluene solution is concentrated to a residue, which is dissolved in hot hexane. Insolubles are removed by filtration and the filtrate is concentrated to an off-white powder. Yield: 45.7 g (HPLC purity 96%), 92% of theory.
Alternative Step E: 8-chloro-6,11-dihydro-11-(1-methyl-piperidylidene)-5H-benzo[5,6]cyclohepta[1,2-b]pyridine
A solution of 177 g (0.49 mole) of a product of Steo D above in 480 mL (814.1 g, 5.31 mole) of trifluoromethanesulfonic acid at 90° -95° C. for 18 hours under nitrogen. Completeness of the reaction is determined by thin-layer chromatography. The cooled reaction is quenched with ice-water and the pH is adjusted to 6 with barium carbonate. The product is extracted into methylene chloride, which is concentrated under reduced pressure to about 1 liter and washed with water. The product is extracted into 1 N hydrochloric acid, which is treated with 30 g of Darco, and filtered through celite. The pH of the filtrate is adjusted to 10 with 50% aqueous sodium hydroxide and the product is extracted into methylene chloride, which is removed under reduced pressure. The residue is dissolved in hot hexane, which is filtered to remove insolubles. The filtrate is concentrated to a residual beige powder. Yield: 126 g (HPLC purity 80%), 65% of theory.
EXAMPLE 3
Step A: 3-methyl-2-pyridinecarboxamide
A solution of 2-cyano-3-methylpyridine (30.0 g, 0.25 mole) in 500 mL of 6N sodium hydroxide:ethanol (1:1) is stirred at ambient temperature overnight. The product is extracted into ethyl acetate, which is dried (MgSO 4 ) and concentrated to a residue containing 26.6 g (0.19 mole, 76%) of 3-methyl-2-pyridinecarboxamide.
Step B: N-phenyl-3-methyl-2-pyridinecarboxamide
To 3-methyl-2-oyridinecarboxamide (15.0 g, 0.11 mole) are added BF 3 .OEt 2 (14.0 mL, 0.11 mole) and tetrahydrofuran (75 mL). After about 5 minutes, aniline (10.3 g, 0.11 mole) is slowly added and the solution is heated at reflux for 5 hours. The reaction is cooled and diluted with water and the product is extracted into ethyl acetate. The solvent is removed and the residue is purified by silica gel chromatography to give 8.32 g (0.39 mole, 35%) of N-phenyl-3-methyl-2-pyridinecarboxamide. Step C: 3-[2-(3-chlorophenyl)ethyl]-N-(1-phenyl)-2- ° pyridine carboxamide
To a solution of N-phenyl-3-methyl-2-pyridinecarboxamide (1.0 g, 4.71 mmol) in 20 mL of dry tetrahydrofuran at-50° C. is added 2 equivalents of n-butyllithium. Sodium bromide (0.05 g) is added followed by m-chlorobenzyl chloride (0.80 g, 4.95 mmol) dissolved in 3 mL of tetrahydrofuran. The mixture is stirred at -50° C. for 0.5 hour, diluted with water and the organic phase is separated. The solvent is removed under vacuum and the residue is purified by silica gel chromatography yielding 1.14 g (3.38 mmol, 72%) of 3-[2-(3-chlorophenyl)ethyl]-N-(1-phenyl)-2-pyridinecarboxamide.
This last compound can be emoloyed in Step C of Example 2 above in place of 3-[2-(3-chlorophenyl)ethyl]- N-(1,1-dimethylethyl)-2-pyridine carboxamide to provide the same product, i.e., 3-[2-(3-chlorophenyl)ethyl]-2pyridine carbonitrile.
EXAMPLE 4
Step A: N-(1,1-dimethylethyl)-3-methyl-2-pyridine carboxamide
2-cyano-3-methyl pyridine (400 g) is suspended in t-butyl alcohol (800 mL) and the mixture heated to 70° C. Concentrated sulphuric acid (400 mL) is added dropwise over 45 minutes. The reaction is complete after a further 30 minutes at 75° C. The mixture is then diluted with water (400 mL), charged with toluene (600 mL) and brought to pH 10 with concentrated aqueous ammonia. The temperature is kept at 50-55° C. during the work up. The toluene phase is separated, the aqueous layer re-extracted and the combined toluene phases are washed with water. Removal of the toluene yields an oil from which solid product may crystallize. Product yield of 97% determined by internal standard assay on gas chromatograph.
Step B: 3-[2-(phenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide
Tetrahydrofuran (125 mL), N-(1,1-dimethylethyl)-3-methyl-2-pyridine carboxamide (1 equivalent) and sodium bromide (1.3 g) are charged and cooled to -40° C. under nitrogen. Two equivalents of n-butyllithium are then added over 40 minutes. When half the n-butyllithium is added the mixture turns purple. Benzyl chloride (1.05 equivalents) is then added dropwise (1:1 solution in tetrahydrofuran) over 40-50 minutes while the temperature is maintained at -40° C. After 30 minutes at -40° C., the mixture is diluted with water (250 ml) and the organic phase separated. This phase is dried over sodium sulphate and the solvent removed yielding an oil from which solid product may crystallize. Product yield of 94% determined by internal standard assay on gas chromatograph.
Step C: Cyclization to 5,6-dihydro-11H-benzo[5,6]cyclohepta[1,2-b]pyridin-11-one
Polyphosphoric acid (123.75 g) and water (1.25 mL) are heated to 200° C. 3-[2-(phenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide is then added. After 30 minutes at 200° C. the mixture is allowed to cool. Then the mixture is diluted with water and toluene is added. The mixture is brought to pH 10 with 40% aqueous NaOH. An internal standard assay on gas chromatograph determined a yield of 58% for 5,6-dihydro-11H-benzo-[5,6]cyclohepta[1,2-b]pyridin-11-one. Crystallization of title compound from toluene-hexane gave m.p 118.5°-119.7° C.
EXAMPLE 5
Step B: 3-[2-(3-chlorophenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide
31.5 g of 2-t-butyl-carboxamido-3-methyl pyridine is dissolved in 600 mL of dry tetrahydrofuran and the resulting solution is cooled to -40° C. Two equivalents of n-butyllithium in hexanes are added while the temperature is maintained at -40° C. The solution turned deep purple-red. 1.6 g of sodium bromide is added and the mixture is stirred. A solution of 26.5 g (0.174 mole) m-chlorobenzylchloride in 125 mL of tetrahydrofuran is added while the temperature is maintained at -40° C. The reaction mixture is stirred until the reaction is complete as determined by thin layer chromatography. Water is added to the reaction until the color is dissipated. The reaction mixture is extracted with ethyl acetate, washed with water, and concentrated to a residue. A yield of 92% for the product is shown by chromatography.
Step C: 3-[2-(3-chlorophenyl)ethyl]picolinic acid
3-[2-(3-chlorophenyl)ethyl]-N-(1,1-dimethylethyl)-2-pyridine carboxamide (1.0 mole, 317g), sulfuric acid (325 mL) and water (300 mL) are refluxed at about 130° C. for aporoximately 2 hours. Completeness of the reaction is determined by thin layer chromatography. The reaction mixture is cooled to about 35° C. and added to ice (2 kg). The mixture is then brought to about pH 11 with 50% sodium hydroxide. Additional ice (1 kg) is added, followed by ethyl acetate (1 liter) and hexane (525 mL). The mixture is acidified to about pH 4 with sulfuric acid and stirred for about 1 hour. Crude product is isolated by filtration, washed with water and hexane and optionally dried at about 50° C. Then the crude product is dissolved in ethyl acetate by refluxing at about 75° C. After treating the solution with decolorizing carbon (5 g), the filtrate is concentrated and cooled to about 15° C. Purified product is isolated by filtration, washed with hexane: ethyl acetate (3:1) and dried at about 50° C. A second crop may be obtained by concentrating the mother liquor and recrystallizing from ethyl acetate as described above. The yield of product is shown to be 60%.
Step D: Cyclization to 8-chloro-5,6-dihydro-11H-benzo[5,6]cyclohepta[1,2-b]pyridin-11-one
A stream of anhydrous HCl gas is passed into a suspension of 3-[2-(3-chlorophenyl)ethyl]picolinic acid (0.5 mole) and tetrachloroethane (1500 mL) maintained by cooling at about 25° C. After about 1 hour, 64 mL of oxalyl chloride is added. A slight stream of HCl is passed through the mixture for 25 hours. Completion of the reaction is checked by thin layer chromatography. The reaction is then cooled in an ice bath to about 5° C. and with stirring 1 mole of AlCl 3 is added in about 1 hour. The reaction mixture is kept at ice bath temoerature for 22 hours. Then another 0.25 mole of AlCl 3 is added and the reaction is continued for another 3 hours. After this 870 mL of 3.5% aqueous HCl is added to the reaction mixture at below 25° C. The bottom oil layer is separated and re-extracted with 3×400 mL of 3.5% aq. HCl. The combined water layers are washed with 2×200 mL of ether.
Added to the water layer are 1300 mL of benzene and 100 g of supercel. This is followed with a simultaneous addition of 480 mL of 50% aqueous NaOH and 2 kg of ice to maintain the temperature at 20°-25° C. the cake is filtered and washed with 2×180 mL of toluene. The two layers of filtrate are separated and the water layers are re-extracted with 2×260 mL of toluene.
The combined toluene layers are washed with 200 mL of 5% aqueous NaHCO 3 , 2×250 mL of 20% aqueous NaCl, dried over Na 2 SO 4 and simultaneously treated with 5 g of Darco. The solution is filtered and the solvent is removed leaving light tan solids of title product, m.p. 99°-101° C., yield 79%.
EXAMPLE 6
Ethyl chloroformate (8.5 mL, 9.65 g, 0.089 mole) is slowly added at 80° C. to a solution of 8-fluoro-11-(1-methyl-4-piperidylidene)-6,11-dihydro-5H-benzo[5,6]cyclohepta[1,2-b]pyridine (5.4 g, 0.0175 mole) and triethylamine (3.6 mL, 2.61 g, 0.026 mole) in 60 mL of toluene. Following complete addition, the temperature is maintained at 80° C. for 1 hour. The reaction mixture is treated with charcoal, filtered, and concentrated to a residue. Following purification by silica gel chromatography and crystallization from pentane, 4.10 g (0.011 mole) of 8-fluoro-6,11-dihydro-11-(1-ethoxycarbonyl-4-piperidylidene)-5H-benzo[5,6]cyclohepta[-1,2-b]pyridine is obtained in 63% yield.
By analogous procedures, the corresponding 8-chloro, 8-bromo, 8,9-dichloro, 9-chloro, and 9-fluoro analogs of this 8-fluoro-11-(1-ethoxycarbonyl-4-piperidylidene) compound can be prepared.
EXAMPLE 7
A solution of 8-fluoro-6,11-dihydro-11-(1-ethoxycarbonyl-4-piperidylidene)-5H-benzo[5,6]cyclohepta[1,2-b]pyridine (3.6 g, 0.0098 mole) and potassium hydroxide (4.5 g, 0.094 mole) in 50 mL of ethanol:water (1:1) is heated at reflux for 66 hours. The reaction mixture is diluted with brine and the product is extracted into ethyl acetate. The solution is concentrated to a residual solid which is washed with acetone/ethyl acetate to yield 2.76 g (0.0094 mole) of 8-fluoro-11-(4-piperidylidene)-6,11-dihydro-5H-benzo[5,6]cyclohepta[1,2-b]pyridine.
By analogous procedures, the corresponding 8-chloro, 8-bromo, 8,9-dichloro, 9-chloro and 9-fluoro analogs of this 8-fluoro-11-(4-piperidylidene) compound can be prepared.
EXAMPLE 8
A solution of (1-ethoxycarbonyl-4-piperidinyl)[3-[2-(3-chlorophenyl)ethyl]-2pyridinyl]methanone hydrochloride (0.5 g, 1.25 mmol) (prepared by reacting the corresponding 1-methyl-H-piperidinyl compound with ethyl chloroformate) in 1.5 mL of trifluoromethane sufonic acid is stirred at ambient temperature for 24 hours. The reaction is diluted with ice and water, neutralized with barium carbonate, and the product extracted into ethyl acetate. The solvent is removed and following purification of the residue by silica gel chromatography, 8-chloro-6,11-dihydro-11-(1-ethoxycarbonyl-4-piperidylidene)-5H-benzo[5,6]-cyclohepta1,2-b]pyridine is obtained.
The compound 8-chloro-6,11-dihydro-11-(4-piperidylidene)-5H-benzo[5,6]cyclohepta[1,2-b]pyridine can be prepared by the above method by substituting (4-piperidinyl)[3-[2-(3-chlorophenyl)ethyl]-2-pyridinyl]methanone in place of the (1-ethoxycarbonyl-4-piperidylidene)[3-[2-(3-chlorophenyl)ethyl]-2-pyridinyl]methanone hydrochloride.
While the present invention has been described in conjunction with the soecific embodiments set forth above, many alternatives, modifications and variations thereof will be apparent to those of ordinary skill in the art. All such alternatives, modifications and variations are intended to fall within the spirit and scope of the present invention.
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A process for the preparation of piperidylidene-dihydro-dibenzo[a,d]cycloheptene or aza-derivatives thereof and intermediates in such process are disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the invention
This invention relates to an animation device, such as an animated picture, a publicity display means or advertisement panels showing an image obtained by the arrangement in successive planes of sheets comprising transparent and opaque elements adapted to be disposed one behind the other, in which device there is provided a means of at least partial modification of the relative spacing of the sheets in relation to one another.
2. Description of the prior art
In the field of publicity it is often desired to draw the attention of customers by images which appear to be in relief and which are animated. Very many lighting processes have been used for this purpose. Most of these processes and the device which put them into practice nevertheless require complicated and expensive technical means, necessitating permanent electrical or mechanical installations, or at least expensive and bulky equipment which is difficult to maintain and the installation of which takes a long time. Illuminated panels composed of a large number of electric bulbs, cinematographic projection, and automatons may be mentioned as known technical publicity means permitting animation.
American Pat. No. 3,314,180 discloses a device recreating an image in relief which is composed of various superimposed transparent supports, each of which carries a portion of the image which is to be recreated. In this patent the transparent supports are vibrated at a frequency at least equal to 15 Hz in order to obtain a three-dimensional image "so that the pictured objects seem solid from front to back". The means proposed by this American patent comprise resilient fastening of the edges of the supports and a vibration period at most equal to the persistance time of the image on the retina, because it is required to obtain an illusion of an image which has volume but appears to be fixed. A certain blurring of the image necessarily results from the vibrations.
SUMMARY
The present invention provides an animation device which completely departs from the prior art in respect of its means and its results, and which does not hesitate to show the images in successive planes.
It is an object of the invention to provide animation devices which utilise only economical means, which are easily installed in position, and which make it possible to develop a publicity theme by producing images giving the impression of movement, thus creating an illusion of animation of an image in three dimensions which is clear and free from blurring.
Another object of the invention is to provide devices suitable for numerous fields of presentation, comprising for example not only show window displays but also advertisement panels, or animated pictures.
A further object of the invention is to present an animated image which can be accompanied by a change of scene with a certain impression of calm which is favourable to the attraction of the customer.
According to the invention these aims are achieved in a device of the kind first described above through the fact that the sheets are disposed so as to be movable and free in respect of clearance in relation to one another, and that the means of modifying the relative spacing of the sheets in relation to one another acts at intervals of time at least equal to 0.1 second (10 Hz), preferably between 0.5 and 10 seconds (120 to 6 times per minute).
The fact that the sheets are so disposed as to be movable and free in respect of clearance fundamentally distinguishes the invention from the previous known arrangement in which the resilient elements maintain a practically constant distance at the edge of the sheets, thus practically permitting variation of spacing only by vibration in the centre of the sheets.
The invention on the other hand permits free variation of spacing of the sheets, thus permitting substantial variations of lighting, shade, and even of scene by changing the lighting of the planes, without the ambient lighting being modified.
In the invention the eye of an observer perceives at every moment an image which is clear although moving, because it is essential that the modifications of arrangements should be relatively slow so that the eye can follow the movements.
It is advantageous that the sheets of transparent or opaque materials (in which latter case they may be cut out) should carry traced, drawn, or applied elements, such as drawings, lines, flat colourings, stencilling, etc., and that they should be joined together in accordion fashion.
It is also advantageous that the device should be mounted in a frame containing, face to face, a front and a back which are both fixed and each of which may optionally be composed of a sheet containing elements contributing towards the formation of the image.
In one embodiment the movable sheets, which are optionally connected in accordion fashion, are suspended in the frame between the front and the back and a mechanism positively moves at least two of these sheets towards and/or away from one another.
It is very advantageous that the frame should contain at least one fixed lighting source disposed laterally, and also that the sheets, when they are joined in accordion fashion, should be disposed with the joints vertical.
In a variant the means of modifying the relative spacing of the sheets in relation to one another is composed of an air blower.
The means according to the invention have the effect that the arrangement of the shadows cast by the opaque elements on one another and even on the transparent coloured elements depends on the instantaneous relative arrangement of the sheets. If the sheets are in a fixed position in relation to one another, the lighting will produce shadows which give an impression of relief. If the relative arrangements of the sheet are varied by the device according to the invention, this results in concomitant modification of the distribution of the shadows on the different sheets, that is to say on the different planes of the image. This then results in a very surprising illusion of animation of the image. The effect of relief through distribution of shadows and through the changing of planes in the lighting by the means described, on the one hand, and the illusion of animation which results from the variations of shadow, on the other hand, are essential to the invention, and the shadow and the change of lighting then constitute, through their effect and through the change of scene which results therefrom, an intangible means the use of which according to the invention contributes towards the results obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows diagrammatically a preferred form of construction of a device according to the invention, shown in perspective after removal of the front face and part of its frame,
FIG. 2 is a detail view of part of the device shown in FIG. 1,
FIG. 3 is a view in horizontal section on the line III--III, FIG. 1,
FIG. 4 shows a set of sheets intended to produce an animated image in the device shown in FIGS. 1 and 3,
FIG. 5 shows in the flat state the set of sheets shown in FIG. 4,
FIG. 6 is a diagrammatic side view of another form of device according to the invention,
FIG. 7 is a plan view of a detail of FIG. 6, and
FIG. 8 shows a set of sheets intended to produce an animated image in the device shown in FIG. 6.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIGS. 1, 2, and 3 there is shown a preferred form of a device according to the invention which may serve as an animated picture, a publicity display means, or an advertising panel. A frame 80 has four sides 81, 82, 83, 84, an opaque back 85, and a face 86, FIG. 3, formed by a projecting portion 87 of the frame. The face 86 comprises a fixed sheet 86' of glass or transparent synthetic material.
Two horizontal rods 88, 89 are fixed to the frame, respectively in the top and bottom portions. The two rods respectively carry pairs of blades 94, 95 which fasten sheets 91, 93 which can be disposed in the frame one behind the other between the front and the back. The sheets 91, 93 are fixed on the pairs of blades 94, 95 by any means known per se, such as by adhesion or by gripping in a slit in the blades. The blades 94, 95 are mounted for articulation and face one another in a V-arrangement on the rods 88, 89, and are normally held close together by any resilient means known per se, such as a rubber part or a spring, tending to close the V.
Two shafts 96, 97 respectively pass through the space between the sides of the V's, each being carried at one end in a fixed bearing (not shown), and at the other end in the slow output shaft connection of an electric micromotor 100, 101. The shafts 96, 97 each respectively carry two palette-shaped cams 102, 103 each of which is slipped between the two sides of a V of the blades 94, 95. The cam may for example, be made of sheet metal of a thickness of 1 mm and with a dimension of from 12 to 50 mm in the direction in which they move the V's apart, so that the sheets 91, 93 can be moved together or moved apart by from 12 to 50 mm.
If the micromotors 100, 101 are operated with an output shaft speed of a frequency lower than the relaxation frequency of the resilient system formed by the sheets, the V's, and their springs, synchronous modifications of the relative spacing of the sheets in relation to one another will be obtained. It is important that an observer sees at every moment a clear image and that the impression of animation results not from an effect of moving but from a variation of the zones of light and shade of the elements of the sheets on one another. It is for this reason that there is no disadvantage in having a set of sheets and return springs having a predetermined relaxation time. A speed of rotation of the shafts of the micromotors of from 3 to 60 revolutions per minute, corresponding to from 6 to 120 movements towards and away from one another per minute, that is 0.5 to 10 movements per second, is in conformity with the invention.
Very attractive results have been obtained at speeds of from 8 to 15 movements per minute, that is at least 0.1 per second, of the sheets away from one another, representing for example the breathing of a person.
The image is to be obtained through the arrangement in successive planes of sheets comprising transparent elements and opaque elements. The set of sheets to be introduced for this purpose in the display unit is joined together in accordion fashion, for example, as illustrated in FIG. 4, and is thus ready for introduction into the apparatus shown in FIGS. 1, 2, and 3. Each of these sheets comprises transparent, coloured or uncoloured, or cut-out elements and opaque elements distributed so as to obtain a representational or non-representational overall aesthetic effect.
FIG. 5 shows the three sheets 91, 92, 93, which are assumed to be pressed correspondingly against one another.
Any drawings provided on the fixed sheet 86' and on the back 85 may contribute, together with the sheets 91, 92, 93, towards forming the desired image or decor.
The frame is, in addition, provided on its side uprights 81 and 83 with two electric lamps 104 illuminating laterally the sheet 91 or the sheet 92, depending on their position, so that in combination with the variations of spacing of the sheets there are obtained variations of colour, lighting, and shade cast by the elements on one another, thus giving the image an appearance of a changing decor.
In order to increase the strength of the construction the two shafts 96, 97 are driven by two micromotors, but it would be possible to use a single micromotor driving only the top shaft, or to drive the bottom shaft by a chain and pinion drive.
In the preferred embodiment of the invention there has been described a particular arrangement of a suspension and positive driving mechanism for at least two sheets. Another mechanism exactly fulfilling the same functions would be similarly convenient, for example one in which the sheets are suspended on short upper slides perpendicular to the front and to the back of the frame, an eccentric drive being used to move the sheets apart and towards one another.
Another embodiment of the invention is illustrated in FIGS. 6 and 7. This form of construction is suitable for optical projection, by means of a back projector of a kind known per se, of an image obtained by modifying the relative spacing of four sheets 11, 12, 13, 14 of an accordion-folded document 10, the sheets of which carry opaque and transparent elements, as illustrated in FIG. 8.
A back projector 70 of a kind known per se, and therefore containing a powerful means of lighting its worktable, is provided on this worktable with a blower plate 171 the sides of which receive the ends of four pipes 172, 173, 174, 175 fastened at 179 on adjusting slides 180 carried by the plate 171 and connected to an air blower 176 through a set of valves contained in a casing 177. The valves can be controlled by an electronic programmer 178 of a kind known per se, distributing the blown air sometimes from the right-hand side of the table, sometimes from the left-hand side, and sometimes from both sides simultaneously.
If the document 10 is disposed on the blower plate 171 in such a manner that the air blows sometimes from the right and sometimes from the left in the direction of the sheets, substantially parallel to the sheets and perpendicularly to the folds, this results in a modification of from 1 to 2 cm of the total relative spacing of the illuminated sheets, thus providing through projection an attractive effect of animation.
With regard to the frequency of the changes of air blowing, the limits according to the invention will be respected, that is to say they will preferably be of the order of from 0.5 to 10 seconds, or if need be from 0.5 to 0.1 second, without ever using a higher frequency. Animation by a blowing device according to the invention may be applied to all kinds of devices suitable for performing the invention, particularly devices for vertical images which, as described in connection with the first embodiment, are carried by frames or panels or suspended by any known means, such as pivots, hooks, rings, or slides.
It is emphasised that the descriptions given above are of examples only of embodiments of the invention, and that these descriptions can give only a slight idea of the actually surprising effect produced by devices according to the invention.
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Animation of an image is effected by providing transparent and opaque figures on sheets arranged one behind the other in spaced relation and by modifying the spacing at intervals in the range of 0.1 to 10 seconds and preferably in the range of 0.5 to 10 seconds.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Divisional of U.S. application Ser. No. 10/370,837, filed Feb. 21, 2003, entitled “AUTONOMIC SERVICE ROUTING USING OBSERVED RESOURCE REQUIREMENT FOR SELF-OPTIMIZATION,” which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of distributed computing, including Web services and grid services, and more particularly to the routing of a service request to a service instance within a service providing infrastructure.
2. Description of the Related Art
Web services represent the leading edge of distributed computing and are viewed as the foundation for developing a truly universal model for supporting the rapid development of component-based applications over the World Wide Web. Web services are known in the art to include a stack of emerging standards that describe a service-oriented, component-based application architecture. Specifically, Web services are loosely coupled, reusable software components that semantically encapsulate discrete functionality and are distributed and programmatically accessible over standard Internet protocols.
Conceptually, Web services represent a model in which discrete tasks within processes are distributed widely throughout a value net. Notably, many industry experts consider the service-oriented Web services initiative to be the next evolutionary phase of the Internet. Typically, Web services can be defined by an interface such as the Web services definition language (WSDL), and can be implemented according to the interface, though the implementation details matter little so long as the implementation conforms to the Web services interface. Once a Web service has been implemented according to a corresponding interface, the implementation can be registered with a Web services registry, such as Universal Description, Discover and Integration (UDDI), as is well known in the art. Upon registration, the Web service can be accessed by a service requester through the use of any supporting messaging protocol, including for example, the simple object access protocol (SOAP).
In a service-oriented application environment supporting Web services, locating reliable services and integrating those reliable services dynamically in realtime to meet the objectives of an application has proven problematic. While registries, directories and discovery protocols provide a base structure for implementing service detection and service-to-service interconnection logic, registries, directories, and discovery protocols alone are not suitable for distributed interoperability. Rather, a more structured, formalized mechanism can be necessary to facilitate the distribution of Web services in the formation of a unified application.
Notably, the physiology of a grid mechanism through the Open Grid Services Architecture (OGSA) can provide protocols both in discovery and also in binding of Web services, hereinafter referred to as “grid services”, across distributed systems in a manner which would otherwise not be possible through the exclusive use of registries, directories and discovery protocols. As described both in Ian Foster, Carl Kesselman, and Steven Tuecke, The Anatomy of the Grid, Intl J. Supercomputer Applications (2001), and also in Ian Foster, Carl Kesselman, Jeffrey M. Nick and Steven Tuecke, The Physiology of the Grid, Globus.org (Jun. 22, 2002), a grid mechanism can provide distributed computing infrastructure through which grid services instances can be created, named and discovered by requesting clients.
Grid services extend mere Web services by providing enhanced resource sharing and scheduling support, support for long-lived state commonly required by sophisticated distributed applications, as well as support for inter-enterprise collaborations. Moreover, while Web services alone address discovery and invocation of persistent services, grid services support transient service instances which can be created and destroyed dynamically. Notable benefits of using grid services can include a reduced cost of ownership of information technology due to the more efficient utilization of computing resources, and an improvement in the ease of integrating various computing components. Thus, the grid mechanism, and in particular, a grid mechanism which conforms to the OGSA, can implement a service-oriented architecture through which a basis for distributed system integration can be provided-even across organizational domains.
Within the computing grid, a service providing infrastructure can provide processing resources for hosting the execution of distributed services such as grid services. The service providing infrastructure can include a set of resources, including server computing devices, storage systems, including direct attached storage, network attached storage and storage area networks, processing and communications bandwidth, and the like. Individual transactions processed within the service providing infrastructure can consume a different mix of these resources.
It is known in the grid services context to route requests to particular service instances hosted within a specified service providing infrastructure according to the queue length of the particular service instance. The logical selection of a particular service instance based upon a queue lengths represents an attempt to minimize response time by placing requests for service processing in the shortest possible queue. Similarly, the processing capabilities of the hosting service providing infrastructure further can be taken into account in selecting a particular service instance.
More particularly, a particular service instance able to process requests at twice the rate of other service instances can have equal processing throughput as the other service instances where the particular service instance has a queue which is twice as long as the queue of the other service instances. Still, the queue length selection strategy can be overly coarse-grained and does not match the resource requirements of a requested service to the available resources of the service providing infrastructure. Specifically, in the conventional circumstance, a mere scalar benchmark can be associated with the whole of a service providing infrastructure. Consequently, the granular components of the service providing infrastructure are never taken into account.
BRIEF SUMMARY OF THE INVENTION
The present invention is a service request routing system and method. In accordance with the present invention, individual service requests can be routed to service instances within selected service hosts having resource components most compatible with the resource requirements and consumption patterns of the service requests. In this way, unlike the conventional circumstance in which a mere scalar benchmark can be associated with the whole of a service providing infrastructure, the granular components of the service providing infrastructure of the grid host can be taken into account when routing service requests to service instances.
A service request routing system can include a model table configured to store resource models. A monitor can be coupled to the model table and programmed both to model resource consumption in a service providing infrastructure, and also to store the modeled resource consumption in the model table. A router also can be coupled to the model table. Specifically, the router can be programmed to route each service request to a corresponding service instance disposed in an associated service host having a service providing infrastructure. In a preferred aspect of the invention, the associated service host can include a grid host in a grid computing system.
Importantly, the routing can be based upon a matching of resource components of the service providing infrastructure to a resource model for the service request. Additionally, in the preferred aspect, each resource model in the model table can be a time series model. Finally, the resource components can form a resource vector corresponding to the service providing infrastructure. In this regard, each resource component in the resource vector can include a resource selected from the group consisting of a server type, bandwidth, and storage system type. Other resources can include more granular computing resources, for instance cache size or CPU speed. Furthermore, a comparator further can be included which can be programmed to compare a scalar cost of each resource vector to determine a relative cost between individual resource vectors.
A method for routing service requests to service instances in a service providing infrastructure can include receiving a service request and computing resource vectors for at least two service hosts. Each service host can have a corresponding service providing infrastructure. A resource model can be retrieved for the service request. Accordingly, the retrieved resource model can be matched to each of the resource vectors to identify a best-fit resource vector. Finally, the service request can be routed to a selected service host associated with the identified best-fit resource vector.
In a preferred aspect of the invention, for each of the resource vectors at least two scalar resource components can be computed. In this regard, the scalar components can include server type, server performance, server capacity, processing bandwidth, communications bandwidth, storage type, storage capacity and storage performance. Also, a scalar cost can be computed for each of the resource vectors. In this way, the scalar costs can be compared to determine a more cost-effective resource vector.
To produce the resource models, processing of received service requests can be monitored and individual resource components can be identified in the service hosts which are consumed during the processing. Consequently, the resource models can be produced for the service requests based upon the identified individual resource components in the service hosts. Notably, the producing step can include the step of computing a time series model for each of the service requests based upon the identified individual resource components.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
There are shown in the drawings embodiments which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
FIG. 1 is a block illustration of a services grid configured for routing service requests to service hosts within a service providing infrastructure having resources which best match the resource requirements of the requested service in accordance with the present invention; and,
FIG. 2 is a flow chart illustrating a process for routing service requests to service hosts within a service providing infrastructure having resources which best match the resource requirements of the requested service in the grid of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a method and system for routing service requests to service instances in selected service providing infrastructure. Specifically, the granular resource requirements of a service can be matched to the granular resources within a resource set associated with a service providing infrastructure hosting an instance of the requested service. Based upon a best-fit matching of resource requirements of the requested service to resource availability of a host service providing infrastructure, the request for service processing can be assigned to a service instance hosted within the matched service providing infrastructure. In this way, the mere routing of service requests based upon a course-grained, scalar evaluation of a service providing infrastructure can be avoided.
FIG. 1 is a block illustration of a services grid configured for routing service requests to service instances hosted within a service providing infrastructure having resources which best match the resource requirements of the requested service in accordance with the present invention. As will be apparent to the skilled artisan, the services grid can be a Web services grid configured with one or more grid hosts 120 communicatively linked to one another in a grid fashion across a computer communications network 110 , for instance the Internet. Individual requesting clients 190 can request access to Web services from one or more of the grid hosts 120 . Specifically, as is well-known in the art, SOAP encoded messages can be exchanged between requesting clients 190 and the grid hosts 120 . The messages can include requests to discover the location of particular Web services and well as responses to the requests in which the network location of the requested Web services are revealed.
The grid hosts 120 can be disposed within a server computing device in a centralized fashion, or across multiple server computing devices in a distributed fashion. In either case, a Web server 140 can be provided which can be configured to respond to network requests for content, such as markup documents. As will be understood by one of ordinary skill in the art, the Web server 140 can be configured to handle hypertext transfer protocol (HTTP) messages and to distribute markup such as hypertext markup language (HTML) formatted documents, extensible markup language (XML) formatted documents, and the like.
The Web server 140 can be communicatively linked in the grid host 120 to an application server 150 . Application servers are well-known in the art and typically are configured to process machine code, whether in an interpreted manner, or in a native format. Conventional application servers process server-side logic such as scripts and servlets. In any event, the application server 150 can be linked to a Web services engine 160 configured to instantiate individual Web services in one or more Web services containers in the grid hosts 120 . The Web services instances, in turn, can access the resources 130 of the grid host 120 . It will be recognized by the skilled artisan that the collection of resources 130 can be considered the foundation of a service providing infrastructure. To that end, the resources 130 can include server computing devices and processes, storage systems, and communications and computing bandwidth.
Importantly, a grid service mechanism 170 can be disposed in each grid host 120 . The grid service mechanism 170 can implement a grid services interface such as that defined by OGSA and specified, for example, according to the Globus Project, Globus Toolkit Futures: An Open Grid Services Architecture, Globus Tutorial, Argonne National Laboratory (Jan. 29, 2002). As is well-known in the art, an OGSA compliant grid services interface can include the following interfaces and behaviors:
1. Web service creation (Factory)
2. Global naming (Grid Service Handle) and references (Grid Service Reference)
3. Lifetime management
4. Registration and discovery
5. Authorization
6. Notification
7. Concurrency
8. Manageability
In that regard, the grid services mechanism 170 can include a factory interface able to clone instances of selected Web services into new or pre-existing application containers using a “Factory Create Service”.
Significantly, the grid services mechanism 170 can instantiate clone instances of a requested Web service across one or more remote grid hosts 120 . In particular, consistent with the intent of grid architectures, where processing loads experienced by individual remote grid hosts 120 exceed acceptable or pre-specified capacities, others of the individual remote grid hosts 120 can be selected to host new instances of selected Web services. In any event, responsive to receiving service requests for processing in a specified Web service, regardless of any particular instance of the specified Web service, a routing process 200 B can select a specific service instance within a grid host 120 to handle the service request.
Significantly, in selecting the specific service instance, the resources 130 associated with the service providing infrastructure of the grid host 120 of the specific service instance can be considered. More particularly, the resource availability of the grid host 120 can be matched to the resource requirements of the service request. To undertake the resource matching, for each transaction processed in a grid host 120 , a monitor process 200 A can monitor the utilization of resources 130 in the grid host 120 so as to establish a resource requirements and consumption model for the transaction. The established model for each transaction can be stored in a model table 200 C.
Subsequently, the router can establish a resource vector for each grid host 120 under consideration during the routing process. The resource vector can include scalar values for the individual resources 130 forming the foundation of the service providing infrastructure of the grid host 120 . Examples can include available processing bandwidth, available communications bandwidth, storage type, capacity and responsiveness, server type, etc. Each resource vector established for the service providing infrastructure of a grid host can be stored in a vector table 200 D. Additionally, a cost element can be computed for the vector so that individual vectors in the vector table 200 D can be compared to one another in a scalar fashion.
When a service request is received in the routing process 200 B, the routing process 200 B can identify the transaction type associated with the service request. Based upon the transaction type, the model for the transaction type can be retrieved from the model table 200 C and matched to the resource vectors in the vector table 200 D which are associated with grid hosts 120 having either available service instances able to handle the received service request, or the ability to instantiate service instances able to handle the received service request. In this regard, a best-fit algorithm can be applied to select the appropriate grid host 120 to handle the request.
FIG. 2 is a flow chart illustrating a process for routing service requests to service hosts within a service providing infrastructure having resources which best match the resource requirements of the requested service in the grid of FIG. 1 . Beginning in block 210 , a grid service request can be received. In block 220 , the service type can be identified. In block 230 , the resources of available grid hosts configured to host service instances of the requested service type can be queried to establish respective resource vectors. Additionally, in decision block 230 , it can be determined if a model has been computed for the service type.
If in decision block 240 a model cannot be located for the identified service type, in block 280 , the grid host configured to host service instances of the requested service type which demonstrates the highest availability in terms of queue length or scalar performance can be selected. Otherwise, in block 250 , the resource model for the service type can be retrieved and in block 260 , a best-fit analysis can be applied to the model and the resource vectors of the set of grid hosts able to host service instances of the requested service type. Based upon the best-fit analysis of block 260 , in block 270 the service request can be routed to the service instance within the specified grid host.
The present invention can be realized in hardware, software, or a combination of hardware and software. An implementation of the method and system of the present invention can be realized in a centralized fashion in one computer system, or in a distributed fashion where different elements are spread across several interconnected computer systems. Any kind of computer system, or other apparatus adapted for carrying out the methods described herein, is suited to perform the functions described herein.
A typical combination of hardware and software could be a general purpose computer system with a computer program that, when being loaded and executed; controls the computer system such that it carries out the methods described herein. The present invention can also be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein, and which, when loaded in a computer system is able to carry out these methods.
Computer program or application in the present context means any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following a) conversion to another language, code or notation; b) reproduction in a different material form. Significantly, this invention can be embodied in other specific forms without departing from the spirit or essential attributes thereof, and accordingly, reference should be had to the following claims, rather than to the foregoing specification, as indicating the scope of the invention.
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A service request routing system and method includes a model table configured to store resource models. A monitor is coupled to the model table and programmed both to model resource consumption in a service providing infrastructure, and also to store the modeled resource consumption in the model table. A router is coupled to the model table, and the router is programmed to route each service request to a corresponding service instance disposed in an associated service host having a service providing infrastructure. The associated service host includes a grid host in a grid computing system.
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TECHNICAL FIELD
[0001] This invention generally relates to inflatable packers used to complete subterranean wells and in particular to hydraulically actuated inflatable packers. More specifically, this invention relates to hydraulically actuated inflatable packers that are inflated by a fluid filtered from a gravel laden slurry or other fluid with suspended solids.
BACKGROUND OF THE INVENTION
[0002] Oil and natural gas may be obtained from subterranean geologic formations, referred to as reservoir, by drilling wells that penetrate hydrocarbon-bearing formations. In order to obtain hydrocarbons from a wellbore, the well usually must be completed.
[0003] Well completion involves the design, selection, and installation of equipment and materials in or around a wellbore for conveying, pumping, or controlling the production or injection of fluids from and/or to the wellbore. After a well has been completed, production of oil and gas may begin. Sand or silt flowing into the wellbore from unconsolidated formations may lead to an accumulation of fill within the wellbore which may cause a reduction of production rates and damage to surface and subsurface production equipment. The fill, often referred to as migrating sand, has the possibility of packing off around subsurface production equipment, or may enter the production tubing and therefore enter production equipment. Sand is highly abrasive, and if it enters production streams, it may cause the erosion of tubing, flowlines, valves and other processing components and equipment. Erosion and abrasion caused by sand production often increases operational and maintenance expenses, and in severe cases may lead to a total loss of the well. Gravel packing is a means of controlling sand production. Gravel packing is the placement of relatively large sand (i.e., “gravel”) around the exterior of a sand screen or liner, which includes slotted sand screens, perforated sand screens, and various other liner types and screens. The gravel acts as a filter to remove formation fines and sand from oilfield fluids.
[0004] A gravel pack completion known in the art comprises a sand screen that is placed in the wellbore and positioned within an unconsolidated formation. The sand screen may be connected to a tool that includes a production packer and a cross-over. The tool is connected to a work string or a production tubing string. Gravel is then pumped in a slurry down the tubing and through the cross-over, thereby flowing into the annulus between the sand screen and the wellbore. The slurry comprises a liquid supporting suspended solids. The solids are often referred to as “gravel”. The liquid leaks off into the formation and/or through the sand screen, which is sized to prevent the solids in the slurry from flowing through. Thus the solids are deposited in the annulus around the sand screen where it forms a gravel pack. The sand screen prevents the gravel pack from entering into the production tubing. The gravel must be sized for proper containment of the formation sand, and the sand screen must be designed in a manner to prevent the flow of the gravel through the sand screen.
[0005] Often during well completions there is a need to seal off sections of the wellbore. One reason to seal off a section of a wellbore is the need to isolate those areas in which an adequate gravel pack can not be obtained, such as below the bottom of the gravel pack screens where adequate circulation is difficult to achieve. Another reason to seal off a section of a wellbore is that in some formations, such as across a major or minor shale section, a gravel pack completion is not desirable. Still another reason to seal off a section of a well bore is because when one or more sections are to be completed and another section is not going to be completed, the non-completed section often needs to be isolated from the sections that will be completed. This is due to the fact that when non-completed sections are not isolated, the gravel, which is tightly packed around the gravel pack screens after a gravel pack, may be able to migrate to these non-completed sections, thereby limiting the effectiveness of the gravel pack completion. Another reason to isolate a section of the wellbore is to prevent or limit acceleration of the gravel migration effect due to the flow of produced fluids. Sand screens exposed to gravel migration due to the flow of produced fluids may experience direct production of formation sand which could result in equipment damage, formation collapse and even the loss of the well.
[0006] Well known in the art are inflatable packers, usually comprising an annular elastomeric bladder, which have been used to seal off sections of wellbores for the reasons discussed above. When the bladder is filled by a by a pressurized fluid, it inflates the packer causing the exterior of the elastomeric body to seal against the wellbore. This produces a wellbore seal that prohibits fluid flow past the packer.
[0007] A problem with inflatable packers known in the art is the difficulty of sending fluid to the bladder to inflate the bladder. The time consumed in using known inflatable packers includes the time needed for an extra step either prior to the gravel pack step or after the gravel pack step to send a specialized tool down the wellbore to inflate the packer.
[0008] Thus, there is a need for an improved inflatable packer which reduces the known problems in sending fluid to the bladder to inflate the bladder, and eliminates the need for an extra step either prior to or after a gravel pack to inflate the bladder.
SUMMARY OF THE INVENTION
[0009] The present invention describes tools and methods of completing a wellbore that comprise an isolation packer with a particulate filter and inflatable element. The isolation packer is adapted to direct a gravel laden slurry to the particulate filter, where the filter removes a substantial amount of the particulate matter from the gravel laden slurry thereby producing an inflating fluid that is substantially free of particulate matter. The inflating fluid then inflates the inflatable element thus creating a seal in the wellbore.
[0010] This invention offers a number of benefits over conventional wellbore completion tools. Usually a pre-gravel pack trip would be undertaken to isolate a sump area, for instance, with a cement plug or an open hole packer. This pre-gravel pack trip comprise additional steps that are costly, time consuming and are often difficult to perform and unreliable in their outcome. The present invention provides a means of achieving the desired results in the same trip into the well as the gravel pack operation. The ability to inflate the inflatable isolation packer during a gravel pack completion can save time and expense by eliminating an additional trip into the well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above advantages as well as specific embodiments will be understood from consideration of the following detailed description taken in conjunction with the appended drawings in which:
[0012] FIG. 1 is a cross section of a wellbore showing a prior art gravel pack completion apparatus.
[0013] FIG. 2 is a cross section of a wellbore showing a gravel pack completion apparatus that includes an embodiment of the present invention.
[0014] FIGS. 3A and 3B are cross sections of a wellbore showing a gravel pack completion with both a typical isolation packer ( FIG. 3A ) and with a cup packer ( FIG. 3B ) with the particulate filter located near an uphole end of the conduit.
[0015] FIG. 4 is a cross section of a wellbore showing an embodiment of the present invention with the inflatable element shown in an inflated state.
[0016] FIG. 5 is a partial cut away view of another embodiment of the present invention comprising an alternative channel.
[0017] FIG. 6 is a partial cut away view of the present invention comprising an alternative channel with the particulate filter located near an uphole end of the alternative channel.
[0018] FIG. 7 is a partial cut away view of the alternative channel embodiment of the present invention showing the inflatable element in an inflated state.
[0019] FIG. 8 is a cross section of a wellbore showing another embodiment of the present invention in an openhole completion.
[0020] FIG. 9 is a cross section of a wellbore showing the embodiment of the present invention in an openhole completion with the inflatable element in an inflated state.
[0021] References in the detailed description correspond to like references in the figures unless otherwise indicated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to the attached drawings, FIG. 1 is a depiction of the prior art and illustrates a wellbore 10 that has penetrated a subterranean zone 12 that includes a productive formation 14 . The wellbore 10 has a casing 16 that has been cemented in place. The casing 16 has a plurality of perforations 18 which allow fluid communication between the wellbore 10 and the productive formation 14 . A well tool 20 is positioned within the casing 16 in a position adjacent to the productive formation 14 , which is to be gravel packed.
[0023] The present invention can be utilized in both cased wells and open hole completions, as well as vertical wells and non-vertical wells. For ease of illustration of the relative positions of the producing zones in FIGS. 1-4 , a cased well having perforations will be used. More detailed illustrations of the invention being utilized in an open hole completion are shown in FIGS. 8-9 .
[0024] Still referring to FIG. 1 , the well tool 20 comprises a tubular member 22 attached to a production packer 24 , a closing sleeve 26 , and one or more sand screen elements 28 . Blank sections of pipe may be used to properly space the relative positions of each of the components. An annulus area 34 is created between each of the components and the wellbore casing 16 . The combination of the well tool 20 and the tubular string extending from the well tool to the surface can be referred to as the production string.
[0025] Still referring to FIG. 1 , in a gravel pack operation the packer 24 is set to ensure a seal between the tubular member 22 and the casing 16 . Gravel laden slurry is pumped down the tubular member 22 , exits the tubular member through ports in the closing sleeve 26 and enters the annulus area 34 below the production packer 24 . In one typical embodiment the particulate matter (gravel) in the slurry has an average particle size between about 40/60 mesh-12/20 mesh, although other sizes may be used. Slurry dehydration occurs when the carrier fluid leaves the slurry. The carrier fluid can leave the slurry by way of the perforations 18 and enter the formation 14 . The carrier fluid can also leave the slurry by way of the sand screen elements 28 and enter the tubular member 22 . The carrier fluid flows up through the tubular member 22 until the closing sleeve 26 places it in the annulus area 36 above the production packer 24 where it can leave the wellbore 10 at the surface. Upon slurry dehydration the gravel grains should pack tightly together. The final gravel filled annulus area is referred to as a gravel pack.
[0026] An area that is prone to developing a void during a gravel pack operation is the area 42 below the lowest sand screen element 28 , sometimes referred to as the “sump”. A gravel pack void in the sump 42 is particularly problematic in vertical wells in that it can allow the gravel from above to settle and fall into the voided sump.
[0027] Production of fluids from the productive formation 14 can agitate or “fluff” the gravel pack and initiate the gravel to migrate and settle within the sump 42 . This can lead to the creation of voids in the annulus areas 38 adjacent to the sand screen elements 28 and undermine the effectiveness of the entire well completion.
[0028] As used herein, the term “sand screen” refers to wire wrapped screens, mechanical type screens and other filtering mechanisms typically employed with sand screens. Sand screens need to be have openings small enough to restrict gravel flow, often having gaps in the 60-12 mesh range, but other sizes may be used. Sand screens of various types are produced by Halliburton, among others, and are commonly known to those skilled in the art.
[0029] FIG. 2 illustrates one particular embodiment of the present invention where an upper set of perforations 60 and a lower set of perforations 62 will be completed utilizing a gravel pack completion. The lower set of perforations 62 will be isolated from the upper set of perforations 60 . An inflatable isolation packer 50 is run into the wellbore 10 below the lowest sand screen element 28 . A conduit 52 extends from the gravel inflated isolation packer 50 and provides communication with the annulus area 38 that will be gravel packed. The conduit 52 may be generally referred to as a passageway, and more specifically referred to as a shunt tube. A second conduit 53 may be utilized below the isolation packer 50 .
[0030] Between the conduit 52 and the gravel inflated isolation packer 50 is a particulate filter 54 . Likewise, a particulate filter 59 is placed between conduit 53 and the isolation packer 50 . In this way, either or both of the conduits 52 , 53 allow gravel laden slurry to travel from the annulus area 38 to the particulate filters 54 , 59 where the gravel laden slurry is filtered, thereby providing an inflating fluid. The inflating fluid is then communicated to an inflatable element 56 that provides the sealing mechanism between the tubular member 22 and the casing 16 . The inflatable element 56 may be an expandable bladder. The particulate filter 54 could be any device known in the art that separates the particulate matter in the gravel laden slurry from the carrying fluid. Some examples of particulate filters include, but are not limited to: wire-wrapped screens and wire meshes.
[0031] A conduit, such as conduit 52 and/or conduit 53 , is just one way of enabling the communication of the gravel laden slurry to enter the inflatable isolation packer 50 . Other embodiments can be used, such as connecting the inflatable isolation packer 50 to a flow channel which is integral to the screen, or a shunt tube. All of these embodiments would include a particulate filter to prevent particulates such as gravel from entering the inflatable element 56 . In addition, all of these embodiments may include a check valve device to prevent any reverse flow out of the inflatable isolation packer 50 .
[0032] The inflation of the inflatable element 56 will typically be done with a fluid that is filtered from a gravel laden slurry. This fluid will be an inflating fluid that is substantially free of particulates such as gravel. The inflation of the inflatable element 56 can be performed in conjunction with a gravel pack completion operation of the well.
[0033] The inflatable element 56 may be constructed utilizing an inner elastomeric element that retains the pressurized fluid that is used to inflate the packer. The inflatable element may comprise more than one layer of material, such as utilizing an expandable mesh as an outer layer for durability. Often a plurality of metal reinforcing members can be located in the annulus between the elastomeric element and the outer expandable mesh, these provide additional strength to the packer and can improve reliability. The typical construction can be in the manner of conventional packers, these methods and materials being well known to those skilled in the art.
[0034] FIGS. 3A and 3B illustrate alternate embodiments of the invention where the particulate filter 54 is no longer located adjacent to the inflatable element 56 , but rather is now located near the uphole end of the conduit 52 . The particulate filter 54 may be located at various locations on the well tool 20 so long as the particulate filter is able to filter the particulates from the gravel slurry so that an inflating fluid is produced that is substantially free of particulate matter and can be used to inflate the inflatable element 56 . Multiple conduits may be used, one or more with ports as depicted in FIG. 2 in addition to one or more without ports as shown in FIG. 3A , as long as at least one conduit supplies inflating fluid through a particulate filter that can inflate the inflatable element.
[0035] FIG. 3B shows the use of a cup packer 55 placed below the entrance to conduit 52 but above the first opening of sand screen elements 28 . As is known in the arts, the use of a cup packer, such as cup packer 55 , creates a pressure seal between well tool 34 and the well bore wall 16 except for the passage way through the conduit, such as conduit 52 , or the conduits allowing a forced flow through the conduit or conduits.
[0036] FIG. 4 illustrates the embodiment of the invention as described in FIG. 2 after a gravel pack operation has been performed. The inflatable element 56 of the inflatable isolation packer 50 is expanded and provides a seal between the tubular member 22 and the casing 16 . The upper and lower set of perforations 60 and 62 have been properly gravel packed and protected from the producing formation 14 . The inflatable isolation packer 50 acts to isolate the gravel pack completed lower set of perforations 62 from the gravel pack completed upper set of perforations 60 . Also shown in FIG. 4 is the use of a second isolation packer 150 which can be used and operated in a manner similar to isolation packer 50 .
[0037] For ease of installation and to ensure proper placement relative to the components of the well tool 20 , the conduit 52 that extends from the inflatable isolation packer 50 will typically be attached to the exterior of the well tool 20 in some manner, such as by welding. It is also possible for the conduit 52 to be replaced by a fluid pathway forming an alternative channel within a sand screen element, as described with respect to FIGS. 5-7 . Also, the particulate filters may be located adjacent or near the inflatable element 56 .
[0038] Referring now to FIG. 5 , there is depicted a partial cut away view of an apparatus 64 that is an alternative channel embodiment of the invention. Apparatus 64 has an outer tubular 66 . A portion of the side wall of outer tubular 66 is an axially extending production section 68 that includes a plurality of openings 70 . Another portion of the side wall of outer tubular 66 is an axially extending nonproduction section 72 that is distinguished from the production section 68 by the lack of openings 70 . It should be noted by those skilled in the art that even though FIG. 5 has depicted openings 70 as being circular, other shaped openings may alternatively be used without departing from the principles of the present invention. In addition, the exact number, size and shape of openings 70 are not critical to the present invention, so long as sufficient area is provided for fluid production therethrough and the integrity of outer tubular 66 is maintained.
[0039] Still referring to FIG. 5 , disposed within outer tubular 66 and on opposite sides of each other is one or more channels 74 , only one channel 74 being visible. Channels 74 provide circumferential fluid isolation between production section 68 and nonproduction section 72 of outer tubular 66 . Channels 74 may be generally referred to as passageways.
[0040] Still referring to FIG. 5 , disposed within channels 74 is a sand control screen assembly 78 . The sand control screen assembly 78 may include a base pipe 80 that has a plurality of openings 82 which allow the flow of production fluids into the production tubing. The exact number, size and shape of openings 82 are not critical to the present invention, so long as sufficient area is provided for fluid production and the integrity of base pipe 80 is maintained. Positioned around base pipe 80 is a fluid-porous, particulate restricting, sintered metal material such as plurality of layers of a wire mesh that are sintered together to form a porous sintered wire mesh screen 84 . Sand screen 84 is designed to allow fluid flow therethrough but prevent the flow of particulate materials of a predetermined size from passing therethrough. It should be understood by those skilled in the art that other configurations of the sand screen assembly 78 may be used in conjunction with the alternative channel embodiment 64 of the invention, for instance, the sand screen assembly may also have a screen housing located between the channels 74 and the sand screen 84 , or different screening materials may be used in stead of the sand screen 84 .
[0041] Still referring to FIG. 5 , in this embodiment, the channels 74 are analogous to the conduit 52 from FIGS. 2-4 , in that a gravel laden slurry may travel down the channels 74 to a particulate filter 54 , which filters out particulates such as gravel. Once the gravel laden slurry is filtered, a substantially particulate-free fluid thereby communicates with an inflatable isolation packer 50 and expands inflatable element 56 . FIG. 6 shows another embodiment of the alternative channel apparatus 64 wherein the particle filter 54 is located nearer the uphole end of the alternative channel 74 , instead of being adjacent to the inflatable isolation packer 50 . FIG. 7 shows the alternative channel apparatus 64 with the inflatable element 56 expanded to form a seal with the casing 16 to isolate the annular area 38 from the space 86 below the packer
[0042] FIG. 8 illustrates an embodiment of the gravel inflated isolation packer 50 utilized in an openhole environment. This embodiment comprises a tubular member 22 , a conduit 52 , two particulate filters 54 , an expandable element 56 , an upper packer head 88 , and a lower packer head 90 . This illustration shows an embodiment of the present invention wherein the conduit 52 extends out both the upper packer head 88 and the lower packer head 90 . The conduit 52 provides two pathways, one for communication to the expandable element 56 , and the second for communication to annular areas 92 and 94 .
[0043] FIG. 9 shows the inflatable isolation packer 50 as illustrated in FIG. 8 and described above with the inflatable element 56 in an inflated state and filled with inflating fluid. The inflated inflatable element 56 forms a seal between in the wellbore thereby isolating annular area 92 from annular area 94 .
[0044] The inflatable isolation packer 50 acts to isolate a first zone from a second zone within the well. In FIG. 4 , an annulus area that is gravel packed is being isolated from a lower annulus area of the well that is also gravel packed. Other embodiments can be used to separate a gravel packed annulus area from a non-gravel packed annulus area, a gravel packed annulus area from a sump area or other combinations such as these. In other embodiments, a lateral wellbore may be isolated from a main wellbore, multiple lateral wellbores may be isolated from each other, and length of a lateral wellbore being gravel packed may be effectively shortened. The ability to inflate the inflatable isolation packer 50 during a gravel pack completion can save time and expense by eliminating an additional trip into the well.
[0045] FIGS. 1-3 shows the invention used between two gravel packed zones, whereby the invention is isolating the two gravel packed zones from each other. This embodiment can be used to selectively work on or produce from the separate zones.
[0046] In another embodiment the invention may be placed below the lowest perforation or at the bottom of the well. This embodiment may be used to isolate the lower areas from the completed zones without permanently reducing the total depth of the well. Thus, the well could be functionally plugged back to where the inflatable isolation packer was located and leaving open the option of removing the inflatable isolation packer for the completion of deeper zones in the future.
[0047] The discussion and illustrations within this application may refer to a vertical wellbore that has casing cemented in place, or is an openhole bore, and comprises casing perforations to enable communication between the wellbore and the productive formation. It should be understood that the present invention can also be utilized with wellbores that have an orientation that is deviated from vertical.
[0048] The particular embodiments disclosed herein 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. 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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Tools and methods for completing a wellbore that comprise an isolation packer with a particulate filter and inflatable element. The isolation packer is adapted to direct a gravel laden slurry to the particulate filter, where the filter removes a substantial amount of the particulate matter from the gravel laden slurry thereby producing an inflating fluid that is substantially free of particulate matter. The inflating fluid then inflates the inflatable element thereby creating a seal in the wellbore.
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SUMMARY
Some embodiments include method of decreasing the number of doses of dextromethorphan that can be administered while increasing efficacy, comprising orally administering an effective amount of erythrohydroxybupropion or a prodrug thereof to a human being in need of treatment with dextromethorphan.
Some embodiments include a method of reducing an adverse event associated with treatment by dextromethorphan, comprising co-administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human patient in need of dextromethorphan treatment, wherein the human patient is at risk of experiencing the adverse event as a result being treated with dextromethorphan.
Some embodiments include a method of decreasing dextrorphan plasma levels comprising co-administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need of treatment with dextromethorphan, wherein the erythrohydroxybupropion, or a prodrug thereof, is administered on the first day of at least two days of treatment with dextromethorphan, wherein a decrease in the dextrorphan plasma level occurs on the first day that erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without erythrohydroxybupropion or a prodrug thereof.
Some embodiments include a method of decreasing dextrorphan plasma levels comprising co-administering hydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need of treatment with dextromethorphan, wherein the hydroxybupropion, or a prodrug thereof, is administered on the first day of at least two days of treatment with dextromethorphan, wherein a decrease in the dextrorphan plasma level occurs on the first day that hydroxybupropion, or a prodrug thereof, and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without hydroxybupropion or a prodrug thereof.
Some embodiments include a method of decreasing dextrorphan plasma levels comprising co-administering bupropion and dextromethorphan to a human being in need of treatment with dextromethorphan, wherein the bupropion is administered on the first day of at least two days of treatment with dextromethorphan, wherein a decrease in the dextrorphan plasma level occurs on the first day that bupropion and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without bupropion.
Some embodiments include a method of decreasing dextrorphan plasma levels comprising co-administering threohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need of treatment with dextromethorphan, wherein the threohydroxybupropion, or a prodrug thereof, is administered on the first day of at least two days of treatment with dextromethorphan, wherein a decrease in the dextrorphan plasma level occurs on the first day that threohydroxybupropion, or a prodrug thereof, and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without threohydroxybupropion or a prodrug thereof.
Some embodiments include a method of decreasing dextrorphan plasma levels comprising co-administering bupropion and dextromethorphan, for at least eight consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the eighth day, the dextrorphan plasma level is lower than the dextrorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without bupropion for eight consecutive days.
Some embodiments include a method of decreasing dextrorphan plasma levels comprising co-administering hydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least eight consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the eighth day, the dextrorphan plasma level is lower than the dextrorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without hydroxybupropion, or a prodrug thereof, for eight consecutive days.
Some embodiments include a method of decreasing dextrorphan plasma levels comprising co-administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least eight consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the eighth day, the dextrorphan plasma level is lower than the dextrorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without erythrohydroxybupropion, or a prodrug thereof, for eight consecutive days.
Some embodiments include a method of decreasing dextrorphan plasma levels comprising co-administering threohydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least eight consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the eighth day, the dextrorphan plasma level is lower than the dextrorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without threohydroxybupropion, or a prodrug thereof, for eight consecutive days.
Antidepressant compounds, such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, can be used to improve the therapeutic properties, such as in the treatment of neurological disorders, of dextromethorphan. Bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, regardless of stereochemistry, can be effective in inhibiting or reducing the metabolism of dextromethorphan in some human beings. This may be accomplished by co-administering bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, and dextromethorphan.
Some embodiments include a method of treating a neurological disorder comprising administering an antidepressant compound and dextromethorphan to a human being in need thereof, wherein the human being is an extensive metabolizer of dextromethorphan.
Some embodiments include a method of increasing dextromethorphan plasma levels in a human being in need of treatment with dextromethorphan, wherein the human being is an extensive metabolizer of dextromethorphan, comprising co-administering bupropion with dextromethorphan to the human being.
Some embodiments include a method of inhibiting the metabolism of dextromethorphan, comprising administering bupropion to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as bupropion.
Some embodiments include a method of increasing the metabolic lifetime of dextromethorphan, comprising administering bupropion to a human being in need of treatment with dextromethorphan, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as bupropion.
Some embodiments include a method of correcting extensive metabolism of dextromethorphan, comprising administering bupropion to a human being in need thereof.
Some embodiments include a method of improving the antitussive properties of dextromethorphan comprising administering bupropion in conjunction with administration of dextromethorphan to a human being in need of treatment for cough.
Some embodiments include a method of treating cough comprising administering a combination of bupropion and dextromethorphan to a human being in need thereof.
Some embodiments include a method of treating a neurological disorder comprising administering bupropion and dextromethorphan to a human being in need thereof, wherein the bupropion and dextromethorphan are administered at least once a day for at least 8 days.
Some embodiments include a method of treating a neurological disorder comprising administering about 150 mg/day to about 300 mg/day of bupropion and about 15 mg/day to about 60 mg/day of dextromethorphan to a human being in need thereof.
Some embodiments include a method of increasing dextromethorphan plasma levels in a human being in need of treatment with dextromethorphan, wherein the human being is an extensive metabolizer of dextromethorphan, comprising co-administering hydroxybupropion, or a prodrug thereof, with dextromethorphan to the human being.
Some embodiments include a method of increasing dextromethorphan plasma levels in a human being in need of treatment with dextromethorphan, wherein the human being is an extensive metabolizer of dextromethorphan, comprising co-administering erythrohydroxybupropion, or a prodrug thereof, with dextromethorphan to the human being.
Some embodiments include a method of increasing dextromethorphan plasma levels in a human being in need of treatment with dextromethorphan, wherein the human being is an extensive metabolizer of dextromethorphan, comprising co-administering threohydroxybupropion, or a prodrug thereof, with dextromethorphan to the human being.
Some embodiments include a method of inhibiting metabolism of dextromethorphan, comprising administering bupropion to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as bupropion.
Some embodiments include a method of inhibiting metabolism of dextromethorphan, comprising administering hydroxybupropion, or a prodrug thereof, to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as hydroxybupropion.
Some embodiments include a method of inhibiting metabolism of dextromethorphan, comprising administering erythrohydroxybupropion, or a prodrug thereof, to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as erythrohydroxybupropion.
Some embodiments include a method of inhibiting metabolism of dextromethorphan, comprising administering threohydroxybupropion, or a prodrug thereof, to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as threohydroxybupropion.
Some embodiments include a method of increasing the metabolic lifetime of dextromethorphan, comprising administering hydroxybupropion, or a prodrug thereof, to a human being in need of treatment with dextromethorphan, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as hydroxybupropion.
Some embodiments include a method of increasing the metabolic lifetime of dextromethorphan, comprising administering erythrohydroxybupropion, or a prodrug thereof, to a human being in need of treatment with dextromethorphan, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as erythrohydroxybupropion.
Some embodiments include a method of increasing the metabolic lifetime of dextromethorphan, comprising administering threohydroxybupropion, or a prodrug thereof, to a human being in need of treatment with dextromethorphan, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as threohydroxybupropion.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering bupropion and dextromethorphan to a human being in need of treatment with dextromethorphan, wherein the bupropion is administered on the first day of at least two days of co-administration of bupropion with dextromethorphan, wherein an increase in the dextromethorphan plasma level occurs on the first day that bupropion and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without bupropion.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering hydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need of treatment with dextromethorphan, wherein the hydroxybupropion, or a prodrug thereof, is administered on the first day of at least two days of co-administration of hydroxybupropion, or a prodrug thereof, with dextromethorphan, wherein an increase in the dextromethorphan plasma level occurs on the first day that hydroxybupropion, or a prodrug thereof, and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without hydroxybupropion or a prodrug thereof.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need of treatment with dextromethorphan, wherein the erythrohydroxybupropion, or a prodrug thereof, is administered on the first day of at least two days of co-administration of erythrohydroxybupropion, or a prodrug thereof, with dextromethorphan, wherein an increase in the dextromethorphan plasma level occurs on the first day that erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without erythrohydroxybupropion or a prodrug thereof.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering threohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need of treatment with dextromethorphan, wherein the threohydroxybupropion, or a prodrug thereof, is administered on the first day of at least two days of co-administration of threohydroxybupropion, or a prodrug thereof, with dextromethorphan, wherein an increase in the dextromethorphan plasma level occurs on the first day that threohydroxybupropion, or a prodrug thereof, and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without threohydroxybupropion or a prodrug thereof.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering bupropion and dextromethorphan, for at least five consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the fifth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without bupropion for five consecutive days.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering hydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least five consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the fifth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without hydroxybupropion, or a prodrug thereof, for five consecutive days.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least five consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the fifth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without erythrohydroxybupropion, or a prodrug thereof, for five consecutive days.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering threohydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least five consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the fifth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without threohydroxybupropion, or a prodrug thereof, for five consecutive days.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering bupropion and dextromethorphan, for at least six consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the sixth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without bupropion for six consecutive days.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering hydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least six consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the sixth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without hydroxybupropion, or a prodrug thereof, for six consecutive days.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least six consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the sixth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without erythrohydroxybupropion, or a prodrug thereof, for six consecutive days.
Some embodiments include a method of increasing dextromethorphan plasma levels comprising co-administering threohydroxybupropion, or a prodrug thereof, and dextromethorphan, for at least six consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the sixth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without threohydroxybupropion, or a prodrug thereof, for six consecutive days.
Some embodiments include a method of reducing a trough effect of dextromethorphan comprising, co-administering bupropion with dextromethorphan to a human patient in need of treatment with dextromethorphan, wherein dextromethorphan has a plasma level 12 hours after co-administering bupropion with dextromethorphan that is at least twice the plasma level that would be achieved by administering the same amount of dextromethorphan without bupropion.
Some embodiments include a method of reducing a trough effect of dextromethorphan comprising, co-administering hydroxybupropion, or a prodrug thereof, with dextromethorphan to a human patient in need of treatment with dextromethorphan, wherein dextromethorphan has a plasma level 12 hours after co-administering hydroxybupropion, or a prodrug thereof, with dextromethorphan that is at least twice the plasma level that would be achieved by administering the same amount of dextromethorphan without hydroxybupropion or a prodrug thereof.
Some embodiments include a method of reducing a trough effect of dextromethorphan comprising, co-administering erythrohydroxybupropion, or a prodrug thereof, with dextromethorphan to a human patient in need of treatment with dextromethorphan, wherein dextromethorphan has a plasma level 12 hours after co-administering erythrohydroxybupropion, or a prodrug thereof, with dextromethorphan that is at least twice the plasma level that would be achieved by administering the same amount of dextromethorphan without erythrohydroxybupropion or a prodrug thereof.
Some embodiments include a method of reducing a trough effect of dextromethorphan comprising, co-administering threohydroxybupropion, or a prodrug thereof, with dextromethorphan to a human patient in need of treatment with dextromethorphan, wherein dextromethorphan has a plasma level 12 hours after co-administering threohydroxybupropion, or a prodrug thereof, with dextromethorphan that is at least twice the plasma level that would be achieved by administering the same amount of dextromethorphan without threohydroxybupropion or a prodrug thereof.
Some embodiments include a method of reducing an adverse event associated with treatment by dextromethorphan, comprising co-administering bupropion and dextromethorphan to a human patient in need of dextromethorphan treatment, wherein the human patient is at risk of experiencing the adverse event as a result of being treated with dextromethorphan.
Some embodiments include a method of reducing an adverse event associated with treatment by dextromethorphan, comprising co-administering hydroxybupropion, or a prodrug thereof, and dextromethorphan to a human patient in need of dextromethorphan treatment, wherein the human patient is at risk of experiencing the adverse event as a result of being treated with dextromethorphan.
Some embodiments include a method of reducing an adverse event associated with treatment by dextromethorphan, comprising co-administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human patient in need of dextromethorphan treatment, wherein the human patient is at risk of experiencing the adverse event as a result of being treated with dextromethorphan.
Some embodiments include a method of reducing an adverse event associated with treatment by dextromethorphan, comprising co-administering threohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human patient in need of dextromethorphan treatment, wherein the human patient is at risk of experiencing the adverse event as a result of being treated with dextromethorphan.
Some embodiments include a method of reducing an adverse event associated with treatment by bupropion, comprising co-administering dextromethorphan and bupropion to a human patient in need of bupropion treatment, wherein the human patient is at risk of experiencing the adverse event as a result of being treated with bupropion.
Some embodiments include a method of correcting extensive metabolism of dextromethorphan, comprising administering hydroxybupropion, or a prodrug thereof, to a human being in need thereof.
Some embodiments include a method of correcting extensive metabolism of dextromethorphan, comprising administering erythrohydroxybupropion, or a prodrug thereof, to a human being in need thereof.
Some embodiments include a method of correcting extensive metabolism of dextromethorphan, comprising administering threohydroxybupropion, or a prodrug thereof, to a human being in need thereof.
Some embodiments include a method of improving antitussive properties of dextromethorphan comprising administering bupropion in conjunction with administration of dextromethorphan to a human being in need of treatment for cough.
Some embodiments include a method of improving antitussive properties of dextromethorphan comprising administering hydroxybupropion, or a prodrug thereof, in conjunction with administration of dextromethorphan to a human being in need of treatment for cough.
Some embodiments include a method of improving antitussive properties of dextromethorphan comprising administering erythrohydroxybupropion, or a prodrug thereof, in conjunction with administration of dextromethorphan to a human being in need of treatment for cough.
Some embodiments include a method of improving antitussive properties of dextromethorphan comprising administering threohydroxybupropion, or a prodrug thereof, in conjunction with administration of dextromethorphan to a human being in need of treatment for cough.
Some embodiments include a method of treating cough comprising administering a combination of hydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need thereof.
Some embodiments include a method of treating cough comprising administering a combination of erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need thereof.
Some embodiments include a method of treating cough comprising administering a combination of threohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need thereof.
Some embodiments include a method of treating a neurological disorder comprising administering bupropion and dextromethorphan to a human being in need thereof, wherein the bupropion and dextromethorphan are administered at least once a day for at least 8 days.
Some embodiments include a method of treating a neurological disorder comprising administering hydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need thereof, wherein the bupropion and dextromethorphan are administered at least once a day for at least 8 days.
Some embodiments include a method of treating a neurological disorder comprising administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need thereof, wherein the bupropion and dextromethorphan are administered at least once a day for at least 8 days.
Some embodiments include a method of treating a neurological disorder comprising administering threohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being in need thereof, wherein the bupropion and dextromethorphan are administered at least once a day for at least 8 days.
Some embodiments include an oral sustained release delivery system for dextromethorphan, comprising bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a prodrug of any of these compounds, dextromethorphan, and a water soluble vehicle.
Some embodiments include a method of decreasing the number of doses of dextromethorphan that can be administered without loss of efficacy, comprising orally administering an effective amount of bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a prodrug of any of these compounds, to a human being in need of treatment with dextromethorphan.
Some embodiments include a pharmaceutical composition, dosage form, or medicament comprising a therapeutically effective amount of dextromethorphan, a therapeutically effective amount of an antidepressant, such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, and a pharmaceutically acceptable excipient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot of the mean plasma concentrations of dextromethorphan over time after dosing on Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 2 depicts mean AUC 0-12 of dextromethorphan on Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 3 depicts mean AUC 0-24 of dextromethorphan on Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 4 depicts mean AUC 0-inf of dextromethorphan on Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 5 depicts the fold changes in AUCs of dextromethorphan on Day 8 for subjects administered dextromethorphan alone as compared to dextromethorphan and bupropion.
FIG. 6 depicts mean AUC 0-12 of dextromethorphan on Day 1 and Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 7 depicts mean dextromethorphan trough plasma concentrations for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 8 depicts mean dextromethorphan maximum plasma concentrations on Day 1 and Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 9 is a plot of the mean plasma concentrations of dextrorphan over time after dosing on Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 10 depicts mean dextrorphan maximum plasma concentrations on Day 1 and Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
FIG. 11 depicts mean AUC 0-12 of dextrorphan on Day 1 and Day 8 for subjects administered dextromethorphan alone or dextromethorphan and bupropion.
DETAILED DESCRIPTION
Some embodiments include a method of treating neurological disorders comprising administering a therapeutically effective amount of dextromethorphan and a therapeutically effective amount of an antidepressant, such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, to a person in need thereof.
Some embodiments include a method of enhancing the therapeutic properties of dextromethorphan in treating neurological disorders, comprising co-administering dextromethorphan and an antidepressant, such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds.
Some embodiments include a method of increasing dextromethorphan plasma levels in a human being that is an extensive metabolizer of dextromethorphan, comprising co-administering an antidepressant compound, such as bupropion, and dextromethorphan to the human being.
Some embodiments include a method of inhibiting the metabolism of dextromethorphan, comprising administering an antidepressant compound, such as bupropion, to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as the antidepressant.
Some embodiments include a method of increasing the metabolic lifetime of dextromethorphan, including increasing the elimination half life (T 1/2 ) of dextromethorphan. These embodiments may comprise administering an antidepressant compound, such as bupropion, to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as the antidepressant compound.
Some embodiments include a method of correcting extensive metabolism of dextromethorphan, comprising administering an antidepressant compound, such as bupropion, to a human being in need thereof, such as a human being in need of treatment for pain.
Some embodiments include a method of improving the therapeutic properties of dextromethorphan in treating neurological disorders comprising administering an antidepressant compound, such as bupropion, in conjunction with administration of dextromethorphan to a human being in need of treatment for a neurological disorder.
Some embodiments include a method of treating neurological disorders comprising administering a combination of an antidepressant compound, such as bupropion, and dextromethorphan to a human being in need thereof.
Dextromethorphan has the structure shown below.
Dextromethorphan is used as a cough suppressant. According to the FDA's dextromethorphan product labeling requirement under the OTC Monograph [21CFR341.74], dextromethorphan should be dosed 6 times a day (every 4 hours), 4 times a day (every 6 hours), or 3 times a day (every 8 hours).
Dextromethorphan is rapidly metabolized in the human liver. This rapid hepatic metabolism may limit systemic drug exposure in individuals who are extensive metabolizers. Human beings can be: 1) extensive metabolizers of dextromethorphan—those who rapidly metabolize dextromethorphan; 2) poor metabolizers of dextromethorphan—those who only poorly metabolize dextromethorphan; or 3) intermediate metabolizers of dextromethorphan—those whose metabolism of dextromethorphan is somewhere between that of an extensive metabolizer and a poor metabolizer. Extensive metabolizers can also be ultra-rapid metabolizers. Extensive metabolizers of dextromethorphan are a significant portion of the human population. Dextromethorphan can, for example, be metabolized to dextrorphan.
When given the same oral dose of dextromethorphan, plasma levels of dextromethorphan are significantly higher in poor metabolizers or intermediate metabolizers as compared to extensive metabolizers of dextromethorphan. The low plasma concentrations of dextromethorphan can limit its clinical utility as a single agent for extensive metabolizers, and possibly intermediate metabolizers, of dextromethorphan. Some antidepressants, such as bupropion, inhibit the metabolism of dextromethorphan, and can thus improve its therapeutic efficacy. Similarly, antidepressants may allow dextromethorphan to be given less often, such as once a day instead of twice a day, once a day instead of three times a day, once a day instead of four times a day, twice a day instead of three times a day, or twice a day instead of four times a day, without loss of therapeutic efficacy.
Pain or other neurological disorders may be treated by a method comprising administering a therapeutically effective amount of dextromethorphan and a therapeutically effective amount of an antidepressant compound, such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, to a person in need thereof.
Examples of neurological disorders that may be treated, or that may be treated with increased efficacy, by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, include, but are not limited to: affective disorders, psychiatric disorders, cerebral function disorders, movement disorders, dementias, motor neuron diseases, neurodegenerative diseases, seizure disorders, and headaches.
Affective disorders that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, include, but are not limited to, depression, major depression, treatment-resistant depression and treatment-resistant bipolar depression, bipolar disorders including cyclothymia, seasonal affective disorder, mania, anxiety disorders, attention deficit disorder (ADD), attention deficit disorder with hyperactivity (ADDH), and attention deficit/hyperactivity disorder (AD/HD), bipolar and manic conditions, obsessive-compulsive disorder, bulimia, obesity or weight-gain, narcolepsy, chronic fatigue syndrome, premenstrual syndrome, substance addiction or abuse, nicotine addiction, psycho-sexual dysfunction, pseudobulbar affect, and emotional lability.
Depression may be manifested by changes in mood, feelings of intense sadness, despair, mental slowing, loss of concentration, pessimistic worry, agitation, and self-deprecation. Physical symptoms of depression may include insomnia, anorexia, weight loss, decreased energy and libido, and abnormal hormonal circadian rhythms.
Psychiatric disorders that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, include, but are not limited to, anxiety disorders, including but not limited to, phobias, generalized anxiety disorder, social anxiety disorder, panic disorder, agoraphobia, obsessive-compulsive disorder, and post-traumatic stress disorder (PTSD); mania, manic depressive illness, hypomania, unipolar depression, depression, stress disorders, somatoform disorders, personality disorders, psychosis, schizophrenia, delusional disorder, schizoaffective disorder, schizotypy, aggression, aggression in Alzheimer's disease, agitation, and agitation in Alzheimer's disease.
Substance addiction abuse that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, includes, but is not limited to, drug dependence, addiction to cocaine, psychostimulants (e.g., crack, cocaine, speed, meth), nicotine, alcohol, opioids, anxiolytic and hypnotic drugs, cannabis (marijuana), amphetamines, hallucinogens, phencyclidine, volatile solvents, and volatile nitrites. Nicotine addiction includes nicotine addiction of all known forms, such as smoking cigarettes, cigars and/or pipes, and addiction to chewing tobacco.
Cerebral function disorders that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds include, but are not limited to, disorders involving intellectual deficits such as senile dementia, Alzheimer's type dementia, memory loss, amnesia/amnestic syndrome, epilepsy, disturbances of consciousness, coma, lowering of attention, speech disorders, voice spasms, Parkinson's disease, Lennox-Gastaut syndrome, autism, hyperkinetic syndrome, and schizophrenia. Cerebral function disorders also include disorders caused by cerebrovascular diseases including, but not limited to, stroke, cerebral infarction, cerebral bleeding, cerebral arteriosclerosis, cerebral venous thrombosis, head injuries, and the like where symptoms include disturbance of consciousness, senile dementia, coma, lowering of attention, and speech disorders.
Movement disorders that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds include, but are not limited to, akathisia, akinesia, associated movements, athetosis, ataxia, ballismus, hemiballismus, bradykinesia, cerebral palsy, chorea, Huntington's disease, rheumatic chorea, Sydenham's chorea, dyskinesia, tardive dyskinesia, dystonia, blepharospasm, spasmodic torticollis, dopamine-responsive dystonia, Parkinson's disease, restless legs syndrome (RLS), tremor, essential tremor, and Tourette's syndrome, and Wilson's disease.
Dementias that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds include, but are not limited to, Alzheimer's disease, Parkinson's disease, vascular dementia, dementia with Lewy bodies, mixed dementia, fronto-temporal dementia, Creutzfeldt-Jakob disease, normal pressure hydrocephalus, Huntington's disease, Wernicke-Korsakoff Syndrome, and Pick's disease.
Motor neuron diseases that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds include, but are not limited to, amyotrophic lateral sclerosis (ALS), progressive bulbar palsy, primary lateral sclerosis (PLS), progressive muscular atrophy, post-polio syndrome (PPS), spinal muscular atrophy (SMA), spinal motor atrophies, Tay-Sach's disease, Sandoff disease, and hereditary spastic paraplegia.
Neurodegenerative diseases that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds include, but are not limited to Alzheimer's disease, prion-related diseases, cerebellar ataxia, spinocerebellar ataxia (SCA), spinal muscular atrophy (SMA), bulbar muscular atrophy, Friedrich's ataxia, Huntington's disease, Lewy body disease, Parkinson's disease, amyotrophic lateral sclerosis (ALS or Lou Gehrig's disease), multiple sclerosis (MS), multiple system atrophy, Shy-Drager syndrome, corticobasal degeneration, progressive supranuclear palsy, Wilson's disease, Menkes disease, adrenoleukodystrophy, cerebral autosomal dominant arteriopathy with subcortical infarcts and leukoencephalopathy (CADASIL), muscular dystrophies, Charcot-Marie-Tooth disease (CMT), familial spastic paraparesis, neurofibromatosis, olivopontine cerebellar atrophy or degeneration, striatonigral degeneration, Guillain-Barré syndrome, and spastic paraplesia.
Seizure disorders that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds include, but are not limited to, epileptic seizures, nonepileptic seizures, epilepsy, febrile seizures; partial seizures including, but not limited to, simple partial seizures, Jacksonian seizures, complex partial seizures, and epilepsia partialis continua; generalized seizures including, but not limited to, generalized tonic-clonic seizures, absence seizures, atonic seizures, myoclonic seizures, juvenile myoclonic seizures, and infantile spasms; and status epilepticus.
Types of headaches that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds include, but are not limited to, migraine, tension, and cluster headaches.
Other neurological disorders that may be treated by a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds include, Rett Syndrome, autism, tinnitus, disturbances of consciousness disorders, sexual dysfunction, intractable coughing, narcolepsy, cataplexy; voice disorders due to uncontrolled laryngeal muscle spasms, including, but not limited to, abductor spasmodic dysphonia, adductor spasmodic dysphonia, muscular tension dysphonia, and vocal tremor; diabetic neuropathy, chemotherapy-induced neurotoxicity, such as methotrexate neurotoxicity; incontinence including, but not limited, stress urinary incontinence, urge urinary incontinence, and fecal incontinence; and erectile dysfunction.
In some embodiments, a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, may be used to treat pain, pseudobulbar affect, depression (including treatment resistant depression), disorders related to memory and cognition, schizophrenia, Parkinson's disease, amyotrophic lateral sclerosis (ALS), Rhett's syndrome, seizures, cough (including chronic cough), etc.
In some embodiments, a combination of dextromethorphan and an antidepressant such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds may be used to treat dermatitis.
Pain relieving properties of dextromethorphan may be enhanced by a method comprising co-administering dextromethorphan and an antidepressant, such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, with dextromethorphan.
Pain relieving properties of bupropion may be enhanced by a method comprising co-administering dextromethorphan with bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds.
These methods may be used to treat, or provide relief to, any type of pain including, but not limited to, musculoskeletal pain, neuropathic pain, cancer-related pain, acute pain, nociceptive pain, etc.
Examples of musculoskeletal pain include low back pain (i.e. lumbosacral pain), primary dysmenorrhea, and arthritic pain, such as pain associated with rheumatoid arthritis, juvenile rheumatoid arthritis, osteoarthritis, axial spondyloarthritis including ankylosing spondylitis, etc.
In some embodiments, a combination of dextromethorphan and an antidepressant, such as bupropion, is used to treat chronic musculoskeletal pain.
Examples of neuropathic pain include diabetic peripheral neuropathy, post-herpetic neuralgia, trigeminal neuralgia, monoradiculopathies, phantom limb pain, central pain, etc. Other causes of neuropathic pain include cancer-related pain, lumbar nerve root compression, spinal cord injury, post-stroke pain, central multiple sclerosis pain, HIV-associated neuropathy, and radio- or chemo-therapy associated neuropathy, etc.
The term “treating” or “treatment” includes the diagnosis, cure, mitigation, treatment, or prevention of disease in man or other animals, or any activity that otherwise affects the structure or any function of the body of man or other animals.
Any antidepressant may be used in combination with dextromethorphan to improve the therapeutic properties of dextromethorphan. Dextromethorphan and the antidepressant compound may be administered in separate compositions or dosage forms, or may be administered in a single composition or dosage form comprising both.
Antidepressant compounds that can be co-administered with dextromethorphan include, but are not limited to, bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, clomipramine, doxepin, fluoxetine, mianserin, imipramine, 2-chloroimipramine, amitriptyline, amoxapine, desipramine, protriptyline, trimipramine, nortriptyline, maprotiline, phenelzine, isocarboxazid, tranylcypromine, paroxetine, trazodone, citalopram, sertraline, aryloxy indanamine, benactyzine, escitalopram, fluvoxamine, venlafaxine, desvenlafaxine, duloxetine, mirtazapine, nefazodone, selegiline, sibutramine, milnacipran, tesofensine, brasofensine, moclobemide, rasagiline, nialamide, iproniazid, iproclozide, toloxatone, butriptyline, dosulepin, dibenzepin, iprindole, lofepramine, opipramol, norfluoxetine, dapoxetine, etc., or a metabolite or prodrug of any of these compounds, or a pharmaceutically acceptable salt of any of these compounds.
Bupropion has the structure shown below (bupropion hydrochloride form shown).
Combining bupropion with dextromethorphan may provide greater efficacy, such as greater pain relief, than would otherwise be achieved by administering either component alone. In extensive metabolizers, dextromethorphan can be rapidly and extensively metabolized, yielding low systemic exposure even at high doses. Bupropion, besides possessing antidepressant and analgesic properties, is an inhibitor of dextromethorphan metabolism. Metabolites of bupropion, which include hydroxybupropion, threohydroxybupropion (also known as threohydrobupropion or threodihydrobupropion), and erythrohydroxybupropion (also known as erythrohydrobupropion or erythrodihydrobupropion), are also inhibitors of dextromethorphan metabolism. Thus, bupropion, including a form of bupropion that is rapidly converted in the body (such as a salt, hydrate, solvate, polymorph, etc.), is a prodrug of hydroxybupropion, threohydroxybupropion, and erythrohydroxybupropion.
As explained above, this inhibition may augment dextromethorphan plasma levels, resulting in additive or synergistic efficacy such as relief of neurological disorders including pain, depression, smoking cessation, etc. Thus, while inhibition of dextromethorphan metabolism is only one of many potential benefits of the combination, co-administration of dextromethorphan with bupropion may thereby enhance the efficacy of bupropion for many individuals. Co-administration of dextromethorphan with bupropion may enhance the analgesic properties of bupropion for many individuals. Co-administration of dextromethorphan with bupropion may also enhance the antidepressant properties of bupropion for many individuals, including faster onset of action.
Another potential benefit of co-administration of dextromethorphan and bupropion is that it may be useful to reduce the potential for an adverse event, such as somnolence, associated with treatment by dextromethorphan. This may be useful, for example, in human patients at risk of experiencing the adverse event as a result being treated with dextromethorphan.
Another potential benefit of co-administration of dextromethorphan and bupropion is that it may be useful to reduce the potential for an adverse event, such as seizure, associated with treatment by bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds. This may be useful, for example, in human patients at risk of experiencing the adverse event as a result being treated with bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds.
With respect to dextromethorphan, bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, co-administration may reduce a central nervous system adverse event, a gastrointestinal event, or another type of adverse event associated with any of these compounds. Central nervous system (CNS) adverse events include, but are not limited to, nervousness, dizziness, sleeplessness, light-headedness, tremor, hallucinations, convulsions, CNS depression, fear, anxiety, headache, increased irritability or excitement, tinnitus, drowsiness, dizziness, sedation, somnolence, confusion, disorientation, lassitude, incoordination, fatigue, euphoria, nervousness, insomnia, sleeping disturbances, convulsive seizures, excitation, catatonic-like states, hysteria, hallucinations, delusions, paranoia, headaches and/or migraine, and extrapyramidal symptoms such as oculogyric crisis, torticollis, hyperexcitability, increased muscle tone, ataxia, and tongue protrusion.
Gastrointestinal adverse events include, but are not limited to, nausea, vomiting, abdominal pain, dysphagia, dyspepsia, diarrhea, abdominal distension, flatulence, peptic ulcers with bleeding, loose stools, constipation, stomach pain, heartburn, gas, loss of appetite, feeling of fullness in stomach, indigestion, bloating, hyperacidity, dry mouth, gastrointestinal disturbances, and gastric pain.
Co-administering dextromethorphan and an antidepressant, such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, does not necessarily require that the two compounds be administered in the same dosage form. For example, the two compounds may be administered in a single dosage form, or they may be administered in two separate dosage forms. Additionally, the two compounds may be administered at the same time, but this is not required. The compounds can be given at different times as long as both are in a human body at the same time for at least a portion of the time that treatment by co-administration is being carried out.
In some embodiments, co-administration of a combination of bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, and dextromethorphan results in both bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, and dextromethorphan contributing to the pain relieving properties of the combination. For example, the combination may have improved pain relieving properties as compared to bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, alone or compared to dextromethorphan alone, including potentially faster onset of action.
In some embodiments, the combination may have improved pain relieving properties of at least about 0.5%, at least about 1%, at least about 10%, at least about 20%, at least about 30%, at least about 50%, at least 100%, up to about 500% or up to 1000%, about 0.5% to about 1000%, about 10% to about 20%, about 20% to about 30%, about 30% to about 40%, about 40% to about 50%, about 50% to about 60%, about 60% to about 70%, about 70% to about 80%, about 80% to about 90%, about 90% to about 100%, about 100% to about 110%, about 110% to about 120%, about 120% to about 130%, about 130% to about 140%, about 140% to about 150%, about 150% to about 160%, about 160% to about 170%, about 170% to about 180%, about 180% to about 190%, about 190% to about 200%, or any amount of pain relief in a range bounded by, or between, any of these values, as compared to bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, alone.
In some embodiments, the combination may have improved pain relieving properties of at least about 0.5%, at least about 1%, at least about 10%, at least about 20%, at least about 30%, at least about 50%, at least 100%, up to about 500% or up to 1000%, about 0.5% to about 1000%, about 10% to about 20%, about 20% to about 30%, about 30% to about 40%, about 40% to about 50%, about 50% to about 60%, about 60% to about 70%, about 70% to about 80%, about 80% to about 90%, about 90% to about 100%, about 100% to about 110%, about 110% to about 120%, about 120% to about 130%, about 130% to about 140%, about 140% to about 150%, about 150% to about 160%, about 160% to about 170%, about 170% to about 180%, about 180% to about 190%, about 190% to about 200%, or any amount of pain relief in a range bounded by, or between, any of these values, as compared to as compared to dextromethorphan alone.
Unless otherwise indicated, any reference to a compound herein, such as dextromethorphan, bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, by structure, name, or any other means, includes pharmaceutically acceptable salts; alternate solid forms, such as polymorphs, solvates, hydrates, etc.; tautomers; deuterium modified compounds, such as deuterium modified dextromethorphan; or any chemical species that may rapidly convert to a compound described herein under conditions in which the compounds are used as described herein.
Examples of deuterium modified dextromethorphan include, but are not limited to, those shown below.
A dosage form or a composition may be a blend or mixture of dextromethorphan and a compound that inhibits the metabolism of dextromethorphan, such as bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, either alone or within a vehicle. For example, dextromethorphan and bupropion may be dispersed within each other or dispersed together within a vehicle. A dispersion may include a mixture of solid materials wherein small individual particles are substantially one compound, but the small particles are dispersed within one another, such as might occur if two powders of two different drugs are blended with a solid vehicle material, and the blending is done in the solid form. In some embodiments, dextromethorphan and bupropion may be substantially uniformly dispersed within a composition or dosage form. Alternatively, dextromethorphan and bupropion may be in separate domains or phases within a composition or dosage form. For example, one drug may be in a coating and another drug may be in a core within the coating. For example, one drug may be formulated for sustained release and another drug may be formulated for immediate release.
Some embodiments include administration of a tablet that contains bupropion in a form that provides sustained release and dextromethorphan in a form that provides immediate release. While there are many ways that sustained release of bupropion may be achieved, in some embodiments bupropion is combined with hydroxypropyl methylcellulose. For example, particles of bupropion hydrochloride could be blended with microcrystalline cellulose and hydroxypropyl methylcellulose (e.g METHOCEL®) to form an admixture of blended powders. This could then be combined with immediate release dextromethorphan in a single tablet.
Dextromethorphan and/or an antidepressant, such as bupropion, hydroxybupropion, threohydroxybupropion and erythrohydroxybupropion, or a non-bupropion antidepressant (all of which are referred to collectively herein as “therapeutic compounds” for convenience) may be combined with a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice as described, for example, in Remington's Pharmaceutical Sciences, 2005. The relative proportions of active ingredient and carrier may be determined, for example, by the solubility and chemical nature of the compounds, chosen route of administration and standard pharmaceutical practice.
Therapeutic compounds may be administered by any means that may result in the contact of the active agent(s) with the desired site or site(s) of action in the body of a patient. The compounds may be administered by any conventional means available for use in conjunction with pharmaceuticals, either as individual therapeutic agents or in a combination of therapeutic agents. For example, they may be administered as the sole active agents in a pharmaceutical composition, or they can be used in combination with other therapeutically active ingredients.
Therapeutic compounds may be administered to a human patient in a variety of forms adapted to the chosen route of administration, e.g., orally or parenterally. Parenteral administration in this respect includes administration by the following routes: intravenous, intramuscular, subcutaneous, intraocular, intrasynovial, transepithelial including transdermal, ophthalmic, sublingual and buccal; topically including ophthalmic, dermal, ocular, rectal and nasal inhalation via insufflation, aerosol and rectal systemic.
The ratio of dextromethorphan to bupropion may vary. In some embodiments, the weight ratio of dextromethorphan to bupropion may be about 0.1 to about 10, about 0.1 to about 2, about 0.2 to about 1, about 0.1 to about 0.5, about 0.1 to about 0.3, about 0.2 to about 0.4, about 0.3 to about 0.5, about 0.5 to about 0.7, about 0.8 to about 1, about 0.2, about 0.3, about 0.4, about 0.45, about 0.6, about 0.9, or any ratio in a range bounded by, or between, any of these values. A ratio of 0.1 indicates that the weight of dextromethorphan is 1/10 that of bupropion. A ratio of 10 indicates that the weight of dextromethorphan is 10 times that of bupropion.
The amount of dextromethorphan in a therapeutic composition may vary. For example, some liquid compositions may comprise about 0.0001% (w/v) to about 50% (w/v), about 0.01% (w/v) to about 20% (w/v), about 0.01% to about 10% (w/v), about 0.001% (w/v) to about 1% (w/v), about 0.1% (w/v) to about 0.5% (w/v), about 1% (w/v) to about 3% (w/v), about 3% (w/v) to about 5% (w/v), about 5% (w/v) to about 7% (w/v), about 7% (w/v) to about 10% (w/v), about 10% (w/v) to about 15% (w/v), about 15% (w/v) to about 20% (w/v), about 20% (w/v) to about 30% (w/v), about 30% (w/v) to about 40% (w/v), or about 40% (w/v) to about 50% (w/v) of dextromethorphan.
Some liquid dosage forms may contain about 10 mg to about 500 mg, about 30 mg to about 350 mg, about 50 mg to about 200 mg, about 50 mg to about 70 mg, about 20 mg to about 50 mg, about 30 mg to about 60 mg, about 40 mg to about 50 mg, about 40 mg to about 42 mg, about 42 mg to about 44 mg, about 44 mg to about 46 mg, about 46 mg to about 48 mg, about 48 mg to about 50 mg, about 80 mg to about 100 mg, about 110 mg to about 130 mg, about 170 mg to about 190 mg, about 45 mg, about 60 mg, about 90 mg, about 120 mg, or about 180 mg of dextromethorphan, or any amount of dextromethorphan in a range bounded by, or between, any of these values.
Some solid compositions may comprise at least about 5% (w/w), at least about 10% (w/w), at least about 20% (w/w), at least about 50% (w/w), at least about 70% (w/w), at least about 80%, about 10% (w/w) to about 30% (w/w), about 10% (w/w) to about 20% (w/w), about 20% (w/w) to about 30% (w/w), about 30% (w/w) to about 50% (w/w), about 30% (w/w) to about 40% (w/w), about 40% (w/w) to about 50% (w/w), about 50% (w/w) to about 80% (w/w), about 50% (w/w) to about 60% (w/w), about 70% (w/w) to about 80% (w/w), or about 80% (w/w) to about 90% (w/w) of dextromethorphan.
Some solid dosage forms may contain about 10 mg to about 500 mg, about 30 mg to about 350 mg, about 20 mg to about 50 mg, about 30 mg to about 60 mg, about 40 mg to about 50 mg, about 40 mg to about 42 mg, about 42 mg to about 44 mg, about 44 mg to about 46 mg, about 46 mg to about 48 mg, about 48 mg to about 50 mg, about 50 mg to about 200 mg, about 50 mg to about 70 mg, about 80 mg to about 100 mg, about 110 mg to about 130 mg, about 170 mg to about 190 mg, about 60 mg, about 90 mg, about 120 mg, or about 180 mg of dextromethorphan, or any amount of dextromethorphan in a range bounded by, or between, any of these values.
The amount of bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, in a therapeutic composition may vary. If increasing the plasma level of dextromethorphan is desired, bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, should be administered in an amount that increases the plasma level of dextromethorphan. For example, bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, may be administered in an amount that results in a plasma concentration of dextromethorphan in the human being, on day 8, that is at least about 2 times, at least about 5 times, at least about 10 times, at least about 15 times, at least about 20 times, at least about 30 times, at least about 40 times, at least about 50 times, at least about 60 times, at least about 70 times, or at least about 80 times, the plasma concentration of the same amount of dextromethorphan administered without bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds.
In some embodiments, bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, may administered to a human being in an amount that results in a 12 hour area under the curve from the time of dosing (AUC 0-12 ), or average plasma concentration in the human being for the 12 hours following dosing (C avg ) of dextromethorphan, on day 8, that is at least about 2 times, at least about 5 times, at least about 10 times, at least about 15 times, at least about 20 times, at least about 30 times, at least about 40 times, at least about 50 times, at least about 60 times, at least about 70 times, or at least about 80 times the plasma concentration of the same amount of dextromethorphan administered without bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds.
In some embodiments, bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds, may administered to a human being in an amount that results in a maximum plasma concentration (C max ) of dextromethorphan in the human being, on day 8, that is at least about 2 times, at least about 5 times, at least about 10 times, at least about 15 times, at least about 20 times, at least about 30 times, or at least about 40 times the plasma concentration of the same amount of dextromethorphan administered without bupropion, hydroxybupropion, erythrohydroxybupropion, threohydroxybupropion, or a metabolite or prodrug of any of these compounds.
For co-administration of bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, an increase in the dextromethorphan plasma level can occur on the first day that bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, is administered, as compared to the same amount of dextromethorphan administered without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite of prodrug of any of these compounds. For example, the dextromethorphan plasma level on the first day that bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, is administered may be at least about 1.5 times, at least about at least 2 times, at least about 2.5 times, at least about 3 times, at least about 4 times, at least about 5 times, at least about 6 times at least about 7 times, at least about 8 times, at least about 9 times, or at least about 10 times the level that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds.
In some embodiments, the dextromethorphan AUC on the first day that bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, is administered may be at least twice the AUC that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds.
In some embodiments, the dextromethorphan C max on the first day that bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, is administered may be at least twice the C max that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds.
In some embodiments, the dextromethorphan trough level (e.g., plasma level 12 hours after administration) on the first day that bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, is administered may be at least twice the trough level that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds.
In some embodiments, bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, is administered on the first day of at least two days of treatment with dextromethorphan, wherein a decrease in the dextrorphan plasma level occurs on the first day that bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, and dextromethorphan are co-administered, as compared to the same amount of dextromethorphan administered without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds. For example, the dextrorphan plasma level on the first day may be reduced by at least 5% as compared to the dextrorphan plasma level that would be achieved by administering the same amount of dextromethorphan without bupropion.
In some embodiments, bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, are co-administered for at least five consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the fifth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite of prodrug of any of these compounds, for five consecutive days. For example, the dextromethorphan plasma level on the fifth day (for example at 0 hours, 1 hour, 3 hours, 6 hours, or 12 hours after administration) may be at least 5 times, at least 10 times, at least 20 times, at least 40 times, at least 50 times, at least 60 times, at least 65 times, or up to about 500 times, the level that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, for five consecutive days.
In some embodiments, bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, and dextromethorphan, are co-administered for at least six consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the sixth day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, for six consecutive days. For example, the dextromethorphan plasma level on the sixth day (for example at 0 hours, 1 hour, 3 hours, 6 hours, or 12 hours after administration) may be at least 5 times, at least 10 times, at least 20 times, at least 30 times, at least 50 times, at least 60 times, at least 70 times, at least 75 times, or up to about 500 times, the level that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, for six consecutive days.
In some embodiments, bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, and dextromethorphan, are co-administered for at least seven consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the seventh day, the dextromethorphan plasma level is higher than the dextromethorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, for seven consecutive days. For example, the dextromethorphan plasma level on the seventh day (for example at 0 hours, 1 hour, 3 hours, 6 hours, or 12 hours after administration) may be at least 5 times, at least 10 times, at least 20 times, at least 30 times, at least 50 times, at least 70 times, at least 80 times, at least 90 times, or up to about 500 times, the level that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, for seven consecutive days.
In some embodiments, bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, and dextromethorphan, are co-administered for at least eight consecutive days, wherein, on the eighth day, dextromethorphan has a plasma level, for example at 0 hours, 1 hour, 3 hours, 6 hours, or 12 hours, after co-administering bupropion with dextromethorphan that is at least 5 times, at least 10 times, at least 20 times, at least 30 times, at least 50 times, at least 60 times, at least 70 times, at least 80 times, at least 90 times, at least 100 times, or up to about 1,000 times, the plasma level that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, for eight consecutive days.
In some embodiments, bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, and dextromethorphan are co-administered for at least eight consecutive days, to a human being in need of treatment with dextromethorphan, wherein, on the eighth day, the dextrorphan plasma level is lower than the dextrorphan plasma level that would have been achieved by administering the same amount of dextromethorphan administered without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, for eight consecutive days. For example, the dextrorphan plasma level on the eighth day (for example at 0 hours, 1 hour, 3 hours, 6 hours, or 12 hours after administration) may be reduced by at least 10%, at least 20%, at least 30%, at least 40%, or at least 50%, as compared to the dextrorphan plasma level that would be achieved by administering the same amount of dextromethorphan without bupropion, hydroxybupropion, threohydroxybupropion, erythrohydroxybupropion, or a metabolite or prodrug of any of these compounds, for eight consecutive days.
In some embodiments, bupropion may be administered to a human being in an amount that results in an AUC 0-12 of bupropion in the human being, on day 8, that is at least about 100 ng·hr/mL, at least about 200 ng·hr/mL, at least about 500 ng·hr/mL, at least about 600 ng·hr/mL, at least about 700 ng·hr/mL, at least about 800 ng·hr/mL, at least about 900 ng·hr/mL, at least about 1,000 ng·hr/mL, at least about 1,200 ng·hr/mL, at least 1,600 ng·hr/mL, or up to about 15,000 ng·hr/mL.
In some embodiments, bupropion may be administered to a human being in an amount that results in a C avg of bupropion in the human being, on day 8, that is at least about 10 ng/mL, at least about 20 ng/mL, at least about 40 ng/mL, at least about 50 ng/mL, at least about 60 ng/mL, at least about 70 ng/mL, at least about 80 ng/mL, at least about 90 ng/mL, at least about 100 ng/mL, at least 120 ng/mL, or up to about 1,500 ng/mL.
In some embodiments, bupropion may be administered to a human being in an amount that results in a C max of bupropion in the human being, on day 8, that is at least about 10 ng/mL, at least about 20 ng/mL, at least about 50 ng/mL, at least about 90 ng/mL, at least about 100 ng/mL, at least about 110 ng/mL, at least about 120 ng/mL, at least about 130 ng/mL, at least about 140 ng/mL, at least 200 ng/mL, or up to about 1,500 ng/mL.
Some liquid compositions may comprise about 0.0001% (w/v) to about 50% (w/v), about 0.01% (w/v) to about 20% (w/v), about 0.01% to about 10% (w/v), about 1% (w/v) to about 3% (w/v), about 3% (w/v) to about 5% (w/v), about 5% (w/v) to about 7% (w/v), about 5% (w/v) to about 15% (w/v), about 7% (w/v) to about 10% (w/v), about 10% (w/v) to about 15% (w/v), about 15% (w/v) to about 20% (w/v), about 20% (w/v) to about 30% (w/v), about 30% (w/v) to about 40% (w/v), or about 40% (w/v) to about 50% (w/v) of bupropion, or any amount of bupropion in a range bounded by, or between, any of these values.
Some liquid dosage forms may contain about 10 mg to about 1000 mg, about 50 mg to about 1000 mg, about 10 mg to about 50 mg, about 50 mg to about 100 mg, about 40 mg to about 90 mg, about 200 mg to about 300 mg, about 70 mg to about 95 mg, about 100 mg to about 200 mg, about 105 mg to about 200 mg, about 110 mg to about 140 mg, about 180 mg to about 220 mg, about 280 mg to about 320 mg, about 200 mg, about 150 mg, or about 300 mg of bupropion, or any amount of bupropion in a range bounded by, or between, any of these values.
Some solid compositions may comprise at least about 5% (w/w), at least about 10% (w/w), at least about 20% (w/w), at least about 50% (w/w), at least about 70% (w/w), at least about 80%, about 10% (w/w) to about 30% (w/w), about 10% (w/w) to about 20% (w/w), about 20% (w/w) to about 30% (w/w), about 30% (w/w) to about 50% (w/w), about 30% (w/w) to about 40% (w/w), about 40% (w/w) to about 50% (w/w), about 50% (w/w) to about 80% (w/w), about 50% (w/w) to about 60% (w/w), about 70% (w/w) to about 80% (w/w), or about 80% (w/w) to about 90% (w/w) of bupropion, or any amount of bupropion in a range bounded by, or between, any of these values.
Some solid dosage forms may contain about 10 mg to about 1000 mg, about 50 mg to about 1000 mg, about 10 mg to about 50 mg, about 50 mg to about 100 mg, about 40 mg to about 90 mg, about 200 mg to about 300 mg, about 70 mg to about 95 mg, about 100 mg to about 200 mg, about 105 mg to about 200 mg, about 110 mg to about 140 mg, about 50 mg to about 150 mg, about 180 mg to about 220 mg, about 280 mg to about 320 mg, about 200 mg, about 150 mg, or about 300 mg of bupropion, or any amount of bupropion in a range bounded by, or between, any of these values.
In some embodiments, bupropion is administered at a dose that results in a bupropion plasma level of about 0.1 μM to about 10 μM, about 0.1 μM to about 5 μM, about 0.2 μM to about 3 μM, 0.1 μM to about 1 μM, about 0.2 μM to about 2 μM, 1 μM to about 10 μM, about 1 μM to about 5 μM, about 2 μM to about 3 μM, or about 2.8 μM to about 3 μM, about 1.5 μM to about 2 μM, about 4.5 μM to about 5 μM, about 2.5 μM to about 3 μM, about 1.8 μM, about 4.8 μM, about 2.9 μM, about 2.8 μM, or any plasma level in a range bounded by, or between, any of these values.
In some embodiments, bupropion, hydroxybupropion, or a prodrug of hydroxybupropion, is administered at a dose that results in a hydroxybupropion plasma level of about 0.1 μM to about 10 μM, about 0.1 μM to about 5 μM, about 0.2 μM to about 3 μM, 0.1 μM to about 1 μM, about 0.2 μM to about 2 μM, 1 μM to about 10 μM, about 1 μM to about 5 μM, about 2 μM to about 3 μM, or about 2.8 μM to about 3 μM, about 1.5 μM to about 2 μM, about 4.5 μM to about 5 μM, about 2.5 μM to about 3 μM, about 1.8 μM, about 4.8 μM, about 2.9 μM, about 2.8 μM, or any plasma level in a range bounded by, or between, any of these values.
In some embodiments, bupropion, hydroxybupropion, or a prodrug of hydroxybupropion, may be administered to a human being in an amount that results in an AUC 0-12 of hydroxybupropion in the human being, on day 8, that is at least about 3,000 ng·hr/mL, at least about 7,000 ng·hr/mL, at least about 10,000 ng·hr/mL, at least about 15,000 ng·hr/mL, at least about 20,000 ng·hr/mL, at least about 30,000 ng·hr/mL, up to about 50,000 ng·hr/mL, up to about 150,000 ng·hr/mL, or any AUC in a range bounded by, or between, any of these values.
In some embodiments, bupropion, hydroxybupropion, or a prodrug of hydroxybupropion, may be administered to a human being in an amount that results in a C max of hydroxybupropion in the human being, on day 8, that is at least about 300 ng/mL, at least about 700 ng/mL, at least about 1,000 ng/mL, at least about 1,500 ng/mL, at least about 2,000 ng/mL, at least about 4,000 ng/mL, up to about 10,000 ng/mL, up to about 50,000 ng/mL, or any C max in a range bounded by, or between, any of these values.
In some embodiments, bupropion, hydroxybupropion, or a prodrug of hydroxybupropion, may be administered to a human being in an amount that results in a C avg of hydroxybupropion in the human being, on day 8, that is at least about 200 ng/mL, at least about 300 ng/mL, at least about 700 ng/mL, at least about 1,000 ng/mL, at least about 1,500 ng/mL, at least about 2,000 ng/mL, at least about 4,000 ng/mL, up to about 10,000 ng/mL, up to about 50,000 ng/mL, or any C avg in a range bounded by, or between, any of these values.
In some embodiments, bupropion, threohydroxybupropion, or a prodrug of threohydroxybupropion, is administered at a dose that results in a threohydroxybupropion plasma level of about 0.1 μM to about 10 μM, about 0.1 μM to about 5 μM, about 0.2 μM to about 3 μM, 0.1 μM to about 1 μM, about 0.2 μM to about 2 μM, 1 μM to about 10 μM, about 1 μM to about 5 μM, about 2 μM to about 3 μM, or about 2.8 μM to about 3 μM, about 1.5 μM to about 2 μM, about 4.5 μM to about 5 μM, about 2.5 μM to about 3 μM, about 1.8 μM, about 4.8 μM, about 2.9 μM, about 2.8 μM, or any plasma level in a range bounded by, or between, any of these values.
In some embodiments, bupropion, threohydroxybupropion, or a prodrug of threohydroxybupropion, may be administered to a human being in an amount that results in an AUC 0-12 of threohydroxybupropion in the human being, on day 8, that is at least about 1,000 ng·hr/mL, at least about 2,000 ng·hr/mL, at least about 4,000 ng·hr/mL, at least about 5,000 ng·hr/mL, at least about 8,000 ng·hr/mL, up to about 10,000 ng·hr/mL, up to about 40,000 ng·hr/mL, or any AUC in a range bounded by, or between, any of these values.
In some embodiments, bupropion, threohydroxybupropion, or a prodrug of threohydroxybupropion, may be administered to a human being in an amount that results in a C max of threohydroxybupropion in the human being, on day 8, that is at least about 100 ng/mL, at least about 200 ng/mL, at least about 400 ng/mL, at least about 500 ng/mL, at least about 600 ng/mL, at least about 800 ng/mL, up to about 2,000 ng/mL, up to about 10,000 ng/mL, or any C max in a range bounded by, or between, any of these values.
In some embodiments, bupropion, threohydroxybupropion, or a prodrug of threohydroxybupropion, may be administered to a human being in an amount that results in a C avg of threohydroxybupropion in the human being, on day 8, that is at least about 100 ng/mL, at least about 300 ng/mL, at least about 400 ng/mL, at least about 600 ng/mL, at least about 800 ng/mL, up to about 2,000 ng/mL, up to about 10,000 ng/mL, or any C avg in a range bounded by, or between, any of these values.
In some embodiments, bupropion, erythrohydroxybupropion, or a prodrug of erythrohydroxybupropion, is administered at a dose that results in an erythrohydroxybupropion plasma level of about 0.1 μM to about 10 μM, about 0.1 μM to about 5 μM, about 0.2 μM to about 3 μM, 0.1 μM to about 1 μM, about 0.2 μM to about 2 μM, 1 μM to about 10 μM, about 1 μM to about 5 μM, about 2 μM to about 3 μM, or about 2.8 μM to about 3 μM, about 1.5 μM to about 2 μM, about 4.5 μM to about 5 μM, about 2.5 μM to about 3 μM, about 1.8 μM, about 4.8 μM, about 2.9 μM, about 2.8 μM, or any plasma level in a range bounded by, or between, any of these values.
In some embodiments, bupropion, erythrohydroxybupropion, or a prodrug of erythrohydroxybupropion, may be administered to a human being in an amount that results in an AUC 0-12 of erythrohydroxybupropion in the human being, on day 8, that is at least about 200 ng·hr/mL, at least about 400 ng·hr/mL, at least about 700 ng·hr/mL, at least about 1,000 ng·hr/mL, at least about 1,500 ng·hr/mL, at least about 3,000 ng·hr/mL, up to about 5,000 ng·hr/mL, up to about 30,000 ng·hr/mL, or any plasma level in a range bounded by, or between, any of these values.
In some embodiments, bupropion, erythrohydroxybupropion, or a prodrug of erythrohydroxybupropion, may be administered to a human being in an amount that results in a C max of erythrohydroxybupropion in the human being, on day 8, that is at least about 30 ng/mL, at least about 60 ng/mL, at least about 90 ng/mL, at least about 100 ng/mL, at least about 150 ng/mL, at least about 200 ng/mL, at least about 300 ng/mL, up to about 1,000 ng/mL, or any C max in a range bounded by, or between, any of these values.
In some embodiments, bupropion, erythrohydroxybupropion, or a prodrug of erythrohydroxybupropion, may be administered to a human being in an amount that results in a C avg of erythrohydroxybupropion in the human being, on day 8, that is at least about 20 ng/mL, at least about 30 ng/mL, at least about 50 ng/mL, at least about 80 ng/mL, at least about 90 ng/mL, at least about 100 ng/mL, at least about 150 ng/mL, at least about 200 ng/mL, at least about 300 ng/mL, up to about 1,000 ng/mL, up to about 5,000 ng/mL, or any C avg in a range bounded by, or between, any of these values.
For compositions comprising both dextromethorphan and bupropion, some liquids may comprise about 0.0001% (w/v) to about 50% (w/v), about 0.01% (w/v) to about 20% (w/v), about 0.01% to about 10% (w/v), about 1% (w/v) to about 3% (w/v), about 3% (w/v) to about 5% (w/v), about 5% (w/v) to about 7% (w/v), about 5% (w/v) to about 15% (w/v), about 7% (w/v) to about 10% (w/v), about 10% (w/v) to about 15% (w/v), about 15% (w/v) to about 20% (w/v), about 20% (w/v) to about 30% (w/v), about 30% (w/v) to about 40% (w/v), about 40% (w/v) to about 50% (w/v) of dextromethorphan and bupropion combined, or any amount in a range bounded by, or between, any of these values. Some solid compositions may comprise at least about 5% (w/w), at least about 10% (w/w), at least about 20% (w/w), at least about 50% (w/w), at least about 70% (w/w), at least about 80%, about 10% (w/w) to about 30% (w/w), about 10% (w/w) to about 20% (w/w), about 20% (w/w) to about 30% (w/w), about 30% (w/w) to about 50% (w/w), about 30% (w/w) to about 40% (w/w), about 40% (w/w) to about 50% (w/w), about 50% (w/w) to about 80% (w/w), about 50% (w/w) to about 60% (w/w), about 70% (w/w) to about 80% (w/w), about 80% (w/w) to about 90% (w/w) of dextromethorphan and bupropion combined, or any amount in a range bounded by, or between, any of these values. In some embodiments, the weight ratio of dextromethorphan to bupropion in a single composition or dosage form may be about 0.1 to about 2, about 0.2 to about 1, about 0.1 to about 0.3, about 0.2 to about 0.4, about 0.3 to about 0.5, about 0.5 to about 0.7, about 0.8 to about 1, about 0.2, about 0.3, about 0.4, about 0.45, about 0.6, about 0.9, or any ratio in a range bounded by, or between, any of these values.
A therapeutically effective amount of a therapeutic compound may vary depending upon the circumstances. For example, a daily dose of dextromethorphan may in some instances range from about 0.1 mg to about 1000 mg, about 40 mg to about 1000 mg, about 20 mg to about 600 mg, about 60 mg to about 700 mg, about 100 mg to about 400 mg, about 15 mg to about 20 mg, about 20 mg to about 25 mg, about 25 mg to about 30 mg, about 30 mg to about 35 mg, about 35 mg to about 40 mg, about 40 mg to about 45 mg, about 45 mg to about 50 mg, about 50 mg to about 55 mg, about 55 mg to about 60 mg, about 20 mg to about 60 mg, about 60 mg to about 100 mg, about 100 mg to about 200 mg, about 100 mg to about 140 mg, about 160 mg to about 200 mg, about 200 mg to about 300 mg, about 220 mg to about 260 mg, about 300 mg to about 400 mg, about 340 mg to about 380 mg, about 400 mg to about 500 mg, about 500 mg to about 600 mg, about 15 mg, about 30 mg, about 60 mg, about 120 mg, about 180 mg, about 240 mg, about 360 mg, or any daily dose in a range bounded by, or between, any of these values. Dextromethorphan may be administered once daily; or twice daily or every 12 hours, three times daily, four times daily, or six times daily in an amount that is about half, one third, one quarter, or one sixth, respectively, of the daily dose.
A daily dose of bupropion, may in some instances range from about 10 mg to about 1000 mg, about 50 mg to about 600 mg, about 100 mg to about 2000 mg, about 50 mg to about 100 mg, about 70 mg to about 95 mg, about 100 mg to about 200 mg, about 105 mg to about 200 mg, about 100 mg to about 150 mg, about 150 mg to about 300 mg, about 150 mg to about 200 mg, about 200 mg to about 250 mg, about 250 mg to about 300 mg, about 200 mg about 300 mg, about 300 mg to about 400 mg, about 400 mg to about 500 mg, about 400 mg to about 600 mg, about 360 mg to about 440 mg, about 560 mg to about 640 mg, or about 500 mg to about 600 mg, about 100 mg, about 150 mg, about 200 mg, about 300 mg, about 400 mg, about 600 mg, or any daily dose in a range bounded by, or between, any of these values. Bupropion may be administered once daily; or twice daily or every 12 hours, or three times daily in an amount that is about half or one third, respectively, of the daily dose.
In some embodiments: 1) about 50 mg/day to about 100 mg/day, about 100 mg/day to about 150 mg/day, about 150 mg/day to about 300 mg/day, about 150 mg/day to about 200 mg/day, about 200 mg/day to about 250 mg/day, about 250 mg/day to about 300 mg/day of bupropion, or about 300 mg/day to about 500 mg/day of bupropion; and/or 2) about 15 mg/day to about 60 mg/day, about 15 mg/day to about 30 mg/day, about 30 mg/day to about 45 mg/day, about 45 mg/day to about 60 mg/day, about 60 mg/day to about 100 mg/day, about 80 mg/day to about 110 mg/day, about 100 mg/day to about 150 mg/day, or about 100 mg/day to about 300 mg/day of dextromethorphan, are administered to a human being in need thereof.
In some embodiments, about 150 mg/day of bupropion and about 30 mg/day of dextromethorphan, about 150 mg/day of bupropion and about 60 mg/day of dextromethorphan, about 150 mg/day of bupropion and about 90 mg/day of dextromethorphan, about 150 mg/day of bupropion and about 120 mg/day of dextromethorphan, about 200 mg/day of bupropion and about 30 mg/day of dextromethorphan, about 200 mg/day of bupropion and about 60 mg/day of dextromethorphan, about 200 mg/day of bupropion and about 90 mg/day of dextromethorphan, about 200 mg/day of bupropion and about 120 mg/day of dextromethorphan, about 300 mg/day of bupropion and about 30 mg/day of dextromethorphan, about 300 mg/day of bupropion and about 60 mg/day of dextromethorphan, about 300 mg/day of bupropion and about 90 mg/day of dextromethorphan, or about 300 mg/day of bupropion and about 120 mg/day of dextromethorphan is administered to the human being.
In some embodiments, about 100 mg/day of bupropion and about 15 mg/day of dextromethorphan is administered to the human being for 1, 2, or 3 days, followed by about 200 mg/day of bupropion and about 30 mg/day of dextromethorphan. In some embodiments, about 100 mg/day of bupropion and about 30 mg/day of dextromethorphan is administered to the human being for 1, 2, or 3 days, followed by about 200 mg/day of bupropion and about 60 mg/day of dextromethorphan.
In some embodiments, about 75 mg/day of bupropion and about 15 mg/day of dextromethorphan is administered to the human being for 1, 2, or 3 days, followed by about 150 mg/day of bupropion and about 30 mg/day of dextromethorphan. In some embodiments, about 75 mg/day of bupropion and about 30 mg/day of dextromethorphan is administered to the human being for 1, 2, or 3 days, followed by about 150 mg/day of bupropion and about 60 mg/day of dextromethorphan.
An antidepressant compound, such as bupropion, may be administered for as long as needed to treat a neurological condition, such as pain, depression or cough. In some embodiments, an antidepressant compound, such as bupropion, and dextromethorphan are administered at least once a day, such as once daily or twice daily, for at least 1 day, at least 3 days, at least 5 days, at least 7 days, at least 8 days, at least 14 days, at least 30 days, at least 60 days, at least 90 days, at least 180 days, at least 365 days, or longer.
Therapeutic compounds may be formulated for oral administration, for example, with an inert diluent or with an edible carrier, or it may be enclosed in hard or soft shell gelatin capsules, compressed into tablets, or incorporated directly with the food of the diet. For oral therapeutic administration, the active compound may be incorporated with an excipient and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers, and the like.
Tablets, troches, pills, capsules and the like may also contain one or more of the following: a binder such as gum tragacanth, acacia, corn starch, or gelatin; an excipient, such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid, and the like; a lubricant such as magnesium stearate; a sweetening agent such as sucrose, lactose, or saccharin; or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring. When the dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier. Various other materials may be present as coating, for instance, tablets, pills, or capsules may be coated with shellac, sugar or both. A syrup or elixir may contain the active compound, sucrose as a sweetening agent, methyl and propylparabens as preservatives, a dye and flavoring, such as cherry or orange flavor. It may be desirable for material in a dosage form or pharmaceutical composition to be pharmaceutically pure and substantially non toxic in the amounts employed.
Some compositions or dosage forms may be a liquid, or may comprise a solid phase dispersed in a liquid.
Therapeutic compounds may be formulated for parental or intraperitoneal administration. Solutions of the active compounds as free bases or pharmacologically acceptable salts can be prepared in water suitably mixed with a surfactant, such as hydroxypropylcellulose. A dispersion can also have an oil dispersed within, or dispersed in, glycerol, liquid polyethylene glycols, and mixtures thereof. Under ordinary conditions of storage and use, these preparations may contain a preservative to prevent the growth of microorganisms.
Specifically Contemplated Embodiments
The following are examples of embodiments that are specifically contemplated by the inventor:
Embodiment 1
A method of treating pain or a neurological disorder comprising administering a therapeutically effective amount of dextromethorphan and a therapeutically effective amount of an antidepressant compound, to a person in need thereof.
Embodiment 2
A method of treating pain comprising administering a combination of an antidepressant compound and dextromethorphan to a human being in need thereof.
Embodiment 3
A method of enhancing the pain relieving properties of dextromethorphan, comprising co-administering dextromethorphan and an antidepressant compound.
Embodiment 4
A method of increasing dextromethorphan plasma levels in a human being that is an extensive metabolizer of dextromethorphan, comprising co-administering an antidepressant compound to the human being receiving a treatment that includes administration of dextromethorphan.
Embodiment 5
A method of inhibiting the metabolism of dextromethorphan, comprising administering an antidepressant compound to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as the antidepressant compound.
Embodiment 6
A method of increasing the metabolic lifetime of dextromethorphan, comprising administering an antidepressant compound to a human being, wherein the human being is an extensive metabolizer of dextromethorphan, and wherein dextromethorphan is present in the body of the human being at the same time as the antidepressant compound.
Embodiment 7
A method of correcting extensive metabolism of dextromethorphan, comprising administering an antidepressant compound to a human being in need thereof.
Embodiment 8
A method of improving pain relieving properties of dextromethorphan comprising administering an antidepressant compound in conjunction with administration of dextromethorphan to a human being in need of treatment for pain.
Embodiment 9
A method of improving antitussive properties of dextromethorphan comprising administering an antidepressant compound in conjunction with administration of dextromethorphan to a human being in need of treatment for cough.
Embodiment 10
A method of treating cough comprising administering a combination of an antidepressant compound and dextromethorphan to a human being in need thereof.
Embodiment 11
A method of improving a therapeutic property of dextromethorphan comprising administering an antidepressant compound in conjunction with administration of dextromethorphan to a human being in need of treatment for a neurological disorder.
Embodiment 12
A method of treating a neurological disorder comprising administering a combination of an antidepressant compound and dextromethorphan to a human being in need thereof.
Embodiment 13
A method of treating a neurological disorder comprising administering an antidepressant compound and dextromethorphan to a human being in need thereof, wherein the human being is an extensive metabolizer of dextromethorphan.
Embodiment 14
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or 13, wherein the dextromethorphan and the antidepressant compound are administered in separate dosage forms.
Embodiment 15
A pharmaceutical composition comprising a therapeutically effective amount of dextromethorphan, a therapeutically effective amount of an antidepressant compound, and a pharmaceutically acceptable excipient.
Embodiment 16
An oral dosage form comprising at least 20 mg of dextromethorphan and an effective amount of an antidepressant compound to inhibit the metabolism of dextromethorphan in a human being that is an extensive metabolizer of dextromethorphan.
Embodiment 17
The oral dosage form of embodiment 16, wherein about 30 mg to about 350 mg of dextromethorphan is present in the dosage form.
Embodiment 18
The oral dosage form of embodiment 16 or 17, wherein about 100 mg to about 400 mg of bupropion is present in the dosage form.
Embodiment 19
The oral dosage form of any of embodiments 16, 17, or 18, comprising an amount of bupropion that results in a bupropion plasma level of about 0.1 μM to about 10 μM when the oral dosage form is administered to a human being.
Embodiment 20
The oral dosage form of embodiment 19, comprising an amount of bupropion that results in a bupropion plasma level of about 0.1 μM to about 2 μM when the oral dosage form is administered to a human being.
Embodiment 21
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or 13, wherein bupropion is administered at a dose that results in a bupropion plasma level of about 0.1 μM to about 10 μM.
Embodiment 22
The method of embodiment 21, wherein bupropion is administered at a dose that results in a bupropion plasma level of about 0.3 μM to about 1 μM.
Embodiment 23
The method, composition, or dosage form of any of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the antidepressant compound is bupropion or a metabolite thereof.
Embodiment 24
The method, composition, or dosage form of any of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the antidepressant compound is bupropion.
Embodiment 25
The method, composition, or dosage form of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the antidepressant compound is clomipramine, doxepin, fluoxetine, mianserin, imipramine, 2-chloroimipramine, amitriptyline, amoxapine, desipramine, protriptyline, trimipramine, nortriptyline, maprotiline, phenelzine, isocarboxazid, tranylcypromine, paroxetine, trazodone, citalopram, sertraline, aryloxy indanamine, benactyzine, escitalopram, fluvoxamine, venlafaxine, desvenlafaxine, duloxetine, mirtazapine, nefazodone, selegiline, or a pharmaceutically acceptable salt thereof
Embodiment 26
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 11, 12, 13, 14, 21, 22, 23, 24, or 25, wherein dextromethorphan is administered to the human being for the treatment of cough.
Embodiment 27
A method of treating a neurological disorder comprising administering about 150 mg/day to about 300 mg/day of bupropion and about 30 mg/day to about 120 mg/day of dextromethorphan to a human being in need thereof.
Embodiment 28
A method of treating a neurological disorder comprising administering bupropion and dextromethorphan to a human being in need thereof, wherein the bupropion and dextromethorphan are administered at least once a day for at least 8 days.
Embodiment 29
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, or 27, wherein bupropion is administered to the human being at least daily for at least 8 days.
Embodiment 30
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, or 28, wherein dextromethorphan is administered to the human being at least daily for at least 8 days.
Embodiment 31
The method of embodiment 28, 29, or 30, wherein bupropion is administered in an amount that results in a plasma concentration of dextromethorphan in the human being, on day 8, that is at least 10 times the plasma concentration of the same amount of dextromethorphan administered without bupropion.
Embodiment 32
The method of embodiment 28, 29, 30, or 31, wherein bupropion is administered in an amount that results in an AUC 0-12 of hydroxybupropion, on day 8, that is at least about 3000 ng·hr/mL.
Embodiment 33
The method of embodiment 28, 29, 30, 31, or 32, wherein bupropion is administered in an amount that results in an AUC 0-12 of erythrohydroxybupropion, on day 8, that is at least about 400 ng·hr/mL.
Embodiment 34
The method of embodiment 28, 29, 30, 31, 32, or 33, wherein bupropion is administered in an amount that results in an AUC 0-12 of threohydroxybupropion, on day 8, that is at least about 2000 ng·hr/mL.
Embodiment 35
The method, composition, or dosage form of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 26, 27, 28, 29, 30, 31, 32, 33, or 34, wherein the weight ratio of dextromethorphan to bupropion is about 0.1 to about 0.5.
Embodiment 36
The method of embodiment 27, 28, 29, 30, 31, 32, 33, 34, or 35, wherein the human being is an extensive metabolizer of dextromethorphan.
Embodiment 37
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, or 36, wherein about 150 mg/day of bupropion and about 30 mg/day of dextromethorphan is administered to the human being.
Embodiment 38
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, or 36, wherein about 150 mg/day of bupropion and about 60 mg/day of dextromethorphan is administered to the human being.
Embodiment 39
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, or 36, wherein about 200 mg/day of bupropion and about 30 mg/day of dextromethorphan is administered to the human being.
Embodiment 40
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, or 36, wherein about 100 mg/day of bupropion and about 15 mg/day of dextromethorphan is administered to the human being for about 1 to about 3 days, followed by about 200 mg/day of bupropion and about 30 mg/day of dextromethorphan.
Embodiment 41
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, or 36, wherein about 200 mg/day of bupropion and about 60 mg/day of dextromethorphan is administered to the human being.
Embodiment 42
The method of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, or 36, wherein about 100 mg/day of bupropion and about 30 mg/day of dextromethorphan is administered to the human being for about 1 to about 3 days, followed by about 200 mg/day of bupropion and about 60 mg/day of dextromethorphan.
Embodiment 43
The method of embodiment 4, 5, 6, 7, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, or 42, wherein dextromethorphan is administered to the human being for the treatment of pain.
Embodiment 44
The method of embodiment 43, wherein the pain comprises postoperative pain, cancer pain, arthritic pain, lumbosacral pain, musculoskeletal pain, central multiple sclerosis pain, nociceptive pain, or neuropathic pain.
Embodiment 45
The method of embodiment 43, wherein the pain comprises musculoskeletal pain, neuropathic pain, cancer-related pain, acute pain, or nociceptive pain.
Embodiment 46
The method of embodiment 43, wherein the pain comprises postoperative pain.
Embodiment 47
The method of embodiment 43, wherein the pain comprises cancer pain.
Embodiment 48
The method of embodiment 43, wherein the pain comprises arthritic pain.
Embodiment 49
The method of embodiment 43, wherein the pain comprises lumbosacral pain.
Embodiment 50
The method of embodiment 43, wherein the pain comprises musculoskeletal pain.
Embodiment 51
The method of embodiment 43, wherein the pain comprises neuropathic pain.
Embodiment 52
The method of embodiment 43, wherein the pain comprises nociceptive pain.
Embodiment 53
The method of embodiment 43, wherein the pain comprises chronic musculoskeletal pain.
Embodiment 54
The method of embodiment 43, wherein the pain is associated with rheumatoid arthritis.
Embodiment 55
The method of embodiment 43, wherein the pain is associated with juvenile rheumatoid arthritis.
Embodiment 56
The method of embodiment 43, wherein the pain is associated with osteoarthritis.
Embodiment 57
The method of embodiment 43, wherein the pain is associated with an axial spondyloarthritis.
Embodiment 58
The method of embodiment 43, wherein the pain is associated with ankylosing spondylitis.
Embodiment 59
The method of embodiment 43, wherein the pain is associated with diabetic peripheral neuropathy.
Embodiment 60
The method of embodiment 43, wherein the pain is associated with post-herpetic neuralgia.
Embodiment 61
The method of embodiment 43, wherein the pain is associated with trigeminal neuralgia.
Embodiment 62
The method of embodiment 43, wherein the pain is associated with monoradiculopathies.
Embodiment 63
The method of embodiment 43, wherein the pain is associated with phantom limb pain.
Embodiment 64
The method of embodiment 43, wherein the pain is associated with central pain.
Embodiment 65
The method of embodiment 43, wherein the pain comprises cancer-related pain.
Embodiment 66
The method of embodiment 43, wherein the pain is associated with lumbar nerve root compression.
Embodiment 67
The method of embodiment 43, wherein the pain is associated with spinal cord injury.
Embodiment 68
The method of embodiment 43, wherein the pain is associated with post-stroke pain.
Embodiment 69
The method of embodiment 43, wherein the pain is associated with central multiple sclerosis pain.
Embodiment 70
The method of embodiment 43, wherein the pain is associated with HIV-associated neuropathy.
Embodiment 71
The method of embodiment 43, wherein the pain is associated with radio-therapy associated neuropathy.
Embodiment 72
The method of embodiment 43, wherein the pain is associated with chemo-therapy associated neuropathy.
Embodiment 73
The method of embodiment 43, wherein the pain comprises dental pain.
Embodiment 74
The method of embodiment 43, wherein the pain is associated with primary dysmenorrhea.
Embodiment 75
The method of embodiment 4, 5, 6, 7, 9, 10, 11, 12, 13, 14, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, or 74, wherein 90 mg/day of dextromethorphan is administered to the human being.
Embodiment 76
The method of embodiment 75, wherein 45 mg of dextromethorphan is administered twice a day to the human being.
Embodiment 77
The method of embodiment 75 or 76, wherein 150 mg/day of bupropion is administered to the human being.
Embodiment 78
The method of embodiment 75 or 76, wherein 180 mg/day of bupropion is administered to the human being.
Embodiment 79
The method of embodiment 75 or 76, wherein 200 mg/day of bupropion is administered to the human being.
Embodiment 80
The method of embodiment 75 or 76, wherein 300 mg/day of bupropion is administered to the human being.
U.S. Provisional Application No. 61/900,354 is incorporated by reference herein in its entirety. PCT Application No. PCT/US2014/64184 is incorporated by reference herein in its entirety. U.S. Patent Publication No. 2015/0126543 is incorporated by reference herein in its entirety.
EXAMPLES
Example 1
Fifteen human subjects were randomized into one of two treatment groups receiving either dextromethorphan (DM) alone, or DM in combination with bupropion, as shown in Table 1 below.
TABLE 1
Study Design
Dose Levels
Dura-
Total
Group
Bupropion/DM
Dosing Regimen
tion
Subjects
A
0 mg/60 mg
DM: Twice daily,
Days
8
Days 1-8
1-8
B
150 mg/60 mg
Bupropion: Once daily,
Days
7
Days 1-3; Twice daily,
1-8
Days 4-8
DM: Twice daily, Days
1-8
All subjects were extensive, including ultra-rapid, metabolizers of dextromethorphan as determined by CYP2D6 genetic testing. Dextromethorphan was dosed at 12-hour intervals on Days 1-8, with a final morning dose on Day 8. Bupropion was dosed once daily on Days 1-3, and at 12-hour intervals thereafter, with a final morning dose on Day 8.
Plasma samples were collected for concentration analysis of dextromethorphan, total dextrorphan, bupropion, hydroxybupropion, erythrohydroxybupropion, and threohydroxybupropion on days 1 and 8. Plasma samples for determination of trough concentrations of dextromethorphan were obtained approximately 12 hours after dosing on days 1, 5, 6, and 8.
Concentrations of dextromethorphan, total dextrorphan (unconjugated and glucuronide forms), bupropion, hydroxybupropion, erythrohydroxybupropion, and threohydroxybupropion, were determined using LC-MS/MS. Pharmacokinetic parameters were calculated.
Phenotypic determination of dextromethorphan metabolizer status was performed by calculating the dextromethorphan/dextrorphan metabolic ratio as described in Jurica et al. Journal of Clinical Pharmacy and Therapeutics, 2012, 37, 486-490. Plasma concentrations of dextromethorphan and dextrorphan 3 hours after dosing were used, with a dextromethorphan/dextrorphan ratio of 0.3 or greater indicating a poor metabolizer phenotype.
Results
Plasma concentrations of dextromethorphan were significantly increased with bupropion administration, as illustrated in FIG. 1 and Table 2.
TABLE 2
Mean Day 8 Dextromethorphan Plasma Concentrations (ng/mL)
Time
Dextromethorphan
Dextromethorphan +
(hours)
(Group A)
Bupropion (Group B)
0
1.2
110.6
1
2.4
129.3
2
3.6
153.9
3
3.6
151.6
4
3.3
149.1
6
2.5
150.0
8
1.9
144.4
12
1.1
119.3
24
0.4
95.3
36
0.1
69.0
The AUC of dextromethorphan was significantly increased with administration of bupropion as show in FIGS. 2-4 . As shown in FIG. 5 , administration of bupropion with dextromethorphan resulted in an approximately 60-fold, 80-fold, and 175-fold increase in mean dextromethorphan AUC 0-12 , AUC 0-24 , and AUC 0-inf , respectively on Day 8 as compared to administration of dextromethorphan alone. As shown in FIG. 6 , the increase in dextromethorphan AUC occurred as early as Day 1 (an approximate 3-fold increase in AUC 0-12 ).
Trough plasma concentrations of dextromethorphan were significantly increased with administration of bupropion as illustrated in FIG. 7 and Table 3. Administration of bupropion with dextromethorphan resulted in an approximately 105-fold increase in mean trough plasma concentration of dextromethorphan on Day 8 as compared to administration of dextromethorphan alone.
Mean average plasma concentrations (C avg ) of dextromethorphan on Day 8 increased approximately 60-fold with bupropion administration as compared to administration of dextromethorphan alone. Maximum mean plasma concentrations (C max ) were also significantly increased as illustrated in FIG. 8 .
TABLE 3
Mean Trough Dextromethorphan Plasma Concentrations (ng/mL)
Dextromethorphan
Dextromethorphan +
Fold
(Group A)
Bupropion (Group B)
Change
Day 1
0.7
2.5
3.5
Day 5
1.2
80.9
70
Day 6
1.3
102.2
78
Day 7
1.2
110.6
94
Day 8
1.1
119.3
105
The T max and elimination half life (T 1/2 el ) of dextromethorphan were significantly increased with administration of bupropion on Day 8. The increase of T 1/2 el shows that the metabolic lifetime of dextromethorphan was increased. Administration of bupropion with dextromethorphan resulted in a mean T max of 3.6 hours, compared to 2.3 hours for dextromethorphan alone. Administration of bupropion with dextromethorphan resulted in a mean T 1/2 el of 27.7 hours, compared to 6.6 hours for dextromethorphan alone.
Plasma concentrations of dextrorphan were significantly decreased with bupropion administration, as illustrated in FIG. 9 and Table 4.
TABLE 4
Mean Day 8 Dextrorphan Plasma Concentrations (ng/mL)
Time
Dextromethorphan
Dextromethorphan +
(hours)
(Group A)
Bupropion (Group B)
0
132.4
165.3
1
688.9
190.7
2
959.1
214.9
3
778.1
214.4
4
594.9
205.1
6
324.7
172.5
8
189.6
159.6
12
74.8
152.8
24
12.2
133.0
36
0.1
107.6
As shown in FIGS. 10-11 , there was an approximate 78% reduction in mean dextrorphan C max , and an approximate 55% reduction in mean dextrorphan AUC 0-12 on Day 8 with administration of bupropion.
Phenotypic determination of dextromethorphan metabolizer status showed that no subjects in either treatment arm were poor metabolizers on Day 1. On Day 8 however, 100% of subjects treated with bupropion had converted to poor metabolizer status as compared to 0% of subjects treated with dextromethorphan alone. The mean plasma dextromethorphan/dextrorphan metabolic ratio increased from 0.01 on Day 1 to 0.71 on Day 8 with bupropion administration. The mean ratio in the group administered DM alone was 0.00 on Day 1 and remained unchanged on Day 8.
On Day 8, average plasma concentrations of bupropion, hydroxybupropion, erythrohydroxybupropion, and threohydroxybupropion were at least 10 ng/mL, 200 ng/mL, 20 ng/mL, and 100 ng/mL, respectively after bupropion administration.
As used in this section, the term “fold change” or “fold increase” refers to the ratio of a value for bupropion with dextromethorphan to the same value for dextromethorphan alone (i.e. the value for bupropion with dextromethorphan divided by the same value for dextromethorphan alone).
Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the specification and claims are to be understood in all instances as indicating both the exact values as shown and as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
The terms “a,” “an,” “the” and similar referents used in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of any claim. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
Groupings of alternative elements or embodiments disclosed herein are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
Certain embodiments are described herein, including the best mode known to the inventors for carrying out the invention. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than specifically described herein. Accordingly, the claims include all modifications and equivalents of the subject matter recited in the claims as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is contemplated unless otherwise indicated herein or otherwise clearly contradicted by context.
In closing, it is to be understood that the embodiments disclosed herein are illustrative of the principles of the claims. Other modifications that may be employed are within the scope of the claims. Thus, by way of example, but not of limitation, alternative embodiments may be utilized in accordance with the teachings herein. Accordingly, the claims are not limited to embodiments precisely as shown and described.
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This disclosure relates to methods of improving the efficacy of dextromethorphan, or providing beneficial pharmacokinetic effects to dextromethorphan, comprising co-administering erythrohydroxybupropion, or a prodrug thereof, and dextromethorphan to a human being. Dosage forms, drug delivery systems, and methods related to dextromethorphan and erythrohydroxybupropion or a prodrug of erythrohydroxybupropion are also disclosed.
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BACKGROUND
[0001] 1. Field of Invention
[0002] This method of fiber production relates in general to electrospinning and specifically to MEMS (Micro ElectroMechanical Structures). Using current integrated circuit manufacturing processes, it is feasible that a tiny, compact, self-contained device could be constructed to carry out the process of electrospinning fibers. One of the great benefits of using a MEMS device is that the voltage required to produce a “so called” Taylor Cone would be substantially reduced, and the hydrostatic feed system could be incorporated into the MEMS device through the use of passive wick technology. The incorporation of holey fibers into a MEMS device will also be discussed. The electrospray needle sources could be easily fabricated to produce co-axial arrangements to permit the electrospinning of two or more chemical compounds to form unique and complex fibers.
[0003] 2. Background Description of Prior Art
[0004] There are several current methods of producing fibers for later use in various products; however, there is no easy way to mechanically produce microfibers (10 −6 m mean diameter) and even smaller nanofibers (10 −9 m mean diameter). The microfibers are fibers with a mean diameter of millionths of a meter (um) and the nanofibers are fibers with a mean diameter of billionths of a meter (nm). To give an example of how small that is, a standard sheet of printer paper has an average thickness of about 0.003″ or 0.0762 mm, which is equal to 76.2 μm and 76,200 nm. The wavelength of red light is equal to approx. 690 nm. It is all but impossible to construct a mechanical means or spinning a fiber that has a mean diameter of micrometers, let alone nano-meters! One simple way to do this impossible feat is to use the proven technology of electrospray. Through the use of electrospray technology incorporated into a MEMS device, it is possible to produce an extremely fine fiber that meets this criterion of producing micrometer and nanometer sized diameters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows a SEM (Scanning Electron Microscope) picture or micrograph of a small array of electrospray needles that will be externally wetted to permit electrospraying.
[0006] FIG. 2 : SEM (Scanning Electron Microscope) pictures of black Si for a 5 and 10 minute exposure to plasma
[0007] FIG. 3 shows a SEM (Scanning Electron Microscope) picture or micrograph of a small array of “volcano like” electrospray needles that will be externally wetted to permit electrospraying.
[0008] FIG. 4 shows a SEM micrograph detailing a close up view of a single needle source that is contained in the array.
[0009] FIG. 5 : SEM (Scanning Electron Microscope) close-up of “Volcano-like” emitter
[0010] FIG. 6 : Shows SEM images of the microfabricated chip before and after wetting of polymer-solvent solution
DETAILED DESCRIPTION OF THE INVENTION
[0011] Electrostatic fiber spinning, or “electrospinning,” is a technology that uses electric fields to produce nonwoven materials which are unparalleled in their porosity, high surface area, and the fineness and uniformity of their fibers. The diameters of electrospun fibers are typically hundreds of nano-meters, one to two orders of magnitude smaller than fibers produced by conventional extrusion techniques. These fibers are attracting considerable interest in a wide range of applications, including filters, membranes, composites and biomimetic materials. Despite this surge in interest, the essential features of the process responsible for the formation of such fine fibers have proved elusive to both scientific understanding and engineering control.
[0012] Typically the sub-micron diameter fibers are produced from an aqueous solution by electrospinning and collected as a nonwoven fabric when a charged fluid jet is accelerated down an electric field gradient, solidified, and deposited onto a grounded collector. Similar fibers have been manufactured from over 30 different kinds of polymers in recent years. By contrast, synthetic polymer fibers produced by conventional extrusion-and-drawing processes are typically 10 um to 500 um in diameter, and are collected on spools for forming yarns or woven textiles. Controlling the fiber properties requires understanding how the electrospinning process transforms a millimeter-diameter fluid stream into solid fibers four orders of magnitude smaller in diameter. In the conventional view, electrostatic charging of the fluid at the tip of a nozzle results in the formation of the well-known Taylor cone, from the apex of which a single fluid jet is ejected. As the jet accelerates and thins in the electric field, radial charge repulsion results in “whipping about” of the jet, in a process known as “splaying.” The final fiber size is determined by several factors, such as the electrospray voltage, concentration of solvent to solute, and distance to target. During electrospinning it is normal for the rapid growth of a nonaxisymmetric, or “whipping,” instability that causes bending and stretching of the jet. At low fields, the jet uniformly thins and extends from the nozzle to the collector, while at high fields, and after traveling a short distance, the jet becomes unstable and “whips about”. The use of MEMS devices will enable an effective low field electrospray to be used for electrospinning. An effective means of controlling the “whipping” instability has already been addressed by Dr. John B. Fenn. Dr. Fenn is considered to be an “elder” in the area of electrospray research, and recently won the 2002 Nobel Prize in Chemistry for his pioneering work in electrospray. He is regarded as the “E. F. Hutton” of electrospray—when he speaks, everyone listens! Dr. Fenns idea was to use an alternating voltage at the source to prevent charge buildup on individual fibers. This prevents the typical non-uniform distribution in the laying of electrospun fibers. With the use of tiny MEMS devices, the lower field will enable stable fibers that will not be affected by any “whipping” instability. Another innovation in the field of electrospray and electrospinning technology that was made by Dr. John B. Fenn was to use a “wick” in place of a costly hydrostatic feed pump. The wick is a self-regulating liquid feed system with no moving parts, and can accurately control picoliters (10 −12 L) of fluid. The wick used for electrospray and electrospinning applications could be an internal one or an external one. If an internal wick is used, then the wicking material would have to be enclosed into a needle or some structural material to hold it. This is very difficult when dealing with needles that have diameters in the micrometer range. A better solution would be to use a recent discovery of utilizing special glass optical fibers that contain tiny holes running the length of the fiber, known as “Holey Fibers”. These holey fibers could contain upwards of 200 holes with hole diameters ranging from sub-micron sizes to tens of microns. Together with a suitable MEMS device, single holey fibers or a plurality of holey fibers could facilitate the electrospinning process. When dealing with an externally wetted wick, no actual wicking material is used; the treated surface of a small needle will function adequately. The MEMS devices will benefit greatly from this technology. While the preferred embodiment is a surface that has been treated so as to form a rough surface that can “wick” a solvent-polymer combination, patent priority extends to a MEMS device where nano nozzles are created in which the solvent-polymer solution is delivered via a hydrostatic feed mechanism. The nano fluidic prior art includes nano spray nozzles that have been developed that are hydrostatically fed for electrospray analytical applications, but not for the electrospinning application as disclosed in this patent disclosure.
[0013] To recap the electrospinning process, a polymer, in this case example collagen is dissolved by a suitable solvent and injected under hydrostatic pressure into a conductive needle or capillary. A DC potential of preferably 500 to 1,000 volts, which can be greater or lower than this value depending on the spray source to target gap, is maintained between the electrospray source and a suitable target located at a distance away from the needle sufficient to preclude production of a corona or arc. The voltage is adjusted according the distance, desired fiber diameter and structure. Voltage difference between injection needle and target suited to the given solvent conductivity, polymer, and flow rate, enable a resulting electrostatic field at the needle tip that results in the formation of a Taylor Cone from the tip which issues a micron sized jet diameter which is attracted to, and impacts with, the ground cathode target. Evaporation of solvent from this jet results in a polymer strand of collagen or other polymer. The accumulation of such strands creates a “mat” of polymer having a homogenous diameter ranging from tens of microns or more down to tens of nanometers or less, depending on the concentration and nature of solute, the conductivity and viscosity of liquid, and the potential difference between the needle and target. It has been shown by Wnek et al. of Virginia Commonwealth University (VCU), that electrospun collagen fibers can be produced down to 100 (+/−40) nano meters in diameter. Calf skin dissolved in a suitable solvent was electrospun, and upon Transmission Electron Microscopy (TEM) examination, revealed the same banded appearance characteristic of native polymerized collagen. Various polymers studied yielded fiber diameters in the range of 0.1 to 10 um. It should be noted that nano-extrusion rather than electrospinning of the polymer are an alternative in certain instances.
[0014] Polymer mats produced by this process can have diameters up to tens of microns and thickness of up to hundreds of microns, depending on deposition time. Similarly, it has been found that polymers such as collagen for creating a suitable corneal mat as part of this invention can be derived from a variety of sources. In the preferred embodiment, synthetic collagen such as that manufactured by FibroGen of San Francisco, Calif., is dissolved by a solvent such as 1,1,1,3,3,3 hexaflouro-2-propanol (HFIPA) and electrospun into a fibril diameter of preferably 65 nanometers and spun into a mat that can be trimmed to desired final dimensions. Laser cutting or trimming is preferably employed since fibril terminations must be severed and should not be excessively frayed or tangled. Tangling or fraying can affect bonding to some surfaces. While the resulting polymer “mat” consists of disorganized fibrils, this disorganization can be remedied by using a varying polarity (AC) high voltage source in place of a constant DC potential in the spraying process.
[0015] FIG. 1 shows a two dimensional array of tiny “etched” needles into a silicon base. The main silicon housing 10 is made by using standard integrated circuit techniques, and in this case was designed and fabricated by Manuel Martinez-Sanchez and Luis Velasquez of the Aeronautical and Astronautics Department of MIT as an electrospray emitter for space propulsion of nano satellites. In the MIT application, the spray is a liquid source that produces colloidal droplets that are ejected at high velocity from the MEMS surface. The surface of the silicon device was plasma etched to create a rough topography where “wicking” of a suitable fluid could take place. When this MEMS electrospray emitter was treated with a solution of polymer and suitable solvent and a suitable electric field applied, nanofibers were produced with a density and degree of deposition control not possible heretofore this surprising result.
[0016] In the MIT lab for their nano thruster propulsion research, Dr. Martinez-Sanchez and Dr. Velasquez investigated the wetting properties of several materials such as bare Silicon (with various roughness'), Silicon Dioxide (SiO 2 ), Silicon Nitride (Si 3 N 4 ), Aluminum and black Silicon to various ionic liquids. To modify the wetting properties of regular Silicon, MIT used a surface modification technique. Surface modification techniques can be of physical, chemical or radiative nature. In this case, plasma (radiative) was employed to modify the surface roughness and wetting energy. In particular, experiments proved most successful with black Silicon. Black Silicon results from exposing a regular Si wafer to a plasma dry etch with a chlorine chemistry. The end result is a strong roughening of the surface. The process is conformal, thus translating into good step coverage for microfabricated structures.
[0017] FIG. 2 shows two SEM (Scanning Electron Microscope) pictures of black Si for a five 10 and ten 20-minute exposure to plasma. The results from these first experimental experiences were incorporated into a second set of experiments. In this case we have a set of two-dimensional micofabricated protuberances covered by the porous black Si. The idea behind these experiments was to see how target fluids wetted the chip and if surface tension could drive the liquid to the top of the microfabricated columns.
[0018] FIG. 3 details the individual needles 20 , shown courtesy of M. Martinez-Sanchez, etched into the main silicon housing in a regular grid. The needles would be “wetted” externally when an electrospinning solution is placed inside the main silicon housing and pulled up the individual emitter walls 10 by capillary action.
[0019] FIG. 4 details the structure of a single electrospray MEMS emitter or needle. The walls 10 of each individual needle are nearly smooth, but not completely smooth. The walls 10 have to be treated with a process to create a rough surface. This rough surface will then allow capillary action to “wick” up the solution to be electrosprayed and allow the electrospinning of fibers. The top of the tiny needle comes to a sharp point 20 . This sharp point 20 concentrates the electric field to enable the formation of the “so called” Taylor cone. After the onset of the “so called” Taylor cone, a fine jet of liquid will be emitted from each individual tiny electrospray needle to form electrospun fibers after evaporation of the solvent. Evaporation of the polymer solvent can be increased by exposing the electrospinning apparatus to a partial pressure environment or by passing a drying gas between the source and target.
[0020] FIG. 5 shows a close up SEM (Scanning Electron Microscope) picture or micrograph of a single “volcano like” emitter. The pointed edges are clearly visible. It is at these sharp interfaces where the “so called” Taylor cones will be formed. This type of electrospray emitter will allow for eight individual jets for electrospinning to be produced at the same time. The total number of electrospray jets that could be produced would be equal to eight times the number of individual “volcano like” emitters. If there were one hundred individual “volcano like” emitters in the MEMS array, then the total number of electrospray jets would be eight hundred. This approach allows for the realization of large mats of uniform electrospun fibers to be created in a short amount of time.
[0021] FIG. 6 shows the microfabricated MEMS chip before wetting and after. The image on the left 10 shows the MEMS surface in its dry or non-wetted state. When application of a suitable electrospinning solution is placed on this surface, the treated silicon “wicks up” the liquid 20 through capillary action. This allows for a passive liquid transport mechanism to be realized for fluid delivery to each individual emitter.
Reference Numerals
FIG. 1
[0022] 10 Main structure of the silicon MEMS device housing a two dimensional array of electrospray needles.
FIG. 2
[0023] 10 Black silicon SEM image after five minutes of plasma exposure
[0024] 20 Black silicon SEM image after ten minutes of plasma exposure
FIG. 3
[0025] 10 SEM image of group of individual electrospray emitters, specifically the top corner where the electrospray would emanate from.
[0026] 20 Sidewall of treated silicon of a single “volcano like” electrospray emitter.
FIG. 4
[0027] 10 Close up view showing the structure of a single silicon electrospray needle that makes up the MEMS array.
[0028] 20 Close up view detailing the sharp pointed tip of a single silicon electrospray needle.
FIG. 5
[0029] SEM (Scanning Electron Microscope) close-up of “Volcano-like” emitter
FIG. 6
[0030] 10 SEM images of the microfabricated chip with pointed “pencil like” emitters before wetting of polymer-solvent solution
[0031] 20 SEM images of the microfabricated chip with pointed “pencil like” emitters after wetting of polymer-solvent solution
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A method of fiber production relating in general to electrospinning and specifically to MEMS (Micro ElectroMechanical Structures). Utilizing integrated circuit manufacturing processes, a nanoscale, self-contained device has been developed to execute the process of electrospinning large arrays of fibers and fiber arrays. One of the benefits of using the disclosed MEMS device is that the voltage required to produce a “so called” Taylor Cone would is substantially reduced and the requirement of a hydrostatic feed negated through the use of passive capillarity based wick surface treatment.
CROSS REFERENCE TO RELATED APPLICATIONS
Provisional Application No. 60/526879 was filed on 4 Dec. 2003
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BACKGROUND OF THE INVENTION
The invention is in the field of rock boring machines, and more specifically such machines for reaming substantially vertical holes, or holes at a slight angle from true vertical, by initiating rock boring at ground level and boring a predetermined distance underground. No known down reaming apparatus is capable of boring substantially larger holes (preferably having a diameter of at least four meters) in a substantially continuous manner.
U.S. Pat. No. 3,965,995 issued to Sugden discloses a machine for boring a large diameter blind hole in a sequential, non-continuous manner. The cutterwheel is mounted at the lower end of the machine for rotation about a horizontal tubular support. A gripper assembly secures the machine against the tunnel wall while thrust cylinders thrust the rotatable cutterhead downwardly. As the machine is advanced, the cutterwheel is rotated to make a first cut in the shape of the leading portion of the cutterwheel. The cutterwheel is then retracted out from the cut and is rotated about the axis of the hole. This repositions the cutterwheel so that when it is advanced again, during the next cutting step, it will make a second cut which crosses the first This procedure is repeated until the desired cross-sectional configuration (e.g. circular) of the hole is obtained The above described sequential boring method employing a gripper assembly and thrust cylinders has been found to be time consuming and requires a complex and expensive machine. U.S. Pat. No. 3,965,995 lists numerous prior art shaft forming machines, the disclosures of which are incorporated herein by reference.
U.S. Pat. No. 4,270,618 issued to Owens teaches an earth boring apparatus which is used for boring a blind pilot hole of a relatively small diameter which is subsequently enlarged by raise boring. Initially, the earth boring apparatus is employed to bore a blind pilot hole. Then the apparatus is removed from the hole and a room is blasted at the blind end of the hole. Next, the pilot hole cutterhead is replaced by a reamer and the apparatus is again inserted into the hole. The reamer is an adjustable diameter type and its diameter is increased once it is within the blasted room. The diameter of the reamer is increased by a plurality of cutter carrying arms which swing outwardly from the axis of rotation of the reamer. The earth boring apparatus is then raised from the room upwardly towards the ground surface to bore a hole of the desired diameter.
Similarly, U.S. Pat. No. 4,646,853 issued to Sugden et al. discloses a shaft boring machine having step-wise operation. The machine includes a cutterwheel assembly having a substantially horizontal axis of rotation and having multiple peripherally mounted roller cutter units. Motors are provided for rotating the cutterwheel assembly about its horizontal axis. A cutterwheel carriage and vertical guide columns support the cutterwheel assembly and allow movement of the cutterwheel assembly in a vertical plane. A base frame supports the vertical guide columns. The base frame is slewed in a substantially horizontal plane by a slew drive system. Plunge cylinders mounted on the cutterwheel carriage and the base frame lower and raise the cutterwheel assembly in a vertical plane. A lower gripper ring stabilizes the machine in the shaft and includes a circular track for supporting the base frame and further includes a lower gripper cylinder system for holding the gripper ring stationary in the shaft. An upper gripper ring provides further stabilization of the machine in the shaft and includes an upper gripper cylinder system for holding the upper gripper ring stationary in the shaft. Walking cylinders are mounted on the lower and upper gripper rings for raising and lowering the rings. U.S. Pat. No. 4,646,853 discloses additional prior art patents pertaining to shaft boring machines, the U.S. patent disclosures of which are incorporated herein by reference.
U.S. Pat. No. 4,270,618 issued to Owens cites prior art patents for drilling machines located at an upper level which bore a large diameter hole in a single downward pass, drilling machines at an upper level which first drill a small pilot hole on a single downward pass and then enlarge the pilot hole in a single upward pass, and machines having expandable reamers. These prior art patents are incorporated herein by reference.
U.S. Pat. No. 3,840,272 issued to Crane et al.; U.S. Pat. No. 3,999,616 issued to Crane et al.; U.S. Pat. No. 4,009,909 issued to Robbins et al.; and patents cited therein disclose machines for upward tunneling, as opposed to down reaming.
A need thus exists for a down reaming apparatus capable of boring a large diameter hole in a substantially continuous manner.
A need also exists for this type of down reaming apparatus which is stabilized in the bored shaft by means of non-gripping stabilizer assemblies having rotatable elements which allow vertical movement of the down reaming apparatus within the tunnel.
A need also exists for this type of down reaming apparatus in which a gear assembly is employed to multiply the torque transmitted from the drill string to the cutterhead.
A need also exists for this type of down reaming apparatus in which a weight assembly is secured on the frame of the down reaming apparatus such that loads from rotation of the cutterhead are transmitted through the frame and into the weight assembly.
A need also exists for this type of down reaming apparatus in which the weight stack has a manway therethrough for access by workers to the cutterhead for cutterhead repair and/or reconfiguration.
A need also exists for this type of down reaming apparatus of this type in which the cutterhead diameter can be increased by the addition of a single spacer having a cutter assembly thereon.
SUMMARY OF THE INVENTION
A down reaming apparatus attached to a drill string includes a frame and a rotatable cutterhead. Support for the down reaming apparatus in the tunnel is provided by an upper stabilizer and a lower stabilizer. The upper stabilizer includes an upper stabilizer hub circumferentially disposed around the drill string such that the drill string rotates relative to the upper stabilizer hub. A plurality of wheel assemblies are radially attached to the upper stabilizer hub. Each of the wheel assemblies has rotatable tires adapted to be oriented against the tunnel wall and a rotatable overload wheel which contacts the tunnel wall to stabilize the down reaming apparatus upon compression of the tires.
The lower stabilizer provides additional support for the down reaming apparatus and includes a lower stabilizer hub below the cutterhead such that the cutterhead rotates relative to the lower stabilizer hub. A plurality of wheel assemblies are radially attached to the lower stabilizer hub. Each of the wheel assemblies has a wheel support pivotally attached to the lower stabilizer hub and spaced therefrom by a compressible bumper. The rotatable wheel on the wheel support reacts against the tunnel wall to stabilize the down reaming apparatus.
The weight assembly, comprising a plurality of stacked plates, is secured to the frame of the rock boring apparatus by a plurality of tie rods such that loads from boring with the cutterhead are transmitted through the frame and into the weight assembly. Manways in the weight assembly allow passage of workers therethrough.
In the preferred embodiment of the present invention the upper stabilizer includes six wheel assemblies having removable extensions to accommodate tunnels of varied diameter. Each of the wheel assemblies is comprised of one overload wheel between two compressible tires. Additionally, a torque multiplier assembly is located in the stabilizer hub and includes a rotatable input shaft attached to the drill string. A sun gear meshes with the input shaft, planet gears mesh with the sun gear and are supported by a planet carrier and a ring gear meshes with the planet gears. A rotatable output shaft either meshes with the ring gear while the planet carrier is held stable, or meshes with the planet carrier while the ring gear is held stable, to produce a torque component greater than that of the input shaft.
Preferably, each of the plates of the weight assembly is comprised of a plurality of wedge shaped sections which are radially offset from the adjoining layer of plates. Additionally, the plurality of tie rods are secured through the weight plates by a top plate brace, a bottom plate brace, and jacks which apply a compressive force against the plates to brace them on the frame of the down reaming appartus.
Preferably, the cutterhead of the down reaming apparatus includes a cutterhead body and a plurality of arms radially disposed on the cutterhead body with cutter assemblies on each arm. Each arm is of a different length and the arms are oriented on the cutterhead body such that the lengths of the arms are successively decreased by the same amount from each arm to the next. A plurality of arm extenders having assemblies thereon are oriented in a first position in which each of the arm extenders is attached to one of the arms such that the combined length of each arm and the attached arm extender is substantially equal. To increase the diameter of the cutterhead, a spacer having a cutter assembly is attached to the shortest of the arms and each of the arm extenders is relocated from its first position to a second position on one of the arms that is adjacent to the arm on which the arm extender was attached in the first position. In this manner, the combined length of each of the arms and attached arm extender in the second position is substantially equal, and is greater than the combined length of each of the arms and attached arm extender in the first position, thus increasing the diameter of the cutterhead. To increase the diameter of the cutterhead further, an additional spacer, or spacers, in conjunction with additional relocation of the arm extenders to a position on an adjacent arm is employed. The cutterhead also includes a plurality of cutter assemblies repositionable on the cutterhead at a plurality of locations between the radially disposed arms to balance the cutterhead. Preferably, five radially disposed arms are located on the cutterhead.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention will be evident when considered in light of the following specification and drawing in which:
FIG. 1 is a side elevational view, partially in section, of a down boring apparatus typifying the present invention;
FIG. 2 is an enlarged cross-sectional view of the upper stabilizer hub of the down boring apparatus of FIG. 1 taken along lines 2--2;
FIG. 3 is a cross-sectional view showing the upper stabilizer of the down boring apparatus of FIG. 1 taken along lines 3--3;
FIG. 4 is an enlarged view of the wheel assembly of the upper stabilizer of the down boring apparatus typifying the invention;
FIG. 5 is an enlarged cross-sectional view of the wheel assembly of the upper stabilizer of the down boring apparatus of FIG. 3 taken along lines 5--5;
FIG. 6 is a partially exposed top view of the upper stabiizer of the down boring apparatus typifying the present invention having a torque multiplier assembly;
FIG. 7 is a side elevational view, partially in section, of a first embodiment of the upper stabilizer of the down boring, apparatus of the present invention having a torque multiplier assembly with the planet carrier fixed.
FIG. 8 is a side elevational view, partially in section, of a second embodiment of the upper stabilizer of a down boring apparatus typifying the present invention having a torque multiplier assembly with the ring gear fixed.
FIG. 9 is a cross-sectional view of the weight clamp and of the down boring apparatus of FIG. 1 taken along lines 9--9;
FIG. 10 is a cross-sectional view of the weight plates of the down boring apparatus of FIG. 1 taken along lines 10--10;
FIG. 11 is a cross-sectional view of the spider, or lower weight plate support, of the down boring apparatus of FIG. 1 taken along lines 11--11;
FIG. 12 is an end view of the lower stabilizer of the down boring apparatus typifying the present invention;
FIG. 13 is an enlarged view, partially in section, of the wheel assembly of the lower stabilizer of the down boring apparatus typifying the present invention;
FIG. 14 is a cross-sectional view of the cutterhead of the down boring apparatus of FIG. 1 taken at lines 14--14 and showing a first cutterhead diameter;
FIG. 15 is a cross-sectional view of the cutterhead of the down boring apparatus of FIG. 1 taken at the same location as FIG. 14 and showing a second cutterhead diameter;
FIG. 16 is an enlarged top view of the spacer of the cutterhead of the down boring apparatus typifying the present invention;
FIG. 17 is an enlarged side view of the spacer of the cutterhead of the down boring apparatus typifying the present invention;
FIG. 18 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention having a first diameter;
FIG. 19 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention reconfigured in a second larger diameter by the addition of a single spacer;
FIG. 20 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention reconfigured in a third larger diameter by the addition of two spacers;
FIG. 21 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention reconfigured in a fourth larger diameter by the addition of five spacers; and
FIG. 22 is a schematic view of the cutterhead of the down boring apparatus typifying the present invention reconfigured in a fifth larger diameter by the addition of four single spacers and the substitution of a double spacer for the fifth single spacer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention pertains to an apparatus for reaming, or boring, holes in rock. These holes are preferably substantially vertical holes but may also be oriented at a slight angle from true vertical. More particularly the present invention pertains to down reaming of relatively large holes through rock. The term down reaming pertains to the method of rock boring in which the reaming apparatus initiates rock boring downwardly, as opposed to raise boring in which the apparatus initiates boring a predetermined distance below ground level and is raised towards the earth's surface. The preferred system of down reaming employing the present invention contemplates first boring a relatively small hole (having a diameter of between about nine and fourteen inches) downwardly from the ground surface, or from an underground level, to a predetermined distance therebelow with an apparatus generally known in the art. Next, this initial down hole is expanded to a pilot hole (having a diameter of preferably between about two meters and four meters) by employing a raise boring apparatus known in the art. Finally, this pilot hole is expanded (preferably to a diameter of between about four meters and eight meters) by boring downwardly through this pilot hole from the ground surface to a predetermined location therebelow with a down reamer according to the present invention.
Referring to FIG. 1, such a down reamer 10 is secured to drill string 12 so that various elements of down reamer 10 as described herein rotate with drill string 12 while other elements of down reamer 10 are immobile relative to drill string 12. Drill string 12, which is rotated by a motor means known in the art, passes downwardly through upper stabilizer 14 and weight plates 16. Weight plates 16 are supported by spider 18, and the lower end of drill string 12, designated as stinger 20, passes into spider 18 and is fixedly secured in box insert 22 of spider 18. Torque tube 24 and spider support arms 26 are fixedly secured to the underside of spider 18 and to the upper portion of cutterhead 28. Lower stabilizer 30 is located directly under the central portion of cutterhead 28. As drill string 12 is rotated, upper stabilizer 14 and lower stabilizer 30, being braced against the wall of the bored hole, do not rotate with the drill string 12. Weight plates 16, spider 18, torque tube 24, spider support arms 26, and cutterhead 28 all rotate with drill string 12 in order to facilitate down reaming, with the boring of rock by cutterhead 28 augmented by the downward force applied thereon by the mass of weight plates 16.
Referring now to FIG. 2, the attachment of upper stabilizer 14 onto drill string 12, which allows relative rotation of drill string 12 and inner race 31 with respect to upper stabilizer 14, is now described in detail. Upper stabilizer hub 32 has stabilizer bearings 34 located at each end thereof. Stabilizer bearings 34 allow relative rotation of drill string 12 and inner race 31 with respect to upper stailizer 14. Upper stabilizer 14 is preferably divided into two halves which are joined around drill string 12 and connected by fastening means such as bolts or the like. The inner race 31 located adjacent the upper portion of upper stabilizer hub 32 has an annular seal 36 located therearound. Segmented clamp 38 is attached to drill string 12. Load isolator 40 is located between segmented clamp 38 and drill string 12.
Referring now to FIGS. 3 through 5, the upper stabilizer 14 is described in detail. Upper stabilizer 14 is comprised of a plurality, preferably six, stabilizer legs 42 radially secured to upper stailizer hub 32. Disposed over stabilizer legs 42 are support plates 44. Stabilizer legs 42 include wheel assembly 46 and, optionally, leg extensions 48 bracketed between wheel assemblies 46 and upper stabilizer hub 32. Leg extensions can be of numerous predetermined lengths in order to allow down boring of tunnels of various diameters.
Referring to FIGS. 4 and 5, wheel assemblies 46 are comprised of a pair of wheels 50, each of which includes a hub 52 and a tire 54 which is preferably filled with an elastomeric material such as polyurethane. Alternatively, wheel 50 may be a dulled roller cutter known in the art which is attached to a compressible bumper described below. Hub 52 is rotatable around strut 56. Axle 58 connects hub 52 to strut 56. Located between the two wheels 50 on axle 58 is overload wheel 60 which, like wheels 50, is rotatable on axle 58 relative to struts 56. Overload wheel 60 is preferably comprised of a metal alloy or other nondeformable material. Overload wheel 60 provides additional support for down reamer 10 during boring operations where excessive side forces are encountered which overcompress tires 54 of wheel assemblies 46, due to, for example, narrowing of the bored hole diameter. Thus, it is readily apparent that overload wheel 60 has a radius which is less than that of wheels 50 and the difference between these two radii is selected based upon the amount of compression of wheels 50 that is desired during boring operations. Rotation of wheels 50 and overload wheels 60 allow vertical movement of down reamer 10 during stabilization.
Referring now to FIGS. 6 through 8, two optional torque multiplying gearing assemblies 62 for upper stabilizer 14 are disclosed. These two torque multiplier gearing assemblies 62 are configured to be located within upper stabilizer hub 32. The torque multiplier assembly 62 increases the torque from drill string 12 to cutterhead 28, and reduces the rate of rotation of cutterhead 28 as compared to that of drill string 12. Torque multiplication is desired because, to bore relatively larger diameter holes efficiently, it is necessary to employ greater torque than drill string 12 can transmit without breaking.
Referring specifically to FIG. 6, torque multiplier assembly 62 includes planetary gearing comprising a sun gear 64 axially oriented in upper stabilizer hub 32. Planet gears 66 mesh with sun gears 64. Preferably three planet gears 66 are employed but more or less can also be used in order to obtain a desired amount of torque multiplication. Planet gears 66 mesh with ring gear 68 located adjacent the external periphery of upper stabilizer hub 32. Referring to FIG. 7 a first embodiment of torque multiplier assembly 62 is shown in which approximately a 2:1 ratio for example, of torque multiplication is achieved by employing a fixed planet carrier and output from the ring gear. Specifically, input shaft 70 is attached to drill string 12 and has input shaft seal 72 and input shaft bearings 74 located adjacent thereto. Sun gear 64 meshes with input shaft 70 by means of spline 76. As stated above, sun gear 64 also meshes with planet gears 66, which in turn mesh with ring gear 68. Planet gears 66 rotate on planet gear bearings 78 around planet gear shaft 80. Planet gears 66 are supported by planet carrier 82. As previously stated, planet carrier 82 is fixed in this embodiment. Planet gears 66 in turn mesh with ring gear 68, the output of which is transmitted to output shaft 84. Output shaft 84 is located adjacent the lower portion of upper stabilizer hub 32 and is rotatable by means of output shaft bearings 86. Output shaft seals 88 are located adjacent output shaft 84. In operation, rotation of drill string 12 causes rotation of input shaft 70, spline 76, sun gear 64, planet gear 66, ring gear 68 and output shaft 84.
Referring now to FIG. 8, a second embodiment of torque multiplier assembly 62 is disclosed in which a greater than 2:1 ratio of torque multiplication is obtained. The second embodiment of the torque multiplier assembly 62 of FIG. 8 is substantially identical to the first embodiment of the torque multiplier assembly 62 of FIG. 7 with the exception that in the second embodiment of the torque multiplier assembly 62 ring gear 68 is fixed and output is from planet carrier 82. Thus, in operation of the second embodiment of the torque multiplier assembly 62 of the present invention, rotation of drill string 12 causes corresponding rotation of input shaft 70, sun gear 64, planet gear 66, planet carrier 82, and output shaft 84.
In the above two embodiments of torque multiplier assembly 82, either the ring gear 68 or planet carrier 82 is fixed by the torque reaction applied by the frictional forces of the wheel assemblies 46 and stabilizer legs 42. If the frictional forces are deemed inadequate to react the torque from torque multiplier assembly 62, the above-mentioned dulled roller cutter can be employed as wheel 50 to cut into the rock to increase the torque reaction capabiities.
Referring now to FIGS. 9 through 11, weight assembly 90 of down reamer 10 is described in detail. Weight assembly 90 includes top weight clamp 92, positioned above a plurality of weight plates 16 and spider 18 oriented below weight plates 16. Spider 18 is also termable as a lower weight clamp. Referring to FIG. 9, upper weight clamp 92 includes weight clamp hub 94 oriented around drill string 12. A plurality of weight clamp arms 96 are radially disposed around weight clamp hub 94. Each of weight clamp arms 96 has a tie rod platform 98 on its end remote from weight clamp hub 94. Each tie rod platform 98 has one or more tie rod openings 100 therein.
Referring now to FIGS. 9 and 10, weight plates 16 of weight assembly 90 are described in detail. Each of weight plates 16 is comprised of a high mass material such as lead or a high mass metal alloy. Each weight plate 16 is preferaly comprised of a plurality of wedge shaped sections 102, which may be, for example, five in number. Wedge shaped sections 102 are radially disposed around opening 104 through which drill string 12 passes. Each of wedge shaped sections 102 has tie rod openings 106 therein which are adapted to be aligned with tie rod openings 100 of upper weight clamp 92. Additionally, one or more of wedge shaped sections 102 has a manway hole 108 therethrough. Manway hole 108 has rung 110 therein. Tie rod openings 106 and manway hole 108 are oriented in wedge shaped sections 102 of successive layers of stacked weight plates 16 such that tie rods can pass through the tie rod openings 102 in weight plates 16, and a manway is formed by the manway holes 108 of the stacked weight plates 16 such that an individual can pass therethrough to access cutterhead 28 for modification and/or maintenance thereof. Adjacent layers of weight plates 16 are preferably configured such that the wedge shaped sections 102 of each of the adjacent weight plates 16 are offset to maximize structure integrity of weigh assembly 90.
Now referring to FIG. 11, the spider 18, or lower weight clamp, of weight assembly 90 of down reamer 10 is described in detail. Spider 18 includes a spider hub 112 having a center portion in which stinger 20 of drill string 12 is securedly attached. A plurality of spider arms 114, preferably five in number, are radially disposed on spider hub 112. Each spider arm 114 has tie rod openings 116 passing therethrough. Tie rod openings 116 are oriented on each of spider arms 114 such that tie rod openings 116 are aligned with tie rod openings 106 of weight plates 116 and tie rod openings 100 of upper weight clamp 92 such that tie rods 118 pass through tie rod openings 100, 106, and 116. As shown in FIG. 1, tie rods 118 are secured through upper weight clamp 92, weight plates 16, and spider 18 of weight assembly 90 by jack 120. Thus, tie rods 118 secure weight plates 16 with upper weight clamp 92 and spider 18 of weight assembly 90 such that loads from rotation of cutterhead 28 are transmitted into weight assembly 90 as opposed to into stinger 20 of drill string 12. More specifically, rotation of drill string 12 results in rotation of upper weight clamp 92, weight plate 16 and spider 18 of weight assembly 90, as well as rotation of torque tube 24 and spider support arms 26 located between spider 18 and cutterhead 28, and also rotation of cutterhead 28. Thus, over-turning loads encountered by cutterhead 28 during boring pass from cutterhead 28 through torque tube 24 and spider support arms 26, and into weight assembly 90 and upper stabilizer 14 where the relatively larger diameter of weight plates 16, as compared to that of drill string 12, results in a greater section modulus which allows weight assembly 90 to withstand greater over-turning loads than drill string 12.
Referring now to FIGS. 12 and 13, the lower stabilizer 30 of the down reamer 10 is described in detail. Lower stabilizer 30 includes a lower stabilizer hub 122 comprised of an inner race 124 fixedly secured to rotatable cutterhead 28 and an outer race 126 rotatably attached to inner race 124 by bearings 128. A plurality of wheel assemblies 130 are radially secured to outer race 126. Preferably five wheel assemblies 130 are present. Attachment of wheel assemblies 130 to outer race 126 is by means of pin 132, which is fixedly secured to outer race 126, and pivot sleeve 134 located over pin 132 which is rotatable therearound. Wheel arm 136 is attached to pivot sleeve 134 and is also supported on outer race 126 by a compressible bumper 138. Wheel arm 136 holds wheel mount 142 in which is located rotatable wheel 144.
In operation, as cutterhead 128 rotates, inner race 124 of lower stabilizer 30 rotates as well. However, outer race 126, and wheel assemblies 130 do not rotate with cutterhead 28. Rotatable wheels 144 contact the tunnel wall to provide stabilization for down reamer 10. As compressive forces are encountered by lower stabilizer 30 due, for example, to narrowing of the bored hole diameter, wheel arm 136 pivots on pivot sleeve 134 around pin 132 to stabilize down reamer 10. The length of the pivot stroke of wheel arm 136 is dictated by the degree of compressibility of bumper 138. Rotatable wheels 144 allow vertical movement of down reamer 10 while stabilization is provided by lower stabilizer 30. Rotatable wheels 144 can be, for example, dulled roller cutters known in the art, or, alternatively compressible tires with or without the above described overload wheels.
Referring to FIGS. 14 through 17, cutterhead 28 of down reamer 10 is described in detail. Cutterhead 28 includes a cutterhead body 146 and the plurality of arms 148 radially disposed around cutterhead body 146. Each of arms 148 has attached thereto an arm extender 150. Each arm 148 and arm extender 150 have one or more cutter assemblies 152 secured thereon. Cutter assemblies 152 can include disc cutters or gauge cutters generally known in the art. Cutterhead assemblies 152 are preferably removable from the upper portion of the cutterhead 28 by means of manway holes 108 of weight assembly 90, or adjacent the exterior of down reamer 10. Spacer 154 is adapted to be attached between arm 148 and arm extender 150 to increase the diameter of the cutterhead, as further detailed below. Braces 153 attached adjacent arm extenders 150 and secured thereto are additional cutter assemblies 152 which "float". By "float" it is meant that cutter assemblies 152 can be configured at various locations on any of braces 153. The locations of floating cutter assemblies 152 are varied to load balance the cutterhead when the cutter diameter is increased. More specifically, the forces and moments of each cutter assembly 152, either floating or not, are summed to balance the cutterhead 28. The factors considered in ascertaining the forces and moments of each cutter assembly 152 include the hardness and fracture toughness of the rock being bored.
As shown in FIGS. 16 and 17, spacer 154 includes cutter assembly 156 preferably having a disc cutter 158 known in the art. Spacer 154 is fixedly secured between arm 148 and ar extender 150 by means of bolts 160 or the like.
Referring now to FIGS. 18 and 19, the use of spacers 154 to increase the diameter of cutterhead 28 is further described. Referring specifically to FIG. 18, cutterhead 28 having a first, initial diameter is comprised of a plurality of arms 148. As shown in FIG. 18, five arms 148 are designated therein as 148A, 148B, 148C, 148D, and 148E. However it is to be understood that more or less than five arms 148 may be employed. Each of arms 148A through 148E has a different length, and the length difference between any two adjoining arms 148A through 148E is equal. More specifically, arm 148A has the shortest length of all of arms 148A through 148E. Arm 148E has the greatest length of all arms 148A through 148E. Additionally, the length of arms 148E through 148A preferably decreases in a radial direction around cutterhead 28 such that, as shown in FIG. 18, arm 148D is shorter than arm 148E, arm 148C is shorter than arm 148D, arm 148B is shorter than arm 148C, and, finally, arm 148A is shorter than arm 148B. As stated above, the length difference between any two adjoining arms is the same. An arm extender 150 is attached to each of arms 148A through 148E. Each arm extender is designated as 150A, 150B, 150C, 150D, and 150E based on which of respective arms 148A through 148E the arm extender is attached. Thus, for example, arm extender 150A is attached to arm 148A in FIG. 18. Each of arm extenders 150A through 150E has a length such that the combined length of each of arms 148A through 148E and its attached arm extender 150A through 150E are substantially equal.
Now referring to FIG. 19, the diameter of cutterhead 28 has there been increased from the diameter shown in FIG. 18. Increasing the diameter of the cutterhead 28 is accomplished by the attachment of spacer 154A to arm 148A as shown in FIG. 19. Preferably spacer 154A is attached to the shortest of arms 148A through 148E of cutterhead 28. Next, arm extenders 150A through 150E are reconfigured on arms 148A through 148E by removing each arm extender 150A through 150E from the arm 148A through 148E to which it is attached and reattaching each arm extender 150A through 150E to an arm 148A through 148E adjacent to the arm 148A through 148E to which that particular arm extender 150A through 150E was previously attached. Thus, as shown in FIG. 19, each of arm extenders 150A through 150E has been rotated one position in the counterclockwise direction so that arm extender 150A is now attached to arm 148B, arm extender 150B is attached to arm 148C, arm extender 150C is attached to arm 148D, arm extender 150D is attached to arm 148E and arm extender 150E is attached to spacer 154A which is secured to arm 148A. Thus, the repositioning of arm extenders 150A through 150E on arms 148A through 148E, and the addition of spacer 154A, results in a new, greater length that is substantially equal for each arm and attached, repositioned arm extender. By "substantially equal length" it is meant that upon addition of spacer 154A, arms 148A through 148E and attached arm extenders 150A through 150E have lengths which maintain the desired cutterhead profile (i.e. the relative relationship of the various cutter assemblies 152 on cutterhead 28). Preferably, in order to achieve the desired increase in diameter of cutterhead 28, the above-mentioned difference in length between any two adjacent arms 148A through 148E, multiplied by the number of arms 148A through 148E will be substantially equal to the length of the spacer 154 added to cutterhead 28. In other words, if five arms 148A through 148E are present, the difference in length between any two adjacent arms 148A through 148E will equal one-fifth of the length of spacer 154. Thus, the increase in diameter of cutterhead 28 is equal to the length of spacer 154 divided by the number of arms 148A through 148E. If five arms 148A through 148E are present, the increase in diameter of cutterhead 28 will therefore be equal to one-fifth of the length of spacer 154.
FIG. 20 shows an increase in the diameter of cutterhead 28 over the diameter shown in FIG. 19 by the addition of yet another spacer 154. In FIG. 20, spacer 154B has been attached to arm 148B and all of arm extenders 150A through 150E have been rotated an additional position in the counterclockwise direction so that arm extender 150A is now attached to arm 148C, arm extender 150B is attached to arm 148D, arm extender 150C is attached to arm 148E, arm extender 150D is attached to spacer 154A which is secured to arm 148A, and arm extender 150E is attached to newly added spacer 154B which is secured to arm 148B. Note that newly added spacer 154B has been added to the next shortest arm, namely 148B. It is readily apparent that the diameter of cutterhead 28 can be repeatedly, incrementally increased by the further addition of spacers 154 so that a cutterhead 28 having a diameter as shown in FIG. 21 can be obtained.
In FIG. 21, five spacers, 154A through 154E have been added to the five arms 148A through 148E, respectively. During each incremental spacer addition, arm extenders 150A through 150E were rotated one position in the counterclockwise direction and attached to the adjacent arm 148A through 148E.
FIG. 22 shows a cutterhead 28 having a diameter greater than the diameter shown in FIG. 21 in which five spacers 154A through 154E were added. In FIG. 22, spacer 154A has been removed and spacer 154A' has been added. Spacer 154A' has a length greater than that of spacer 154A, and preferably includes an additional cutter assembly thereon. In addition to the substitution of spacer 154A' for spacer 154A on arm 148A, each of arm extenders 150A through 150E were rotated one position in the counterclockwise direction and attached to the adjacent arm 148A through 148E as previously described. It is readily apparent that the diameter of cutterhead 28 can be further increased from the diameter shown in FIG. 22 by the addition of even more spacers 154A' through 154E' having lengths greater than spacers 154A through 154E. Each of spacers 154A' through 154E' would be incrementally substituted for spacers 154A through 154E, respectively. Furthermore, spacers having a length greater than 154A' through 154E', and preferably having more than two cutter assemblies thereon, could subsequently be added to increase the diameter of cutterhead 28 even further.
While the above described use of spacers 154A through 154E and sequential repositioning of arm extenders 150A through 150E on arms 148A through 148E was made with reference to down reamer 10, it is readily apparent that a cutterhead 28 capable of this type of increase in diameter can be employed on any apparatus employing a rotatable cutterhead, such as a down reamer, a raise borer, a tunnel boring machine, a mobile mining machine, and any and all machines employed in mining tunneling and excavation operations.
It is also to be understood that while the arm extenders 150A through 150E have been described as being repositioned in a counterclockwise direction, arm extenders 150A through 150E may also be repositioned in a clockwise direction, or, alternatively, may be repositioned onto respective arm 148A through 148E which are not necessarily adjacent provided that said repositioning results in a length that is substantially equal for each arm and attached, repositioned arm extender.
The above described embodiments are intended to be descriptive, not restrictive. The full scope of the invention is described by the claims, and any and all equivalents are included.
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A down remaining apparatus has an upper stabilizer which supports the down reaming apparatus in the bored hole. A plurality of wheel assemblies are radially attached to the hub of the upper stabilizer. Each of the wheel assemblies has rotatable tires oriented against the bored hole wall, and a rotatable overload wheel which contacts the tunnel wall upon compression of the tires. A weight assembly comprising a plurality of stacked plates is secured to the frame of the down reaming apparatus and has manways therethrough which allow passage of workers. A lower stabilizer provides additional support for the down reaming apparatus. A plurality of wheel assemblies are radially attached to the hub of the lower stabilizer. Each of the wheel assemblies has a rotatable wheel pivotally attached to the lower stabilizer hub and spaced therefrom by a compressible bumper which reacts against the bored hole wall to stabilize the down reaming apparatus.
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BACKGROUND OF THE INVENTION
The present invention is directed generally to peristaltic type pumps and, in particular, to an improved peristaltic pump arrangement for use in minimizing pump start-up problems.
Peristaltic pumps have a wide variety of applications and are often used because of their accuracy in pumping fluids, as well as their relatively inexpensive construction and assembly. Typical peristaltic pumps comprise a rotatable shaft having several circumferentially spaced tube compression rollers supported thereon which are positioned for orbital movement along a circular path against an elastically occludable tube. The tube includes a fluid inlet and an outlet and is positioned between a fixed tube reaction surface of the pump housing and the compression rollers. Peristaltic pumping is effected when the occludable tube is sequentially depressed or occluded by the compression rollers against the reaction surface. In this regard, as the drive shaft rotates, the compression rollers advance relative to the stationary tube to create peristaltic pumping action on fluid within the tube.
A disadvantage of this type of pump is the fact that the occludable tubing is necessarily elastic and will memorize depressions if the compression rollers remain static. Upon restarting there is a tendency for the pump motor driving the pump not to be able to overcome the added resistance caused by these depressions and, thus, the pump cannot operate. Moreover, there are occasional pump/motor mounting misalignment problems which occur in some installations and such variances in the desired alignment create problems in the sense that the drive shaft may encounter added rotational resistance, thereby inhibiting desired pump starting.
Various approaches have been suggested in the peristaltic pump art for addressing problems associated with the cooperation of compression rollers and the associated occludable tubing. Examples of these approaches are shown in the following U.S. Pat. Nos.: 3,353,491; 3,876,340; 3,990,444; 4,025,241; 4,233,001; and, 4,856,972.
Despite the foregoing approaches in this art there is a continuing desire to improve upon the operation of peristaltic pumps particularly in overcoming torque problems.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, there is provided an improved peristaltic pumping apparatus comprising: a support assembly; motor means connected to the support assembly and having a drive shaft; and a pump housing assembly. Included in the pump housing assembly is means for freely mounting the pump housing assembly on the drive shaft. An occludable tubing is provided which cooperates with the pump housing assembly. The housing assembly includes a tubing support surface against which the tubing is compressed and thereby occluded. Rotatable means are provided on the shaft in the housing and include a plurality of circumferentially spaced compression rollers for selective and individual engagement with the tubing. The rollers are collectively rotated in response to rotation of the drive shaft so as to selectively compress and occlude the tubing to thereby effect peristaltic pumping of fluid through the tubing. A motion arresting means is provided which is positioned to be spaced from and engaged by the pump housing assembly after a predetermined movement of the latter. Limited movement occurs in response to rotation of the drive shaft and compression rollers driving the tubing and the housing assembly. This limited movement allows the rotatable means to gain momentum sufficient to overcome start-up torque resistance and to rotate relative to the tubing, which becomes stationary, to thereby effect peristaltic pumping of fluid through the tubing.
Among of the other objects of the present invention are the provisions of: an improved peristaltic pumping arrangement; an improved peristaltic pumping arrangement which minimizes substantially start-up torque problems caused by increased resistance of the tubing; an improved peristaltic pumping arrangement which overcomes start-up torque problems caused by misalignment of pump and drive motor; and an improved peristaltic pumping arrangement which includes a pump housing that is freely mountable on a drive motor shaft and which is rotatable until it engages stop means for limiting relative movement of the pump housing to thereby allow the pump roller means to gain momentum and thus overcome resistance of the pump roller means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a pumping arrangement made according to the present invention; and,
FIG. 2 is an elevational view of the pump arrangement depicted in FIG. 1 with portions removed for clarity.
DETAILED DESCRIPTION
FIG. 1 relates to one preferred embodiment of a peristaltic pumping system 10 embodying the principles of the present invention. Included in the peristaltic pumping system 10 is a peristaltic pumping apparatus 12 a drive motor 14 therefor. Both the pumping apparatus 12 and its drive motor 14 are mounted on a suitable support assembly 16 which can, for example, be part of an operational device, such as a commercial dishwasher or the like. In this embodiment, the peristaltic pumping apparatus 12 is constructed to advance preselected quantities of liquid detergent and other chemicals as required for a washing cycle of a dishwasher.
Reference is now made to FIGS. 1 and 2 for illustrating the peristaltic pumping apparatus 12 made according to one preferred embodiment of the invention. Included in the apparatus 12 is a pump casing 18 including inlet and outlet tube openings 22 and 20 for receiving fluid connectors 24 that are attached at respective inlet and outlet end portions of a flexibly, resilient squeezable or occludable tubing 26 made of a known type of material. The connector 24 and tubing 26 for the inlet opening 22 are secured to the casing 18 for movement therewith, while the connector 24 and tubing 26 for the outlet opening 20 has a slight clearance 27 therewith so as to allow relative floating movement between the tubing 26 and the casing 18, thereby minimizing undesired stretching and bending of the tubing during rotation of the casing and thus prolonging the life of such tubing.
The pump casing 18 includes a centrally located bearing 28 that is adapted to be slidably disposed on an drive shaft 30 of an electric gear type motor 32 that is secured to a suitable wall 34 of the support assembly 16. A smooth inner surface of the bearing 28 allows the casing 18 to be rotatable relative to the drive shaft 30. The casing 18 has a generally smooth and arcuate inner surface 18a which is adapted to define a path for the U-shaped tubing 26 as well as a reaction surface against which the tubing is selectively compressed and occluded. Also, suitably mounted on the drive shaft 30 is pump roller assembly 36 that comprises a plurality of equidistant and circumferentially spaced tubing compression rollers 38. Each of the compression rollers 38 is mounted for rotation about a shaft 40 that is secured at its opposite ends to a pair of spaced plates 42. A central drive hub 44 is secured to the plates 42 and is fixedly attached, as by a set screw, to the drive shaft 30 for positive rotation therewith. Accordingly, rotation of the shaft 30 drives the plates 42 and their compression rollers 38. In this manner the rollers 38 selectively compress the tubing so as to effect peristaltic pumping in a well-known manner.
The pumping apparatus 12 includes preferably a casing cover 46 cooperating with a central bearing 48 which has a rotatable connection to the drive shaft 30. The bearing 48 is constructed to allow the pump casing cover 46 to be freely mounted on the shaft 30 for reasons which will be explained. As a result of the foregoing relationship, the pumping apparatus 12 will rotate upon rotation of the driving shaft 30 until the casing 18 engages a stop member 50 threadedly mounted on the support assembly 16. As a result, the casing 18 and its associated tubing remain stationary and the compression rollers 38 have gained sufficient momentum to be free to rotate relative to the pump casing 18 and the tubing 26 to thereby sequentially compress and occlude the tubing against the wall 18a. The stop member 50 is spaced sufficiently from the casing 18 so as to allow the rollers to gain sufficient momentum. Referring back to the stop means or motion arresting means 50, it can be defined by a resilient shock absorbing sleeve 52.
Upon energization of the drive motor 32, the operation of the peristaltic pump is accomplished easily. In this regard, the motor 32 drives its shaft 30 and causes rotation of the pump roller assembly 36. Due to, for instance, resistance of the compression rollers 38 against the tubing 26, the rollers will rotate the tubing and thereby the casing 18 until the latter engages the stop member 50. By this time the rollers 38 have sufficient momentum to overcome the resistance caused by the depressions 26a of the tubing and to rotate relative to the stationary tubing 26 in a known manner for effecting the peristaltic pumping.
Because of the arrangement described above, start-up torque problems caused by relatively high resistance of the type created by tube depressions and/or bearing misalignment problems are overcome. Another advantage of the foregoing arrangement is that the pumping apparatus is easy to install and remove.
Another embodiment contemplates use of a compression spring or other elastomeric device 54 between the supporting assembly 16 and the casing 18 so as to tend to urge the latter into disengagement with the stop member 50 to assure starting momentum. The spring 54 functions to additionally assist in overcoming resistance.
Certain changes may be made in the above described apparatus without departing from the scope of the invention involved and it is intended that all matter contained in the description thereof or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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An improved peristaltic pumping arrangement is disclosed as comprising a housing assembly that is freely mounted on a pump drive shaft, an occludable tubing, a plurality of compression rollers being rotatable by the shaft and capable of compressing the tubing and rotatably driving the tubing and housing assembly a limited extent until the housing assembly strikes a stop assembly for arresting limited rotational movement of the housing assembly and tubing thereby allowing the imparting of sufficient torque to pump the fluid.
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FIELD OF THE INVENTION
The invention relates to the use of cellulosic thickeners in coatings which are applied to paper products. In particular the invention relates to improved coating efficiency when a hydrophobically modified cellulosic thickener is used.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,154,899 describes the use of pigment, clay and modified starch ether for coating compositions which are applied to paper during manufacture European Patent Application EP 307-795 describes a pigment dispersion used for paper coating which can contain modified starch, galactomannan, MC (methylcellulose) or CMC (carboxymethylcellulose). A quaternary starch ether is employed in the papermaking method of U.S. Pat. No. 4,840,705.
It is further known from Aqualon® publication 250-11C, Natrosol®--Hydroxyethylcellulose--A Nonionic Water Soluble Polymer--Physical and Chemical Properties, that this cellulosic can be used in coating colors and size press solutions to control water binding, solids holdout and rheology. Hercules Incorporated product data publication 456-2, Natrosol® R in Pigmented Coatings for Paper and Paperboard, contains viscosity data useful for selection of a grade of product for a papermaking application.
U.S. Pat. Nos. 4,834,207, 4,228,277 and 4,243,802 describe hydrophobically modified hydroxyethylcellulose (HMHEC) for use in latex paints and shampoos. Chain lengths from C10 to C24 provide the hydrophobic modification.
Still it remained for the present invention to teach a new and useful coating composition and process of use applicable to paper manufacture.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an aqueous paper coating composition comprising a polysaccharide thickener, characterized in that the thickener is a water soluble hydrophobically modified alkylcellulose and/or hydroxyalkylcellulose. It is preferred that a C12 to C16 alkyl or arylalkyl group modifies a hydroxyethylcellulose as an effective associative thickener.
An improved process for paper manufacture involves the steps:
(1) preparing an aqueous coating composition with hydrophobically modified alkylcellulose and/or hydroxyethylcellulose, pigment and binder,
(2) applying the composition to a semiabsorbent surface;
(3) removing excess composition to provide a uniform coating; and
(4) drying to produce a paper product.
The hydrophobically modified hydroxyalkylcellulose can be added as the sole thickening agent or in combination with other thickening agents. Dry powders or fluid suspensions containing combinations of materials may be used.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1. High shear viscosities of the invention are illustrated in comparison with two controls.
DETAILED DESCRIPTION OF THE INVENTION
In common with other industries the paper and paperboard manufacturers seek to improve productivity and lower mill cost. One of the problems limiting their ability to coat at higher speeds has been nonuniformity and quality defects using existing coating compositions and techniques.
Associative thickeners which associate with themselves are useful in the practice of the present invention providing improved rheology in paper coating compositions applied with a metering blade, rod or air knife. They provide high thickening efficiency with high pseudoplasticity in high solids content coating compositions. During blade coating a hydrophobically modified cellulosic allows lower blade pressures to be used with a resulting improvement in coating quality at high speeds. Lower blade pressure resulting from the use of associative thickeners can reduce water loss to the paper stock, web breaking and streaking, particularly at high coating speed.
In view of the considerable prior effort made to overcome these problems, it was a surprising result to find how efficient the composition and process of the invention were in meeting the aims of the paper industry. By reducing blade pressure, coating speeds can be increased by 10 to 25%. Uniform paper surfaces can be produced using lower amounts of thickeners. Higher productivity can be achieved without sacrifice of quality or significantly increasing costs.
Cellulosic thickening agents having suitable hydrophobic modification are available from the Aqualon Company. A preferred modified cellulosic is Natrosol® Plus. An Aqualon publication, Natrosol® Plus 250-18A, describes how this material functions as an associative thickener in paint, but gives no suggestion of the present invention. Another suitable associative thickener is ethylhydroxyethylcellulose, Bermocoll® EHM 100 from Berol Nobel.
Depending upon the needs of the paper manufacturer it may be desirable to use one or more hydrophobically modified cellulosics in combination with one or more conventional thickeners such as CMC (carboxymethylcellulose) or HEC (hydroxyethylcellulose) Thus by partially replacing CMC or HEC in an existing coating composition with hydrophobically modified hydroxyethylcellulose (HMHEC), it would be possible to lower the high shear viscosity by increments.
Typical ingredients for paper coating compositions in addition to thickeners include: pigments (e.g., kaolin clay, calcium carbonate, gypsum, titanium dioxide, etc.), polymeric binder (e.g., styrene-butadiene latex, protein, starch, etc.), lubricants such as glycols and fatty acids, insolubilizers and defoamers. Once prepared as a coating composition it is usual practice in the industry to measure viscosity and rheology properties of the composition prior to an actual test of the composition. In this way a body of knowledge was built up by comparison of such results with the actual quality and reproduceability provided by any of the compositions tested. For instance, desirable Brookfield viscosities measured at 100 rpm are in the 500 to 3000 mPa.s range, while high shear viscosity is best between 20 and 100 mPa.s.
Kaltec Scientific, Inc., 22425 Heslip Drive, Novi, Mich. 48050 supplies parts and rheogram paper for use with the Model ET24-6 Hercules® Hi-Shear Viscometer which is in common use by the paper industry for evaluation of coating compositions.
DETAILED DESCRIPTION OF THE DRAWING
FIG. 1 illustrates sample rheograms of the invention versus sample rheograms of the prior art. Where slope is high, the high shear viscosity is low, represented by the invention, then the thickener is expected to be less resistant to flow under high shear conditions. The graph plots revolutions per minute (RPM) versus TORQUE (dyne cm). In each Hercules high shear test, the coating sample was subjected to two consecutive shear cycles. The first cycle is represented by (a) and the second cycle by (b); both cycles were conducted from static to 4000 rpm in 20 seconds. Reported values are taken from the (b) cycle since the (a) cycle only serves to break down the excessive structure developed during storage.
The (a) and (b) cycles of HMHEC according to the invention in comparison to the (a) and (b) cycles of two prior art CMC controls clearly show the advantage in terms of relatively low resistance to flow at high shear.
______________________________________Paper Coating Compositions A B C DFormulation Amounts in GramsIngredients (Dry or 100% Active Basis)______________________________________Hydrafine ® 100 100 50 --Hydrasperse ® -- -- -- 50Hydraprint ® -- -- -- 50Hydracarb ® 65 -- -- 50 --Dispex ® N40 -- 0.1 0.1 0.25Dow ® 620 13 16 13 14Penford Gum ® 290 -- -- -- 4Sunrez ® 700M -- -- -- 0.12Flowco ® 501 0.5 1 0.5 1Hercules ® 831 0.2 -- -- 0.25Thickener varied varied varied variedTarget Viscosity 2300 2300 2000 1800Hydrafine ® pigment, No. 1 kaolin clay, J. M. Huber Corp.Hydrasperse ® pigment, No. 2 kaolin clay, J. M. Huber Corp.Hydraprint ® pigment, delaminated clay, J. M. Huber Corp.Hydracarb ® 65 pigment, ground CaCO.sub.3 suspension. Omya Inc.Dispex ® N40 clay dispersant, Allied Colloids Inc.Dow 620 binder, styrene-butadiene latex, Dow Chemical Co.Penford Gum 290 binder, hydroxyethylated starch, Penick & Ford, Ltd.Sunrez ® 700M insolubilizer for starch, Sun ChemicalFlowco ® 501 lubricant, calcium stearate dispersion, MallinckroftHercules ® 831 defoamer, Hercules Incorporated______________________________________
PREPARATION
The paper coating compositions which were used in the following examples were prepared by mixing together the indicated amounts of ingredients. The total solids in weight percent, varied from 58 to 64% for controls and experimental compositions. The coating compositions were all adjusted to pH 8. The usage level of thickener was varied to obtained the target viscosity as measured with a Brookfield Viscosity at 100 rpm.
The following examples illustrate the practice of the invention which has industrial application in paper coating.
EXAMPLE 1
The following example illustrates the effects of the hydrophobically modified (HM) cellulosic ethers on the properties of kaolin clay-based coating colors. Coating colors containing 60% solids (by weight) were prepared based on Formulation A. This formulation comprises of a fine kaolin clay and a styrene butadiene latex as the primary pigment and binder. A variety of hydrophobically modified cellulosic ethers were used to thicken the coating colors to a Brookfield viscosity of 2300 mPa.s at 100 rpm. For comparison purpose, two control coating colors were also prepared using CMC as the thickener. The amount of thickener used and the rheological properties of the colors are summarized in Table 1.
Table 1 contains comparative data for 60% solids coating compositions. The Hercules® high shear viscosities were measured at 22,500 and 45,000 s- 1 respectively.
TABLE 1______________________________________ Hercules Viscosity Brookfield 22500/ Viscosity 45000 Concentration mPa.s @ 100 recipricalThickener Parts rpm seconds______________________________________CMC (control) 2.60 2200 72.2/61.1CMC (control) 1.10 2200 56.2/47.2CMC (control) 0.72 2250 45.5/38.2Natrosol ® Plus 330 0.51 2400 31.9/29.8EHM 100 0.58 2240 38.9/36.8NP-HMHEC 0.57 2400 41.0/35.7______________________________________
As shown in Table 1 all three hydrophobically modified associative thickeners gave improved high shear performance over the three controls.
In Table 1 the control CMCs are of Grade 7 available from the Aqualon Company. Natrosol® Plus Grade 330 and NP-HMHEC (nonylplenyl hydrophobically modified hydroxyethyl cellulose) are available from the Aqualon Company. EHM 100 is a hydrophobically modified ethylhydroxyethylcellulose available from Berol Nobel.
The coating colors were applied onto a light weight paper using a cylindrical laboratory coater (CLC). Acceptable blade coating runnability was observed from the HMHEC thickened colors at web speeds up to 4000 feet per minute. The HMHEC coating color gave lower coat weight (CW) than the CMC controls at the same blade/web gap setting or blade pressure. Table 2 contains comparative results with coating speed in m/min , blade setting gap for the blade for coating in mm, and coating weight in g/m 2 .
TABLE 2______________________________________Thickener Solids Speed Gap CW______________________________________CMC (Control 1) 60.0 1225 4.191 13.3CMC (Control 2) 60.0 1225 4.293 10.6Natrosol ® Plus 330 60.0 1225 4.191 7.8Natrosol ® Plus 330 60.0 1225 4.267 9.3NP-HMHEC 60.0 1225 4.191 8.3______________________________________
EXAMPLE 2
Coating compositions were prepared and tested as in Example 1 except that formulations B, C, and D were used in place of formulation A. Table 3 gives comparative results. The concentration of thickener in each coating was based on 100 parts of pigments(s); Hercules® high shear viscosities were measured at 22500 and 45000 s -1 . AQU-D3082 is a developmental hydrophobically modified hydroxyethylcellulose from Aqualon.
TABLE 3______________________________________ Hercules Concentration Solids ViscosityThickener Formula (parts) (%) 22500/45000______________________________________CMC (control) B 0.80 64 97.2 78.4Natrosol ® Plus B 0.40 64 77.8 68.0330AQU-D3082 B 0.55 64 79.1 70.1NP-HMHEC B 0.40 64 70.8 61.7CMC (control) C 1.40 60 52.8 42.3Natrosol ® Plus C 0.60 60 33.3 27.0330CMC (control) D 0.50 62 113.9 75.6CMC (control) D 0.77 60 90.3 65.2Natrosol ® Plus D 0.22 62 112.5 69.4330Natrosol ® Plus D 0.31 60 75.0 54.8330______________________________________
EXAMPLE 3
Coating compositions were prepared using Formulation D where a starch, i.e. Penford Gum 290, was added as co-binder. Table 4 contains results.
TABLE 4______________________________________ Hercules ViscosityThickener % Add % Solids 22500/45000 S.sup.-1______________________________________CMC 0.30 64 166.7 95.0Natrosol ® Plus 330 0.05 64 143.0 88.8CMC 0.50 62 113.9 75.6Natrosol ® Plus 330 0.16 62 108.3 70.0______________________________________
EXAMPLE 4
A control and experimental sample were further tested for opacity (TAPPI test 7-425), brightness (TAPPI test T-425) and IGT pick test where the velocity-viscosity product at the point of pickoff of the paper by a 31 Pa.s viscosity polyisobitene oil was measured. Table 5 gives comparative results.
TABLE 5______________________________________Thickener CW Opacity Brightness IGT Pick______________________________________CMC 7.2 85.0 77.7 77.5Natrosol ® Plus 330 5.3 85.3 78.5 84.0______________________________________
As shown in the table, the lower coating weight sample of the invention has equivalent opacity and brightness along with a somewhat better resistance to ink pickoff. Equivalent coating quality was obtained for both samples. This illustrates that the low coating weight advantage produced by the invention can be obtained without sacrifice of quality or physical properties.
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Hydroxyalkylcellulose hydrophobically modified with a C12 to C16 alkyl or aralkyl group represents a preferred thickener for a paper coating composition to obtain uniform coating at high speed. The process for manufacture involves: preparing an aqueous coating composition of hydrophobically modified hydroxyethylcellulose, pigment binder and other additives; applying the composition to a paper surface; removing excess composition to produce a uniform coating; and drying to produce a paper product.
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This application is a continuation of application Ser. No. 08/297,914, filed Aug. 31, 1994, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a surface acoustic wave device and a production process thereof.
Generally, a surface acoustic wave (SAW) device comprises a piezoelectric substrate and a comb-shaped interdigital electrode disposed on the substrate, for converting a voltage to a surface acoustic wave or vice versa. The function of the surface acoustic wave device is to convert a radio frequency voltage to a surface acoustic wave having a wavelength of about 10 −5 times by using a comb-shaped interdigital electrode, which causes this wave to propagate on the surface of the piezoelectric substrate and converts again the wave to the voltage by the comb-shaped interdigital electrode.
Frequency selectivity can be provided in accordance with the shape of the interdigital electrode during the two conversion operations between the surface acoustic wave and the voltage, and a filter or a resonator can be constituted by utilizing this characteristic property. Because the propagation speed can be retarded to about 10 −5 times that of an electromagnetic wave, the surface acoustic wave device can be used as a delay device.
The application of the surface acoustic wave device to small, economical filters, resonators, delay lines, etc., has already been done by utilizing the functions described above. In other words, the surface acoustic wave device has been applied to IF filters of television sets, resonators of VTR (vide tape recorder) oscillators, VCOs of cordless telephones, and recently, the application has been expanded to RF filters and IF filters of automobile telephones, mobile telephones, and so forth.
To further expand the utilization in this field, it is important to improve a pass band and power characteristics of the surface acoustic wave device. Particularly in the case of the automobile telephones and the mobile telephones, transmission power is relatively great, that is, 0.6 to 3 W, and a large RF power is applied to a filter of a front-end portion inside the apparatus, particularly, to an antenna duplexer.
The maximum input power of the surface acoustic wave filter has been about 0.2 W up to the present, and the filter lacks sufficient power characteristics. For this reason, a dielectric filter having high power resistance has been used for the antenna duplexer. However, because the dielectric filter is large in scale, it causes a problem when the size of the apparatus is reduced as a whole.
Accordingly, if the power characteristics of the surface acoustic wave device can be improved and the antenna duplexer can be realized by utilizing the surface acoustic wave device, the mobile telephones can be made even smaller, and the effect of utilization in industry becomes greater.
2. Description of the Related Art
The interdigital electrode is used in the surface acoustic wave device as described above, and aluminum (Al) or an aluminum alloy containing a small amount of a different kind of metal (not always a solid solution body in many cases) is generally used because the mass is small and its electrical resistance value is low.
Several proposals have been made for the structure of the antenna duplexer using the surface acoustic wave device. Typical examples are described in Japanese Unexamined Patent Publication (Kokai) Nos. 5-167388 and 5-167389. In order to simplify the filter structure in the duplexer and to secure desired characteristics, Japanese Unexamined Patent Publication (Kokai) No. 5-167388 proposes to constitute a duplexer by using a plurality of band-pass filters each formed by using the surface acoustic wave device. Japanese Unexamined Patent Publication (Kokai) No. 5-167389 proposes to integrate a plurality of surface acoustic wave band-pass filter chips having mutually different center frequency bands and having signal input/output terminals and ground terminals, by storing them in one package so as to minimize the duplexer while keeping excellent isolation.
However, the conventional antenna duplexer does not have characteristics such that the filter can sufficiently withstand the increase of RF power. To evaluate the power resistance or characteristics, the life time at the maximum input power at which the apparatus can be used is generally used as a guideline. The conventional antenna duplexer has a life time of only about 1,600 hours at the 1 W input at an environmental temperature of 85° C. (chip temperature of 120° C.) in an accelerated deterioration test stipulated for the mobile telephones of the NTT specification in Japan, for example. These values are not considered sufficient for the life of mobile telephones, and the values of at least twice are believed necessary.
The main factor that determines the useful life of the surface acoustic wave device is power characteristics of electrode fingers of the filter (interdigital electrode fingers IDT), and an aluminum system alloy film containing a trace amount of copper and formed by sputtering, which is well known as being resistant to migration in the field of semiconductor devices, has been used. However, this alloy is not yet sufficient as the electrode material of the surface acoustic wave device used as the antenna duplexer to which a high power load is applied.
Besides the patent references described above, the following reports have been made regarding the methods of improving electric power of the electrode of the surface acoustic wave device.
1. Change of addition metal in aluminum (Al) system alloy:
The use of an aluminum-titanium alloy (Al-Ti), etc., for example, is described in detail in “Examination of Al System Thin Film Material for SAW Power-Resistant Electrode and Production Method Thereof” (by Yuhara et al.), No. 17th EM Symposium Presume, pp. 7-12. According to this report, the useful life of the surface acoustic wave device can be improved by about 10 times the life of an aluminum-copper (Al-Cu) alloy film by changing the electrode material to an aluminum-titanium (Al-Ti) alloy.
2. Use of aluminum (Al) epitaxial single crystal film:
This method is based on the fact that grain boundary diffusion in stress migration of aluminum (Al) can be restricted by converting the structure to a single crystal, and is reported in papers of the Electronic Data Communication Society, A, Vol. J76-A, No. 2, pp. 145-152 (1993) (by Ieki et al.). According to this report, life time can be improved to 2,000 times that of an aluminum-copper alloy (Al-Cu) film by vacuum evaporation.
In comparison with films formed by sputtering, the useful life of an aluminum-copper alloy (Al-Cu) film formed by vacuum evaporation is much shorter from the beginning (refer to Yuhara et al., and other references), and the improvement in life time is believed to be substantially 20 to 200 times. At present, however, it has been confirmed only that this method can cause epitaxial growth only when the substrate material as the base is quartz, and cannot realize the film when LiTaO 3 or LiNbO 3 , which have been widely used as a substrate material for filters for mobile communication, is employed.
As described above, stress migration in the surface acoustic wave device is analogous to electromigration and stress migration in wiring technology of semiconductor devices, and migration-resistant technology in the semiconductor devices will be useful for the migration-resistant technology in the surface acoustic wave devices. Among them, the following technology has drawn increasing attention.
Namely, it is the method which forms in a laminar form a film of an intermetallic compound of aluminum (Al) and a transition metal between the aluminum (Al) films so as to block electromigration of the aluminum (Al) atoms by the intermetallic compound. This method is reported in U.S. Pat. No. 4,017,890 (J. K. Howard, IBM, April 1977) and in connection with this patent, a report is made by J. K. Howard, J. F. White and P. S. Ho in “J. Appl. Phys., Vol. 49, p. 4083 (1978).
According to these reports, life time becomes maximal when chromium (Cr) is used as the transition metal, and is about 10 times that of the aluminum-copper alloy (Al-Cu). However, when the inventors of the present invention applied this method to the electrode of the surface acoustic wave device, a sufficient effect could not be obtained.
As described above, several methods have been proposed as the prior art technologies for improving the electrode materials, but none of them have provided sufficient power characteristics. Accordingly, development of an electrode material having higher performance has been necessary. As a matter of fact, when the method of improving the power characteristics by the multi-layered structure of the aluminum films (Al) and the intermetallic compound of the aluminum (Al) and the transition metal is applied to the surface acoustic wave device, no effect can be observed but performance actually deteriorates.
FIG. 1 is an explanatory structural view of a surface acoustic wave filer having the conventional three-layered structure. In the drawing, reference numeral 11 denotes a LiTaO 3 piezoelectric substrate, 12 is an Al-1%Cu alloy film, 13 is a Ta film, 14 is an Al-1%Cu film, and 15 and 16 are Al-Ta alloy films.
In the surface acoustic wave filter using this conventional three-layered electrode structure, an 1,000 Å-thick Al-1%Cu alloy film 12 is formed on the LiTaO 3 piezoelectric substrate 11 , a 500 Å-thick Ta film 13 is formed on the former, and a 1,000 Å-thick Al-1%Cu film 14 is further formed on the Ta film 13 . Next, heat-treatment is carried out at 400° C. in vacuum so as to form sufficient Ta-Al (TaAl 3 ) 15 and 16 on the interface between the Al-1%Cu films 12 , 14 , and the Ta film 13 and in the grain boundaries of the Al-1%Cu alloy films 12 , 14 . The electrode structure is then patterned into an interdigital shape to form the electrode. When the useful life of this surface acoustic wave filter is measured by conducting an accelerated deterioration test at a chip temperature of 120° C. and radio frequency power of 1 W, the life expectancy is found to be 100 hours, and drops to {fraction (1/16)} of the life time of a 3,200 Å-thick Al-1%Cu single layered film, that is, 1,600 hours.
FIG. 2 is a graph useful for explaining power characteristics of a surface acoustic wave filter having the conventional three-layered structure.
In the graph, the abscissa represents input power (W) and the ordinate represents life time (mean time to failure: MTTF, hours). Curve a represents an Al-1%Cu single layer film which is not heat-treated, curve b represents an Al-1%Cu/Ta/Al-1%Cu film which is not heat-treated, and curve c represents an Al-1%Cu/Ta/Al-1%Cu film which is heat-treated at 400° C. The substrate (chip) temperature when forming each film is 120° C., and each film has a thickness of 3,200 Å.
According to the J. K. Howard et al. reference described above, the surface acoustic wave filter having the three-layered structure electrode described above should provide longer life at least 20 times that of the Al-1%Cu film. According to experiments, however, the actual life of the Al-1%Cu/Ta/Al-1%Cu film (see curve c) which is formed under the ordinary heat-treatment conditions at 400° C. is much shorter than the life of the Al-1%Cu single layer film (see curve a) which is not heat-treated. This difference results from some differences of a life deterioration mechanism of wirings of semiconductor devices from a life deterioration mechanism of IDT (Interdigital Transducer) of the surface acoustic wave filter.
In short, both electromigration of the Al atoms and static stress migration are involved in the life deterioration of the wirings of the semiconductor devices, whereas the life deterioration of IDT of the surface acoustic wave device mainly results from the dynamic stress migration. Here, the static stress migration means the Al migration driven by the static internal stress of Al films. The dynamic stress migration means the Al migration driven by the dynamic migration of the internal stress caused by the acoustic surface wave propagation. Depending on parameters associated with the life deterioration, exactly opposite actions results in some cases due to the difference of electromigration from the dynamic stress migration. A typical example is the grain size of Al. According to J. B. Ghate, “Electro-migration-Induced failure VLSI Interconnectors”, Solid State Technology, pp. 113-120, 1983, the greater the grain size, the greater the effect of suppressing electromigration and the longer life becomes, in the case of the wirings of the semiconductor devices. On the other hand, according to the aforementioned Yuhara et al. reference, the greater the grain size, the shorter life becomes, in the case of the surface acoustic wave device.
FIG. 3 is a graph useful for schematically explaining the relation between the grain size of the electrode material and life time. The abscissa in the graph represents the grain size, and the ordinate represents life time. As shown in the graph, since electromigration is predominant in the case of the wirings of the semiconductor device, life time becomes longer with the increase of the grain size (see curve b). In the case of the surface acoustic wave (SAW) device electrode, on the other hand, since stress migration is predominant, life time becomes shorter with the increase of the grain size of the electrode material (see curve a). The grain size of the electrode material can be increased by applying heat-treatment.
It can be interpreted from the sequence described above that the cause of deterioration of the Al-1%Cu/Ta/Al-1%Cu film formed conventionally by applying heat-treatment at 400° C. and represented by the curve c in FIG. 2 is this heat-treatment at 400° C., since the grain size becomes greater and stress migration becomes more likely to occur due to this heat-treatment, so life time is reduced. To further support this fact, a three-layered film having the same structure is formed without carrying out the heat-treatment and moreover, in such a manner that the temperature never exceeds 200° C. throughout the full process, so as to constitute the surface acoustic wave filter. When life of this filter is evaluated, the curve b in FIG. 2 can be obtained, and life time is substantially equal to that of the Al-1%Cu single layered film (see curve a).
It can be understood that when the heat-treatment is not carried out at a high temperature of about 400° C., life time can be drastically improved. This is because the grain size can be kept small. In this case, although the grain size remains small and life time is relatively long, the alloy between Al and the transition metal is not formed, between the layers because heat-treatment is not effected, and because the function of a stopper for inhibiting cracks occurring in the film, that is, the growth of voids, does not exist, so life time is not improved in comparison with the Al-1%Cu single layered film which is not heat-treated (see curve a).
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a surface acoustic wave device which can prevent the occurrence of voids in a film while keeping a grain size of an Al-Cu multi-layered film small, and which has a long life time.
It is another object of the present invention to provide a process for producing such a surface acoustic wave device.
These and other objects of the present invention will become more apparent from the following detailed description of preferred embodiments thereof.
According to the present invention, there is provided a surface acoustic wave device which comprises a piezoelectric substrate and an electrode formed on the substrate by alternately laminating a film of aluminum containing at least copper added thereto or an alloy of such aluminum and a copper film. In this case, the electrode is a transducer for converting an electrical signal to a surface acoustic wave.
In the surface acoustic wave device according to the present invention, directions of internal stresses of the film of aluminum containing at least copper or the alloy of such aluminum and the copper film preferably have opposite directions, and moreover, the sum of these internal stresses are zero (0) or compressive (stress on the negative side). When the internal stresses are regulated in this way, stress migration of aluminum can be reduced.
A laminate structure of the aluminum or aluminum alloy film/copper film constituting the electrode can be constituted arbitrarily into a two- or more multi-layered structure, and is preferably a two- or three-layered laminate structure. In such a multi-layered structure, the thickness of each film can be broadly changed in accordance with frequency and other various factors, but is generally and preferably within the range of from about 300 Å to about 10,000 Å.
In a preferred embodiment of the present invention, the electrode can be a two-layered laminate structure of the aluminum-copper alloy film and the copper film. Here, the thickness of the Al-Cu film for 800 to 1,000 MHz filters is preferably from about 1,000 Å to about 5,000 Å, and the thickness of the Cu film is preferably from about 300 to about 1,000 Å.
In another preferred embodiment of the present invention, the electrode can be a three-layered laminate structure comprising two aluminum-copper alloy films and the copper film sandwiched between the aluminum-copper alloy films. The thickness of each of the Al-Cu films for 800 to 1,000 MHz filters is preferably from about 500 Å to about 1,500 Å, and the thickness of the Cu film is preferably from about 300 Å to about 1,000 Å.
In the surface acoustic wave device according to the present invention, it is essentially necessary to add copper to the aluminum or aluminum alloy film constituting the electrode. The amount of addition of copper is preferably from 0.4 to 4 wt% and further preferably, from 0.5 to 1.5 wt% on the basis of the weight of the film. If the amount of addition of copper is below 0.4 wt%, problems such as stress migrations appear, and if it exceeds 4 wt%, on the other hand, fine patterns of IDT can not be delineated by RIE (reactive ion etching) because of copper-based residue.
In the embodiments of the present invention, copper is most preferably added to the aluminum or aluminum alloy film.
The piezoelectric substrate used as the substrate can be those piezoelectric crystal substrates which are ordinarily used in surface acoustic wave devices, such as LiNbO 3 , LiTaO 3 , quartz, ZnO/glass, PZT type ceramics, and so forth. Preferably, LiTaO 3 , such as (36° Y-X)LiTaO 3 and LiNbO 3 such as (64° Y-X)LiNbO 3 , can be used effectively as the piezoelectric substrate.
When a surface acoustic wave device having a piezoelectric substrate and an electrode formed on the substrate is produced, the present invention provides a process for producing a surface acoustic wave device which comprises alternately laminating a film of aluminum containing at least copper added thereto and a copper film on the piezoelectric substrate at a temperature not higher than 200° C.; patterning the resulting laminate structure to form an electrode; and carrying out subsequent processings while maintaining the temperature of not higher than 200° C.
The piezoelectric substrate and the electrode formed on the substrate have already been described above. The electrode can be formed by laminating the respective films into a predetermined film thickness by ordinary film formation technology such as sputtering, CVD (Chemical Vapor Deposition), electron beam deposition, etc., and subsequently patterning the resulting laminate structure into a desired electrode shape.
The method of the present invention can restrict the growth of the grain boundary of the electrode materials by employing the process steps described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view useful for explaining the structure of a surface acoustic wave filter having a three-layered structure according to the prior art;
FIG. 2 is a graph useful for explaining power characteristics of a surface acoustic wave filter having a three-layered structure according to the prior art;
FIG. 3 is a graph useful for explaining the relationship between a grain size of an electrode material and life time;
FIG. 4 is a perspective view useful for explaining the structure of a surface acoustic wave device according to one embodiment of the present invention;
FIG. 5 is a graph useful for explaining experimental results of a film thickness and an internal stress of each of an Al-1%Cu film and a Cu film;
FIG. 6 is a perspective view useful for explaining the structure of a surface acoustic wave filter according to an embodiment of the present invention;
FIG. 7 is an equivalent circuit diagram of the surface acoustic wave filter shown in FIG. 6;
FIG. 8 is a graph showing transmission characteristics of the surface acoustic wave filter according to an embodiment of the present invention;
FIG. 9 is a graph showing power characteristics of the surface acoustic wave filter according to an embodiment of the present invention;
FIG. 10 is an explanatory view of an Al-Cu film electrode structure;
FIG. 11 is a perspective view useful for explaining an Al-Cu/Cu film electrode structure;
FIG. 12 is a schematic view useful for explaining a CuAl 2 crystal structure;
FIG. 13 is a perspective view useful for explaining an Al-Cu/Cu/Al-Cu film electrode structure; and
FIG. 14 is a graph showing the relationship between an internal stress of an alloy film and power characteristics of a surface acoustic wave device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First, an electrode structure which can be advantageously utilized in a surface acoustic wave device according to the present invention, and the function and effect of such an electrode, will be explained.
Generally, it is believed that a film obtained by adding a small amount (about 3 to 4 wt %) of a different kind of metal to Al has a structure in which an alloy between Al and the different kind of metal exists at a grain boundary of Al.
FIG. 10 is an explanatory view of an Al-Cu film electrode structure. In this drawing, reference numeral 21 denotes an LiTaO 3 substrate, 22 is an Al-Cu film, 23 is Al crystal grains, 24 is a grain boundary, and 25 is CuAl 2 . This drawing illustrates an example where the Al-Cu film 22 is deposited on the LiTaO 3 substrate 21 by sputtering or electron beam deposition and is patterned. Basically, it is a polycrystalline structure of Al, wherein a large number of Al crystal grains 23 exist, and CuAl 2 25 segregates at the grain boundary 24 . It is believed that the reason why the Al-Cu film has higher resistance to migration than the Al film is because CuAl 2 25 inhibits fluidization of the Al atoms.
A similar effect can be obtained when Ti, Si, etc., is used as the metal to be added to Al, in place of Cu described above.
Next, we consider the case where a Cu film is formed on the upper surface of the Al film having this structure, with reference to FIG. 11 .
FIG. 11 is an explanatory view of an Al-Cu/Cu film electrode structure. In the drawing, reference numeral 21 denotes a LiTaO 3 substrate, 22 is an Al-Cu film, 23 is Al crystal grains, 24 is a grain boundary, 25 is CuAl 2 and 26 is a Cu film. The drawing illustrates an example where the Al-Cu alloy film 22 is formed on the LiTaO 3 substrate 21 by sputtering or electron beam deposition, the Cu film 26 is formed on the former and the Cu film 26 is then patterned. This is basically a polycrystalline structure of Al. A large number of Al crystal grains 23 exist, and CuAl 2 25 segregates between the grain boundary 24 , the Al-Cu film 22 and the Cu film 26 .
Even when the temperature is as low as below 200° C. when forming the Cu film 26 on the Al-Cu film 22 , a small amount of CuAl 2 25 is formed on the interface between the grain boundary, the Al-Cu film 22 and the Cu film 26 .
The reason for this is believed to be as follows. Cu to be sputtered has large kinetic energy and impinges against Al, and the film is formed while Cu imparts kinetic energy to the Al atoms. Therefore, an effect similar to the effect of local heat-treatment occurs, and CuAl 2 is formed on the interface between the Al-Cu alloy film 22 and the Cu film 26 . The thickness of Cu-Al 2 on the interface is some dozens of angstroms (Å).
Now, let's consider the case where the Al-Cu alloy film is further formed on the film having the structure shown in FIG. 11 .
FIG. 12 is an explanatory view of the CuAl 2 crystal structure. As shown in the drawing, the CuAl 2 crystal has the structure wherein the Cu layers and the Al layers are alternately laminated. Therefore, matching with the Cu film is extremely excellent, and firm bonding can be expected. Because CuAl 2 25 existing in the Al grain boundary 24 of the Al-Cu film 22 shown in FIG. 11 and CuAl 2 25 existing on the interface between the Al-Cu film 22 and the Cu film 26 are the same crystal, mutual bonding strength becomes high.
FIG. 13 is an explanatory view of an Al-Cu/Cu/Al-Cu film electrode structure. In this drawing, reference numeral 21 denotes a LiTaO 3 substrate, 22 is an Al-Cu film, 23 is an AQ crystal grain, 24 is a grain boundary, 25 is CuAl 2 , 26 is a Cu film, 27 is an Al-Cu film, 28 is an Al crystal grain, 29 is a grain boundary, and 30 is CuAl 2 . The drawing illustrates an example where the Al-Cu film 22 is formed on the LiTaO 3 substrate 21 by sputtering or electron beam deposition, the Cu film 26 is formed on the former, and the Al-Cu film 27 is further formed on the Cu film 26 and is patterned. CuAl 2 25 is formed in the grain boundary 24 of the Al crystal grains 23 of the Al-Cu film 22 , CuAl 2 30 is formed in the grain boundary 29 of the Al crystal grains 28 of the Al-Cu film 27 , and CuAl 2 is further formed between the Cu film 26 and the upper and lower Al-Cu films 22 , 27 .
Under such a condition, CuAl 2 25 , 30 existing in the grain boundaries 24 , 29 in the upper and lower Al-Cu films 22 , 27 and CuAl 2 existing on the interface between the Al-Cu films 22 , 27 and the Cu film 26 are strongly bonded to one another, and the Cu film at the center of the film as a whole functions as the framework, while CuAl 2 existing in the grain boundaries of the upper and lower Al-Cu film has a small bone network structure. Accordingly, a film having high resistance to stress migration can be realized at a low temperature of below 200° C. When heat-treatment is applied to the film, CuAl 2 on the interface becomes thick, but because the Al crystal grains grow to a large grain size as described already, the resistance to stress migration drops. Accordingly, heat-treatment at a high temperature above 200° must not be applied.
As described above, the fundamental principle of the present invention lies in that the Al-Cu film and the Cu film are laminated, and the network structure is formed by CuAl 2 formed in the grain boundary of Al in the Al-Cu film with the Cu film being the center, so as to inhibit stress migration.
As described in the afore-mentioned Yuhara et al. reference, also, the fundamental principle of the present invention is based on the concept that the internal stress of the Al alloy film is largely associated with power characteristics (life) of the surface acoustic wave device, power characteristics are high when the stress of the Al alloy film is zero or rather compressive, and power characteristics drop with higher tensile stress.
FIG. 14 is a graph showing the relation between the internal stress of the alloy film and power characteristics of the surface acoustic wave device. This graph cites the data reported previously by Yuhara et al. The axis of abscissa represents the internal stress of the alloy film, and the ordinate represents the stress of the surface acoustic wave device, that is, the tendency of power characteristics. As can be seen from this graph, power characteristics of the surface acoustic wave device are high when the internal stress of the alloy film is zero or compressive, but are deteriorated when the internal stress is tensile.
Accordingly, power characteristics can be improved by arranging the films so that their internal stresses have opposite signals when the multi-layered alloy film is formed, and moreover, the magnitude of the internal stresses are mutually in equilibrium, in order to regulate the internal stress of the film as a whose to zero or somewhat compressive.
Next, several embodiments of the present invention will be explained with reference to the drawings. It is to be understood that these embodiments are merely illustrative and in no way limit the present invention.
FIG. 4 is an explanatory structural view of a surface acoustic wave device according to an embodiment of the present invention. In the drawing, reference numeral 1 denotes a LiTaO 3 substrate, 2 is an Al-1%Cu film, 3 is Al crystal grains, 4 is a grain boundary, 5 is CuAl 2 , 6 is a Cu film, 7 is an Al-1%Cu film, 8 is Al crystal grains, 9 is a grain boundary, and 10 is CuAl 2 . In the surface acoustic wave device of this embodiment, a 1,000 Å-thick Al-1%Cu film 2 is formed on the LiTaO 3 substrate 1 having a piezoelectric property while the temperature is kept below 200° C., a 400 Å-thick Cu film 6 is formed on the former, and a 1,000 Å-thick Al-1%Cu film 7 is formed on the Cu film 6 . In this way, a three-layered film having a total thickness of 2,400 Å is formed. This three-layered laminate film is patterned to form an interdigital electrode (hereinafter referred to as the “three layered film electrode A”).
In the embodiment shown in the drawing, CuAl 2 5 is formed in the grain boundary 4 of the Al crystal grains 3 of the Al-1%Cu film 2 , CuAl 2 10 is formed in the grain boundary 9 of the Al crystal grains 8 of the Al-1%Cu film, and CuAl 2 5 , 10 is also formed between the Cu film 6 and the upper and lower Al-1%Cu films 2 , 7 .
To compare with the three-layered electrode A of this embodiment, an interdigital electrode consisting of a 3,200 Å-thick Al-1%CU single-layered film (hereinafter referred to as the “single-layered film electrode C”) is formed on the LiTaO 3 substrate.
To compare the effect of stress regulation of the three-layered film electrode, an interdigital electrode (hereinafter referred to as the “three-layered film electrode B”) is formed by first forming a 700 Å-thick Al-1%Cu film, a 600 Å-thick Cu film and a 700 Å-thick Al-1%Cu film on the LiTaO 3 and substrate in the total thickness of 2,000 Å and patterning this three-layered laminate film.
To examine the heat-treatment effect of the three-layered film electrode A, an interdigital electrode (hereinafter referred to the “three-layered film electrode A”) is formed by heat-treating the three-layered film electrode A at 400° C. after the film formation.
The thickness of these electrode films is determined in the following way.
A. As a reference a 3,200 Å-thick Al-1%CU single layer film will be considered.
When a surface acoustic wave filter is produced using this Al-1%Cu single layer film as the electrode by the later-appearing method, a transmission band-pass filter of an NTT specifications having 933 MHz as the center frequency can be realized.
In the surface acoustic wave filter, the center frequency changes in accordance with the mass of the electrode due to the mass load effect. Therefore, in order to correctly compare power characteristics when the electrode is changed, it is necessary to bring the mass of the electrode film into conformity with the mass of the electrode of the surface acoustic wave filter using the Al-1%Cu single layer film electrode C so as to prevent frequency fluctuation.
The density of Cu is 8.9, the density of Al is 2.7, and the density of the Cu film is about three times the density of Al. Therefore, the masses of the three-layered film electrodes A, B and AA are substantially the same as the mass of the 3,200 Å-thick Al-1%Cu single layer film electrode as the reference. Accordingly, the surface acoustic wave filters using the three-layered film electrodes A, B and AA exhibit substantially the same characteristics as the 933 MHz filter.
B. The balance of the internal stresses of the multi-layered film electrode must be secured so as to improve power characteristics as already described.
If the substrate temperature and the film formation rate at the time of growth of the multi-layered film are constant, the internal stress of the multi-layered film depends on the film thickness of each layer.
FIG. 5 is a graph useful for explaining the experimental results of the internal stresses of the Al-1%Cu film and the Cu film. In this graph, the abscissa represents the film thickness of the metal film, and the ordinate represents the stress. In the graph, the experimental results of the film thickness of the Al-1%Cu film and the Cu film, and the internal stress are plotted.
When the balance of the internal stress inside the laminate film is taken into consideration, the stress is −6×10 8 N/m 2 (the − sign represents the compressive stress and the +sign represents the tensile stress) in the case of the Cu film at a thickness of 400 Å, and +2×10 8 N/m 2 in the case of the Al-1%Cu film at a film thickness of 1,000 Å in the three-layered film electrode A consisting of the Al-1%Cu film/Cu film/Al-1%Cu film. Therefore, the stress is −2×10 8 N/m 2 in the three-layered film electrode as a whole, and a weak compressive stress is applied. According to FIG. 14 previously explained, this internal stress −2×10 8 N/m 2 is included in a region in which power characteristics of the multi-layered film electrode are not deteriorated.
In the case of the three-layered film electrode B, the stress value is −2×10 8 N/m 2 for the Cu film at a thickness of 600 Å, and 2×2.5×10 8 N/m 2 for each Al-1%Cu film at a thickness of 700 Å. The total stress is 4×10 8 N/m 2 , and is the tensile stress. According to FIG. 14, this internal stress of 4×10 8 N/m 2 is included in the region where power characteristics of the multi-layered film electrode are deteriorated.
FIGS. 6 and 7 are explanatory structural views of the surface acoustic wave filter according to one embodiment of the present invention, wherein FIG. 6 is a perspective view and FIG. 7 is an equivalent circuit diagram. In the drawings, symbol T in denotes an input terminal, T out is an output terminal, R p1 is a first parallel resonator, R p2 is a second parallel resonator, R p3 is a third parallel resonator, R s1 is a first series resonator, R s2 is a second series resonator, and R p11 , R p12 , R p21 , R p22 , R p31 , R s32 , R s11 , R s12 , R s21 and R s22 are reflectors.
The surface acoustic wave filter according to this embodiment is described in detail in Japanese Unexamined Patent Publication (Kokai) No. 5-183380 to which reference is hereby made. The multi-layered film interdigital electrode of this embodiment is formed on a 36° Y-X LiTaO 3 piezoelectric substrate of 1.5×2×0.5 mm, and the first series resonator R s1 and the second series resonator R s2 are connected in series from the input terminal T in , towards the output terminal T out . The first, second and third parallel resonators R p1 , R p2 and R p3 are grounded from the junction between the input terminal and the first series resonator R p1 , from the junction between the first and second series resonators R s1 , R s2 , and from the junction between the second series resonator R s2 and the output terminal.
The reflectors R s11 , R s12 are provided to the first series resonator R s1 and the reflectors R s21 , R s22 are provided to the second series resonator R s2 . The reflectors R p11 , R p12 are provided to the first parallel resonator R p1 , and the reflectors R p21 , R p22 are provided to the second parallel resonator R p2 . Further, the reflectors R p31 , R p32 are provided to the third parallel resonator R p3 .
The 0.5 mm-thick LiTaO 3 piezoelectric substrate is used in such a manner that its 1.5 mm side as the x-axis direction of the crystal axis exists in the transverse direction of the drawing and its 2 mm side exists in the longitudinal direction of the drawing, or in other words, in the propagating direction of the surface acoustic wave. The pitch λ p of the electrodes of the first parallel resonator R p1 , is set to 4.39 μm, its aperture length is set to 160 μm, the aperture length of the first series resonator R s1 is set to 60 μm, and the electrode pitch of the second series resonator R s2 is set to 4.16 μm.
FIG. 8 is a graph showing the transmission characteristics of the surface acoustic wave filter according to one embodiment of the present invention. The abscissa in the graph represents frequency (MHz) and the ordinates represents attenuation (dB). As shown in the graph, the surface acoustic wave filter has the characteristics of a band-pass filter having an about 60 MHz pass band in the proximity of 930 MHz. Attenuation in the pass band is 1.5 dB.
The life test of this surface acoustic wave filter is carried out by selecting a frequency, at which power characteristics are the lowest among the pass band, that is, near 950 MHz in this embodiment, and applying a radio frequency power thereto. At this time, the temperature of the filter chip rises somewhat, but an external temperature is controlled in taking such a temperature rise into consideration in advance, and radio frequency power and its life are controlled while the surface temperature of the filter chip is kept constant.
FIG. 9 is a graph showing the power characteristics of the surface acoustic wave filter according to one embodiment of the present invention. The abscissa in the graph represents input power (W) and the ordinate represents mean time to failure (MTTF). The failure is defined by the degradation of 0.3 dB for 1.5 dB insertion loss in the pass band (see, FIG. 8 ).
Generally, when the MTTF of the electrode of the surface acoustic wave filter relies on the Arrhenius' equation, that is,
1n(MTTF)=A+B/T−n×1n(Pin),
the natural logarithm of the input power (Pin) and the natural logarithm of mean time to failure (MTTF) are expressed by rightwardly descending straight lines. Here, A, B and n are proportional constants.
Besides the surface acoustic wave filter using the electrode of this embodiment, this FIG. 9 shows also the life time of the surface acoustic wave filters using the four kinds of the electrodes described above, respectively. In this measurement, the filter chip temperature T is set to 393K (120° C.).
Curve a in FIG. 9 represents the life time of the surface acoustic wave filter using the Al-1%Cu/Cu/Al-1%Cu film (three-layered film electrode A) which is not heat-treated and has a compressive stress of −2×10 8 N/m 2 . Curve b represents the life time of the surface acoustic wave filter using the Al-1%Cu/Cu/Al-1%Cu film (threelayered film electrode B) which is not heat-treated and has a tensile stress of +4×10 8 N/m 2 . Curve c represents the life time of the surface acoustic wave filter using the Al-1%Cu film (single layer film electrode C) which is not heat-treated, and curve d represents the life time of the surface acoustic wave filter using the Al-1%Cu/Cu/Al-1%Cu film (three-layered electrode AA) which is heat-treated at 400° C. By the way, the substrate temperature when forming each film is 120° C.
In comparison with the surface acoustic wave filter (see curve c) using the conventional Al-1%Cu single layer film (single layer film electrode C), the life time of the surface acoustic wave filter (see curve a) using the Al-1%Cu/Cu/Al-1%Cu film (three-layered film electrode A) of this embodiment, which is not heat-treated and has the compressive stress of −2×10 8 N/m 2 is 120 times.
The life time of the acoustic wave filter (see curve d) having the three-layered film (three-layered film electrode AA) obtained by heat-treating the Al-1%Cu/Cu/Al-1%Cu film (three-layered electrode A) of this embodiment which is not heat-treated and has a compressive stress of −2×10 8 N/m 2 , becomes drastically short, and is shorter than the life time of the surface acoustic wave filter (see curve c) using the conventional Al-1%Cu single film layer (single layer film electrode).
Further, the life time of the Al-1%Cu/Cu/Al-1%Cu film (three-layered film electrode B) which is not heat-treated and has a tensile stress of +4×10 8 N/m 2 (see curve b) is improved in comparison with the life time of the surface acoustic wave filter (see curve c) using the conventional Al-1%Cu single layer film (single layer film electrode C), but is incomparatively shorter than the life time of the surface acoustic wave filter of this embodiment having the internal stress thereof regulated (see curve a).
The surface acoustic wave filter of this embodiment can provide 200,000 hours as the useful life at the time of input of 1W. Accordingly, the filter can be said to have sufficient power characteristics as an antenna duplexer.
Though a general piezoelectric crystal substrate can be used as the piezoelectric substrate, the piezoelectric materials illustrated in this embodiment, such as LiTaO 3 (36° Y cut-X propagation), LiNbO 3 (64° Y cut-X propagation), etc., are effective in order to improve the characteristics of the filter, and the like.
As described above, the present invention employs the multi-layered structure of the Al-Cu film/Cu film/Al-Cu film as the electrode material. Therefore, even in the case of surface acoustic wave devices which cannot be heat-treated at a high temperature due to stress migration, the present invention can drastically improve their power characteristics, and greatly contributes to the improvement in performance of the surface acoustic wave devices such as the surface acoustic wave filters.
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This invention relates to a surface acoustic wave device and a production process thereof. An electrode is formed by alternately laminating a film of an aluminum alloy containing at least copper added thereto and a copper film on a piezoelectric substrate. While the particle size of the multi-layered electrode materials in kept small, the occurrence of voids in the film is prevented and life time of the surface acoustic wave device is elongated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method of delignifying and bleaching cellulosic pulps. More particularly, the invention relates to a totally molecular chlorine-free method of delignifying and bleaching chemical cellulosic pulps using a combination of peracetic acid, ozone and oxygen.
2. Description of the Prior Art
Conventional methods of processing cellulosic pulps generally include multiple delignification steps. In order to obtain a final pulp of sufficient brightness, most industrial processes rely upon bleaching the pulp with chlorine-based bleaching agents. Molecular chlorine and, more recently, chlorine dioxide have been used in these processes. However, the use of chlorine-based bleaching agents has met with increasing objections and strict legislation has been proposed in an effort to force replacement of such chlorine bleaches in lignocellulose processes with non-chlorine based bleaches.
The pulp and paper industry has devoted substantial efforts to the development of chlorine-free or reduced chlorine bleaching processes. One such effort has been the development and implementation of oxygen bleaching systems. U.S. Pat. No. 3,832,276 to Roymoulik discloses one oxygen delignification process. Oxygen itself, however, cannot produce pulps of sufficiently high brightness and quality for many commercial applications. U.S. Pat. No. 4,626,319 to Kruger et al. teaches the use of oxygen and hydrogen peroxide in the dilignification and bleaching of cellulose. The ineffectiveness of oxygen in the bleaching of pulps has led other researchers to investigate the use of ozone as a bleaching agent, either alone or following an oxygen bleaching stage. Oxygen and ozone bleaching of cellulosic pulps are generally carried out separately because ozone is intolerant of alkaline conditions and oxygen is inefficient in an acidic environment.
For a review of the literature relating to the ozone bleaching of fibrous materials reference can be made to Medwich v. Byrd, Jr. "Delignification and Bleaching of Chemical Pulps with Ozone: a Literature Review" Tappi Journal, 207-213, March 1992.
U.S. Pat. No. 4,080,249 to Kempf teaches the use of a mixture of about 0.1 to 20% ozone in oxygen or air to delignify and bleach cellulose pulp. The delignification and bleaching sequence may include a first stage where oxygen is employed as a reactant in the presence of an alkali.
U.S. Pat. No. 5,074,960 to Nimz et al. teaches the use of ozone in the presence of a C 1-3 fatty acid to remove lignin from a cellulosic or lignocellulosic pulp. The ozone is present at a concentration of about 0.1 to 10% in a gaseous phase consisting of air or oxygen.
In the prior bleaching processes which employ oxygen and ozone in separate stages or individual unit operations, there is a substantial change in the process pH from strongly alkaline for oxygen delignification to very acidic for ozone delignification. The control of pH is critical at these two extremes. For this reason, the oxygen and ozone treatments are separated. They are conducted in separate towers and the pulp is washed between each treatment. In ozone treatments, oxygen is presented as a carrier-gas and occupies almost 90% of the total weight of the gas stream but oxygen is essentially inert and inactive under the process conditions employed in these reactions.
SUMMARY OF THE INVENTION
The object of this invention is to provide a method for delignification and bleaching cellulosic pulp employing a combination of per. acetic acid (Pa), ozone (Z) and oxygen (0) in a single operation, e.g., without dividing the process into separate stages by intermediate washing steps. This and other objects are achieved in accordance with the present invention which, in one embodiment, provides a method for the delignification and bleaching of cellulosic pulp which comprises reacting a cellulosic pulp with peracetic acid, ozone and oxygen under an acidic pH.
The process of the present invention results in a high brightness pulp having reduced color while substantially decreasing or eliminating the presence of organochlorine from the reaction effluent.
BRIEF DESCRIPTION OF THE DRAWING
The single Figure is a schematic illustration of an installation for carrying out the delignification and bleaching process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention can be used for the delignification and/or bleaching of hardwood or softwood mechanical, chemical or chemimechanical pulps such as Kraft and sulfite pulps. However, the high lignin content of refiner mechanical pulps generally makes them undesirable for use in the invention.
Prior to delignification, the pulp (brownstock) is treated witch a chelating agent to passivate transition metal ions in the pulp. The presence of transition metal ions in the pulp during the process of the present invention is disadvantageous for two reason: it depletes the amount of the chemicals added to the pulp and it generates byproducts which reduce pulp yields. The metal ions can react with the peracetic acid, the peroxide generated in the process, ozone and oxygen to produce hydroxy radicals. These hydroxy radicals attack the cellulose in the pulp and reduce yields.
Any chelating agent conventionally used in the paper industry should be useful in the present invention. A typical example of a useful chelating agent is ethylenediamine tetraacetic acid (EDTA). The chelating agent is employed in a conventional manner and amount. It is typically applied to the pulp in an amount of about 100 mg to 5 g per 100 g oven dried (O.D.) pulp.
Acidic conditions are required for reaction of the chelating agent. The pulp is typically adjusted to a pH in the range of approximately 1 to 5 and, more preferably, 2 to 3 using an acid such as sulfuric acid. Because the reduction in chlorinated by-products is a principal objective of the present invention, hydrochloric acid is preferably not used to make the pH adjustment.
The treatment of the pulp to remove transition metal ions is preferably conducted on a low consistency pulp, for example, a pulp having a consistency in the range of approximately 3 to 12%. This ensures that the chelating agent and acid coat the pulp fibers. After treatment with the chelating agent, the pulp is dewatered preferably by passage through a twin roll press. The consistency of the pulp is thereby increased to about 20% or greater and, more typically to about 20 to 35% and, most typically to about 20 to 25%. These higher consistencies are required for the subsequent delignification reaction which is a solid-gas heterogenous reaction, the effectiveness of which is controlled by oxygen/ozone mass transfer. By increasing the consistency of the pulp, faster reaction rates and a more efficient reaction condition are achieved; the reaction is focused on attacking the lignin on the surface of the pulp fibers.
The dewatered pulp is preferably treated with peracetic acid and low pressure steam in order to enhance the subsequent reaction with ozone and oxygen. Peracetic acid buffers the pulp at pH in the range of 1 to 6, and it reacts selectively with the lignin in the pulp. Accordingly, by treating the pulp with peracetic in this manner, the peracetic acid reacts with the lignin and opens up the fiber structure of the pulp. This allows the oxygen and ozone subsequently added to the pulp to infiltrate the pulp fiber and enhances their reaction on the pulp.
Generally, oxygen delignification processes are conducted under alkaline pH. The present process is unique in that the oxygen reaction is carried out under acidic conditions. While this reaction is generally less efficient under acidic conditions, by pretreating the pulp with the peracetic acid in this manner, the oxygen reaction under these conditions is enhanced.
The peracetic acid is added to the pulp as a solution in water having a concentration of approximately 40% to 50%(w/v). In order to enhance the reaction of the peracetic acid and open the fiber structure to enable the oxygen and ozone to react efficiently with the pulp, the peracetic acid is added to the pulp in an amount of about 0.5 to 5 g per 100 g O.D. pulp. The pulp is heated with low pressure steam to a temperature of approximately 50° to 60° C. In order to limit thermal damage to the pulp fibers, higher temperatures are preferably avoided at this stage of the process.
The peracetic acid and steam treated pulp is mixed as it is fed by a screw conveyor-mixer to a down flow retention tower. Preferably, the peracetic acid is allowed to react on the pulp for at least 5 minutes in the retention tower. The pulp may actually be retained in the tower for up to 1 or more hours. The peracetic acid tends to be exhausted early and the pulp is not damaged by further retention.
The next stage of the process of the invention is carried out under elevated pressures in a plug flow reaction tube. The pressures are typically about 40 to 120 psi. Magnesium sulfate solution, peracetic acid solution, and ozone/oxygen gas mixture are added to the pulp immediately upstream of a high shear mixer. Magnesium sulfate is added to the pulp as a viscosity protector. Other magnesium salts may be used for this purpose in a manner well known in the art. The magnesium salt is typically employed in an amount of approximately 0.5 to 5% wt. based upon O.D. pulp.
Peracetic acid is again added to the pulp, a typical amount for this addition being about 0.2 to 1.0%. This peracetic acid treatment fulfills three objectives: (1) it acts as a pH adjustor for the pulp for acid ozone/oxygen delignification, (2) it acts as an effective and selective delignifying agent in the presence of oxygen and ozone, and (3) it acts as a viscosity protector during the ozone treatment of the pulps. Both the delignifying efficiency and selectivity of the peracetic are believed to result in decreased ozone demand to treat the pulp, thus maintaining gas volumes at a manageable level.
The ozone/oxygen gas mixture contains from approximately 3 to 12% ozone based upon the total weight of the gas mixture. The ozone/oxygen gas mixture is preferably added to the pulp using a perforated gas sparger in an amount of about 0.2 to 2.0 g ozone per 100 g O.D. pulp. It is believed that by using low doses of ozone for pulp treatment, a stronger pulp than possible from a three-stage O-Z-Pa treatment can be produced.
Perforated gas spargers are commercially available. These spargers are designed to introduce the gas into the pulp as microbubbles. In adding the ozone/oxygen gas mixture to the pulp, it is important to avoid the formation of large bubbles which may produce channeling and lower mass transfer. The use of microbubbles accomplishes this objective.
Ozone is a very strong oxygenating agent and, therefore, it is necessary to control this stage of the delignification reaction so as not to degrade the cellulose. As previously indicated, the reaction is carried out in a plug flow reaction tube. Typically, the ozone reacts on the pulp for approximately 2 to 10 minutes. To limit the ozone reaction and thereby limit degradation of the pulp, it is preferable not to add additional heat to the reaction at this stage. Hence, the temperature of the pulp will be approximately 50° to 60° C. Once the plug exits the reaction tube, the ozone reaction is essentially complete and little or no unreacted ozone remains in the pulp. Accordingly, at this stage, the pulp can be heated to enhance the reaction of the oxygen.
For the oxygen reaction, the pulp is typically heated to a temperature of approximately 90° to 120° C. and pressurized to approximately 90 to 120 psi. To further enhance the oxygen reaction, the pulp is fluffed as it is introduced to a pressurized reactor vessel where the oxygen reacts on the pulp under the high temperature and high pressure conditions. This reaction requires approximately 10 minutes to 1 hour.
As illustrated in the attached drawing of the present invention, brownstock pulp from a pulp washer 10 at a consistency of about 10% is mixed with sulfuric acid and a chelant (EDTA) to chelate and passivate the transition metals in the pulp. Sulfuric acid is added to adjust the pH to about 3. The pulp is then fed to a twin roll press 12 for dewatering.
The pressate from the press 12 is returned via line 13 from which it is used to dilute the brownstock. This treatment acidifies the brownstock and reduces the amount of acid required to bring the pH of the pulp into the desired pH range. The pulp consistency after passage from the twin roll press is adjusted to about 20 to 25%. At the outlet of the twin roll press, the acidified pulp is mixed with peracetic acid from line 14 (0.5% w/w on O.D. pulp basis) and low pressure steam from line 15. The pulp temperature at this point is adjusted to 50°-55° C., respectively. The pulp is then fed through a mixer-feeder 16 (essentially a screw feeder) to a down flow retention tube 18.
At the end of the down flow retention tube, the pulp is pumped by a high consistency pump 20 such as a clove rotor pump to a high shear mixer 22. At the outlet of the high consistency pump 20, before the entrance to the high shear mixer 22, a compressed oxygen/ozone mixture of about 12% w/w ozone on oxygen is metered onto the pulp from feed 24 using a perforated gas sparget (not shown), and the pulp is mixed with magnesium sulfate and additional peracetic acid which are fed from reservoirs 26 and 28 respectively. The ozone charge on pulp is maintained at about 0.5% (w/w on o.d pulp basis). In the high shear mixer 22, the pulp is mixed with the reactants and then fed into a plug-flow tubular reactor 30. The pulp retention time in the tubular reactor 30 is adjusted to ensure the complete reaction with the pulp and consumption of the ozone (typically about 5 to 6 minutes is required). At the end of the tubular reactor 30 only the pulp, oxygen, magnesium sulfate and a small amount of unreacted peracetic acid remains. At this point, the pulp is pressurized to 0.6 to 0.8 MP and heated to about 100° C. with high pressure steam, in a steam mixer 32. This can be done without degrading the pulp at this stage.
Via fluffer 33 including rotating trays 34 and rotor 35, located at the top of the oxygen reactor 36, the pulp is fluffed and injected into oxygen reactor 36, thus increasing the interaction between the pulp and oxygen gas. High/medium consistancy oxygen reactors are available commercially, e.g., Kamyr high consistency tray type oxygen reactors. At the end of the fluffer 33, the pulp is diluted at 44 with the acid filtrate from the pulp washer pressate tank 42 and is then blown to a blow tank 46. The oxygen gas vented from the blow tank by outlet 48 may be reclaimed for the generation of ozone after proper clean up. Pulp from the oxygen blow tank exits via pump 50 for further treatment.
The process of the present invention is unique in that the entire treatment of the pulp is carried out under acidic conditions including the oxygen delignification of the pulp and the oxygen is derived from the ozone-oxygen gaseous mixture. The oxygen is activated to react under acidic conditions by using peracetic acid and by a thermal activation step. In this invention, unlike the conventional bleaching processes where oxygen delignification of pulp is carried out separately under alkaline condition, the treatment of pulp with peracetic acid, ozone and oxygen is carried out as a single operation (i.e., without intermediate washing steps) under acidic conditions.
By carrying out the delignification in a single-step and under high consistency, the hardware required to bleach the pulps is greatly reduced. Also, the volume of the liquor to be recirculated to the recovery plant is reduced to about 1/3 to 1/4 of the conventional oxygen-ozone processes. Since the practice of this invention does not require two different pH controls, the pH control strategy is simple and straight forward. The use of peracetic acid in the process results in lower kappa number and higher strength pulp than normally obtained from the conventional oxygen and ozone delignification process. This should result in a stronger bleached pulp of 90% ISO brightness at relatively lower chemical charge.
Following delignification, the delignified pulp may be alkali extracted in a conventional manner and bleached with either chlorine dioxide (D) and/or hydrogen peroxide (P) to yield a high strength and high brightness pulp. By using alkaline hydrogen peroxide instead of chlorine dioxide, a "zero-effluent" discharge can be achieved.
Other additives which are normally employed in conventional delignification and bleaching reactions may be employed in the present process.
Further variations and modifications of the foregoing will be apparent to those skilled in the art and are intended to be encompassed by the invention as defined in the appended claims.
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A method for delignification and bleaching of cellulosic pulp which comprises reacting a cellulosic pulp with peracetic acid, ozone and oxygen under conditions of acidic pH. The ozone substantially completely reacts with the pulp and, thereafter, the oxygen reacts with the pulp under under an acidic pH.
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This application is a continuation of application Ser. No. 08/617,526, filed Mar. 15, 1996 now abandoned, which is a continuation-in-part of application Ser. No. 08/405,150, filed Mar. 16, 1995 now abandoned.
BACKGROUND OF THE INVENTION
Traditional methods of selectively carving patterns in textile fabrics have developed numerous problems. A significant problem is the ability to precisely carve a very exact pattern or carve in exact registration with a pattern printed in color. In addition, non-precise carving can weaken and even destroy the textile fabric.
The present invention solves these problems in a manner not disclosed by the known prior art.
SUMMARY OF THE INVENTION
An apparatus and method for selectively carving textile fabric by selectively applying chemicals containing a liquid repellent either alone or with a chemical such as dye to a textile fabric and subsequently finishing said fabric. The textile fabric is then rewetted by the application of liquid. The printed areas containing liquid repellant remain dry and the areas without liquid repellent are selectively wetted out. The textile fabric is then subjected to pressurized heated gas which selectively carves the dry areas printed with liquid repellent leaving the wetted areas protected and uncarved. As an alternative embodiment, the yarns that make up a textile fabric can be individually treated with a liquid repellent prior to being formed into a textile fabric.
It is an advantage of this invention that the carved patterns can be as precise as any available patterning process.
It is another advantage of this invention that the means of carving the textile fabric is very exact so that the textile fabric remains relatively intact.
Yet another advantage of this invention is that the carved patterns can be in exact registration with a printed pattern.
Still another advantage of this invention is that carving can be extremely complex with the only limits being those of the patterning process utilized.
These and other advantages will be in part apparent and in part pointed out below.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other objects of the invention, will become more apparent from the following detailed description of the preferred embodiments of the invention when taken together with the accompanying drawings in which:
FIG. 1 is the schematic side elevation view of an apparatus for selectively applying chemicals containing liquid repellent either alone or with a colorant such as a dye to a moving textile fabric in a pattern arrangement;
FIG. 2 is a schematic side elevation view of an apparatus for rewetting the textile fabric and carving the textile fabric that has been treated with a liquid repellent, as was previously disclosed in FIG. 1;
FIG. 3 is another schematic side elevation view of a multiple position rotary screen printer in which chemicals containing liquid repellent with a colorant such as dye are selectively applied by two of the four rotary print heads;
FIG. 4 is a schematic side elevation view of an apparatus for rewetting the textile fabric and carving the textile fabric that has been treated with a liquid repellent, as was previously disclosed in FIG. 3;
FIG. 5 is a schematic side elevation view of apparatus for heated, pressurized fluid stream treatment of a moving textile fabric to carve a pattern on the surface thereof;
FIG. 6 is an enlarged, broken-away sectional of the fluid stream distributing manifold housing of the manifold assembly as illustrated in FIG. 5;
FIG. 7 is an enlarged broken-away sectional view of an end portion of the fluid stream distributing manifold housing;
FIG. 8 is a perspective view of a textile fabric that has been selectively carved by means of the present invention; and
FIG. 9 is a perspective view of a textile fabric that has yarns that have been pretreated with a liquid repellant, whereby the pretreated yarns have been selectively carved by means of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings, initially to FIG. 1, an indefinite length of textile fabric 12, from a supply roll 18 passes over an idler roll 32 and into a dyeing apparatus 16. The dyeing apparatus 16 can be literally any type of known textile dyeing apparatus. Dye is defined as being literally any type of colorant that can be utilized on textile fabrics. The mechanism displayed in FIG. 1 is a single head, textile rotary screen printer, such as one that is manufactured by Johannes Zimmer Vermogensver-Waltungsgmbh located at Ebentaler Strase 133, Klagenfurt 9020, Austria. This dyeing apparatus 16 includes a mesh print screen 20 and a squeegee 21. The mesh print screen 20 is opposite a support roll 26 with the textile fabric 12 passing therebetween. The chemicals from the mesh print screen 20 are applied to the textile fabric in a selectively patterned arrangement. The chemicals include a liquid repellent which can be of literally any type including fluorocarbons, silicones, waxes, and so forth. The chemicals may include a colorant such as a dye, sculpturing agents, texturing agents, dye resists, and so forth.
Samples of rotary print screens can be found in U.S. Pat. No. 5,259,307, issued on Nov. 9, 1993, which is incorporated by reference as if fully set forth herein and U.S. Pat. No. 5,247,882, issued on Sep. 28, 1993 and is incorporated by reference as if fully set forth herein, and U.S. Pat. No. 5,127,321, issued on Jul. 7, 1992, which is also incorporated by reference as if fully set forth herein.
Another means for applying streams of dye to textile fabrics by selective deflection of dye streams with pressurized gas can be found in U.S. Pat. No. 5,161,395, which issued on Nov. 10, 1992, which is incorporated herein by reference. Yet another method of dyeing textiles is disclosed in U.S. Pat. No. 5,330,540, which issued on Jul. 19, 1994, which involves a rotating roll and brush dispersal unit. This disclosure is also incorporated herein by reference. Still another means of dyeing textile fabrics includes a method of producing a plurality of streams of atomized droplets of marking materials to produce a pattern on the substrate, such as that disclosed in U.S. Pat. No. 5,211,339, which issued on May 18, 1993. Once again, the disclosure thereof is incorporated herein by reference. These textile dyeing methods are not meant to be all inclusive and this invention can be utilized with literally any type of known textile dyeing technology. In addition, the textile fabric 12 can be any type of textile fabric with the exception of natural fibers. This is the full spectrum of textile fabrics in which the face finish can be altered by heat that includes those that are merely napped and extends all the way to carpeting. These textile fabrics can be of any construction such as woven, tufted, knitted, nonwoven or flocked.
The textile fabric 12 then passes into a finishing apparatus 34 that typically includes a hot air oven. However, this step can include any of the fixing, steaming, or drying steps that would take place in textile fabric finishing and depends on the type of textile fabric and the desired effect. The textile fabric 12 then moves to take-up roll 14 for collection.
As shown in FIG. 2, the textile fabric 12 from take-up roll 14 is now positioned as supply roll 218. The textile fabric 12 then passes over a first idler roll 232 and into a tank of liquid 234, around a second idler roll 236 and then through a pair of nip rolls 240 and 242 to squeeze out the excess liquid, then around third idler roll 244 to direct the textile fabric 12 to the pressurized heated gas carving head 10. The pair of nip rolls 240 and 242 are placed under pressure by means of an air cylinder (not shown). The liquid is preferably water. However, a multitude of liquids would suffice such as a 95% water and 5% urea combination, alcohol, and so forth.
The textile fabric 12 then passes over a support roll 226 with a pressurized heated gas carving head, generally indicated at 10 on the other side and directly above the textile fabric 12. The surface of the textile fabric 12 passes closely adjacent to the heated gas discharge outlet 116, as shown in FIGS. 5 and 6, of elongate gas distributing manifold assembly 30 of pressurized heated gas carving head 10. Only the portions of the textile fabric 12 that were printed with liquid repellent and remain dry will be carved, thereby affecting the surface of the textile fabric 12 in the treated areas such as lowering the height of the pile if the textile fabric 12 is a pile textile fabric. These carved areas are designated by numeral 246, with the normalized areas designated as 247. The carved textile fabric 12 then passes over a fourth idler roll 249 and into a hot air dryer 280 at a temperature in the range of 230 to 425 degrees Fahrenheit to provide evaporation of remaining liquids. The carved textile fabric 12 then passes onto take-up roll 214 as a finished carved product. As shown in FIG. 8, the carved textile fabric 12 is demonstrated with both the carved areas 246 and normalized areas 247. Carving can result in any one of the following characteristics selected from the group including melted fibers, shrunk fibers, displaced fibers, altered sheen, altered fiber tip definition, altered shade, altered color, altered pile direction, and swollen fibers. These characteristics can vary in magnitude according to process conditions used to obtain a multitude of aesthetic effects.
Referring now to FIG. 3, which is analogous to FIG. 1, with the exception of four rotary screen print heads instead of just one rotary screen print head. An indefinite length of textile fabric 312, from a supply roll 318 passes over an idler roll 332, and into a dyeing apparatus 316. The dyeing apparatus 316, in this case, is a four position rotary screen printer. An illustrative example, but not limited to is a rotary screen printer such as one that is manufactured by Johannes Zimmer Vermogensver-Waltungsgmbh located at Ebentaler Strase 133, Klagenfurt 9020, Austria. This dyeing apparatus 316 includes a first mesh print screen 320 and a first squeegee 321, a second mesh print screen 340 and a second squeegee 341, a third mesh print screen 350 and a third squeegee 351, and a fourth mesh print screen 360 and a fourth squeegee 361. These four mesh print screens 320, 340, 350, and 360 are positioned over a belt conveyor 319 having a endless belt 355 that rotates between a first roll 326 and a second roll 327. The textile fabric 312 passes between the four mesh print screens 320, 340, 350, and 360 and the conveyor belt 319 which is supported by support plate 371. The conveyor belt 319 and support plate 371 serve the same function as the support roll 26 in FIG. 1.
The chemicals from the first mesh print screen 320 are applied to the textile fabric 312 in a selectively patterned arrangement as indicated by portion 381. The chemicals from the second mesh print screen 340 are applied to the textile fabric 312 in a selectively patterned arrangement as indicated by portion 382. The chemicals from the third mesh print screen 350 are applied to the textile fabric 312 in a selectively patterned arrangement as indicated by portion 383. The chemicals from the fourth mesh print screen 360 are applied to the textile fabric 312 in a selectively patterned arrangement as indicated by portion 384. The chemicals from the first mesh print screen 320 and the third mesh print screen 350 contain a liquid repellent. As previously mentioned, this liquid repellent can be of literally any type including fluorocarbons, silicones, waxes, and so forth. The textile fabric 312 then passes into a finishing apparatus 334 that typically includes a hot air oven. However, this step can include any of the fixing, steaming, or drying steps that would take place in textile fabric finishing and depends of the type of textile fabric 312 and the desired effect. The textile fabric 312 then moves to take-up roll 314 for collection.
Referring now to FIG. 4, which is virtually identical to FIG. 2, the textile fabric 312 from take-up roll 314 is now positioned on supply roll 218. The textile fabric 312 then passes over a first idler roll 232 and into a tank of liquid 234, around a second idler roll 236 and then through a pair of nip rolls 240 and 242 to squeeze out the excess liquid, then around third idler roll 244, which is utilized merely to alter the angle of direction of the textile fabric 312. The pair of nip rolls 240 and 242 are placed under pressure by means of a air cylinder (not shown). The liquid is preferably water. However, a multitude of liquids would suffice such as a 95% water and 5% urea combination, alcohol, and so forth.
The textile fabric 312 then passes over a support roll 226 with a pressurized heated gas carving head, generally indicated at 10 directly opposite and above the textile fabric 312. The surface of the textile fabric 312 passes closely adjacent to the heated fluid discharge outlet 116 as shown in FIGS. 5 and 6, of elongate fluid distributing manifold assembly 30 of the pressurized heated gas carving head 10. Only the portions of the textile fabric 312 that were printed with liquid repellent and remain dry will be carved, thereby affecting the surface of the textile fabric 312 in the treated areas such as lowering the height of the pile if the textile fabric 312 is a pile textile fabric. These carved areas are designated by numerals 381 and 383, with the untreated areas designated as 382 and 384, respectively. The carved textile fabric 312 then passes over a fourth idler roll 249 and into a hot air dryer 280 at a temperature in the range of 230 to 425 degrees Fahrenheit to provide evaporation of remaining liquids. The carved textile fabric 312 then passes onto take-up roll 214 as a finished carved product. Carving can result in any one of the following characteristics selected from the group including melted fibers, shrunk fibers, displaced fibers, altered sheen, altered fiber tip definition, altered shade, altered color, altered pile direction, and swollen fibers. These characteristics can vary in magnitude according to process conditions used to obtain a multitude of aesthetic effects.
As illustrated in FIGS. 2 and 4, the pressurized heated gas carving head 10 includes a source of compressed gas, such as an gas compressor 38, which supplies pressurized gas to an elongate gas header pipe 40. The type of gas is preferably air. Header pipe 40 communicates by a series of gas lines 42, spaced uniformly along its length with a bank of individual electrical heaters indicated generally at 44. The heaters 44 are arranged in parallel along the length of heated fluid distributing manifold assembly 30 and supply heated pressurized gas thereto through short, individual gas supply lines, indicated as 46, which communicate with assembly 30 uniformly along its full length. Gas supply to the heated fluid distributing manifold assembly 30 is controlled by a master control valve 48, pressure regulator valve 49, and individual precision control valves, such as needle valves 50, located in each heater gas supply line 42. The heaters 44 are controlled in a suitable manner, as by temperature sensing means located in the outlet lines 46 of each heater, with regulation of gas flow and electrical power to each of the heaters to maintain the heated fluid at a uniform temperature and pressure as it passes into the manifold assembly 30 along its full length.
Typically, for carving textile fabrics containing thermoplastic yarns, the heaters are employed to heat gas entering the manifold assembly to a predetermined manifold temperature somewhere in the range of 400°-1000° Fahrenheit. However, said range of manifold temperatures may be between the lowest temperature that will affect the fiber properties and the maximum temperature the heater system can produce. The preferred manifold temperature for any given textile fabric 12 depends upon: the components of the textile fabric, the construction of the textile fabric; the desired effect, the speed of transport of the textile fabric, the pressure of the heated pressurized gas; the tension of the textile fabric, the proximity of the textile fabric to the pressurized heated gas carving head 10, the moisture content of the fabric, and others.
The heated fluid distributing manifold assembly 30 is disposed across the full width of the path of movement of the textile fabric 12 and closely adjacent the surface thereof to be treated. Although the length of the manifold assembly may vary, typically in the treatment of textile fabric materials, the length of the manifold assembly may be seventy-six inches or more to accommodate textile fabrics of up to about seventy-two inches in width. However, the length of the manifold assembly can be tailored to conform to virtually any fabric width.
Details of the heated fluid distributing manifold assembly 30 may be best described by reference to FIGS. 5-6. As seen in FIG. 5, which is a partial sectional elevation view through the assembly, there is a first large elongate manifold housing 54 and a second smaller elongate manifold housing 56 secured in fluid tight relationship therewith by a plurality of spaced clamping means, one of which is generally indicated at 58. The manifold housings 54, 56 extend across the full width of the textile fabric 12 adjacent its path of movement.
As best seen in FIG. 5, first elongate manifold housing 54 is of generally rectangular cross-sectional shape, and includes a first elongate gas receiving compartment 81, the ends of which are sealed by end wall plates suitable bolted thereto. Communicating with bottom wall plate through fluid inlet openings, one of which, 83, is shown in FIG. 5, and spaced approximately uniformly therealong are the gas supply lines 46 from each of the electrical heaters 44, as shown in FIGS. 2 and 4. The heaters 44 are controlled in suitable manner, as by temperature sensing means 47 located in the outlet lines 46 of each heater as shown in FIG. 5. A single temperature sensing means 47 can be used as a representative sample for the entire bank of individual heaters. Although economical, the use of one temperature sensing means results in less accuracy. The regulation of air flow and electrical power to each of the heaters maintains the heated fluid at a uniform temperature and pressure as it passes into the manifold assembly along its full length. The temperature of the first elongate fluid receiving compartment 81 is monitored by thermocouple 102 whose input controls the bank of heaters in order to maintain uniform carving of textile fabric 12 across the entire width thereof.
The manifold housings 54, 56 are constructed and arranged so that the flow path of gas through the first housing 54 is generally at a right angle to the discharge axes of the gas stream outlets of the second manifold housing 56.
As best seen in FIGS. 5 and 6, manifold housing 54 is provided with a plurality of gas outlet passageways 86 which are disposed in uniformly spaced relation along the plate in two rows to connect the first gas receiving compartment 81 with a central elongate channel 88.
Baffle plate 92 serves to define a gas receiving chamber in the compartment 81 having side openings or slots 94 to direct the incoming heated gas from the bank of heaters in a generally reversing path of flow through compartment 81. Disposed above channel-shaped baffle plate 92 is compartment 81 between the gas inlet openings 83 and gas outlet passageways 86 is an elongate filter member 100 which is a generally J-shaped plate with a filter screen disposed thereabout.
As seen in FIGS. 5, 6 and 7, a second smaller manifold housing 56 comprises first and second opposed elongate wall members, each of which has an elongate recess or channel 108 therein. Wall members are disposed in spaced, coextensive parallel relation with their recesses 108 in facing relation to form upper and lower wall portions of a second gas receiving compartment 110, in the second manifold housing 56. The gas then passes through a third gas receiving compartment 112 in the lower wall member of manifold housing 56 which is defined by small elongate islands 111 approximately uniformly spaced along the length of the member, as shown in FIG. 7. A continuous slit 116 directs heated pressurized gas from the third gas receiving compartment 112 in a continuous sheet across the width of the fabric onto the surface of the moving textile fabric 12. Typically, in the treatment of textile fabrics such as pile fabrics containing thermoplastic pile yarn, the continuous slit 116 of manifold 56 may be 0.015 to about 0.030 of an inch in thickness. For precise control of the heated gas streams carving the fabric, the continuous slit 116 is preferably maintained as close to fabric surface as possible, typically less than 0.025-0.050 inches. However, this distance from the face of the textile fabric 12 can be as much as 0.100 of an inch and still produce good pattern definition.
Second manifold housing 56 is provided with a plurality of spaced gas inlet openings 118 (FIGS. 5 and 6) which communicate with the elongate channel 88 of the first manifold housing 54 along its length to receive pressurized heated gas from the first manifold housing 54 into the second gas receiving compartment 110.
Another embodiment would be to treat the yarn or fibers with a chemical containing a liquid repellant either alone or with a colorant such as dye prior to weaving, knitting, needling or tufting the fibers into a textile fabric. This textile fabric is then processed in the same manner as shown in FIGS. 2 and 4. The textile fabric 12, 312 is now positioned as supply roll 218. The textile fabric 12, 312 then passes over a first idler roll 232 and into a tank of liquid 234, around a second idler roll 236 and then through a pair of nip rolls 240 and 242 to squeeze out the excess liquid, then around third idler roll 244 to direct the textile fabric 12, 312 to the pressurized heated gas carving head 10. The pair of nip rolls 240 and 242 are placed under pressure by means of an air cylinder (not shown). The liquid is preferably water. However, a multitude of liquids would suffice such as 95% water and 5% urea combination, alcohol, and so forth.
The textile fabric 12, 312 then passes over a support roll 226 with a pressurized heated gas carving head, generally indicated at 10 on the other side and directly above the textile fabric 12, 312. The surface of the textile fabric 12, 312 passes closely adjacent to the heated gas discharge outlet 116, as shown in FIG. 6, of elongate gas distributing manifold assembly 30 of pressurized heated gas carving head 10. Only the portions of the textile fabric 12, 312 that were treated with liquid repellent and remain dry will be carved, thereby affecting the surface of the textile fabric 12, 312 in the treated areas such as lowering the height of the pile if the textile fabric 12, 312 is a pile textile fabric. The carved textile fabric 12, 312 then passes over a fourth idler roll 249 and into a hot air dryer 280 at a temperature in the range of 230 to 425 degrees Fahrenheit to provide evaporation of remaining liquids. The carved textile fabric 12, 312 then passes onto take-up roll 214 as a finished carved product. As shown in FIG. 9, the carved textile fabric 12 is demonstrated with both the carved areas 446 and normalized yarns 447. Carving can result in any one of the following characteristics selected from the group including melted fibers, shrunk fibers, displaced fibers, altered sheen, altered fiber tip definition, altered shade, altered color, altered pile direction, and swollen fibers. These characteristics can vary in magnitude according to process conditions used to obtain a multitude of aesthetic effects.
EXAMPLE
As best illustrated by FIGS. 3 and 4, a Zimmer rotary screen printer is utilized with a 125 mesh print screen, a speed of five yards per minute, a squeegee size of two inches in diameter and a magnet setting of six. The Zimmer printer is manufactured by Johannes Zimmer Vermogensver-Waltungsgmbh located at Ebentaler Strase 133, Klagenfurt 9020, Austria. The print paste utilized by first mesh print screen 320 and third mesh print screen 350 is a mixture of one to three percent disperse dye mix such as Transit Blue BLF manufactured by Ciba-Geigy Corporation located at 3400 Westinghouse Blvd., P.O. Box 7648, Charlotte, N.C. 28241. The liquid repellant makes up approximately five percent of the total solution. The liquid repellant is FC 251 manufactured by Minnesota Mining & Manufacturing Company (3M) located at 3M Center, St. Paul Minn. 55144-1000. There is a gum for thickening that constitutes approximately one percent of the total solution and has a viscosity of 700 to 2000 cps. The remainder of the solution is water.
The heat set aspect of the textile fabric finishing that occurs in the finishing apparatus 334 is a hot air oven that is at a temperature of 350 degrees Fahrenheit that treats the textile fabric 312 for one minute.
The rewetter is a tank of water providing a liquid bath 234. The nip rolls 240, 242 form a rewet pad and utilize an air cylinder with 50 p.s.i. of air pressure applied thereto for placing pressure on the textile fabric 312.
The pressurized heated gas carving head 10 is a hot air nozzle with a continuous slit 116 with a 0.017 inch opening. The temperature is 750 degrees Fahrenheit with an air pressure of 1.5 pounds per square inch. The speed of the textile fabric 312 past the support roll 226 is eight yards per minute. There is a distance of 0.90 inches between the heated fluid discharge outlet 116 and the support roll 226, as shown in FIG. 6.
As the invention may be embodied in several forms without departing from the spirit or essential character thereof, the embodiments presented herein are intended to be illustrative and not descriptive. The scope of the invention is intended to be defined by the following appended Claims, rather than any descriptive matter hereinabove, and all embodiments of the invention which fall within the meaning and range of equivalency of such Claims are, therefore, intended to be embraced by such Claims.
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An apparatus and method for selectively carving textile fabric by selectively applying chemicals containing a liquid repellent either alone or with other chemicals such as dye to a textile fabric and subsequently finishing said fabric. The textile fabric is then rewetted by the application of liquid. The printed areas containing liquid repellant remain dry and the areas without liquid repellent are selectively wetted out. The textile fabric is then subjected to pressurized heated gas which selectively carves the dry areas printed with liquid repellent leaving the wetted areas protected and uncarved. As an alternative embodiment, the yarns that make up a textile fabric can be individually treated with a liquid repellent prior to being formed into a textile fabric.
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This application is a division of application Ser. No. 07/549,635 filed Jul. 6, 1990, and now U.S. Pat. No. 5,038,332, which application is a continuation of prior application, Ser. No. 07/036,557 filed Apr. 9, 1987, now abandoned.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to an optical information recording medium provided thereon with a mark indicative of a reference position, particularly a recording medium of the type in the form of a card, and an information recording-reproducing apparatus for such a recording medium.
As the forms of a recording medium on which information is recorded by the use of a light and the recorded information is read out, there are known various types such as the form of a disc, the form of a card and the form of a tape. Among these, an optical information recording medium in the form of a card (hereinafter referred to as the optical card) has a great expected demand as a compact, light-weight and readily portable medium of great recording capacity.
Referring to FIG. 1 of the accompanying drawings which is a schematic plan view of an example of such an optical card, reference numeral 101 designates the optical card, reference numeral 103 denotes tracking tracks, and reference numeral 107 designate areas in which track numbers are recorded.
The card is scanned by a light beam modulated in accordance with recording information and stopped down into a minute spot, whereby information as a row of optically detectable recording pits (information tracks) is recorded on the optical card.
In order that at this time, information may be accurately recorded and reproduced without the trouble of intersection between information tracks being caused, the position of application of the light beam must be controlled in a direction perpendicular to the scanning direction (auto-tracking, which will hereinafter be referred to as AT). Also, in order that the minute spot may be stably applied in spite of the bending and mechanical error of the optical card, control must be effected in a direction perpendicular to the surface of the optical card (auto-focusing, which will hereinafter be referred to as AF).
A recording-reproducing method will now be described with reference to FIG. 1. Initially, the light beam lies at the home position outside the recording area. The light beam is then moved relative to the optical card 101 in the direction of arrow D to find a track to be recorded or reproduced, and scans this track in the direction of arrow F, thereby effecting recording or reproduction. Here, as means for detecting whether that track is a desired track, track numbers 107 (hereinafter referred to as the pre-format) pre-recorded on the extensions of the tracking tracks 103 as illustrated in FIG. 2 of the accompanying drawings are read and the read content is inspected to thereby determine whether the track is the desired track. Also, by making reference to the track number and the control information, whether that track is recorded can be known and thus, so-called overwriting, which means that information is further written on the recorded track by mistake, can be prevented.
In such an optical card, however, the tracking tracks which should not originally be discontinuous become partly discontinuous in the track number portion, and this provides disturbance to the AT control- circuit system, which is undesirable in control. Also, track addresses as information data are preformed and therefore, where there is a defect such as a pin-hole at the location whereat this track number is formed, there has been a problem that malfunctioning occurs when the track number as data is read.
So, it would occur to mind to preform only tracking tracks on the recording medium instead of preforming addresses on the recording medium. In this case, however, there is a problem that when a desired recording portion is sought after, the spot fails to follow the desired track in the edge portion or goes beyond the final track and deviates from the surface of the medium.
On the other hand, the recording speed and reproducing speed of the optical information recording medium will be more and more improved by advancement in the future. Also, various modulation and demodulation systems will be adopted depending on how the medium is used. In the prior-art mediums, the aforementioned point has not been taken into account, and this has led to a disadvantage that it is difficult to secure mutual interchangeability in high-degree applied systems.
A first object of the present invention is to eliminate the aforementioned disadvantage regarding the formation of track addresses and to provide an optical information recording medium in which confirmation of a reference position can be reliably accomplished by a simple construction and overwriting can be avoided.
A second object of the present invention is to provide a recording-reproducing apparatus for such an optical information recording medium.
A third object of the present invention is to further eliminate the aforementioned disadvantage regarding the mutual interchangeability and to provide an optical information recording medium of simple construction which can also be used with high-degree systems which handle a plurality of types of mediums.
The first object of the present invention is achieved by an optical information recording medium which has tracking tracks arranged at intervals and recording portions provided between said tracking tracks and on which information is recorded by application of a light beam thereto, and in which an optically detectable mark indicative of a reference position is provided at at least one location in at least one of said recording portions.
The second object of the present invention is achieved by an information recording-reproducing apparatus having a light source, lens means for imaging the light beam from the light source on a recording medium, a photodetector for receiving the light from the recording medium, detector means for detecting a reference position mark on the recording medium on the basis of the signal from the photodetector, means for beginning auto-tracking on the basis of the signal from the detector means, and means for controlling a tracking actuator on the basis of the signal from the detecting means to start recording and reproduction of information from a predetermined position on the recording medium.
The third object of the present invention is achieved by an optical information recording medium which has tracking tracks arranged at intervals and recording portions provided between said tracking tracks and on which information is recorded by application of a light beam thereto, and in which an optically detectable mark indicative of the type of the medium is provided at at least one location on said recording portions.
Other objects and features of the present invention will become apparent from the following detailed description of the embodiments thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing an example of the optical information recording medium according to the prior art.
FIG. 2 is an enlarged plan view of a portion of FIG. 1
FIG. 3 is a plan view showing an embodiment of the optical information recording medium of the present invention.
FIG. 4 is a perspective view showing an example of a recording-reproducing apparatus for the medium shown in FIG. 3.
FIG. 5 shows the light-receiving surfaces of photodetectors shown in FIG. 4.
FIG. 6 is a plan view of the medium illustrating the recording process
FIG. 7 is an enlarged view of a portion of FIG. 3.
FIGS. 8 and 9 show the wave forms of detection signals.
FIG. 10 is an enlarged view of a portion of FIG. 3.
FIG. 11 shows the wave form of a signal detected from a medium type identifying pattern.
FIG. 12 illustrates another example of the medium type identifying pattern.
FIG. 13 is a block diagram showing an example of the signal processing circuit in the apparatus shown in FIG. 4.
FIG. 14 is a plan view showing another embodiment of the optical information recording medium of the present invention.
FIG. 15 is an enlarged plan view of a portion of FIG. 14.
FIG. 16 shows the wave form of a detection signal.
FIG. 17 is an enlarged view of a portion of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 is a schematic plan view of an optical card to which the present invention is applied. In FIG. 3, the optical card 1 comprises a substrate formed of a plastic material or the like, and a recording layer 2 formed on the substrate and formed of a silver salts material, a dye, a chalcogen material or the like on which information can be optically recorded. Tracking tracks 3 1 , 3 2 , 3 3 , 3 4 , 3 5 , . . . , 3 n-4 , 3 n-3 , 3 n-2 , 3 n-1 , 3 n preformed in the form of continuous lines are disposed parallel and at equal intervals on the recording layer 2. Recording portions for recording information thereon are provided between adjacent tracks. That is, tho optical card 1 has recording portions between all adjacent tracking tracks. Marks 5 1 and 5 2 (hereinafter referred to as the G marks) indicative of optically detectable reference positions are formed at two locations in said recording portions (i.e., at each one location in each different recording portion). A medium identifying pattern 6 is formed on that recording portion in which the G mark 5 2 is provided.
FIG. 4 illustrates the construction of an embodiment of an optical information recording-reproducing apparatus for effecting recording and reproduction on the optical card of the present invention. A beam emitted from a light source 11 such as a semiconductor laser is collimated by a collimator lens 12 and is divided into three beams by a diffraction grating 13. These beams are imaged on the optical card 1 as shown in FIG. 3 by an objective lens 14 and form beam spots S 1 , S 2 and S 3 , respectively. The optical card 1 is moved in the direction of arrow R by drive means, not shown, and is scanned by said beam spots in the direction in which the tracking tracks extend. The reflected lights of the beam spots S 1 , S 2 and S 3 again pass through the objective lens 14, are reflected by a beam splitter 15 and are projected onto photodetectors 17, 18 and 19 by a condensing lens system 16. The condensing lens system 16 is an astigmatic system and is arranged to effect AF in a well-known astigmatic type. The photodetectors are arranged as shown in FIG. 5. In FIG. 4, reference numeral 20 designates a prism for converting the cross-section distribution of the collimated light beam from an ellipse to a circular shape, and reference numeral 21 denotes a mirror for directing the light beam to the objective lens 14. The photodetector 18 has its light-receiving surface divided into four as indicated by A, B, C and D in FIG. 5. The operation of recording information on the optical card by the use of the aforedescribed apparatus will now be described with reference to FIG. 6. First, when information is to be recorded on a recording portion 10, spots S 1 , S 2 and S 3 are applied to the tracking track 34, the recording portion 10 and the tracking track 3.sub. 5, respectively. These spots are scanned in the direction of arrow F of FIG. 3 relative to the card 1 by movement of the optical card 1 as shown in FIG. 4. The reflected light from the spot S 1 enters the aforementioned photo-detector 17, and the reflected light from the spot S 3 enters the photodetector 19, and a tracking signal is detected from the output signals of these photodetectors. That is, if the spots S 1 and S 3 deviate relative to the tracking tracks 3 4 and 3 5 , there occurs a difference between the intensities of the lights entering the photodetectors 17 and 19, and a tracking signal is obtained by comparing the signals from the light-receiving surfaces of these photodetectors. On the basis of this tracking signal, the spots S 2 and S 3 are moved together in a direction (direction D) perpendicular to the scanning direction by tracking means (for example, in FIG. 4, means for moving the objective lens 14 in a direction Z in the optical head), whereby AT is effected. A record pit 9 is accurately recorded in the recording portion 10 along the tracking tracks 3 4 and 3 5 by the spot S 2 . The recorded pit is indicated by a broken line in FIG. 3.
The function of the G marks will now be described. FIG. 7 is an enlarged view showing the portion in which the G mark 5 2 is provided. Actually, the G mark 5 2 is formed in the form of a discontinuous broken line as shown in FIG. 7.
Initially, the light spot S 1 lies at the home position 4, and when this light spot S 1 is moved in a direction D by optical head driving means, the level of the detection signal 22 of the reflected light of the spot S 1 varies as shown in FIG. 8. That is, when the spot S 1 is moved in the direction D and crosses the tracking track 3 n (23) the first variation appears, and the level likewise varies each time the spot S 1 crosses the tracking track 3 n-1 (24), the tracking track 3 n-2 (25) and the G mark 5 2 (26). If at this time, the speed of movement of the spot is constant, it can be discriminated by the use of a time measuring circuit that the spot has crossed the G mark 5 2 , because the time between 25 and 26, the time between 23 and 24 and the time between 24 and 25 differ apparently from one another. Subsequently, when the light spot S 1 has come onto the tracking track 3 n-3 (as indicated at 27 in FIG. 8), the light spot S 3 lies on the tracking track 3 n-2 as is apparent in FIG. 6 and therefore, the movement of the light spot is stopped.
Subsequently, in this state, the card, 1 is moved in a direction F to feed the spot to position on the card 1, whereafter the card 1 is moved in a direction to feed the spot to position q (FIG. 3). The variation in the signal level obtained from the reflected light of the light spot S 2 is low when the spot has been fed to position p in FIG. 9, and then the direction of feeding of the card is reversed and the time during which the variation is high is measured while the spot is passing the G mark 5 2 , and if this said time is longer than a predetermined time, the G mark is judged, and if there is no variation in the signal until the spot arrives at the point q, it is judged that the current track is the reference track on which the desired G mark is provided. By disposing the preformed G marks at predetermined locations on the card 1 as described above, the reference track can be reliably identified even if track numbers are not disposed for the tracking tracks. On the basis of this reference track, information is recorded on the parallel recording portions in succession while the spot is moved in the direction of arrow D of FIG. 3. When another G mark 5 1 is detected, the recording portion provided with that G mark is judged as the final track and thus, recording is terminated,
That is, in the present embodiment, the surface of the medium is divided into a recording area 8 and nonrecording areas 7 1 and 7 2 , and the boundaries therebetween are indicated by G marks 5 1 and 5 2 . Tracking tracks 3 n , 3 n-1 and 3 n-2 provided in the recording area 7 2 are not used for the recording of information, but are merely used as guard tracks. For example, if the recording portion most adjacent to the home position is set as the reference track, when the light spot is moved in the direction D of FIG. 3 and has crossed the tracking track which is first to appear, an AT control circuit tries to rapidly follow the track and therefore, light pickup (namely, the light spot) also moves rapidly and moreover, greatly. As a result, there may occur the malfunctioning that the light spot follows the next track due to overshoot. Accordingly, in the present embodiment, more than two tracking tracks 3 n , 3 n-1 , 3 n-2 are provided outside the recording portion on which the G mark 5 2 is provided, whereby the introduction into these tracking tracks is reliably accomplished, and then the detection of the G mark 5 2 is started.
Also, tracking tracks 3 1 , 3 2 , 3 3 likewise provided in the non-recording area 7 1 are used as guard tracks. That is, when during the access to the tracks, the G mark 5 1 fails to be detected by mistake and the spot goes past the final track, the spot is drawn in by any one of these guide tracks to thereby prevent the spot from jumping out of the surface of the medium. Desirably, two or more tracking tracks should be formed outside the G mark 5 1 .
The G mark 5 2 which is a discontinuous pattern as shown in FIG. 7 is particularly preferable in that a detection signal appears clearly when the spot crosses such G mark, but the G mark may be a strip-like pattern to obtain a similar effect.
Also, by providing G marks at the q side also as indicated at 5 3 and 5 4 in FIG. 3, the location interposed between HIGH signals of predetermined time widths is judged as the reference track between positions p and q, whereby reliable detection of the reference position which is hardly affected by flaws or dust can be accomplished.
When the present invention is applied to an optical card as in the aforedescribed embodiment, it is desirable that the width W 1 of the tracking track shown in FIG. 6 be 2.5 μm or greater. The reason for this will hereinafter be described.
An optical information recording medium usually has a transparent protectively layer provided on a recording layer on which a beam spot is imaged. The diameter of the light beam on the surface of the protective layer is greater than the diameter of the spot on the recording layer. Accordingly, even if dust or the like adheres to the surface of the protective layer, the influence thereof upon signal detection will be small. In optical discs or the like, on the basis of such a principle, the track width is of the order of 1-2 μm to achieve high density. In optical cards, however, the card thickness is limited to the order of 0.8 mm from the viewpoint of making the size of the optical cards common to the size of ordinary credit cards. Accordingly, the thickness of the transparent protective layer must unavoidably be of the order of 166 to 1/2.5 of the thickness of the optical discs, and when the influence of dust or the like is taken into account, the width of the tracking tracks must be 2.5 μm or greater. For the same reason, it is desirable that the interval between the tracking tracks, i.e., the width W 2 of the recording portion, be 2.5 μm or greater.
The function of the medium identifying pattern will now be described. FIG. 10 is a fragmentary enlarged view of the optical card of FIG. 3. The medium identifying pattern 6 (hereinafter simply referred to as the pattern) is formed by a pre-format or a light spot on the extension of the track on which there is the G mark 5 2 . The feature of this pattern is that it is a pre-format entirely different from the other data recording portions and it is of the type which does not depend on the speed during the read-out and can accomplish processing by a very simple circuit without using a circuit for reproducing and demodulating the other data recording portions. The type shown in FIG. 10 is a kind of FM modulation system, and the signal 29 detected by the aforementioned photodetector 18 (spot S 2 ) is such as shown in FIG. 11. At first, the time t 1 from the rising until the rising of the signal is measured N times (in FIG. 11, two times) and the average value thereof is calculated, and that value is used as the reference time thereafter. As regards the decision expression for 1 and 0, when t 1 is the reference time and T is the measured time, if for example, T >2t 1 , 0 is judged, and if 0.5t 1 <T<2t 1 , 1 is judged. Accordingly, in the case of FIG. 11, the signal is judged is "0110". Further, to improve the reliability, the whole is constructed of a repetition pattern at each M bits (in the present embodiment, M=4) and comparison is made for each M bits with each 1 bit deviated, and when the same bit pattern continues, that pattern is recognized as the number inherent to the medium. In the case of FIG. 12, the eight bit in the input bit row is wrong and therefore, the same bit pattern continues in the ninth comparison and as a result, the number "6.sub.(15) " inherent to the medium is recognized.
For example, when the pattern "6.sub.(15) " (the present embodiment) is defined as a medium of MFM modulation and speed of 100 mm/sec. and the pattern "1" is defined as a medium of 8-14 conversion and speed of 200 mm/sec., when the recording-reproducing apparatus is of the MFM modulation type and reads the pattern at a speed of 100 mm/sec., if the pattern information is "1", the recording-reproduction speed is set to 200 mm/sec. in accordance with the pattern information and the modulating-demodulating circuit is changed over from MFM modulation to the 8-14 conversion side, whereby recording and reproduction on the medium of 8-14 conversion become possible. In the case of an apparatus which does not have a modulating-demodulating circuit of 8-14 conversion, information having the meaning that "recording and reproduction are impossible" is sent to an apparatus of a higher rank, not shown, which controls the recording-reproducing apparatus, or it is made known to the operator by a buzzer, a lamp or the like provided on the recording-reproducing apparatus that "recording and reproduction are impossible".
Thus, recording and reproduction on a variety of mediums become possible by simple hardware and software Also, in FIG. 3, the pattern 6 is disposed on the track on which the G mark 5 2 is present, and this is for the purpose of preventing the area in which data can be recorded from decreasing, and the effect of the present invention will still be obtained even if the pattern 6 is disposed on any other track.
As described above, when a mark for identifying the medium is provided in a part of the recording portion, the identification of the medium can be reliably accomplished by a simple construction and such a recording medium can be used with a system in which a plurality of kinds of mediums are handled.
Besides the above-described embodiment, various applications of the present invention are possible. For example, the shape of the medium is not limited to a card-like shape, but a tape-like shape or the like is also applicable.
An example of the information recording and reproducing apparatus according to the present invention will now be described in more detail.
FIG. 13 is a block diagram showing an example of the construction of the signal processing of the circuit in the apparatus shown in FIG. 4. In FIG. 13, the outputs of the light-receiving surfaces B and C of the photodetector 18 are input to an adder 37 and the outputs of the light-receiving surfaces A and D of the photodetector 18 are input to an adder 38, and the outputs of these adders are differentiated by a differential amplifier 39, whereby an AF signal is obtained from a terminal C 1 . Also, the outputs of these adders are added together by an addition amplifier 40, and during reproduction, an information signal RF is obtained from a terminal C 2 . The outputs of photodetectors 17 and 19 are differentiated by a differential amplifier 41, move the objective lens 14 in the direction Z (FIG. 4) through a switch 42 and are input to a tracking actuator 43 which effects AT.
When information is to be recorded, optical head drive means 45 moves the entire optical head of FIG. 4 in the direction D of FIG. 3 by the instruction from a central processing unit (CPU) 44. Thereupon, the spot S 1 , which has so far lain at the home position 4 crosses the tracking track and a track crossing pulse as shown in FIG. 8 is output from the photodetector 17. At this time, the switch 42 is in its open state. The track crossing pulse is input to a time measuring circuit 31 and the interval between the pulses is measured. The time measuring circuit 31 is reset each time the pulse is input thereto, thereby starting time measurement. A time corresponding to the interval between the tracking track and the G mark is set in a time set circuit 32, This set time and the output of the time measuring circuit 31 are compared by a comparing circuit 33, and when the next pulse is detected within the set time, it is judged that the G mark has been crossed, and a signal is sent to the CPU 44 to stop the movement of the optical head. Simultaneously therewith, the switch 42 is closed to effect introduction of AT.
Subsequently, with AT being applied, the card 1 is fed to position p in the direction F of FIG. 3, whereafter it is fed to position q in the direction L, and the introduced recording portion is scanned by the spot S 2 . Thereupon, a signal as shown in FIG. 9 is output from the addition amplifier 40. This output signal is input to a time measuring circuit 34, by which the time of the HIGH state is measured. The measured time is compared by a comparing circuit 36 with a time corresponding to the length of the G mark preset in a time set circuit 35, and when these are coincident with each other, it is confirmed that the track which is then being scanned is the reference track, and a sign for starting recording is sent to the CPU 44. If the signal as shown in FIG. 9 is not output, the spot S 2 is moved to the adjacent recording portion and the operation is repeated until the G mark is detected.
When the G mark is confirmed as described above, the CPU 44 sends a jump pulse to the tracking actuator 43 to thereby move the objective lens and apply the spot S 2 to the recording portion neighboring the reference track. Then, information is recorded while the card is reciprocally moved in the directions L and F. When the recording of information on this recording portion is completed, the spot S is moved to the next recording portion and recording of information is continued to be effected. Thus, information is recorded on the recording portions of the recording area 8 in succession while the spot S 2 is moved. When all the information is recorded, the spot S 2 is moved to the home position 4, thus completing a series of operations. Where additional recording of information is to be effected on the thus recorded card, the reference track is confirmed as previously described, whereafter the recording area is scanned by the spot S 2 and the recorded final recording portion is found out, and recording is started from the next recording portion.
In the above-described embodiment, each one recording portion provided with a G mark is provided at the opposite sides of the recording area, but a plurality of such recording portions may be provided at each of the opposite sides of the recording area. FIG. 14 is a schematic plan view showing such an embodiment, and FIG. 15 is an enlarged plan view of the non-recording area 7 2 in FIG. 14. In FIGS. 14 and 15, members similar to those in FIG. 3 are given similar reference characters and need not be described in detail. In the present embodiment, a plurality of recording areas provided with G marks 5 1 , . . . , 5 i are provided at each of the opposite sides of the recording area 8. Also, the recording areas provided with the G marks are formed with G mark identifying patterns 10 1 , . . . . , 10 i indicative of the locations of these recording portions.
Description will now be made of a method of detecting the reference track when the card 1 of FIG. 14 is used. Initially, the light spot S lies at the home position 4 and here, introduction of AF is effected and thereafter, AF control always continues to be effected. Thereafter, the optical head as shown in FIG. 4 is moved in the direction D and when the spot S is scanned in the direction D, the level of the detection signal of the reflected light of the spot S varies as shown in FIG. 16. That is, when the spot S is moved in the direction D and has crossed the tracking track 3 n , the first variation appears, and variation occurs each time the spot S likewise crosses the tracking track 3 n-1 , 3 n-2 .
This signal is counted k times and when the light spot has come onto the tracking track 3 n-k , the movement of the light spot is stopped and the spot is introduced in this tracking track, whereby AT control is effected. Even if at this time, a drive system, not shown, for moving the light spot is stopped, the light spot actually tends to go past several tracks due to the mechanical accuracy. Also, an error occurs when the spot is introduced to effect AT control. If the value of k is set so that the error resulting from these two factors is smaller than i-k, where i is the number of data tracks in which the G marks between the tracking tracks are present, the G mark is present without fail on the track into which the spot has been introduced.
Subsequently, in this state, the card is fed in the direction of arrow L. The variation in the signal level obtained from the then reflected light of the light spot S is such as shown in FIG. 9, and if the time during which the signal level is high is measured while the spot is passing the G mark 5 and that time is a predetermined time or longer, the G mark is judged. Simultaneously therewith, the distance from the card feed starting position a of the light spot S (see FIG. 15) to the G mark 5 is measured and this value is used as the reference position in the direction parallel to the tracks.
Subsequently to the detection of the G mark, a G mark identifying pattern 10 is detected by the scanning of the spot S. The G mark identifying pattern 10, as shown in FIG. 17, is recorded in a format similar to that of the aforementioned medium identifying pattern 6, and can be read in a manner similar to that described in connection with FIG. 12, for example.
The number of the types of this pattern corresponds to the number of G mark tracks, and in FIG. 15, patterns 1, 2, . . . , i correspond to the G marks 5 1 , 5 2 , . . . , 5 i . Accordingly, by reading of these patterns, identification of the G mark, namely, the position on the card at which the G mark of this recording portion lies, can be known.
For example, when information is to be recorded on the first recording portion like the recording pit 9 of FIG. 14, the G marks and the G mark identifying patterns are detected as previously described. If those patterns are m, the spot S is moved by m tracks in the direction D, whereafter recording is started. This movement of the spot S is accomplished not by movement of the optical head, but for example, only by the tracking actuator as previously described (the kick operation). In this kick operation, the error during the track movement hardly occurs and therefore, information can be recorded from a correct position. The recording operation after this is entirely similar to the case of FIG. 3.
The portion 7 1 of FIG. 14 likewise has a plurality of recording portions provided with G marks. When recording is to be effected downwardly from the uppermost portion of the recording area 8, the G mark in the portion 7 1 is used as the reference position. In this case, the G mark identifying patterns are designated by 1, 2, 3, . . . , i from below to above as viewed in FIG. 14, so that they are vertically symmetrical with respect to the direction orthogonal to the tracking tracks. Thus, the positioning method when the light beam is moved from the outer side toward the center of the card can be carried out with respect to the non-recording area 7 1 by the same processing as that with respect to the non-recording area 7 2 .
In the above-described embodiment, even if flaws, dust or the like is present between the home position 4 and the first tracking track 3 n and a signal equal to the track crossing signal as show in FIG. 16 is produced, when the number of G mark tracks is i and the count number of the crossing signal is k, there will be no problem if the error signal is an error signal of i-k times.
Also, even if dust, flaws or the like are present on the G mark tracks and AT control cannot be effected and there is any track on which no G mark can be detected, the position reference can be found normally if the G marks on the other tracks can be detected.
Thus, in the embodiment of FIG. 14, detection of the G marks is accomplished reliably and quickly.
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Disclosed is an information recording-reproducing apparatus including a light source for emitting a light beam, a lens device for imaging the light beam from the light source on an optical information recording medium, a photodetector for receiving light from the recording medium and for outputting a plurality of types of signals, a detector for detecting a mark indicative of a reference position on the recording medium on the basis of a corresponding signal from the photodetector and for outputting a signal, a device for initiating auto-tracking on the basis of the signal from the detector, a tracking actuator for moving the lens device, and a device for controlling the tracking actuator to start recording and reproduction of information from a predetermined position on the recording medium after the auto-tracking has been initiated.
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BACKGROUND OF THE PRESENT INVENTION
1. Field of the Invention
The present invention relates to the field of digital signal processing and, more specifically, to a method and apparatus for broadcasting, and synchronizing a VCO to, a serial digital signal.
2. Background Art
Electronic communication of serial digital data is straightforward if the sending clock frequency and phase are known by the receiver, but problems arise when the transmitted data clock frequency and phase are unknown. In such situations, the exact phase of the sending clock can be inferred by the temporal positioning of the received data bits, a technique that is currently in practice. In such a scheme, a receive voltage controlled oscillator is affected by a phase comparator, detecting the phase of the receive clock on the receipt of each data bit. The result of this phase comparison can be applied to the voltage control input of the VCO to achieve the locking of phase of the receiver to the incoming data. This technique, however, is only useful when the transmitter clock is within the capture range of the receiver VCO/phase locking loop. The receiver must have prior knowledge of the expected incoming data rate for effective phase locking to occur.
The transmitted data rate may vary from transmission to transmission, provided some means is provided to inform the receiving station as to the approximate sending data rate. Typically, pilot tones precede the data message, indicating the following data rate, and can be used by the receiving station to set its receive clock to an approximate frequency, whereby subsequent phase locking can occur once the data transmission begins.
Although a parallel bus is ideal for interconnecting a distributed multi-channel system, for a point-to-point connection, the use of fiber optics is desirable, particularly as distances increase. An optical fiber is a filament (e.g., glass or plastic) that is formed in such a way that light is constrained to travel along it. Signal transmission is achieved by modulating the power of a light-emitting diode (LED) or small laser coupled to the fiber. A phototransistor at the end opposite the LED converts the received light back to an electrical signal for eventual signal processing.
Optical fibers have numerous advantages over electrical cabling. Optical fibers neither generate, nor are prone to, electromagnetic interference and, as they are insulators, ground loops cannot occur. On the other hand, electrical cabling may generate undesirable radio frequency signals.
Many fiber optic systems are currently available. One fiber optic system, manufactured by Sharp Corporation, consists of a transmitter and a receiver that both operate from of a 5 volt power supply, and provide connection through logic levels. The transmitter works by turning on an LED when the logic input is high, and the receiver provides a logical high output when sufficient light is received at the other end of the interconnecting cable.
Since the receiver must pick up and amplify the LED signal from a photodiode, very high gains must be used, and the signals must be AC coupled. As a result, the output of the receiver is a replica of the logic level at the transmitter, but the LED must be alternating on and off at a high rate for the receiver to function properly. Minimum signal rate requirements of 100 kHz are not uncommon.
Further, Tdlh (delay time from transmitter turning on to receiver output going high) is different from Tdlh (delay time from transmitter turning off to receiver output going low). Assume that 8 channels each consisting of 24-bits of digital information are transmitted over a fiber optic cable. These 192 bits of information cannot simply be set end to end and sent to the transmitter, since if all of the bits were zero, the LED would not alternate on and off, causing the receiver to malfunction. Also, if a long string of bits has the same polarity, the receive logic has no way of knowing how many bits of that same polarity have passed. To accurately convey data, then, some clock information (regular changes in the data pattern) must exist in the data stream to give clues to the receive logic as to the data transmission rate.
In the following discussion, Non Return to Zero Inverted (NRZI) encoding is understood to apply. In NRZI, transmitted data is represented by a transition within the channel from one binary condition to the other, and such a transition is noted as a transmitted `1`. Periods of time without transitions, however, may or may not equivalently represent the data sequence to be transmitted. The data to be transmitted, a sequence of data 1's and 0's, is transformed via a modulation code, prior to transmission. At the receive end, the sequence of received transitions, is decoded into the original data 1 and 0 sequence by a receive decoder.
The main purpose for modulation coding is to provide adequate transmit clock information. An adequate modulation coding scheme is one that allows a continuous stream of data zeros or ones to be represented by a channel pattern that contains enough transitions (channel 1's) that the receive clock can accurately infer the transmit clock's phase.
Several techniques for receiving standardized modulation codes are available. For example, FM coding is commonly used to convey digital data. In the FM modulation scheme, two transmit clock cycles are used to represent each serially transmitted data bit. A data `1` is represented by two channel transitions (two channel `1`s), and a data `0` is represented by a single channel transition (single channel `1`).
In the case of FM coding, the receiver can deduce the correct receive clock frequency by the receipt of a single data `1`, which is represented by two transitions, one during each transmit clock period. However, if the data message happens to contain only data zeros, the receiver, not knowing the transmit clock frequency, will not be capable of knowing whether the message was correctly a stream of data `0`s, or incorrectly, a stream (half as long) of `1`s, at half the original clock frequency.
FM could be used to unambiguously communicate a message, and achieve clock synchronization as well, provided the data was previously grouped into blocks of predefined length, and sufficient extra bits were used to define the clock frequency, such as a long string of 0's appended to each block, and a unique synchronization pattern was added to denote the beginning of each data block. Such a synchronization pattern could consist of a period of two or more clocks without a channel transition, which would normally violate the FM encoding rules for real data.
Such a system would suffer from extreme inefficiency, as more than two clock periods would be required to communicate each data bit, leading to a wide required channel bandwidth. The presence of bit jitter on the received transition would make the accurate determination of the correct receive clock frequency very difficult. Such bit jitter problems can be reduced by increasing the number of appended data 0's to the message, to more accurately define the correct receive clock frequency, but this leads to yet further reductions in the scheme's efficiency, in terms of data transmitted versus required channel bandwidth.
The SDIF-2 (Sony Digital Interface Format), the PD (ProDigi) format, and the AES/EBU interface all allow transmission of audio digital data from recorder to recorder. SDIF-2 and PD formats do not include clock information in the data signal, and require a separate connection between devices to accomplish synchronization. Although the AES/EBU interface is self-clocking and self-synchronizing through a single serial interface, it is designed to transmit only 2 channels at a bit rate of 3.072 MHz and a sample rate of 48 kHz. Additionally, the AES/EBU interface uses FM channel code, which has a high overhead (50%) and is designed to transmit over a single twisted wire pair.
It is desirable to be able to send more than two channels of digital audio information between two or more devices without having to provide a separate synchronization channel or connection. Further, it is desirable to have a self-clocking, self-synchronizing interface format with high data efficiency, able to synchronize over a wide range of sampling rates.
SUMMARY OF THE INVENTION
The invention is directed towards a digital audio interface protocol that carries multiple channels of digital audio information serially between a transmitting (master) digital audio tape recorder and a plurality of receiving (slave) recording units. Using a three stage process, the circuitry of the present invention allows the slave VCO's to "lock on" to the transmitting rate of the serial digital data stream without the aid of any explicit sampling information. The interface protocol is adaptable for all types of digital audio applications, including synchronous operation of multiple recording units.
Herein is described a simple means for communicating digital data without prior knowledge of the transmitting station's data rate, provided by a unique synchronization pattern embedded in the transmitted data patterns' format. Also, a means is described that allows a receiving station to infer from the unique synchronization pattern the exact transmitted frequency and phase, over an unlimited range of transmitted data rates.
The present invention describes a novel channel coding scheme and a novel decoding scheme for that channel coding that makes the inference of the correct transmit clock frequency and phase possible at the receive end of the channel. Further, this invention allows the communication of a large data rate over a reasonably small communication channel bandwidth.
In one example, 192 bits of data are transmitted as a group with 256 transmit clocks, constituting a single data `frame`. The data could represent 12 audio channels of 16 bits quantization each or equivalently 8 channels of 24 bits each. Alternatively, 24 channels of 8 bit audio (voice channels or data bytes) could be transmitted.
The modulation code, and integral synchronization pattern is developed as follows: The 192 data bits are divided into 48 groups of 4 bits each, with a binary `1`, appended to the end of each group. The groups are serially transmitted, one at a time, where data ones are each represented by a channel transition, and data 0's are represented by the absence of a transition (in NRZI fashion). The transmission of this data consumes 240 of the 256 channel clocks allotted to a data frame. Subsequently, ten 0's are transmitted (sync pattern), followed by a 1 (sync period terminator), 4 user bits, and a final 1 marking the end of the sequence. The user bits may be used to define the number of channels transmitted. Since the repetition of data frames is frequent and continuous, a single user bit location can be used to communicate a serial bit stream, expressing a single bit per frame.
The interface protocol of the present invention sets up "frames" of digital audio data. Each frame includes a sync word, four user bits, and 8 channels of 24 bit data. The frame begins with a 10-bit sync word consisting of 10 consecutive zeros. After the sync word comes 4 user bits followed by 8*24 digital audio sample bits (192 bits). In the data frame, each group of 4 user or sample bits is preceded and followed by a bit that is always a logical "1". This clocking information insures that at least one "1" is encountered during every 5 bits of the data frame. The interface protocol allows the VCOs of the slave recording units to "lock" onto the sample rate of the data stream without the need for explicit sample rate information.
The synchronization of each receive units' VCO to the sample rate of the data stream is accomplished in three stages. Stage 1 is a "coarse" control. A counter counts the maximum number of consecutive zeros received in the data stream per each frame to locate the 10-bit sync word field. If more than 11 consecutive zeros are counted, the frequency of each receive units' VCO is decreased. If less than 8 consecutive zeros are counted, the frequency of each receive units' VCO is increased. If between 8 and 11 consecutive zeros are counted, the VCO is considered within stage 1 limits, and control of the VCO passes to stage 2.
Stage 2 is a "fine" control that adjusts the frequency of each receive units' VCO so that each receive unit detects 256 clocks for every occurrence of the sync word. A counter counts VCO clocks between consecutive sync words. If more than 257 clocks per sync word are counted, the frequency of the VCO is decreased. If less then 255 clocks are counted per sync word, the frequency of the VCO is increased. If between 255 and 257 clocks per sync word are counted, the VCO is considered within stage 2 limits, and control of the VCO passes to stage 3.
Stage 3 controls the phase of each receive units' VCO. A phase detector compares the phase of the VCO clock to that of the data stream. The output of the phase detector indicates whether the phase of each receive units' VCO is ahead or behind the phase of the data stream, and adjusts the phase of each receive units' VCO accordingly.
The present invention includes circuitry producing two logic outputs (based on the outputs of the three stages) that drive a charge pump used to correct the frequency and phase of each receive units' VCO. The interface protocol allows a receiving unit to derive a clocking signal from the data stream over a wide range of data sample rates.
SUMMARY OF THE DRAWINGS
FIG. 1 illustrates a single data frame organized using the present invention.
FIG. 2A and 2B illustrate the structure and operation of a simple flip-flop phase detector.
FIG. 3 illustrates a VCO for use in the preferred embodiment of the present invention.
FIG. 4 illustrates a charge pump for use in the preferred embodiment of the present invention.
FIG. 5 shows a graph of expected frequency vs. voltage for the VCO of FIG. 3.
FIG. 6(A-B) is a flowchart illustrating the operation of the preferred embodiment of the present invention.
FIG. 7 illustrates a block diagram of one system for implementing the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the present invention is described. The preferred embodiment discusses a method and apparatus for broadcasting eight channels of 24-bit digital audio data. In the following description, numerous specific details, such as number of channels, number of bits per channel, fiber optic cabling, etc., are described in detail to provide a more thorough description of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known features have not been described in detail so as to not obscure the present invention.
The digital audio data of the preferred embodiment is broadcast in a 256 bit format. Each bit is encoded and its value is determined by the existence or non-existence of a logical level transition (0 to 5 volts or 5 to 0 volts) on the rising edge of a nominal 12.288 MHz clock. A logical level transition is interpreted as a bit value of one, while no transition is interpreted as a bit value of zero.
Since audio data is sent continuously, without pauses or gaps, the present invention includes means in the data format for identifying the beginning of each data sequence (sample), so that the receiver can determine the meaning of each of the different bits. This "sync" pattern is clearly identified and distinguishable from all conceivable data patterns.
The digital input data begins with a 10-bit sync pattern consisting of 10 zeros. Using NRZI coding, the sync word is represented by the absence of data transitions over 10 clock periods. The data bits that follow consist of 4 user bits and 8 channels of 24-bit samples (192 bits). These data bits are modulated such that there is a bit value of 1 for every 5 data bits, thus adding 48 bits to the data. The result is 10 sync bits plus 246 encoded data bits.
In the preferred embodiment, eight channels of 24-bit data are transmitted, totalling 192 bits. One convenient way to drive a digital system uses a clock that is divided by a binary n-bit counter, where n is some integer value. The digital processes operate based upon a signal that the counter generates every time it rolls over. It is therefore advantageous to append enough additional bits to the 192 bits of data to create a "frame" that contains a total number of bits equal to a power of 2. These additional bits consist of clock information and a synchronizing pattern. In the preferred embodiment, 64 additional bits are added to the 192 data bits to produce a sample consisting of 256 channel bits. This conveniently permits an 8 bit counter (2 8 ×256) to be used in the digital logic. Of course, any number of additional bits can be added to the data bits without departing from the scope of the present invention.
FIG. 1 illustrates a single frame of data organized using the present invention. The frame 101 is comprised of 256 bits of digital information. Each bit is either a logical one or a logical zero. The first bit (bit 0) and every fifth bit thereafter is a logical one. These clocking bits 105 serve as temporal signposts for the receive logic. Between bit 0 and bit 5 are four user bits 103 that may be used to provide time code, voice data or control information, for example. Between every fifth bit from bit 5 to bit 245 are four digital data bits 104. The data bits 104 represent 8 channels of information (channels 0 through 7), with 24 bit quantization per each channel. Bits 246 to 255, the last 10 bits of data frame 101, are dedicated to the sync pattern 102. In the preferred embodiment, sync pattern 102 is comprised of 10 consecutive logical zeros. Bit 0 of the next data frame 101 is referred to as the sync pattern termination bit because it terminates the 10 consecutive zeros of the sync pattern with a logical one.
The interface protocol of the present invention can be used with any sampling frequency, including the three sampling frequencies recommended by the AES: 32 kHz, 44.1 kHz, and 48 kHz. If each sample period contains 256 channel bits, then 48K samples per second produces a transmit clock of 12.288 MHz. If all of the data bits were ones, the resulting maximum frequency at the receiver would be a 6.144 MHz square wave. Since the Tdhl and Tdlh on a fiber optic cable may not be equal, and some number of zeros are permitted between ones (the data), it is possible to receive patterns where the time periods between ones are not exact multiples of the transmit clock period. This can cause confusion at the receiver, especially at higher data rates, where the clock period approaches the difference in delay time. For the Sharp fiber optic transmitter/receiver pair, the maximum clock rate is about 20 MHz. Some data patterns clocked at a higher rate can become difficult to read with certainty.
To properly receive the data, the receiver logic should include a clock oscillator that can be synchronized to the incoming data rate. This clock is used to drive a shift register that receives its data from the optical receiver. A logical one is inputted if there is a transition at the optical receiver since the last clock pulse, a logical zero if not. Logic can be applied to the system to: (1) synchronize the oscillator, (2) start the shift register, and (3) remove the extra ones in the modulation scheme.
In modems and disk drives that convey data through an analog medium, the data rate is established ahead of receive time, and it is a fairly simple matter to set a VCO close to the receive frequency and allow a phase locked loop to adjust the VCO until phase lock (which implies frequency lock) is achieved. When the receive frequency is unknown, traditional phase locked loops can force the VCO to incorrectly lock onto rational multiples (like 3/4 or 5/3) of the transmit clock frequency.
In the preferred embodiment, the present invention receives data over a wide range of sample rates. As a result, traditional phase-locking and synchronizing techniques cannot be used. Instead, the transmitted data has ones inserted in the data stream, but the data bits themselves can be either ones or zeros. The phase detector that synchronizes the receive clock determines phase error at the receipt of a data one, represented by a channel transition. The receive clock runs at a fairly constant rate, so that it is able to function in the presence of zeros, where no transitions occur. At the end of the longest allowed string of zeros, the VCO is still correct within certain limits.
One simple phase detector is a flip-flop. FIGS. 2A and 2B illustrate the structure and operation of a simple flip-flop phase detector. In FIG. 2A, the channel information OPTO OUT from the optical transmission system is XORed at gate 202 with the non-inverted output of flip-flop 203. Flip-flop 203 is clocked by the output of XOR gate 202 (XOR OUT). The inverted output of flip-flop 203 is connected to its data input. XOR gate 202 acts as a pulse generator, and is used to clock flip-flop 201. The output of the VCO (VCO OUT) is coupled to the data input of flip-flop 201. The output of the phase detector is taken from the non-inverted output of flip-flop 201 (FLOP OUT).
FIG. 2B illustrates the operation of the phase detector. The XOR gate 202 outputs a brief positive pulse at each received transition. The receive VCO is coupled to the data input of flip-flop 201. Consequently, flip-flop 201 indicates whether the VCO's phase is ahead or behind the position of the channel transition in OPTO OUT.
The rising edges of the output of XOR gate 202 and the VCO output are marked with arrows as a reminder that these are the points in time where meaningful transitions in the signal can occur. The rising edges of the VCO are coincident with the boundaries of bit cell 205, and any channel transition within these boundaries is interpreted as a one in that VCO cycle. The absence of a transition indicates a zero. If the transmission delay is always constant, the received bits fall in the center of the bit cells 205, but variations in delay due to rise and fall times or unusual data patterns cause the received bits to fall somewhat on either side of the bit cell counter. Excessive bit shift (jitter) can cause the bits to fall outside the bit cell boundaries and lead to receive errors.
XOR gate 202 clocks flip-flop 201, the output of which indicates clock phase error. The falling edges of the clock define the bit cell boundaries, equally-spaced, on both sides of the incoming transition centers. If the output of flip-flop 201 is connected to the VCO, the receive system will tend to force the VCO to a phase relationship with the channel transitions in OPTO OUT, where channel transitions are coincident with the falling edges of the clock.
The output voltage of a typical flip-flop is from 0 to 5 volts. If the VCO is set to run at the correct frequency with an input voltage of 2.5 V, flip-flop 201 alternates high and low in a random pattern, with an average voltage of 2.5 V. Any other average voltage applied to the VCO forces the VCO to a different average frequency, implying a loss of phase lock.
If the VCO runs 10% too fast with a 5 V input, and 10% too slow with a 0 V input, then if 2.5 V is used as an input voltage, the VCO will alternately run at either + or -10% of the correct frequency, with an average that is the correct frequency. Since the frequency of the oscillator is constantly changing, so is its phase, relative to the transmit clock. Because the bit cell boundaries are defined by the clock, they, too, change constantly (clock jitter), with the average being of the correct phase.
If the receive clock drifts in phase by 1/2 a clock cycle, the clock's rising edges coincides with the center of the received transitions, and the received data has no margin for jitter. With no margin for jitter, the data cannot be reliably received. The maximum allowable jitter can be no greater than 1/2 a clock period for both the data and the clock, if data is to be reliable. To allow the most margin for jitter, the clock should be very stable.
If the phase of the clock runs 10% too fast or too slow, it will go through a full clock cycle of phase change in 10 clock cycles. In this case, if the interface protocol allowed for 5 continuous zeros, the clock phase could be off by a full half cycle by the time the next channel transition was expected. Flip-flop 201 is set in one of its two possible conditions by the transition that precedes the 5 clockless bit periods, and maintains this state, controlling the VCO, until the next transition is received. In an interface protocol that permits 5 continuous zeros, the VCO has to be limited to a much narrower range to avoid jitter problems.
If one zero is allowed between data bits, as in Frequency Modulation (FM), the total period that the flip-flop could be left unaffected is 2 full clock periods. Using FM encoding, if the phase of the clock runs 10% too fast or too slow, the maximum clock jitter is +/-20% of a bit cell. Since +/-50% of a bit cell represents failure, +/-20% may be an acceptable VCO specification for receiving FM code. In the case of a disk drive, it allows the speed of the drive motor to vary by as much as a few percent (changing the received data rate) without losing data.
The maximum number of continuous zeros in a code is called the run length of the code, and is equal to 1 in FM. In the preferred embodiment of the present invention, the run length is 4. In other words, 4-bits of data are separated by intentionally placed ones, limiting the maximum run length and providing clock information. The 192 bits of data are grouped into 48 quadruplet bit groups. As shown in FIG. 1, the addition of a 1 to the beginning of each 4-bit group produces 48 quintuple bit groups, or 240 bits total. Out of the allowed 256 bits per frame, 16 extra bits remain for special user bits and a synchronization pattern.
The 16 bit space contains a defined sync period 102 (a defined length assists in clock frequency control), and user bits 103 that may ultimately carry control information, voice data, or time code. In the preferred embodiment, these user bits occupy the first 6 positions in the 16 bit space, (preceded and followed by ones) leaving a 10 bit sync period.
In the preferred embodiment, the receive VCO can lock onto and receive data at sample rates ranging from 32 kHz to 64 kHz. At 256 bits per frame, this corresponds to channel clock frequencies of 8.192 MHz to 16.384 MHz. Thus, using the preferred embodiment, the optical system's minimum signal rate requirement of 100 kHz is satisfied.
When the interface of the preferred embodiment is first connected between the transmit and receive devices, the receive VCO must be able to immediately adjust in both frequency and phase to the incoming data pattern. One unambiguous synchronization pattern that provides information about sample rate is a long run-length violation of many zeros in the sync pattern area. In the preferred embodiment, the 10 bit sync word is comprised of 10 consecutive zeros.
Many VCOs are currently available. One VCO that is quite stable utilizes a varicap tuning diode and an inductor. This relatively simple oscillator circuit provides a 50% duty cycle output at frequencies exceeding 20 MHz. FIG. 3 illustrates a VCO for use in the preferred embodiment present invention. Capacitor C1 is coupled between the VCO input and ground. The first terminal of varicap tuning diode TD1 is coupled to the VCO input and the other terminal is coupled to the first terminals of capacitors C2 and C3, and inductor L1. The second terminal of inductor L1 is coupled to ground. The second terminal of capacitor C2 is coupled to the first terminal of resistor R1 and to the input of the HCU04, comprised of inverters 301 and 302. The second terminal of capacitor C3 is coupled to the first terminal of resistor R3. The second terminal of resistor R3 is coupled to the output of the HCU04, the second terminal of resistor R2, and to the input of inverter series 303. The second terminal of resistor R1 is coupled to in the output of inverter 301 and to the first terminal of capacitor C5. The second terminal of capacitor C5 is coupled to the input of inverter 302 and to the first terminal of resistor R2. The output of the VCO in FIG. 3 is taken from the output of inverter series 303.
Some tuning diodes have a capacitance range of approximately 16 to 1. One such tuning device, the Motorola MVAM108, shows a capacitance of about 500 pf at 1 volt. Since the frequency of the circuit is inversely proportional to the square root of capacitance, the frequency range of such an oscillator is as much as 4 to 1.
Power supply VS is coupled through resistor R4 to the first terminal of capacitor C4 and to inverters 301 and 302. The second terminal of capacitor C4 is coupled to ground. The resistor R4 in series with the voltage supply limits the current that can be drawn, since the HCU04 is operated in its linear mode, requiring considerable supply current. All of the capacitors in the VCO circuit are ceramic or monolithic parts in the preferred embodiment. Feedback capacitor C3 and resistor R3 are adjusted to obtain a constant RF voltage at the top of the inductor, over the full range of control voltages (approx. 1 V). The inductor should be a resistor-like part, with a Q value in the range of 50 or greater.
The VCO of FIG. 3 has a frequency range of approximately 4 to 1. If the flip-flop phase detector of FIG. 2 is used to control the VCO, the VCO's phase changes with each passing cycle, and the phase detector, with a 0 to 5 volt output range, is unable to deliver the full 0 to 8 volts required to achieve a 4 to 1 frequency range. Further, bypass capacitor C1 at the input of the VCO (necessary for operation) presents a substantial load to flip-flop 201.
In the preferred embodiment, C1=1500 pf, C2=22 pf, C3=10 pf, C4=0.1 μf, C5=10 pf, L1=680 nH, R1=R2=100 kΩ, R3=3.3 kΩ, and R4=20 Ω. Of course, these values are given for purposes of example only. It will be apparent to one skilled in the art that other component values, or even an entirely different variable VCO structure, may be used with the present invention without departing from the spirit and scope of the present invention.
FIG. 4 shows a charge pump circuit that uses general purpose transistors, two diodes, and a pair of capacitors to allow 0 to 5 volt logic levels to affect the VCO over a 0 to 5 V range. The first terminal of capacitor C7 is coupled to input terminal A, and the second terminal of capacitor C7 is coupled to the input terminal of diode D1 and the emitter of n-type transistor Q1. The collector of transistor Q1 is coupled to voltage supply VCC. The first terminal of capacitor C8 is coupled to input terminal B, and the second terminal of capacitor C8 is coupled to the output terminal of diode D2 and the emitter of p-type transistor Q2. The collector of transistor Q1 is coupled to ground. The bases of transistors Q1 and Q2, the output terminal of diode D1, and the input terminal of diode D2 are all coupled to the output of the charge pump circuit, as well as to the first terminal of resistor R6. The second terminal of resistor R6 is coupled to ground through capacitor C6. The output of the charge pump circuit is coupled to the input of the VCO.
In the preferred embodiment of the present invention, C7=C8=33 pf, C6=0.33 μf, and R6=100 Ω.
The circuit has two logic inputs: Input A receives a brief positive 5 V pulse to increase the control voltage (increasing VCO frequency), and input B receives a brief negative 5 V pulse to lower the control voltage (decreasing VCO frequency).
The leakage current of the tuning diode is small. The control voltage is stored on bypass capacitor C1, and modified by the charge pumping behavior of the capacitors, transistors and diodes. To understand the circuit's operation, imagine the voltage on capacitor C1 is 4 volts. Input A is normally low, and capacitor C7 will have about 4 volts across it. When input A goes high, the voltage across the capacitor C7 changes to 1 volt, of opposite polarity. This voltage change requires additional current, supplied from the driving circuit, through diode D1, and into capacitor C1, adding slightly to the charge of capacitor C1. When input A falls (maybe 100 nsec later), the voltage across the capacitor C7 changes back to almost its original 4 V value. The current to do this is delivered through the transistor at this time, and the resulting current in this phase of operation barely affects the charge stored on capacitor C1.
Each time input A goes high, capacitor C1 has a slight amount added to its charge, resulting in a step change in voltage of about 12 millivolts. The operation of input B is substantially identical to that of input A, except that the polarity is reversed.
When the circuit is operating, the charge on capacitor C1 is continuously modified by the action of the A and B inputs, forcing the VCO to the correct frequency. At the predetermined clock and data rates, the charge currents occur frequently enough to control the VCO, in spite of the small amount of leakage in the varicap.
Resistor R6 in series with the capacitor C6, connected at the output of the phase detector, allows the system to be stable. Since phase is the integral of frequency in the VCO, and the charge pump essentially integrates pumped charges, the combination of the VCO and the charge pump leads to conditional stability. The series resistor and the capacitor tend to further stabilize the system.
A phase compensation pulse is derived each time a phase error is detected. In the absence of the capacitor C6, if all of these pulses were added to capacitor C1, the frequency of the VCO would change at each step. When the VCO phase finally became correct, the frequency would be too far shifted by all of the accumulated charges. Consequently, the reverse process would take place, with a series of similar, but opposite polarity charges.
If just one pulse is applied, capacitor C1 initially is charged by about 12 millivolts, but the capacitor C6 remains at the starting voltage, prior to the charge pulse. In time, the 12 mV addition to capacitor C1 partially drains into capacitor C6 through resistor R6 (TC=330 nsec). The ultimate change in control voltage is only about 3 mV, but the phase shift (in the required direction) during the period that the control voltage was peaked at 12 mV is sufficient to add phase correction but only slightly affects long term frequency.
FIG. 5 shows a graph of expected frequency versus voltage, calculated from the varicap data sheet values. Some allowance was made for feedback, coupling and stray capacitances. As illustrated in FIG. 5, a 1 volt step, from 1 volt to 2 volts, corresponds to about a 30% change in frequency at the low end of the control range, while the same size step, from 6 to 7 volts, corresponds to about a 14% change in frequency at the upper end.
Averaging these values gives a 22% per volt VCO constant. Assuming linearity, a 3 millivolt step changes the VCO frequency by about 0.06 percent.
If the VCO in FIG. 3 and the charge pump in FIG. 4 are used to phase lock to a data steam, and the VCOs control voltage is set just one 3 mV step off, and initially its phase was correct, about 800 clock cycles would be required for the phase to drift the allowable maximum of 50% of a clock period. Using this technique, and allowing a long run length violation of 10 zeros as a synchronization pattern, the VCO could not be more than 1% of a clock cycle off at the end of the sync pattern, an extremely small and acceptable amount of clock jitter.
If the initial VCO frequency is 1% off from the correct receive clock rate, then the receive VCO will drift, relative to the transmit clock, at such a rate that 25 VCO clocks pass in the time required for the phase relationship to change by 1/2 a clock cycle. Using the present invention, where the maximum run-length is 4, during 25 clock cycles a minimum of 5 channel transitions would be received. If the phase detector applies a correcting pulse to the receive VCO for each of these 5 transitions, each correcting the frequency by .06%, a 0.3% long-term frequency change is achieved. Coupled with the 1% transient frequency change, the correction would be sufficient to enable the phase change to be constant (if two frequencies are the same, they have a constant, but not necessarily identical, phase relationship). From this point on, the system can deliver further phase clocking pulses to the VCO to achieve phase lock with the transmit clock, ultimately bringing the long-term receive VCO frequency to the correct value.
A means is now described for recognizing the sync pattern of the preferred embodiment, and for setting the VCO to within 1% of the correct frequency, so that a phase detector can take over control and cause the VCO to lock to the data stream.
The sync pattern of the preferred embodiment is terminated by the sync pattern termination bit, as shown in FIG. 1. If the sync pattern is detected using a run length violation detector, this first `post sync` transition serves as a timing marker. In the preferred embodiment, this post sync timing marker occurs once every 256 VCO cycles, if the frequency is correct. Although circuitry can be derived to control the receive VCO to meet this end, reliable sync period detection is still required.
The receive VCO of the preferred embodiment has a potential range (after production tolerances) of over 4 to 1 in frequency. Using the component values given above, the expected output range should be from 5 MHz to 25 MHz. If the incoming signal is at a 32 kHz sample rate (8.192 MHz transmit clock), and the receive VCO is at the upper limit (25 MHz, ratio=3.05:1), then the sync period (10 zeros, 11 clock periods of time) is received as over 33 consecutive zeros, indicating that the receive clock rate is too high. On the other hand, if the data is transmitted at 64 kHz (16.384 MHz transmit clock), and the VCO receive clock started up at 5 MHz (ratio=3.3:1), the same 10 zero sync pattern is received as approximately 4 consecutive zeros, indicating that the receive clock frequency is too low.
As the transmitted data could be all 1's, all 0's, or a mixed combination of the two, the inclusion of a data 1 at the end of each group of 4 bits provides sufficient transmit clock information for the receive clock to acquire synchronization. Although the frame sync period of ten 0's provides the opportunity for the receive clock to fall out of lock, it is sufficiently short and infrequent to not pose a problem. The sync period however, is sufficiently long so that, even in the case of transmitting a message containing 0's is unambiguously identifiable.
When the receiver first attempts to decode the incoming digital message, it has no prior knowledge of the data rate, and therefore, neither the transmitter's clock frequency or phase. The receiver has incorporated into it a voltage controlled oscillator, that the receiver decoding circuitry can use to bring the receive VCO into frequency and phase lock with the transmitter, using the data frame's sync pattern as a reference.
Initially, the receiver VCO is not in phase with the incoming data pattern, as the frequencies of the transmitter clock and the receive VCO could be widely different. As a result of this unpredictable frequency discrepancy, the frame sync period will appear to be any number of receive clock periods long. Even if the receive VCO is running at the correct frequency, since it is not in phase lock, and the received data transitions are subject to some expected, random, temporal jitter, the ten (transmit) clock period frame sync pattern could appear at the receiver to be as few as 9 or as many as 12 receive clocks in length. Controlling the receive VCO until the apparent sync period is of the expected length (10 clocks) would be difficult or impossible, due to the random and unpredictable phase relationship of the transmit and receive clocks. Further, the accuracy to which the receive clock could be controlled when using the sync period as a measure of clock frequency is too crude to begin normal phase comparison between the data transitions and the receive clock. The receive clock inaccuracy would be beyond the capture range of the receive phase locked loop.
In the preferred embodiment three stages are used in combination to align the frequency and phase receive VCO. The first stage must bring the VCO to within a close enough frequency so that the second stage may recognize the sync pattern and establish a 256 clocks per sync period relationship. The third stage then attempts to phase lock the VCO.
Accordingly, the preferred embodiment of the present invention uses three techniques in combination to properly align the frequency of the receive VCO:
1. Adjust the receive VCO such that the sync period appears to be sufficiently close to the target of ten receive clocks that the sync pattern can be unambiguously identified and not confused with normal data patterns;
2. Adjust the receive VCO so that the number of receive clocks that transpire between sync terminator transitions is sufficiently close to the correct number of 256 so that the phase locking mechanism can capture;
3. Phase lock the receive VCO in normal fashion.
The first step brings the receive VCO close enough to the transmit frequency to permit the second step to recognize the sync pattern and establish the 256 clocks per sync pattern relationship. Since the third step may actually skip a clock pulse attempting to phase lock, the second stage should stop correcting the VCO when it is between 255 and 257 clocks per sync, inclusive, and allow the third stage to take over control of the VCO. This hierarchy assures that the receive VCO is within+/-1% of the correct frequency when the third stage attempts to phase lock.
Since the data may jitter considerably within the bit cell window, it may be difficult to recognize when phase lock is achieved. However, assuming that the VCO frequency is within the limits of the second stage, so that the VCO is within 1% of the correct frequency, phase lock using the third stage is inevitable. Correspondingly, a signal should be sent to the receive logic to indicate when the receive VCO frequency is within stage 2 limits; that is, when the system is very likely phase locked, and the data is reliable.
The 256 bit frame of the preferred embodiment is structured such that the maximum number of ones in any one frame is 246 and the minimum number of ones is 50, depending on the one's content of the data channel. An 8 bit transition counter is incremented at the receipt of each channel transition, so that at least one and as many as five complete frames will be received each time the 8 bit counter rolls over. Similarly, at least one and as many as five sync patterns is received between transition counter rollovers.
Another counter is arranged to count the number of continuously received zeros (driven by the receive VCO), and the maximum count is made to set flip-flops, depending on established limits (i.e., maximum of 12, minimum of 8 continuous zeros). The values of these flip flops are clocked into registers at the rollover of the transition counter to indicate the degree and direction of any gross VCO error. If the continuous zero count got to eight, but never got to 13, then the VCO is within stage l limits, and control is passed to stage 2.
Stage 2 consists of a sync terminator bit detector and a 9 bit VCO counter. The sync terminator detector outputs a pulse when the first transition is received after a run of at least 8 zeros. When this pulse is received, the VCO counter is evaluated and reset. The VCO counter counts the number of receive VCO periods since the last sync terminator bit. The value in the VCO counter, prior to reset, determines if the VCO is out of frequency lock range. Because the sync terminator detector output marks the beginning of the data sequence, it is useful in the receive logic that converts the received data into usable information.
The second stage detector outputs a signal to the receive logic to indicate phase lock, delaying the signal by at least one transition counter rollover to give stage 3 adequate time to guarantee lock.
The order of priority of the three stages favors the first stage, then the second, and then the third, the phase locking stage, since if the VCO is out too far out of bounds, stages 2 and 3 can cause erroneous operation of stage 1.
FIG. 6 is a flowchart illustrating the operation of the preferred embodiment of the present invention. At step 601, the digital information is fed to the receive device, typically through an interface of some type. At step 602, stage 1 operation begins. At step 603, the interface circuitry counts the maximum number of zeros received that are terminated by a data one. At decision block 604 the question is asked, "Less than 8 zeros?" If the answer is yes, the system waits for the next frame counter rollover at step 605, sends control signals to increase the frequency of the receive VCO at step 606, resets the consecutive zero counter at step 607 and repeats stage 1 operation at step 602. If the answer is no, the question is presented at decision block 608, "More than 11 zeros?" If the answer is yes, the system waits for the next frame counter rollover at step 609, sends control signals to decrease the frequency of the receive VCO at step 610, resets the consecutive zero counter at step 607 and repeats stage 1 operation at step 602. If the answer is no, the system enables stage 2 circuitry at step 611 and begins stage 2 operation at step 612.
At step 613, the system counts the number of receive VCO clocks between receptions of the sync pattern. At decision block 614, the question is asked, "less than 255 clocks?" If the answer is yes, the VCO counter is reset at step 615 and control signals are sent to increase the receive VCO frequency at step 616. If the answer is no, the question is presented at decision block 617, "More than 257 clocks?" If the answer is yes, the VCO counter is reset at step 618 and control signals are sent to decrease the receive VCO frequency at step 609. If the answer is no, the system enters stage 3 operation at step 620.
At decision block 621 the question is asked, "Within stage 1 limits?" If the maximum number of consecutive zeros received per frame counter rollover is outside the acceptable limits of stage 1 operation (<8 or >11), control returns to stage 1 at step 602. If the number of consecutive zeros is still within the limits of stage 1 (>7 and <12), the system asks the next question at decision block 623, "Within stage 2 limits?" If the number of VCO clocks received per sync pattern occurrence is outside the acceptable limits of stage 2 operation (<255 or >257), control returns to stage 2 at step 612. If the number of VCO clocks is still within the acceptable limits of stage 2 operation (>254 and <258), control passes to step 625.
At step 625 the phase of the receive VCO is compared with the phase of the digital data signal. At decision block 626 the question is presented, "VCO's phase behind?" If the answer is yes, a control pulse is sent to the input of the receive VCO at step 627 to increase the phase of the VCO, and operation continues at step 620. If the answer is no, the question is asked at decision block 628, "VCO's phase ahead?" If the answer is yes, a control pulse is sent to the input of the receive VCO at step 629 to decrease the phase of the VCO, and operation continues at step 620. If the answer is no, the system transmits a signal at step 630 indicating that phase lock has been achieved, and control passes to step 620 to maintain phase-locked operation.
A block diagram of one system for implementing the preferred embodiment of the present invention is illustrated in FIG. 7. The digital data signal 712 is connected to the input of pulse generator 701. Pulse generator 701 receives the NRZI digital data signal from the interface transmission system and outputs a pulse every time it detects a transition in signal 712. The output of pulse generator 701 is coupled to frame detector 702, data separator 703 and phase detector 704. Frame detector 702 monitors the number of transitions in the data signal 712, and outputs a signal after every 256 transitions. Data separator 703 takes pulse output 714 and separates the data information from the clocking information, converting the clocking information into logic levels for use by priority selector 705. Phase detector 704 compares the phase of pulse output 714 with that of VCO output 713, and outputs a signal indicating whether VCO output 713 is ahead or behind in phase.
Priority selector 705 is coupled to frame detector 702 and data separator 703, as well as data logic 706 and VCO output 713. Priority selector 705 determines whether the receive VCO 708 is within stage 1 or stage 2 limits, and outputs to output controller 707 a signal indicating the current stage and the required direction of frequency correction for VCO 708. Output controller 707 decodes the information from priority selector 705, data logic 706, and phase detector 704, and issues control pulses via lines 709 and 710 to VCO 708 to adjust the frequency and phase of the oscillator. VCO output 713 is used to clock digital data input signal 712 to decode the digital information.
In the preferred embodiment, the receive VCO is controlled through two logic outputs that drive the charge pump. During Stage 1 or stage 2 correction, the pulse duration of the A and B outputs can be very long, since a correction pulse occurs every 256 channel transitions or at the receipt of each sync terminator bit. For this purpose, the pulse can be several VCO clocks long. On the other hand, in the phase locking stage, stage 3, a pulse is expected at each channel transition, so the correction pulse should be narrow (less than one transition wide).
During lock, the VCO in the preferred embodiment runs at a maximum frequency of 16.384 MHz, with a period of 61 nsec. The A and B signals may be a gated version of the VCO, giving a 30 nsec pulse. For capacitor C7 to be charged or discharged by 5 volts during this short time period, a significant impulse current must be delivered. This current could be lowered and spread over a longer time by placing a resistor in series with the capacitor, but for the peak current to be lowered to reasonable levels (like 10 mA), the resistor would have to be as large as 470 ohms. This would cause a 47 nsec time constant with a value of 100 pf for capacitor C7, and in a 30 nsec half-clock, the charge would only be partially conducted to the VCO input capacitor.
This is particularly the case at high VCO frequencies, where the VCO sensitivity to control voltage is at a minimum. For best operation, the VCO voltage-to-frequency characteristic should be exponential, where locking characteristics are constant over the entire VCO range. Purposefully limiting the A and B pin input currents causes an extra non-exponentiality at high VCO frequencies.
Thus, a digital audio data format and apparatus that is auto-clocking and auto-synchronizing is described.
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A digital audio interface protocol carries multiple channels of digital audio information serially between a transmitting digital audio tape recorder and a plurality of receiving recording units. Using a three stage process, the circuitry of the present invention allows the receiving VCO's to "lock on" to the sampling rate of the serial digital data stream without any explicit sampling information. In a first stage, the VCO frequency is adjusted until a sync pattern is properly received. In a second stage, the VCO frequency is adjusted to oscillate a preselected number of times between sync pattern occurrences. In a third stage, the VCO phase is adjusted to match the phase of the serial data stream.
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BACKGROUND OF THE INVENTION
This invention relates to an auxiliary support mechanisms, such as those used to support the keyboard of a personal computer. The present invention permits the angle of the auxiliary work surface to be adjusted to improve the ergonomics of the work surface.
FIELD OF THE INVENTION
Personal Computers (PCs) have become ubiquitous in many industry and office environments. The input means most commonly used appears to be the keyboard. However, it is generally thought that use of a keyboard that is not positioned properly can lead to repetitive motion injury such as carpal tunnel syndrome. Thus, it is important to be able to properly position the keyboard.
One line of advances was the development of the auxiliary support mechanisms to position, for instance, a keyboard where a PC user would find it convenient. The earliest of these was developed by Hannah et al. (U.S. Pat. No. 4,826,123) and used a four-bar parallelogram linkage. Another approach was that of McConnell (U.S. Pat. No. 5,257,767) which used a four-bar non-parallelogram trapezoidal linkages. Yet another distinctly different approach to positioning, for instance, a keyboard, was my own development (U.S. Pat. No. 5,924,664) which used a five-bar mechanism including a slider joint.
Some keyboard support surfaces heretofore available have incorporated a tilt adjustment device allowing the keyboard support surface to be adjusted over a range of tilt angles. For instance, U.S. Pat. No. 6,148,739 to Martin, U.S. Pat. No. 6,135,405 to Jones et al., U.S. Pat. No. 5,961,231 to Ambrose, U.S. Pat. No. 5,775,657 to Hung, U.S. Pat. No. 5,704,299 to Corpuz, Jr., et al., and U.S. Pat. No. 5,692,712 to Weinschenk, Jr., et al. Nonetheless, the range of available tilt angles available has been limited.
Ergonomists advise us that the lowest risk of repetitive motion injury occurs when the keyboard angle is slightly negative so that the bottom of the front edge (i.e, the edge of the keyboard closest to the user) of the keyboard is higher than the bottom of the rear edge (i.e, the edge of the keyboard furthest from the user) of the keyboard. Accordingly, there was a need for a shelf adjustment mechanism that provides an improved means of achieving the ergonomically desired negative tilt.
BRIEF SUMMARY OF THE INVENTION
One aspect of the present invention is to provide an adjustable support for computer keyboards and the like. In such an embodiment, the adjustable support may include a support member shaped to retain an associated keyboard thereon. The support member may be pivotally mounted to shift about a generally horizontal pivot axis to define a tilt angle for the support member and the keyboard with respect to a user, wherein the tilt angle is adjustable within a predetermined tilt range. Desirably, the tilt angle is adjustable between +10/−25 about 0 and −15° relative to horizontal.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view of a shelf adjustment mechanism for an adjustable support for keyboards and the like embodying the present invention;
FIG. 2 is a top view of a shelf adjustment mechanism for an adjustable support for keyboards and the like embodying the present invention;
FIG. 3 is a cross-sectional view of the shelf adjustment mechanism of FIG. 2 taken along line 200 - 200 ;
FIG. 4 is a perspective view of a top member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 5 is a top view of a top member for an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 6 is a side view of a top member for an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 7 is a perspective view of a pivoting member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 8 is a side view of a pivoting member for an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 9 is a top view of a pivoting member for an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 10 is a perspective view of a first slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 11 is a top view of a first slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 12 is a front view of a first slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 13 is a side view of a first slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 14 is a side view of an assembly of a top member, a pivoting member and a first slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 15 is a side perspective view of an assembly of a top member, a pivoting member and a first slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 16 is a rear perspective view of an assembly of a top member, a pivoting member and a first slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 17 is a perspective view of a second slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 18 is a front view of a second slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 19 is a side view of a second slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention;
FIG. 20 is a top view of a second slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention taken along line 20 - 20 ;
FIG. 21 is an exploded perspective view of a second slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention and a slot insert;
FIG. 22 is a rear perspective view of a second slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention and a slot insert;
FIG. 23 is an exploded perspective view of a second slotted member of an auxiliary shelf mounting surface for an embodiment of the present invention and an alternative slot insert;
FIG. 24 is a rear view of an assembly of a top member and a pivoting member of a preferred embodiment of an adjustment mechanism of the present invention;
FIG. 25 is a perspective view, taken from below and behind, showing an assembly of a top member and a pivoting member of a preferred embodiment of an adjustment mechanism of the present invention;
FIG. 26 is an enlarged view of the portion of FIG. 25 designated by circle B;
FIG. 27 is a top view of a molded washer useful in a preferred embodiment of the present invention;
FIG. 28 is a side view of a molded washer useful in a preferred embodiment of the present invention;
FIG. 29 is a perspective view of a molded washer useful in a preferred embodiment of the present invention;
FIG. 30 is a cut-away view of the molded washer of FIG. 27 taken along line A-A; and
FIG. 31 is a rear view of a molded washer useful in a preferred embodiment of the present invention.
FIG. 32 is a perspective view of a shelf adjustment mechanism with an auxiliary shelf for an adjustable support for keyboards and the like embodying the present invention.
DETAILED DESCRIPTION OF THE INVENTION
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. Additionally, unless the context requires otherwise, similarly numbered parts in the several drawings are intended to correspond.
Turning to FIG. 1 , the adjustable support mechanism 100 to which the shelf adjustment mechanism of the present invention can be incorporated includes substantially any conventional adjustable support mechanism. For instance, the adjustable support mechanism could be any of the three dramatically different styles exemplified by the parallelogram linkage of Hannah et al. (U.S. Pat. No. 4,826,123), the four-bar non-parallelogram trapezoidal linkage of McConnell (U.S. Pat. No. 5,257,767), or my five-bar mechanism including a slider joint (U.S. Pat. No. 5,924,664).
FIG. 1 also shows knob 120 which moves bar 160 within slot 130 . Slot 130 is situated in the top surface of box member 150 . Box member 150 is attached to platform support 110 , and in turn pivotal member 140 .
FIG. 2 provides a top view of a preferred embodiment of the adjustment mechanism of the present invention. FIG. 2 thus shows knob 120 which moves within slot insert 130 from above. Slot insert 130 is situated in the top surface of box member 150 and is generally of a diagonal orientation. In the embodiment of the present invention illustrated in FIG. 2 , the slot insert 130 (and thus the corresponding slot) is much closer to point 210 on the front surface of box member 150 that slot insert 130 (and thus the corresponding slot) is to point 220 on the front surface of box member 150 .
Again, in FIG. 2 , box member 150 is preferably welded to platform support 110 .
FIG. 3 provides a cross-sectional view of the mechanism of FIG. 2 taken along line 200 - 200 . FIG. 3 reveals that knob 120 is mounted on bar 160 . This mounting is secured by mounting means 315 , which typically can be a screw, a rivet, an adhesive, or any other conventional mechanical or chemical means of securing two components, or alternatively, knob 120 can be an integral structure of bar 160 .
Also seen in FIG. 3 is the support connecting member 360 which is joined to support 100 (not shown in this FIG.) by pivot axes that pass through apertures 350 and 355 . Pivotal member 140 is also connected to support 100 by the pivot axis that passes through aperture 350 . Mounted on top of pivotal member 140 is support member 110 .
Bar 160 runs from knob 120 through slot insert 130 in box member 150 , through slot insert 340 in support connecting member 360 , and to pivot connection 300 which connects bar 160 pivotally to support connecting member 360 . In a particularly preferred embodiment of the present invention, bar 160 is separated from support connecting member 360 by a washer 320 . It is further preferred that washer 320 is fabricated from a plastic such as palycarbonate so as to provide a frictional resistance to the movement of bar 310 .
Also shown in FIG. 3 is a spring member 330 which generally urges the support platform assembly into a preset neutral position. Desirably, spring member 330 has sufficient force to resist the deformation caused by placing an average weight keyboard on the auxiliary platform without pushing the keyboard into the steepest negative keyboard angle that can be achieved by the mechanism.
FIG. 4 shows the top perspective of platform support 110 and flanges 400 , which flanges were concealed in FIG. 1 whereas FIG. 5 shows the top view of, and FIG. 6 shows a side view of, platform support 110 .
FIG. 7 shows the top perspective of pivotal member 140 and apertures 350 on each side of pivotal member 140 for pivotally mounting pivotal member 140 to support connecting member 360 . FIG. 8 shows the side view of, and FIG. 9 shows a top view of, pivotal member 140 .
FIG. 10 provides a prospective view of a preferred embodiment of box member 150 with slot 1030 into which slot insert 130 is to be placed. FIGS. 11 , 12 and 13 show, respectively, a top, front and side view of box member 150 , and in FIGS. 11 and 12 , slot 1030 . Also visible in FIGS. 10 , 11 , 12 and 13 is foot member 1050 of box member 150 .
FIGS. 14 , 15 and 16 show, respectively a side, top perspective and rear perspective view of an assembly including platform support 110 ; pivotal member 140 , and box member 150 . Note that foot member 1050 of box member 150 sits below platform support 110 .
FIGS. 17 , 18 , 19 & 20 show various aspects of support connecting member 360 . Specifically, FIG. 17 shows a prospective view of support connecting member 360 and illustrates left and right flanges 1750 having apertures 1720 & 1730 which admit pivot axes that connect support 100 to the shelf adjustment mechanism of the present invention in this embodiment. FIG. 17 further shows slot 1710 and apertures 1740 through which the upper and lower slot inserts are connected.
FIG. 18 shows a frontal view of support connecting member 360 with left and right flanges 1750 as well as slot 1710 and apertures 1740 . FIG. 19 shows a side view of support connecting member 360 with a side flange 1750 having apertures 1720 & 1730 .
In the embodiment of the present invention illustrated in FIGS. 17 & 18 , slot 1710 is substantially parallel to the front edge of support connecting member 360 so that the shortest distance between slot 1710 and point 1760 on the front edge of support connecting member 360 is substantially the same distance as the shortest distance between slot 1710 and point 1770 on the front edge of support connecting member 360 .
FIG. 20 is a view taken along line 20 - 20 in FIG. 19 and provides a top down view of connecting member 360 with left and right flanges 1750 as well as slot 1710 and apertures 1740 .
FIGS. 21 , 22 & 23 show connecting member 360 and the placement of slot inserts 340 into slot 1710 in connecting member 360 . These figures also illustrate side flanges 1750 and their associated apertures 1720 & 1730 .
In the operation of the embodiment of the present invention illustrated in FIGS. 1-23 , the movement of knob 120 , and thus bar 160 , toward point 170 of FIG. 1 causes box member 150 to move toward point 190 relative to support connecting member 360 , which is under box member 150 . This motion of box member 150 —which shortens the distance between bar 160 and support member 110 —effectively lifts the front edge of support member 110 and increases any “negative angle”. Conversely, the movement of knob 120 , and thus bar 160 , toward point 180 of FIG. 1 causes box member 150 to move away from point 190 relative to support connecting member 360 , which is under box member 150 . This motion of box member 150 —which lengthens the distance between bar 160 and support member 110 —effectively pushes the front edge of support member 110 down, thereby decreasing the “negative angle” of the mechanism.
The motion of bar 160 between points 170 and 180 in FIG. 1 causes knob 120 to travel in an arc. In an alternative embodiment of the present invention, knob 120 is replaced with a cover mechanism that slides along the top surface of box member 150 . Desirably, this cover mechanism can accommodate the variable amount of bar 160 that projects above the top surface of box member 150 and thus this cover mechanism increases or decreases the “negative angle” of the support shelf without moving the cover mechanism out of contact with the top surface of box member 150 .
In a further embodiment of the present invention bar 160 with its anchor 300 is replaced with a slide mechanism that travels in the slots. Desirably, the slide mechanism is substantially I shaped having a bottom portion that is too wide to permit the slide mechanism to rise up out of the slots and a top portion that is too wide to permit the slide mechanism to sink down and out of the slots. In a more preferred version of this embodiment of the present invention, the underside of the top portion of the support connecting member 360 about slot 1710 has a track that engages the bottom portion of the slide mechanism so as to further prevent the slide mechanism from moving out of the slots.
Functionally this slide mechanism is substantially the equivalent of the moving bar 160 mechanism in that when the slide mechanism is moved toward point 170 of FIG. 1 , this movement of the slide mechanism causes box member 150 to move toward point 190 relative to support connecting member 360 , which is under box member 150 . Again, this motion of box member 150 —shortens the distance between bar 160 and support member 110 —effectively lifting the rear edge of support member 110 and reducing any “negative angle”. Conversely, the movement of the slide mechanism toward point 180 of FIG. 1 causes box member 150 to move away from point 190 relative to support connecting member 360 , which is under box member 150 . This motion of box member 150 —lengthens the distance between bar 160 and support member 110 —effectively pushes the rear edge of support member 110 down, thereby increasing the “negative angle” of the mechanism.
While the mechanism of the present invention can be fabricated out of substantially any conventional materials, it is believed that if slot inserts 340 are made of plastic such as polycarbonate, there is an improvement in the performance of the device of the present invention. Similarly, a performance improvement was observed when bar 160 was made of steel and coated with black oxide. Likewise, if washer 320 is made of a plastic such as polycarbonate, the frictional interaction between washer 320 and bar 160 is increased so as to substantially reduce any “spontaneous” movement of bar 160 from an extreme position toward the center of the slot. It is also desired that spring member 330 is made of spring steel.
It is also desired that the lower portion of slot inserts 340 in support connecting member 360 are tapered outward so as to reduce frictional contact at that point between the slot inserts and bar 160 .
FIG. 24 illustrates a preferred embodiment of how bar 160 is pivotally connected to the inventive mechanism at pivot connection 300 . As shown in FIG. 24 , bar 160 projecting through slot 340 with knob 120 at its distal end. In the preferred embodiment of the present invention shown in FIG. 24 , bar 160 is separated from support connecting member 360 by a washer 320 .
FIG. 25 shows pivot connection 300 from another perspective and identifies region B which is enlarged in FIG. 26 . In FIG. 26 , a preferred embodiment of pivot connection 300 can be seen in greater detail. Specifically, pivot connection 300 , in this preferred embodiment, includes a machine screw 2410 that communicates through spring washer 2430 (for instance, a steel spring washer), bar 160 and support connecting member 360 to lock nut 2420 and secures bar 160 to support connecting member 360 .
FIG. 27 provides a top view of a particularly preferred embodiment of washer 320 . In this embodiment, two parallel ridges 2450 are molded into washer 320 . Also shown in this figure is washer aperture 2440 , which is offset from the center of washer 320 . but along a line that runs through the center of washer 320 .
FIG. 28 provides a side view of the preferred embodiment washer 320 shown in FIG. 27 . In FIG. 28 , bar 160 can be seen within the valley formed by parallel ridges 2450 .
FIG. 29 provides a further view of the preferred embodiment washer 320 shown in FIG. 27 from another perspective. Also seen in this view are washer aperture 2440 and parallel ridges 2450 .
FIG. 30 provides a cross-sectional view of washer 320 taken along line A-A in FIG. 27 . This figure illustrates the valley formed by parallel ridges 2450 on washer 320 .
FIG. 31 provides a bottom view the preferred embodiment of washer 320 shown in FIGS. 27-30 . This view shows washer aperture 2440 , which is offset from the center of washer 320 . but along a line that runs through the center of washer 320 .
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The present invention concerns a mechanism for adjusting the angle of an auxiliary support mounted on an auxiliary support mechanism. The mechanism may have a first member having a plurality of surfaces mounted on the end of an auxiliary support mechanism. The mechanism may also have a second member having a plurality of surfaces slideably enveloping said first member. The mechanism may still further have a third member movably connected to the auxiliary support mechanism as well as a spring member.
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FEDERAL SPONSER RESEARCH
[0001] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0002] Not Applicable
BACKGROUND
[0003] 1. Field of Invention
[0004] This invention relates to a drywall tool, specifically to use on drywall, sheet rock and cement board where a flat smooth even joint is required. More specifically it relates to a hand tool and method for spreading drywall compound or plaster and leaving a fixed height and width of plaster over a joint between two sections of drywall.
[0005] 2. Description of Prior Art
[0006] Difficulty of obtaining a smooth flat uniform surface between the joints and butt ends of drywall boards, gypsum boards, sheet rock boards, cement boards & other construction boards is well known in the industry. All of these and similar boards are described herein as “drywall boards” for the purposes of these specifications. A reliable and easy method along with a tool to spread the drywall compound, cement, grout, plaster, etc, to obtain this flat surface has been the search of the construction industry for a long time. All of these compounds and similar compounds are described herein as “joint compound” for the purposes of this specification.
[0007] In an ideal situation and in skilled hands with experience a worker, one could spread joint compound properly over a drywall board joint and obtain, in most cases, a very flat and acceptable joint. The problem in industry today is that the ideal conditions and the skilled workers are a variable today especially in the rapidly expanding housing and commercial industries. By ideal conditions one would want the drywall boards to be nailed or screwed flat to the studs so that each section of board is at the same level as the board next to it which would allow for a uniform thickness of joint compound to be applied. In most construction applications, these ideal conditions do not which always occur causing the joint surface to have valleys and hills that makes creating a constant depth of joint compound become difficult. This creates a challenge to the worker to obtain a smooth and flat surface because the two drywall board surfaces are at two different heights. Usually to compensate for this problem a skilled worker knows to apply several thin layers of joint compound. This method requires a lot of time to complete because each layer of joint compound must dry before the next layer can be applied. It is common to have at least 3 layers and sometimes more to build up the level of compound to obtain a nice flat surface. One of the most commonly used joint compounds requires the worker to wait 24 hours after the first coat is applied before the next before adding an additional coat, according to it's directions. Therefore three coats could take as long as three days or longer just to build up the surface of one joint. Care must be taken not to allow each layer to be too thick since it is common that the joint compound could crack presenting additional difficulties to obtain a smooth flat surface.
[0008] The other item effecting ideal joint preparation is spreading the joint compound over a butt end joint. Butt end joints are not recessed and are at the actual height of the wall board. Applying the tape automatically brings the height of the joint higher than that of the surface of the drywall board. This requires many layers of joint compound to be applied at different widths for each application. It is not unusual to sand the joint surface between each layer to help obtain a flat surface. Sanding the joint creates a lot of fine dust creating an unhealthy environment and possibly a hazardous situation. The worker is required to wear a mask to guard against this dust entering their lungs and of course this process takes additional time above and beyond that of the compound drying time and the time to apply the next coat. Any process that reduces sanding in itself has many benefits.
[0009] As mentioned before many events can affect the ideal conditions heeded to obtain smooth flat joints. Even when the conditions are not ideal, a very skilled worker with a lot of experience in most cases can produce a very flat surface. It may require extra days of applying thin layers of compound or extra sanding but these workers will usually get the correct result Their skills are more art than science in obtaining a flat surface. The real problem in the industry is that most workers preparing joints on drywall surfaces do not have this dexterity of hand coordination to obtain good uniform flat joints when ideal conditions are not met and sometimes even when ideal conditions are present.
[0010] The industry has been in search of a tool and method to turn the art of getting a flat smooth drywall joint from an art to more of a science. A tool where a semi-skilled or even unskilled worker can get a flat smooth joint under any conditions. The following examples illustrate some known hand tools that attempt to accomplish this task; U.S. Pat. No. 2,800,672 to Gilyan (1957) discloses a tool for plastering joints. This is a combination tool which includes a straight edge blade and a curved blade. The idea is that the curved blade can be used first over the joint and then the straight edge can be used to feather the joint by adding another layer of joint compound. It is known in the industry that a curved blade does not result in a good smooth & flat joint. Usually a curved blade allows for an excessive amount of joint compound and cracking of the compound can occur during curing. In addition such a wide curve requires a steady hand to stay within the recess joints of two boards. If a worker allows the curve blade to leave the recessed area, it creates more difficulty to obtain a smooth joint. This usually requires a lot of sanding to level the high spot.
[0011] U.S. Pat. No. 2,934,936 to Vernon (1960) discloses various tools call taping trowels. One tool in particular again utilizes the curved blade concept. Actually two different curves on each side of the hand trowel. The concept is to apply an inner coat using the first smaller width, larger radius curve to to fill the joint with joint compound and after curing use the other side which has a wider width, smaller diameter curve to apply the next outer joint. Again this has similar problems as the prior patent and is not used in current techniques.
[0012] U.S. Pat. No. 3,878,581 to Perna (1974) is a variety of finishing tools for wallboard surfaces. In particular is one tool that is made up of several rigid & non-flexible plates with a laminated elastomeric blade of rubber or composite. This again has a curved blade concept as part of this combination tool and would have similar problems as the other two patents mentioned above.
[0013] U.S. Pat. No. 4,654,919 to Liberman (1987) discloses a spreader tool to apply plaster to wallboard. This tool is different than the above mentioned tools in the fact that the blade edge is flat like a normal trowel and is not cut as a curve. Instead the blade is bent into a curve position thus allowing for a worker to apply a “curved” layer as the trowel is angled and after curing, the edges of the curved compound joint could be feathered smooth using the straight edge of the blade. Actually this would be a harder to use product than the first three patents mentioned because as the tool is angled to obtain the curve, if the angle of the tool changes, the thickness of the curve would also change. The industry has determined that a curved first coat does not lead to a better joint. In most cases it creates more problems.
[0014] Finally U.S. Pat. No. 6,606,758 B1 to Fridman (2003) discloses a serrated tool for plaster over a surface joint. This products uses a trowel that has two sets of serrated edges on both of the blade ends and a cut out notch with straight edges of 3 to 4 inches. This tool, to get good results, is to be held at a 35 to 45 degree angle when using it to cover the tape. The tool when spreading compound would create a squared extrude area in the center and smaller extruded triangle rows of joint compound at the serrated edges. The tool being large would require a steady hand while covering a wide area. The serrated edges will build up joint compound on the flat part of the drywall board, only requiring more joint compound to be applied to smooth those edges This requires much more finishing sanding and time for the worker.
Objects & Advantages
[0015] Accordingly, these and other known tools of prior art fail to address the main problem of obtaining smooth flat joints using a simple method to overcome the skill required of a worker and when ideal conditions are not met. Therefore the need for a simple low cost tool and method to obtain flat, even joints of drywall is desired in the industry and has not been solved. This is why today you still see a flat edge trowel being used in the industry instead of any of the other inventions mentioned.
[0016] The invention I detail has several objects and advantages;
[0017] (a) very low cost available in a polymer or steel construction
[0018] (b) a tool that is simple to use even with an unskilled worker or a do-it-yourself homeowner
[0019] (c) a tool that uses a smallest amount of joint compound to obtain the proper joint and requires only the smallest amount of sanding in the final process.
[0020] (d) a tool that can be utilized when drywall board is applied with uneven surfaces and on butt joints and still obtain a smooth flat joint surface
[0021] (e) a tool to speed up the finished surface preparation from several days to with in 48 hours or less.
SUMMARY
[0022] In accordance with the present invention a drywall tool resulting in flat even joints comprised of a trowel with a handle and blade. The blade is notched in the center and the rest of the blade is flat with a straight edge to spread the joint compound over the joint and drywall tape to allow for an easy method to obtain a flat extruded bead with square edges as a simple first step to match even and uneven drywall board joints, using the minimal amount of joint compound, resulting in easy use by unskilled workers and minimal finishing sanding.
DRAWINGS
[0023] In the drawings a more detailed and complete appreciation of the present invention and various advantages can be realized by reference to the detailed description that will accompany the drawings in which:
[0024] FIG. 1 : is the invention showing the drywall trowel with flat surface on both ends of the blade and a flat notch with straight edges that allows for a flat extruded build up of joint compound to an exact desired height to occur over the drywall joint and tape while the flat end will remove any excess joint compound.
[0025] FIG. 2A to FIG. 2E : shows the method steps where in the first process step the drywall tool is used and the other steps that occur to create an even joint.
REFERENCE NUMERALS IN DRAWINGS
[0000]
11 blade
12 handle
13 flat edge of blade
14 notch
15 dry wallboard
16 tapered edge of drywall board
17 drywall tape
18 edge of two drywall boards
19 depth of joint compound after use of invention
20 filled in of the flat extruded surface and sides
21 final coat of joint compound if necessary
DETAILED DESCRIPTION
Description—FIG. 1 —Drywall Tool
[0037] A detailed description of the preferred embodiment of the present invention follows with reference to accompanying drawings in which elements are indicated by reference numerals. In FIG. 1 , the blade 11 is a flat and straight edge with no curves. The blade can be metal or polymer materials that is attached to a handle 12 made of similar or dissimilar materials and made to be molded with the blade or attached separately. The blade 11 is designed to be larger than the two recessed edges of the dry wall board for optimal use. The edge of the blade 11 is located opposite of the handle and consists of three different areas; two flat straight edges 13 on each side of the blade and in the center area a notched section 14 . The two flat edges 13 will remove and spread joint compound along the joint when moved parallel to the joint. The notched section 14 will allow for a flat amount of joint compound to remain on the joint of a certain height with straight edges. The height and width will be fixed to the specific height and width desire to equal that of the final surface of joint which is that of the height of the drywall board. The optimal width can vary between of 2 to 3 inches sized to cover the drywall tape. The notch depth is most effective at a height of 1/16 to ⅛ of an inch but can vary as much as ¼ of an inch. Once cured the second step will use a standard straight edge drywall trowel to fill in each side of the resulting valley between the drywall and the extruded flat surface created by the invention.
FIGS. 2A-2E Method of Drywall Tool and Completing the Process
[0038] The method of the drywall tool and finishing process of the joint is show in detail in FIG. 2A and FIG. 2B . Two drywall boards 15 of a certain thickness are placed side by side creating a joint. The drywall edges 16 are usually recessed where the drywall tape 17 is applied in the center of the joint created by the two drywall boards 15 .
[0039] In FIG. 2A and FIG. 2C the drywall tool loaded with joint compound is applied over the drywall tape 17 and moved paralleled with the drywall joint leaving a flat extruded amount of drywall compound 19 in the drywall board recessed area 16 . The two edges of the blade of the drywall tool will remove all the dry wall compound from the recessed area leaving behind a flat extruded surface of drywall compound with straight edges of a fixed height 19 . The first step of the process is completed and an amount of time is given for the joint compound to dry and cure.
[0040] In FIG. 2A and FIG. 2D shows the next step after curing has occurred. With a typical straight edge putty knife or blade, a second coat is applied to fill the recessed areas between the drywall 15 and the extrude surfaced made earlier by the invention. This filled area is labeled 20 and should completely fill the drywall recessed area 16 . This area can be filled completely in this step but depending on the situation a third skim coat 21 may be applied with a wider straight edge trowel or putty knife to fill any remaining vallies. This process allows for a continuous filling of the recessed areas or small valleys eliminating any need for rigorous sanding to smooth joints between coating. Typically a very light sanding may be required after the final coat to adjust the surface appearance to reflect the same look as the drywall board. The amount of sanding, if required, is very small producing limited dust compared to traditional methods currently being utilized and creates a better environmental condition for the worker.
Advantages
[0041] From the description above a number of advantages of my drywall tool resulting in flat even surfaces is evident;
[0042] (a) low cost available in a polymer or steel construction
[0043] (b) a tool that is simple to use even with an unskilled worker or a do-it-yourself homeowner
[0044] (c) a tool that uses a small amount of joint compound to obtain the proper joint and requires only the smallest amount of sanding in the final process
[0045] (d) a tool that can be utilized when drywall board is applied with uneven surfaces and on butt joints and still obtain a smooth flat joint surface
[0046] (e) a tool to speed up the finished surface preparation from several days to with in 48 hours or less.
[0047] (f) a simple method that produces flat even surfaces every time.
Operation—FIGS. 2A-2E, 1
[0048] The manner of using the drywall tool resulting in flat even joints can be described as a two, sometimes three, step process where the worker simply takes the tool holding the handle 12 and filling the blade 11 with joint compound then move the blade across the tape into the recessed area in a side ways manner spreading drywall compound in the recessed area Then placing notched 14 between the recess joint 16 on the drywall board over the drywall tape 15 . Moving the blade 11 parallel over the drywall tape 17 will leave an extruded amount of drywall 16 on the tape and recessed through the notch 14 of the blade 11 .
[0049] The flat edges 13 of the blade 11 will remove any drywall compound in the recessed area allowing for a flat extruded amount of compound to remain over the tape of a certain height. This process will continue over all joints and when finished the worker will allow the joint compound to cure. Once cured the worker will fill the remaining area with joint compound with a regular straight edged trowel. A final skim coat can be applied to fill in any remaining valleys giving a flat even surface of the joint.
Conclusion, Ramifications, and Scope
[0050] Accordingly, the reader can see this is a very simple tool to be used yet consistently yields excellent flat smooth joints. There has been a strong interest by manufacturers who produce these tools to have exclusive rights to bring this tool to commercial use. Trial after trial by various level of skilled workers and do-it yourself home owners have yielded excellent results with this dry wall tool and method. The industry recognizes the difficulty of obtaining flat even joints and the problems that occur when the joint is not smooth in the finished product.
[0051] The invention I detail has several advantages; very low cost to manufacture the product making it available to everyone. A tool that is simple to use even with an unskilled worker or a do-it-yourself homeowner. A tool that uses a small amount of joint compound to obtain the proper joint and requires only the smallest amount of sanding in the final process. A tool that can be utilized when drywall board is applied with even and uneven surfaces along with butt joints and still obtain a smooth flat joint surface. A tool to speed up the finished surface preparation from several days to with in 48 hours or less.
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A method and a drywall tool for making flat and even joints for the construction industry are disclosed. This innovative hand tool for making flat even joints includes a central section that is a cut out notch allowing for an extruded amount of drywall compound that produces a sufficient width and height to be placed over the drywall tape within the drywall recessed or butt joints. Once this cures, a simple fill in step using a standard towel allows these process steps to be accomplished by an unskilled worker, while producing flat and even joints, requiring less time, and dust.
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BACKGROUND OF THE INVENTION
Embodiments of the present invention relates generally to semiconductor devices and, more specifically, to damascene gates having protected shorting regions and related methods for their manufacture.
Current integrated circuit (IC) designs often employ contact sizes, gate sizes, and operating voltages that risk unintentional contact etching and/or contact-to-gate electrical shorts. Gate corners are particularly susceptible to such contact-to-gate shorts. One solution to this problem is increasing the space between contacts and gate corners. Such solutions are unsatisfactory, however, due to the increase in gate size necessitated by such increased space and the attendant impairment of device performance.
SUMMARY OF THE INVENTION
The invention provides damascene gates with protected shorting regions, as well as methods for their manufacture.
A first aspect of the invention provides a method of forming a damascene gate with protected shorting regions, the method comprising: forming a damascene gate having: a gate dielectric atop a substrate; a gate conductor atop the gate dielectric; a conductive liner laterally adjacent the gate conductor; a spacer between the conductive liner and the substrate; and a first dielectric atop the gate conductor; removing a portion of the conductive liner; and depositing a second dielectric atop a remaining portion of the conductive liner, such that the second dielectric is laterally adjacent both the first dielectric and the gate.
A second aspect of the invention provides a method of forming a damascene gate with protected shorting regions, the method comprising: forming a damascene gate having: a gate dielectric atop a substrate; a gate conductor atop the gate dielectric; a conductive liner laterally adjacent the gate conductor; a spacer between the conductive liner and the substrate; and a first dielectric atop the gate conductor; and depositing a second dielectric atop a portion of the substrate, the gate dielectric, the conductive liner, and the spacer, wherein the second dielectric forms a protected shorting region above at least one upper corner of the gate conductor.
A third aspect of the invention provides a damascene gate comprising: a gate dielectric atop a substrate; a gate conductor atop the gate dielectric; a conductive liner laterally adjacent the gate conductor; a spacer between the conductive liner and the substrate; a first dielectric atop the gate conductor; and a second dielectric atop the conductive liner and laterally adjacent both the first dielectric and the spacer.
A fourth aspect of the invention provides a damascene gate comprising: a gate dielectric atop a substrate; a gate conductor atop the gate dielectric; a conductive liner laterally adjacent the gate conductor; a first dielectric atop at least a portion of the gate conductor; a spacer between the conductive liner and the substrate; and a second dielectric atop a portion of the substrate, the spacer, the conductive liner, and the first dielectric, wherein the second dielectric forms a protected shorting region above at least one upper corner of the gate conductor.
The illustrative aspects of the present invention are designed to solve the problems herein described and other problems not discussed, which are discoverable by a skilled artisan.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
These and other features of this invention will be more readily understood from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings that depict various embodiments of the invention, in which:
FIGS. 1A-C show cross-sectional side views of a method of forming a damascene gate with protected shorting regions according to one embodiment of the invention;
FIGS. 2A-B show cross-sectional side views of a method of forming damascene gates with protected shorting regions according to alternative embodiments of the invention; and
FIG. 3 shows a flow diagram of illustrative methods according to various embodiments of the invention.
It is noted that the drawings of the invention are not to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1A , a damascene gate 100 is shown, the gate comprising a substrate 10 , a gate dielectric 12 , a spacer 20 , a conductive liner 30 , a gate conductor 40 , and a first dielectric 50 . Areas A and B show the upper corner regions of gate conductor 40 which, as noted above, are areas of the gate 100 particularly susceptible to contact-to-gate electrical shorts.
The materials of each gate element may be those typically employed. Materials other than those enumerated below will be known to one skilled in the art and are within the scope of the present invention. For example, substrate 10 may include silicon, germanium, silicon germanium, silicon carbide, and those consisting essentially of one or more III-V compound semiconductors having a composition defined by the formula Al X1 Ga X2 In X3 As Y1 P Y2 N Y3 Sb Y4 , where X 1 , X 2 , X 3 , Y 1 , Y 2 , Y 3 , and Y 4 represent relative proportions, each greater than or equal to zero and X 1 +X 2 +X 3 +Y 1 +Y 2 +Y 3 +Y 4 =1 (1 being the total relative mole quantity). Other suitable substrates include II-VI compound semiconductors having a composition Zn A1 Cd A2 Se B1 Te B2 , where A 1 , A 2 , B 1 , and B 2 are relative proportions each greater than or equal to zero and A 1 +A 2 +B 1 +B 2 =1 (1 being a total mole quantity). In some embodiments, the substrate 10 may include amorphous or polycrystalline silicon.
Gate dielectric 12 may include, for example, oxide, silicon oxide, silicon dioxide, silicon oxynitride, silicon nitride (Si 3 N 4 ), tantalum oxides, alumina, hafnium oxide (HfO 2 ), hafnium silicate (HfSi), plasma-enhanced chemical vapor deposition oxide, tetraethylorthosilicate, nitrogen oxides, nitrided oxides, aluminum oxides, zirconium odixe (ZrO 2 ), zirconium silicate (ZrSiO x ), high K (K>5) materials, and/or combinations thereof.
Conductive liner 30 may include, for example, hard metals, such as tungsten, molybdenum, osmium, iridium, or alloys thereof.
Gate conductor 40 may include, for example, aluminum, an aluminum-copper alloy, cobalt, cobalt silicide, copper, metal silicide, nickel, nickel silicide, a nitrided metal, palladium, platinum, a refractory metal, such as ruthenium, tantalum nitride, titanium, titanium aluminum nitride, titanium nitride, titanium silicide, a titanium-tungsten alloy, and/or tungston carbon nitride, and/or combinations thereof.
First dielectric 50 may include, for example, oxide, silicon oxynitride, silicon nitride, low-pressure tetraethylorthosilicate, high-temperature oxide, furnace oxide, plasma-enhanced chemical-enhanced deposition oxide, low-pressure oxide, hafnium oxides, tantalum oxides, aluminum oxides, oxygen dielectrics, nitrogen dielectrics, and/or combinations thereof.
In FIG. 1B , gate 100 has been selectively masked (not shown) and etched to remove an upper portion of conductive liner 30 .
In FIG. 1C , a second dielectric 60 is deposited atop the remaining portion of conductive liner 30 such that second dielectric 60 is between and laterally adjacent both spacer 20 and first dielectric 50 . In some embodiments, including the one shown in FIG. 1C , second dielectric 60 is also laterally adjacent a portion of gate conductor 40 .
Second dielectric 60 may include, for example, oxide, silicon oxynitride, silicon nitride, low-pressure tetraethylorthosilicate, high-temperature oxide, furnace oxide, plasma-enhanced chemical-enhanced deposition oxide, low-pressure oxide, hafnium oxides, tantalum oxides, aluminum oxides, oxygen dielectrics, nitrogen dielectrics, high dielectric constant (high K (e.g., K>5)) material, and/or combinations thereof.
In some embodiments of the invention, the material(s) of the second dielectric 60 differ(s) from the material(s) of first dielectric 50 . As used herein, “differ,” “different,” and “differs” are meant to include different proportions of materials as well as different materials themselves.
Second dielectric 60 may be deposited by any number of techniques, the choice of which may vary, of course, based on the material(s) employed. Suitable deposition techniques include any now known or later developed techniques appropriate for the material to be deposited including but are not limited to, for example: chemical vapor deposition (CVD), low-pressure CVD (LPCVD), plasma-enhanced CVD (PECVD), semi-atmosphere CVD (SACVD) and high density plasma CVD (HDPCVD), rapid thermal CVD (RTCVD), ultra-high vacuum CVD (UHVCVD), limited reaction processing CVD (LRPCVD), metalorganic CVD (MOCVD), sputtering deposition, ion beam deposition, electron beam deposition, laser assisted deposition, thermal oxidation, thermal nitridation, spin-on methods, physical vapor deposition (PVD), atomic layer deposition (ALD), chemical oxidation, molecular beam epitaxy (MBE), plating, or evaporation.
Gate 100 of FIG. 1C may be further processed, including, for example, polishing, such as by chemical mechanical polishing (CMP).
FIGS. 2A-B show alternative embodiments of the invention. In FIG. 2A , an etch-resistant second dielectric 160 is deposited and etched such that it lies atop first dielectric 150 , conductive liner 130 , spacer 120 , and a portion of substrate 110 . In the embodiment shown in FIG. 2A , the upper corners of gate conductor 140 are again protected from contact-to-gate electrical shorts by second dielectric 160 .
FIG. 2B shows yet another embodiment of a gate 200 according to the invention. Here, second dielectric 160 of FIG. 2A has been etched to expose the gate for easy contacting while leaving the upper corners of gate conductor 140 covered by two portions of second dielectric 160 , 162 .
The material(s) included in second dielectric 160 , 162 may be as described above. In some embodiments of the invention, the material(s) of second dielectric 160 , 162 is (are) different than the material(s) of first dielectric 150 .
FIG. 3 shows a flow diagram depicting illustrative methods according to various embodiment of the invention. At 51 , a damascene gate is formed, the damascene gate including a gate conductor ( 40 , FIG. 1A ) within a substrate ( 10 , FIG. 1A ), a conductive liner ( 30 , FIG. 1A ) laterally adjacent the gate conductor, a spacer ( 20 , FIG. 1A ) between the conductive liner and the substrate, and a dielectric ( 50 , FIG. 1A ) atop the gate conductor. Methods and techniques for formation of such a damascene gate are conventional and would be known to one skilled in the art. For purposes of brevity, therefore, they shall not be further described herein.
At S 2 , the flow can follow one of two paths, depending on the gate-forming method desired. Taking the first path, at S 3 , a portion of the conductive liner 30 is removed and, at S 4 , a new dielectric ( 60 , FIG. 1C ) is deposited atop the remaining portion of the conductive liner 30 . Thus, the first path results in a damascene gate such as that shown in FIG. 1C .
Taking the second path, at S 5 , a dielectric ( 160 , FIG. 2A ) is deposited above one or more upper corners of the gate conductor (e.g., the dielectric is deposited atop the first dielectric ( 150 , FIG. 2A ), conductive liner ( 130 , FIG. 2A ), spacer ( 120 , FIG. 2A ), and a portion of the substrate ( 110 , FIG. 2A )). Thus, the first path, up to S 5 , results in a damascene gate such as that shown in FIG. 2A . Continuing the second path, a portion of the deposited dielectric may optionally be removed at S 6 , resulting in a damascene gate such as that shown in FIG. 2B .
The foregoing description of various aspects of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of the invention as defined by the accompanying claims.
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The present invention relates generally to semiconductor devices and, more specifically, to damascene gates having protected shorting regions and related methods for their manufacture. A first aspect of the invention provides a method of forming a damascene gate with protected shorting regions, the method comprising: forming a damascene gate having: a gate dielectric atop a substrate; a gate conductor atop the gate dielectric; a conductive liner laterally adjacent the gate conductor; a spacer between the conductive liner and the substrate; and a first dielectric atop the gate conductor; removing a portion of the conductive liner; and depositing a second dielectric atop a remaining portion of the conductive liner, such that the second dielectric is laterally adjacent both the first dielectric and the gate.
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This is a continuation of copending application Ser. No. 07/285,191 filed on Dec. 16, 1988 now U.S. Pat. No. 5,010,724.
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a package, in which a yarn carrier spun in a ring spinning frame is rewound in a following rewinding machine to make packages and to an apparatus for performing this method.
The production of packages takes place by means of cone winding frames or machines, on which yarn carriers, called cops, are wound off and rewound to packages, whilst during winding off, a simultaneous check is made on the thread for defects and for removing the latter. The yarn carriers are produced in the spinning mill and transported to the rewinding machines. Ring spinning frames are almost exclusively used for producing the yarn carriers.
It is known to reduce the transportation path between the ring spinning frame and the rewinding machine in that said two means are juxtaposed as a so-called compound or composite system and are interlinked by a conveyor, e.g. a conveyor belt. The conveyor belt is used for conveying the full yarn carriers from the ring spinning frame to the cone winding frame. On the latter the yarn carriers are taken from a magazine, from which they are supplied to the individual winding positions.
Such composite system already has a relatively high degree of automation. Following onto the ring spinning frame, spinning of the yarn carriers takes place, preparation occurs for the doffing thereof, after which spinning is stopped and the yarn carriers are raised from the spinning spindles and placed onto the conveyor belt. The gripping of the empty yarn carriers from the conveyor belt and the placing thereof on the spinning spindles and then the start of spinning also takes place on the ring spinning frame. Following the spinning of the yarn carriers, they are discharged on the conveyor belt to the winding frame and simultaneously the empty yarn carriers are placed onto the conveyor belt. This leads to automatic conveying of the full yarn carriers from the ring spinning frame to the cone winding machine and the automatic conveying of the empty tubes or carriers from the cone winding machine back to the spinning frame.
In the cone winding machine the yarn carriers are removed from the conveyor belt of the ring spinning frame and transferred to the conveyor system of the cone winding machine. In a preparatory station the thread is sought on the yarn carrier and held and then the yarn carrier is conveyed to the winding station, where the thread is gripped and connected to the package thread, after which the thread is unwound from the yarn carrier. This is followed by the inspection of the empty yarn carrier with respect to yarn residue and subsequently the conveying of the empty yarn carrier back to the conveyor belt of the ring spinning frame, where the empty yarn carrier is transferred to the conveyor belt.
In connection with ring spinning machines use is also made of attachment means, which can fulfill several functions. The attachment means travel along the spinning frame. When a thread break is noted, the attachment means is stopped, the spindle is stopped and raised from the spinning frame. This is followed by the search for the thread end on the yarn carrier, then the latter is again placed on the spinning spindle, the ring traveler is threaded and the thread is attached on the supply cylinder of the drawing frame, after which the attachment means again starts its displacement.
Despite this relatively high degree of automation in the known compound system, on the ring spinning frame, the starting spinning in the case of a batch change, the thread break removal during doffing and the removal of rolls, as well as on the winding machine the removal of faults occurring thereon and the processing of ejected yarn carriers must be carried out manually by the spinner or winder.
Finally, in the case of the compound system it is also possible to use cleaning means on the ring spinning frame, as well as production data acquisition means. Despite the fact that the known compound system constitutes an advance compared with the separate arrangement of the ring spinning frame and cone winding machine, a large number of manipulations are still required thereon.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to develop a method of the aforementioned type for making packages such that the yarn can be rewound from the ring spinning spindle with less manipulations onto the package and wherein the degree of utilization of the ring spinning frame is increased and due to the possibility of using different rovings, it will be possible to increase the flexibility of the ring spinning frame.
According to the invention this and other objects of the invention are attained in that the rewinding of the yarn carrier to packages takes place on the ring spinning frame.
The present invention also covers an apparatus, whose function is to permit an optimum performance of the method.
According to the invention objects of the invention are attained by an apparatus, in which for each group of spinning stations on the ring spinning frame there is provided a rewinding device, which carries a winding station for rewinding the yarn carrier spun on the spinning stations to packages and comprising gripping means for removing and supplying the yarn carrier from and to a spinning station and for conveying the yarn carrier from and to the winding station.
The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectional elevation view of a ring spinning frame with a rewinding device, the winding station of which is fixed and the gripping device of which is movable;
FIG. 2 is a sectional view similar to that of FIG. 1, but with a movable rewinding device;
FIG. 3 is a partially sectional elevation view similar to that of FIG. 2 with a movable rewinding device and in which individual drives are provided for each spindle and for the ring movement;
FIG. 4 is a partially sectional elevation view similar to that of FIG. 2 on which rewinding of the yarn carrier takes place directly from the spinning station;
FIG. 5 is a partially sectional elevation view similar to that of FIG. 2 for the illustration of the starting spinning process;
FIGS. 6a to 6d illustrate different winding types on yarn carriers for ring spinning frames; and
FIGS. 7 and 8 show diagrams of the ring rail movement as a function of time.
In the drawings, similar elements are designed at like reference numerals.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is based on the idea that a reduction of the expenditure for producing a package by unwinding the yarn carrier spun in the ring spinning machine can be achieved, if the winding off of the yarn carrier arriving from the ring spinning frame takes place directly on the latter or at the particular spinning station. It is important that no constructional changes have to be made on the ring spinning frame. Only the operation differs, in that it is no longer necessary to remove simultaneously the full yarn carriers from the spinning stations and to simultaneously engage empty yarn carriers and instead each spinning station spins the yarn carrier until it is full, whereby it is then removed and an empty tube is engaged. Thus, the yarn carriers become full in a random sequence and, after establishing the end of the spinning process, there are successively removed from the spinning station and replaced by an empty tube. The rewinding of the full yarn carriers to packages also takes place successively in the same way. For carrying out all the manipulations on the ring spinning frame use is made of a rewinding device, which is arranged on the longitudinal side of the ring spinning frame. It is important that a rewinding device has a fixed association with one group of spinning stations, which means that there is no need for a conveyor belt, such as is used in the known compound systems. It is appropriate for the areas of the individual groups to overlap.
A rewinding device 12 shown in FIG. 1 is arranged on the longitudinal side of a ring spinning frame 1. The latter can be a random, known model, whereof only those parts are diagrammatically shown, which have a link with the present invention. The construction of the ring spinning frame 1 is assumed as known. A drawing frame 3 for each spinning station is provided on a machine column 4 below a not shown creel with rovings 2. Each spinning station 5 includes a rotating spindle 6, on which is placed a yarn carrier 7 in the form of a tube. Spindle 6 of spinning station 5 is driven via a belt drive 8 by a common driving shaft 9 or by a single spindle drive. The thread running up onto the yarn carrier 7 is threaded into a rotating ring traveller which, as a result of its rotation, brings about the winding of the spun yarn.
The left-hand side of the drawing is homologously constructed, so that it has been omitted. In the known compound system handling means are arranged on either side of the ring spinning frame, which are used for removing the full yarn carriers and for inserting empty tubes.
FIG. 1 shows the rewinding device 12, such as is necessary for performing the inventive method. Rewinding device 12 essentially comprises a winding station 14 and a gripping device 15. Rewinding device 12 is used for a group of spinning stations 5. The rewinding device 12 is allocated to each group. The winding station 14 has a holder 16 for receiving full yarn carrier 7. Holder 16 is arranged at the base of the winding station 14. At this point, as seen in FIG. 3, due to the rotation of the yarn carrier, a yarn carrier nozzle 19 seeks and grasps the end of the yarn to be wound off, supplies it to a yarn joining device 17 and connects it to the yarn of the package. Yarn carrier nozzle 19 can be pivoted into the position shown by broken line. The yarn joining device 17 can be a yarn knotter or yarn splicer of any suitable conventional design.
Above the yarn joining device 17 are arranged control or inspection devices 18 for inspecting the yarn during its passage for defects. Above the control or inspection devices 18, is arranged a cross-wound package 20 driven by a rotary driving roller 21 arranged on the circumference thereof, whereby the yarn to be wound on is passed through a grooved drum of cross-wound package 20 an is placed thereon. The grooved drum can be replaced by any different yarn laying system.
Joining device 17, control or inspection devices 18 and yarn carrier nozzle 19 are of any suitable conventional type and a detailed description thereof appears to be unnecessary.
The function of the gripping device 15 of rewinding device 12 is to perform all the necessary manipulations to maintain the spinning process with empty yarn carriers 7'. The gripping device 15 has a column 22 on which a gripper arm 23 is rotatable and movable up and down. The gripper arm 23 grips the full yarn carrier 7, removes it from the spinning station 5, swings it to the side and sets it down in a waiting station. The latter can be located on a rotary table 24, where there can be further stations for receiving empty and full yarn carriers. The gripper arm 23 now grips an empty yarn carrier 7' positioned on rotary table 24, raises it and engages it on the spindle 6 of spinning station 5. The gripper arm 23 can then bring the full yarn carrier 7 placed on rotary table 24 into the holder 16 of winding station 14, where the thread is wound off and removed to cross-wound package 20. It is also possible to use two gripper arms, one of which is used for changing the yarn carrier 7 on the ring spinning frame 1 and the other for the interchange to and from the winding off station. If a thread break occurs,, the only partly spun yarn carrier 7 is removed by the gripper arm 23 from the spinning station 5 in the same way as a full yarn carrier is brought into the waiting station on rotary table 24, where the partly full yarn carrier 7 is wound off in the same way as a full yarn carrier.
Thus, changing a yarn carrier 7 at spinning station 5 comprises the detection of the end of the spinning process, stopping the spindle and removing the yarn carrier 7 by gripper arm 23.
There can be two different constructions of the rewinding device 12. Either both the winding station 14 and the gripping device 15 are movable, cf. FIG. 2, or the winding station 14 is fixed and the gripping device 15 moves along the group of spinning stations 5 associated therewith, cf. FIG. 1. In both cases the gripping device 15 moves along, optionally together with the winding station 14, within the rang of the associated spinning stations 5 of the group, transfers the yarn carrier 7 from spinning spindle 6 directly into the winding off position of winding station 14, or into a waiting position upstream of the winding-off position, e.g. on rotary table 24.
The conveying of the full, partly full and empty yarn carriers 7 now takes place within the rewinding device 12. The replacement of the full yarn carriers 7 at the spinning stations 5 can take place at any time, because the full yarn carrier is produced individually. Nevertheless it is possible to have a time check for each spinning station 5 for establishing the operating time. In the same way rewinding can take place during the displacement of the gripping device 15 or the complete winding device 12, or when the winding station 14 is stationary. The individual spinning of the individual yarn carriers 7 at the spinning stations 5 makes it possible for spinning to be continued at the other spinning stations 5 when changing a full yarn carrier.
FIGS. 2 and 3 show the rewinding device 12, in which both the winding station 14 and the gripping device 15 are movable. The rewinding device 12 is constructed as a carriage or trolley, provided with rollers 25, which run on rails 26, which are fixed to the machine column 4 for the ring spinning frame 1.
In FIG. 3 the ring spinning frame 1 is equipped with individual drives for spindles 6. Each spinning station 5 is equipped with a motor drive 27. The ring carrier 10' with the traveller 10 for each spinning station 5 is also moved up and down via a spindle drive 29 by an individual motor drive 28.
FIG. 4 shows the ring spinning frame 1 with the rewinding device 12 which is movable. The spindles 6 are driven by individual motor drives 27, whilst the ring rail 10" with the ring traveller 10 is moved up and down by the main drive of ring spinning frame 1. It is also possible to use an individual ring carrier drive.
The difference of the construction of FIG. 4 as compared with FIG. 3 is that the winding off of the yarn carrier 7 takes place in the spinning station 5. Yarn guidance and feeding shown in simplified diagrammatic form is performed by using a guide pulley 40. Here again the yarn end is caught by the thread seeking nozzle and transferred to the thread joining device 17.
The arrangement shown in FIG. 4 will probably only be used in special cases, because during the winding off of the yarn carrier 7 the spinning station 5 cannot be put into operation. However, it is advantageous that the motor drive 27 can be used for speeding up the running off of the yarn.
Independently on whether a full or a partly full yarn carrier 7 is removed from the spinning station 5, this is followed by the initial spinning of the thread by applying the yarn carrier 7, as shown in FIG. 5.
As seen from FIG. 5, a starter yarn 31 is removed from a reserve or store bobbin 30 and placed on an empty yarn carrier 7', e.g. by clamping or winding. In this case the empty yarn carrier 7' has a yarn clamp 33. The starter yarn 31 is threaded on ring traveller 10' by a traveller threader 32 and an air nozzle 32'. A yarn laying or application arm 36 is then swung out and the starter yarn 31 is taken along with it. Then a cutter 37 cuts the starter yarn 31 and the latter is raised to a run-out cylinder of the drawing frame 3, where initial spinning takes place. The reserve spool or bobbin 30 is appropriately located on the movable winding device 14. If the rewinding device 14 is fixed, then the reserve bobbin 30 is to be constructed to be movable with the gripping device 15.
The individual spinning at each spinning station 5 with the known ring rails, cf. FIG. 6 results in that in place of the conventional cop winding, it is possible to use a winding referred to as random winding, cf. FIGS. 6a and (b). For reasons of completeness a parallel winding (FIG. 6c) and a combination winding (FIG. 6d) are also shown. There are two variants of the random winding (FIG. 6b), which only differ in the movement of the ring rail. The movement sequence over the time is shown in the two diagrams illustrated in FIGS. 7 and 8, respectively showing variants 1 and 2. Spinning can start and be broken off at a random point. The rail ring periodically always performs the same lifting movement.
By fitting the rewinding device 12 on the ring spinning frame 1 package production is greatly simplified. The gripping device 15 can also be used for the independent starting of the spinning spindles 6 during a batch change, i.e. on changing the roving or changing the machine setting.
Due to the fact that each spinning station 5 is individually changed, whilst the other spinning stations 5 continue to run, the production capacity is increased. The rewinding device 12 is required for each group of spinning stations 5. Spinning on the ring spinning frame 1 can take place without production loss, if the number of yarn carriers 7 for each group is greater by one or more yarn carriers than the number of spinning stations in a group.
If the spinning station 5 is provided with an individual ring carrier movement, in the case of a full yarn carrier there can be a backwinding and an underwinding, as in the known duffing process, so that with the rewinding device 12, the known yarn carrier change (doffing process), and spinning start can take place without initial spinning. If the automatic initial spinning and automatic thread break removal are not required, these processes can also be performed manually and the automatic initial spinning device shown in FIG. 5 can be obviated.
If, as is now conventional with cap winding, the yarn carriers of a group are to be simultaneously completely spun, they are successively replaced by empty yarn carriers. The full yarn carriers are kept ready for rewinding in an intermediate store or reservoir, e.g. in a rotary table.
The yarn carrier nozzle can also be used to remove yarn residues from the yarn carrier after winding off and for this purpose the yarn carrier must be rotated. This can take place in the rewinding station or in an adjacent station.
During the winding of yarn, a different starter yarn must be separated from the yarn being wound. This takes placed on detecting the starter yarn in the thread cleaner and subsequent cutting of this yarn. The yarn residue remaining on the yarn carrier is sucked off, in the manner described hereinbefore. It is always necessary to bring the completely empty yarn carrier to the initial spinning means.
The device means 12 can also fulfill additional functions, e.g. roving step, blowing off and cleaning the ring spinning frame, monitoring the ring spinning frame by means of sensors and changing the ring traveller 10.
The finished packages 20 are appropriately placed on a conveyor belt and conveyed away at the end of the ring spinning frame.
There has been disclosed heretofore the best embodiment of the invention presently contemplated. However, it is to be understood that various changes and modifications may be made thereto without departing from the spirit of the invention.
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Packages, particularly cross-wound packages are produced directly at a ring spinning frame. In a method and apparatus for making packages a rewinding device is provided for a group of spinning stations. The rewinding device comprises a fixed winding station and a gripping device movable along the group of spinning stations. The rewinding device is able to perform all the manipulations for starting up a spinning process with empty yarn carriers. It is also possible to change the full yarn carriers and mount the empty yarn carriers on a spinning frame, remove thread breaks and carry out spinning following a batch change. Spinning of the individual yarn carriers takes place individually, so that when replacing one yarn carrier, the other spinning stations continue to operate. This leads to a high production rate of the ring spinning frame and simultaneously reduces costs for rewinding compared with known systems.
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CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates to the art of paper-making, and more specifically, it relates to a novel structure employed to contain the aqueous paper-making stock leaving the head box and flowing onto the traveling screen. In particular, a structure called a "deckle board" is caused to travel along with the lateral edges of the screen for a distance sufficient to allow the liquid stock to drain through the screen to form a solid mat, and then to cause the deckle board to be removed from contact with the edges of the screen.
DESCRIPTION OF RELATED ART INCLUDING INFORMATION DISCLOSED UNDER 37 CFR 1.97 AND 37 CFR 1.98
British Patent 468,527 discloses the use of traveling deckle straps along the lateral edges of the paper-making web immediately following the introduction of the pulp slurry onto the web. The belt is pulled by the moving web and has no independent movement of its own. The belt is not positioned to contain all of the slurry on the web; some of it leaks out the lateral edges. U.S. Pat. No. 1,734,929 teaches the use of a heavy belt positioned perpendicular to the paper-making web, and at times, with a stationary deckle board on top of the belt. The belt does not exactly match the web and leaks from the web occur. The belt is pulled by the web and has no movement of its own. The use of such a device has proven to be limited to slow speeds. Other patents such as U.S. Pat. Nos. 231,169; 407,534; 742,239; 1,581,655; and 1,898,372 are similar in operation to U.S. Pat. No. 1,734,929, described above. None of the prior art patents show any means for keeping the belt pressed against the web so as to form a tight, nonleaking joint.
BRIEF SUMMARY OF THE INVENTION
This invention provides a pair of parallel deckle belt means movable from an operational position to a nonoperational position; the belt means including an endless belt driven around two spaced pulleys at an adjustable speed adapted to match the speed of the Fourdrinier fabric at the slice, positioning the belt to form a nonleaking junction with the fabric from the first contact between the slurry and the fabric to a short distance downstream where the liquid slurry has been transformed into a solid self-supporting web of paper on the fabric; said belt means being movable between the limits of (1) an operational position where said belt contacts said fabric which is then flooded with an aligned flow of paper-making slurry at the slice and (2) a nonoperational position where said belt is lifted above and out of contact with said fabric for servicing and positioning operations. This invention eliminates the forces producing waves in the slurry, which, in turn, produces an uneven weight profile in the paper web.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The novel features believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a top plan view of the traveling deckle board of this invention;
FIG. 2 is an end elevational view of the deckle board of this invention in the "running position";
FIG. 3 is the same elevational view as that of FIG. 2 when rotated to the "off position".
FIG. 4 is a perspective view of the supporting structure for the traveling deckle board of FIGS. 1-3 slowing its axis for rotation;
FIG. 5 is a front elevational view of the supporting structure of FIG. 4;
FIG. 6 is a top plan view of the supporting structure of FIGS. 4 and 5;
FIG. 7 is an end elevational view of the connection between the supporting structure of FIGS. 4-6 to the traveling deckle board of FIGS. 1-3;
FIG. 8 is a cross-sectional view of a portion of the supporting structure of FIGS. 4-6;
FIG. 9 is a top plan view of the assembled traveling deckle board of this invention.
FIGS. 10 and 11 show two views of the connecting arm 52 of the deckle board structure of FIGS. 1-3 to the supporting base of FIGS. 4-6; and
FIGS. 12-13 show two views of the transition piece used to guide the grooved belt 25 as it joins the edge of the traveling screen.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to the modern process of manufacturing paper from an aqueous slurry of cellulosic fibers which are deposited on a traveling horizontal fabric; the process being usually referred to as the "Fourdrinier" process. Furthermore this invention relates to the first portion of the process, sometimes called the "Fourdrinier section" or the "wet end", where the papermaking slurry of about 99.5% water and 0.5% cellulose fibers is first spread over the fabric and water is sucked downward through the fabric so as to leave a damp deposit of cellulosic fibers on the fabric to be dried sufficiently so as to be pulled off the fabric in the form of a sheet of paper. The machine of this invention is employed to keep the slurry on top of the traveling fabric until sufficient water is removed to form the cellulosic fibers into a fragile sheet supported on the Fourdrinier fabric. The machine of this invention provides a low wall that moves at the same speed as the fabric and prevents the slurry from running off the edges of the traveling fabric until the damp paper sheet is formed and no water remains to run off the edges. The low wall which keeps water from running off the edges of the moving fabric has been employed in the past and has become known as a "deckle board". Various modifications of the deckle board have been proposed and tried in the past, some of which are described above. None have been entirely satisfactory, generally because the deckle boards have allowed leaks to occur and thereby have caused the edges of the paper to be thin where the leaks occurred. The present invention employs an endless belt which can be placed against the edge of the paper-making fabric and adjusted in speed to match that of the fabric, and made to stay in contact with the fabric long enough to minimize any loss of water and detach itself from the fabric as soon as the damp paper is strong enough to support itself and not fall apart. The slurry exiting the head box 29 contacts the moving belt 25 moving in the direction of arrow 51 and spreads evenly across fabric 30 without producing any uneven weight profile of fibers across the fabric. The resultant sheet of paper has a uniform consistency. When the deckle board is kept stationary a severe wave is generated which produces an uneven weight profile of fiber in the paper. Because corrections and adjustments must always be made to meet unexpected conditions, the present invention provides a moving "deckle board" mounted on a pivoting support so as to permit instantaneous removal of deckle board 25 from the fabric 30 and subsequently instantaneous return to its production location at the edge of fabric 30. This permits ease of adjustment for whatever reason.
In FIGS. 1-3 there are shown the principal features of the machine of this invention. A continuous belt 25 which serves as a moving deckle board is driven about a driving pulley or roll 23 and a driven pulley or roll 24. The outside surface of belt 25 is smooth and the inside surface is a tongue-and-groove configuration to match the tongue-and-groove outside surface of rolls 23 and 24. This sawtooth shape substantially eliminates slippage and thereby permits the smooth outside surface to form a smooth edge for the paper being produced. The grooved rolls and grooved pulleys can be so well adjusted that guidance of the critical edge of the belt is not a problem. Driving roll 23 is, in turn, driven by motor 20 with driving belt 22 around motor pulley 21 and roll pulley 38. Motor 20 and rolls 23 and 24 and associated equipment are mounted on L-frame base 37 which, in turn, is pivotally mounted supported on support shaft 41 on stationary machine base 42. When the machine is in the "running" position as indicated in FIG. 2, belt 25 is in contact with fabric 30 and prevents any leaking of the fiber slurry. When the machine is in the "off" position as shown in FIG. 3 belt 25 is not in contact with fabric 30 by reason of the fact that frame base 37 and all equipment attached thereto has been pivoted 90 degrees about shaft 41. It should be noted that belt 25 extends outwardly beyond the working edge of roll 23 so that only the edge of belt 25 touches fabric 30 and not the edge of roll 23. The deckle belt 25, as seen in FIGS. 1 and 2, has a return or inoperative portion spaced outwardly of the fabric 30 which is slightly elevated above the plane of the fabric 30. Of course, when a deckle belt 25 is employed on each of the side edges of fabric 30, the return portions face oppositely from each other and are disengaged from fabric 30 at all times. This feature materially lengthens the life of fabric 30 and belt 25 by eliminating the abrasion that would occur if the edge of roll 23 rubbed against fabric 30 as well as belt 25. Belt 25 and roll 23 are actually tilted at angle 55 (about 1 degree) so as to eliminate any touching of the belt to the fabric 30 except along a line where the edge of belt 25 touches fabric 30. The only possible friction occurs where the belt 25 first touches fabric 30 and where it leaves fabric 30 for its return to complete the loop of travel.
The necessary adjustment features are provided by slide base 28, adjustable slide 31, locking nut 26, and adjustment bolt 27 for motor 20; and similarly, by slide base 32, adjustable slide 33, adjustment bolt 35, and locking nut 36 for grooved roll 23 and pulley 38. There also is stop bolt 56 that is adjustable to provide the proper angle between belt 25 and fabric 30 when in the running position of FIG. 2.
In FIGS. 4-8 there is shown the structure of the machine base, labeled simply as 42 in FIGS. 1-3. Machine base 42 includes two spaced parallel base strips 43 joined to two shaft supporting structures. The shaft supporting structures are identical supports for shaft 41 which is the central axis about which the machine of this invention rotates. The shaft supporting structures include a mounting base 44 resting on a cross-support 47 and supporting upwardly extending eye-plate 45 upon which rests shaft 41.
FIGS. 9-13 illustrate the complete machine of this invention, which is the combination of the machine of FIGS. 1-3 mounted rotatably on the support structure of FIGS. 4-8. The machine of FIGS. 1-3 is supported by two spaced support arms 52 and its caps 40 which, in turn, are attached rotatably to shaft 41 of FIGS. 4-8 by way of being affixed to L-frame base 37.
It may be seen that the traveling belt 25 forms a short wall on both lateral edges of the traveling fabric 30 allowing the paper web to form with no disturbing influences. If all goes well the traveling wall formed by belt 25 continues to function throughout long periods of time because the wall is continuously being established, used, and removed over the first several feet of the paper making process. Furthermore, if any malfunction should occur along the edges of the newly formed paper web the entire edge-sealing machine of this invention can be instantaneously lifted up and away from the paper web, e.g., by the action of hydraulic or pneumatic cylinders until the malfunction can be corrected, and then the machine can be instantaneously restored to its edge-sealing position.
It is also a preferable in the use of this machine to minimize the destructive wear-and-tear which this machine might inflict upon the fabric of the paper-making web. The contact between belt 25 and fabric 30 can be minimized by tilting the axes of rolls 23 and 24 so that belt 25 contacts fabric 30 along a line rather than in a plane. By tilting axle 34 about 1 degree toward the center of fabric 30 contact 53 (see FIG. 2) between belt 25 and fabric 30 will be reduced to a line contact eliminating all scuffing as belt 25 cuts across fabric 30 as it leaves driven roll 24 and comes into contact with fabric 30 and at the downstream end where it comes away from fabric 30 to follow the surface of driving roll 23.
FIG. 12-13 are two views of a transition piece 54 shown in FIG. 13 to be lying close to driven roll 24. The purpose of transition piece 54 is to minimize the turbulence produced when the wet slurry from the head box 29 contacts the grooved belt 25 coming around driven roll 24 to form the low edge wall that keeps the slurry on the fabric as it is sucked through the fabric to form the paper film. Without the presence of transition piece 54 the slurry flow parallel to the "travel" direction of belt 25 would be met at roll 24 with a belt traveling perpendicular to the "travel" direction until the belt 25 eventually assumed the parallel direction, and this short distance might result in eddy currents in the slurry which would be contrary to the desired calm flow needed to produce a uniform paper density. The shape of the transition piece 54 extends the straight line of belt 25 farther upstream close to the exit from head box 29 and fills in the space where belt 25 moves across the flowing slurry exiting the head box. The exact position of the transition piece 54 is adjustable by the operator to provide the maximum dampening of turbulence in the wet slurry so as to produce the smoothest sheet of paper. At the high speeds of modern paper-making machines, e.g., 1000 fpm the transition piece 54 may not be needed if the rushing slurry bridges the small gap covered by transition piece 54. Nevertheless transition piece 54 is provided to prevent turbulence if it is needed. Any suitable framework may be used to appropriately position transition piece 54 with respect to the fabric 30, head box 29 and belt 25. Such framework may be connected to mounting base 47.
There are shown in FIG. 9 two alternative improvements which may be of assistance in preparing a smooth paper deposit from the slurry. These are embodied in rolls 49 and stabilizer bar 50. It sometimes happens that belt 25 develops vibrations, which clearly are not desired in the paper-making process where a steady deposit of fibers is necessary to produce a quality paper product at a high rate of production. In any event, should such vibrations occur they may be eliminated by the smoothing effect of spaced idler rolls 49 pressing against grooved belt 25, or stabilizer bar 50 pressing outwardly against belt 25. The rolls 49 or stabilizer bar 50 may be biased against the inside surface of belt 25.
Various other features of this invention may be modified in a wider sense in order to meet certain special conditions or changes visualized in the operation of this invention. For example, pulleys 23 may be made to a slightly different design in order to be larger or smaller, and thereby better set the speed of belt 25, and better match the speed of papermaking web 38. There may be other reasons to change the speed of belt 25 above or below the speed of web 38. The sizes and speeds of other parts of the machine may, of course, be modified for other reasons, such as because the operator chooses to feel his way along through several speeds until he finds the preferred combination.
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes e.g., splash guards and cleaning showers may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A machine for adjustably placing a low dam moving along each lateral edge of a Fourdrinier fabric so as to contain the paper-making slurry on the fabric without leaking over the edges of the fabric while the moving fabric is subjected to sufficient suction treatment to render the slurry immobile on the fabric. The principal object of this invention is to maintain the slurry in a steady flow pattern substantially free of any waves while the slurry is forming a self-supporting paper web.
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TECHNICAL FIELD
[0001] The present invention relates to an inkjet recording device capable of printing to a mesh-like medium.
BACKGROUND ART
[0002] A printing apparatus for printing to a material, such as fabric or film, is conventionally known.
[0003] As an example of such a printing apparatus, Patent Literature 1 discloses a configuration for forming an image on a fabric. The printing apparatus of the Patent Literature 1 applies a sublimation ink to a fabric as print target while winding the fabric in its longitudinal direction and heats the applied sublimation ink to a predetermined temperature. In this printing apparatus, a preheater having a far-infrared ray lamp is placed under the fabric to which the sublimation ink is applied, and the preheater heats the fabric to dry the sublimation ink.
CITATION LIST
[Patent Literature]
[Patent Literature 1]: JP-A-2006-265813
Summary of Invention
[Technical Problem]
[0004] Generally, the fabric has a mesh-like structure. And, typically, through holes penetrating from the top surface to the bottom surface of the fabric are formed, although the size of the through hole may vary depending on the material property of the fabric. Furthermore, the through holes may be formed in another medium excepting the fabric.
[0005] Thus, in a situation when printing to a medium in which through holes penetrating from the top surface to the bottom surface are formed, after an ink is applied or hit to the top surface, what is called a bleed-through may occur, i.e., the ink may penetrate to the bottom surface through the through hole.
[0006] The bleed-through of the ink itself would not be a problem, as far as the bleed-through ink is dried without contact with any other positions.
[0007] However, in a configuration in which a drier is provided under the fabric as in the Patent Literature 1, when the bleed-through ink happens to adhere to the dryer, a problem may occur in which the ink further adheres to another positions of the fabric that is in contact with the dryer, thereby spreading contamination over the fabric or the overall apparatus.
[0008] In order to solve the above problem, it is an object of the present invention to provide an inkjet recording device that can dry a medium immediately after printing or bleed-through ink, while preventing the medium or the bleed-through ink from being in contact with a dryer.
[Solution to Problem]
[0009] An inkjet recording device in accordance with the invention includes: an inkjet head for discharging an ink onto a mesh-like medium which has through holes penetrating from a top surface (i.e., printing surface) to a bottom surface; a feeder for feeding the mesh-like medium in a feed direction; and a dryer for drying the mesh-like medium hit by the ink discharged from the inkjet head, wherein the dryer has a blower placed under the mesh-like medium for applying an air flow to the bottom surface of the mesh-like medium with the top surface hit by the ink.
[0010] With this configuration, the medium is applied with an air flow sent from the blower below. Due to this, the medium itself receives the upward force of the air flow, which dries the ink while preventing the medium from being in contact with the dryer. Therefore, this prevents the bleed-through ink from adhering to the dryer, which can prevent the medium or the apparatus body from being contaminated.
[0011] Furthermore, in the inkjet recording device in accordance with the invention, the blower is preferably placed adjacent to a printing position at which the inkjet head is placed.
[0012] According to this configuration, since no other component is placed between the printing position and the blower, the ink can be dried immediately after printing to the medium, which can reduce the possibility that the bleed-through ink is in contact with any positions of the inkjet recording device.
[0013] Furthermore, this configuration provides an operation and effect that the medium can be effectively loaded with a tension.
[0014] Specifically, conventionally, the medium is loaded with a tension by putting the medium onto a tension bar, and causing the tension bar to pull the medium. The tension bar is typically positioned far from the printing position. However, if the tension bar is too far from the printing position, the tension may be insufficient at the printing position due to the weight of the medium itself and the elongated medium. Furthermore, some medium (especially fabric) may include a portion that can be easily tensioned and a portion that is difficult to be tensioned. When a tension is given to such a medium, non-uniformity in tension occurs in the medium. When the medium is not tensioned or non-uniformity in tension is occurring in the medium at the printing position, a wrinkle or floating may occur in the medium. When any wrinkle or floating occurs in the medium particularly at the printing position, distortion, misalignment, non-uniformity or the like in printing may occur, so it is required that the medium is preferably loaded with a uniform tension at the printing position.
[0015] Thus, with the configuration as described above, since the medium is applied with an air flow sent from the blower below at a position very close to the printing position, applying a tension continuously from the printing position prevents the occurrence of misalignment and non-uniformity in the medium, and suppresses distortion in the medium at the printing position, which can stabilize a hitting position of the ink to enhance the printed image quality.
[0016] In the inkjet recording device in accordance with the invention, a cover in which a plurality of ventilating holes are formed is preferably provided between the blower and the mesh-like medium.
[0017] According to this, an air flow sent from the blower can be distributed over the plurality of ventilating holes of the cover, which can uniformly apply the air flow to the medium.
[0018] In the inkjet recording device in accordance with the invention, a heater is preferably provided in the blower so that the blower sends a heated air flow. Furthermore, preferably, a heating temperature of the heater can be adjusted.
[0019] According to this, a temperature of the ink is controlled so as not exceeding a sublimation temperature and a reaction temperature, and the ink can be dried more rapidly to a extent of not affecting the printed image quality.
[0020] In the inkjet recording device in accordance with the invention, preferably, a platen is provided under the printing position at which the inkjet head is placed, and the platen includes: an ink receiver that is formed concave downward so as to receive the ink which has bled through the mesh-like medium; and an end edge portion formed on a top end on a downstream side of the ink receiver so that the end edge portion is in contact with the bottom surface of the mesh-like medium.
[0021] According to this, when is in printing, the bleed-through ink falls into the ink receiver, which can suppress the adhesion of the bleed-through ink to the platen. Furthermore, by using an air flow from the blower under the medium, a contact pressure at which the medium is in contact with the end edge portion of the ink receiver can be reduced. Therefore, the contact pressure of the medium can be reduced for suppressing the occurrence of contamination and preventing the wearing of the end edge portion.
[0022] Furthermore, in the inkjet recording device in accordance with the invention, preferably, an amount of the air flow from the blower can be adjusted.
[0023] According to this, the drying condition and the tension can be changed depending on the medium type, so an optimum printing condition can be chosen.
[Advantageous Effects of Invention]
[0024] According to the inkjet recording device of the invention, the bleed-through ink can be dried without contacting with the dryer, which can prevent the adhesion of contamination to the medium or the apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a schematic side view of an inkjet recording device in accordance with the invention.
[0026] FIG. 2 is a view illustrating a cover.
DESCRIPTION OF EMBODIMENTS
First Embodiment
[0027] A suitable embodiment of the invention is described with reference to the drawings. FIG. 1 shows a schematic side view of an inkjet recording device. Referring to FIG. 1 , a mesh-like medium 10 having through holes is indicated by a broken line. For example, the medium 10 may be a fabric, a film or the like, but is not limited to them.
[0028] In the embodiment, the medium 10 is fed in a direction from right to left in the figure (in an arrow direction in FIG. 1 ). On the upstream side of the feed direction, the medium 10 is unprinted and wound around a pull roll 11 . The medium 10 pulled out from the pull roll 11 is put onto a tensioning bar 13 positioned at a level lower than the pull roll 11 and is given a predetermined tension by the tensioning bar 13 .
[0029] The medium 10 put onto the tensioning bar 13 is fed to a printing position A at which an inkjet head (which may be hereinafter simply referred to as a “head”) 20 for printing is placed. At the printing position A, the medium 10 is almost horizontal and the head 20 is placed above the top surface of the medium 10 .
[0030] Note that, on the upstream side of the printing position A, a feed roller 12 for feeding the medium 10 in the feed direction is provided. The feed roller 12 is rotationally driven to feed the medium 10 in the feed direction.
[0031] A platen 16 is placed under the medium 10 at the printing position A. The platen 16 includes an ink receiver 18 that is formed concave downward. The ink receiver 18 is a container-like portion formed to receive the bleed-through ink, when the ink hitting the top surface of the medium 10 bleeds through.
[0032] And, the platen 16 further includes an end edge portion 22 formed on the top end of the wall surface on the downstream side of the ink receiver 18 , so that the end edge portion 22 is in contact with the bottom surface of the medium 10 . Specifically, the medium 10 is pulled from the end edge portion 22 toward the bottom of the figure and loaded with a tension. Thus, by forming the end edge portion 22 , a predetermined tension can be given to the medium 10 at the printing position A in conjunction with a tension given by a blower described later.
[0033] At a predetermined position adjacent to and on the downstream side of the printing position A, a blower 26 for applying an air flow to the bottom surface of the medium 10 with the top surface hit by ink is provided.
[0034] The blower 26 may be in any form as far as it is placed under the medium 10 and can send an air flow to the medium 10 .
[0035] Preferably, the blower 26 is a variable air-flow amount type blower in which the amount of air flow can be adjusted. Specifically, the amount of air flow of the blower 26 can be preferably adjusted by controlling the number of revolutions of the motor for driving the blower 26 .
[0036] Furthermore, a heater may be provided to the blower 26 in order to send a heated air flow (hot air flow). With the heater placed on the air inlet side of the blower 26 , the blower 26 can take in an air heated by the heater and send the air flow. Preferably, the heating temperature of the heater can be adjusted. With the adjustable heating temperature, the blower 26 can send an air flow at a temperature appropriate for the air temperature and ink type, thereby controlling the temperature of the ink so that the temperature of the ink will not exceed the sublimation temperature and the reaction temperature.
[0037] The heater that can send a heated air flow can dry the bleed-through ink more rapidly. Note that, when the air temperature is so high that a heated air flow is not required, the heater may be switched off to send a non-heated air flow.
[0038] Note that, a cover 28 in which a plurality of ventilating holes 29 , 29 , . . . , 29 are formed is placed between the upper portion of the blower 26 and the bottom surface of the medium 10 . Without the cover 28 , an air flow from the blower 26 is concentrated to one point of the medium 10 , which may cause non-uniformity in drying the bleed-through ink or instability in the tension loaded on the medium 10 . Then, with the cover 28 , an air flow from the blower 26 is distributed over the plurality of ventilating holes 29 , so the media 10 is uniformly applied with the air flow.
[0039] FIG. 2 shows an example of the cover 28 .
[0040] The cover 28 is placed over the blower 26 and enclosed by a plurality of side panels 31 , so that an air flow from the blower 26 will not escape to the outside, and a top panel 32 in which a plurality of ventilating holes 29 , 29 , . . . , 29 are formed is placed on the top. The top panel 32 is formed along and in parallel to the bottom surface of the medium 10 . In the embodiment, since the medium 10 gradually declines in the feed direction, the top panel 32 has a tilt angle corresponding to the tilt angle of the medium 10 .
[0041] The ventilating holes 29 may typically have a circular cross section, but the cross section is not limited to be circular and may be elliptical or elongated.
[0042] Also, the ventilating holes 29 may be smaller in size and more closely spaced than those shown in FIG. 2 .
[0043] As shown in FIG. 1 , the medium 10 with the bleed-through ink dried by an air flow from below sent by the blower 26 is put onto a tensioning bar 30 positioned at a lower level on the downstream side of the feed direction and is given a predetermined tension by the tensioning bar 30 .
[0044] Then, the medium 10 is wound by a wind roll 34 through the tensioning bar 30 .
[0045] As described above, since the blower 26 is provided adjacent to the printing position A, the medium 10 at the printing position A is reliably given the tension, which can prevent the slack of the medium. This maintains constant the position (level) at which the ink hits the medium, which can prevent distortion of printing at the printing position A to enhance the printed image quality and prevent misalignment, non-uniformity and the like of the medium. Furthermore, the contact pressure of the medium 10 onto the end edge portion 22 on the downstream side of the ink receiver 18 of the platen 16 can be reduced, which can suppress the occurrence of contamination and prevent the wearing of the end edge portion 22 .
[0046] Furthermore, the cover 28 in which the plurality of ventilating holes 29 , 29 , . . . , 29 are formed allows the medium to be uniformly applied with an air flow from the blower 26 . This provides uniformity in the tension on the medium.
[0047] Furthermore, the blower 26 provided with the heater can apply a heated air flow to the bottom surface of the medium 10 , allowing the bleed-through ink to be more rapidly dried. Preferably, the heating temperature of the heater can be adjusted.
[0048] Furthermore, the platen 16 includes: the ink receiver 18 ; and the end edge portion 22 disposed on the downstream side of the ink receiver 18 so that the medium 10 is contact with the end edge portion 22 . This allowing the contact pressure at which the medium 10 is in contact with the end edge portion 22 of the ink receiver 18 to be reduced, thereby causing the contact pressure of the medium 10 to be reduced, which can suppress the occurrence of contamination and prevent the wearing of the end edge portion 22 .
[0049] Furthermore, since the amount of air flow from the blower 26 can be adjusted, the drying condition and the tension can be changed depending on the type of the medium 10 , so an optimum printing condition can be chosen.
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Provided is an inkjet printing apparatus that can dry a medium immediately after printing or bleed-through ink while preventing the medium or bleed-through ink from being in contact with a dryer. In an inkjet printing apparatus including an inkjet head ( 20 ) for discharging ink onto a mesh-like media ( 10 ) having througth holes penetrating from the top surface, which is the printing surface, to the bottom surface, a feeder ( 12 ) for feeding the mesh-like medium ( 10 ) in a feed direction, and a dryer for drying the mesh-like medium ( 10 ) hit by ink discharged from the ink-jet head ( 20 ), the dryer has a blower ( 28 ) aced under the mesh-like medium 10 ) for applying an air flow to the bottom surface of the mesh-like medium ( 10 ) with the top surface hit by the ink.
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This invention was made with Government support. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
The field of the invention is automatic gain control (AGC) circuits employed in microwave frequency applications.
The function of an AGC circuit is to maintain a constant output level in the presence of varying input levels. Conventional AGC circuits typically employ feedback techniques. Compensation circuits or bandwidth limitations are used to maintain loop stability in the presence of parasitic reactances, resulting in reducing the settling speed of the AGC circuit.
An AGC circuit is described in "A 2 to 8 GHz Leveling Loop Using a GaAs MMIC Active Splitter and Attenuator," Gary S. Barta et al, 1986 Microwave and Millimeter Wave Monolithic Circuits Symposium, pages 75-79. The circuit described used an op-amp feedback loop to provide the proper voltages to a GaAs FET attenuator.
An object of the present invention is to provide a microwave signal automatic gain circuit characterized by fast settling times.
A further object is to provide a microwave signal automatic gain circuit operable over a relatively wide bandwidth and which provides a constant characteristic impedance.
SUMMARY OF THE INVENTION
The invention is an automatic gain circuit (AGC) wherein the AGC attenuation factor is automatically adjusted to compensate for variations in the input signal power so as to maintain a constant output signal level, and which employs a reed- forward control loop to adjust the attenuation factor. Thus, an AGC circuit in accordance with the invention comprises a means for splitting the input microwave signal into first and second signal paths. A variable RF attenuator is disposed in the first signal path to selectively attenuate the microwave signal in the first signal path in response to attenuator control signals, the attenuation factor of the attenuator being dependent on the control signals. In the preferred embodiment, the attenuator comprises a monolithic GaAs voltage controlled device.
The AGC circuit further comprises a feed forward control loop, comprising an RF detector responsive to the microwave signal in the second path for providing a detector signal indicative of the power of the input microwave signal. A circuit means is responsive to the detector signals for generating the attenuator control signals so as to increase or decrease the attenuation factor of the attenuator as required to maintain a constant output signal power level from the attenuator. A main advantage of this AGC circuit is its fast settling time. The settling time of the circuit is significantly faster than conventional circuits using feedback techniques.
A further advantage of the preferred embodiment of the invention is the use of a GaAs attenuator which provides a constant characteristic impedance as the attenuation is varied. The resulting lower phase shift makes the invention particularly useful in applications such as signal combining or radar detection where system phase errors must be tightly controlled.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become more apparent from the following detailed description of an exemplary embodiment thereof, as illustrated in the accompanying drawings, in which:
FIG. 1 is a functional block diagram of an AGC circuit employing the invention.
FIG. 2 is a plot of the control voltages versus attenuation for a GaAs attenuator employed in the AGC circuit of FIG. 1.
FIG. 3 is a plot of the control voltages as a function of the input signal level for a GaAs attenuator employed in the AGC circuit of FIG. 1.
FIG. 4 is a simplified schematic diagram of a shaper circuit as used in the AGC circuit of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A functional block diagram of an AGC circuit 50 embodying the invention is shown in FIG. 1. The circuit 50 comprises a two-way power divider 52 which splits the input signal into two channels 54 and 56. One channel output is connected to a voltage controlled attenuator 60. The GaAs devices 62, 64 and 66 comprising the attenuator 60 function as voltage variable resistor elements and are configured in a T attenuator configuration. By appropriate selection of the series (62, 64)and shunt (66) elements, the attenuator 60 can provide variable attenuation while maintaining a constant input and output impedance.
Power dividers suitable for use as divider 52 are commercially available, such as the model DS-331 available from Adams Russell, 80 Cambridge Street, Burlington, Mass. 01083. This power divider splits the input power equally between the two channels 54 and 56. Other power split ratios could be used, provided the gains in the feed forward loop are appropriately adjusted.
Attenuators suitable for the purpose of device 60 are commercially available, such as the model MA4GM301 GaAs attenuator device available from MACOM, 100 Chelmsford Street, Lowell, Mass. 01851. This device comprises the three GaAs field effect transistors (FETs) 62, 64 and 66, which are depletion mode devices and are used as voltage variable resistors. The GaAs FET is a three terminal device with the gate being the control element. The gate is inherently isolated from the conducting channel, while charge present at the gate controls the resistance of the channel. As the gate bias of the FET is made more negative than the source, the FET channel resistance increases. The resistance of the FET devices can be changed in less than a nanosecond. These devices also provide very low capacitance from source to drain, and therefore approach the performance of ideal resistors.
Other types of attenuator device could be used in a similar attenuator configuration. For example, PIN diodes could be employed, but would require additional circuit elements such as resistors or inductors to couple control current through the device while isolating the RF path. In contrast, the conducting channel of the GaAs FET device is inherently isolated from the control gate.
A plot of attenuation versus both the attenuator series control voltage V 1 and shunt control voltage V 2 for the attenuator 60 is shown in FIG. 2. When driven with these voltages, the attenuator provides an attenuation range of 20 dB and a constant characteristic impedance of 50 ohms. The constant characteristic impedance provides the characteristic of low attenuator phase shift versus attenuation. FIG. 3 shows a plot of the control voltages V 1 , V 2 as a function of the input signal level (dBm). Thus, the resistance of the series devices 62, 64 is greatest for the maximum input signal level, and is reduced as the input signal level decreases. The resistance of the shunt device 66 is least for the maximum input signal level, and increases as the input signal level decreases.
The other power divider output channel 56 drives a low-level RF diode detector 72 which operates in the "square-law" region and provides a voltage output V D closely proportional to the input power of the input microwave signal. The detected voltage V D is then applied to the shaping circuit 80. Diode detectors suitable for use as detector 72 are commercially available, such as the model ACTM-1001 available from Advanced Control Components, P.O. Box 4928, Clinton, N.J. 08809.
A simplified schematic of the shaping circuit 80 is shown in FIG. 4. In this circuit, inverting amplifier A1 increases the level of the detector output V D and drives inverting amplifier A2 and non-inverting amplifier A3. The output of amplifier A2 drives a first shaping circuit 82 comprising resistors R7, R8, R9 and R10 and diode D1. The control signal V 2 , at the output of circuit 82, can be adjusted to provide a characteristic closely resembling that of signal V 2 in FIGS. 2 and 3. Amplifier A3 drives a similar second shaping circuit 84 comprising resistors R13, R14, R15 and R16 and diode D3. The control signal V 1 , at the output of circuit 84, can also be adjusted to closely resemble the control signals V 1 in FIGS. 2 and 3. Diodes D2 and D4 prevent V 1 and V 2 from going sufficiently positive to damage the attenuator 60.
The gains of amplifiers A1, A2, and A3 are carefully selected so that as the signal power into the power divider 52 is varied, the voltages V 1 and V 2 increase or the attenuation as required to maintain a constant output signal level. The devices selected for amplifiers A1-A3 are wide bandwidth devices with settling times of better than 20 nanoseconds. Amplifier devices suitable for use as amplifiers A1-A3 are commercially available; for example the model EL2022 devices available from Elantec, Inc., 1996 Tarob Court, Milpitas, Calif. 95035, are suitable for the purpose. With the use of such shaper circuit elements, in combination with the GaAs attenuator 60 and diode detector 72, AGC circuit response times of faster than 50 nanoseconds are achievable.
For a particular AGC application wherein the microwave input signal has a frequency of 1.3 GHz, the following exemplary resistance values may be used in the circuit of FIG. 4 to provide an AGC circuit bandwidth of greater than 500 MHz.
______________________________________Resistor Value (Ohms)______________________________________R1 100R2 2000R3 3600R4 500 ohm potentiometerR5 150R6 680R7 100 ohm potentiometerR8 50R9 10R10 510R11 330R12 820R13 100 ohm potentiometerR14 50R15 10R16 510______________________________________
By way of example only, the circuit of FIGS. 1 and 3 could be used in such applications as an adaptive antenna combiner system, which requires a constant signal level to function properly. The AGC circuit described above is capable of providing a constant signal level output when fast input pulses (100 nanoseconds) are received. While the circuit of FIGS. 1 and 4 provides 20 dB of AGC range, additional range can be obtained, e.g., by cascading identical AGC circuit stages.
It is understood that the above-described embodiment is merely illustrative of the possible specific embodiments which may represent principles of the present invention. Other arrangements may readily be devised in accordance with these principles by those skilled in the art without departing from the scope of the invention.
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An automatic gain control (AGC) circuit for microwave applications is disclosed. The AGC circuit includes a power divider for splitting the signal to be controlled into two signal paths. In one signal path the signal is passed through a GaAs monolithic attenuator. In the other signal path, an RF detector provides a detector output signal to a shaper circuit, which responds to the detector signal to provide control signals to the attenuator. Thus, the AGC circuit employs a feed forward technique for gain control, to provide fast settling times for the circuit.
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BACKGROUND—FIELD OF THE INVENTION
This invention relates to washing clothes in the home, particularly to an automatic washing machine which operates in a seemingly paradoxical manner and which will automatically wash a full sized load in the home without a requirement for space dedicated to a laundry facility in the home and which, while drastically reducing the size and weight from that of a standard automatic washing machine, increases cleaning efficiency and reduces environmental pollution to a greater extent than heretofore possible.
BACKGROUND—DESCRIPTION OF THE PRIOR ART
Ever since modern machines moved washday activities inside, there has been a long recognized and unfilled need to eliminate the requirement for a dedicated laundry room in living units while still having the capability to wash clothes without making an outside trip and without having to do it by hand.
Another long recognized and unfilled need is the lack of laundry facilities in a living unit such as an apartment or mobile home which does not have a designated laundry area set aside and dedicated to full time occupancy by laundry machines. This need has been recognized as is evidenced by many inventions of compact or portable machines. However, these inventions have such a greatly reduced capacity or increased inconvenience that it has not been commercially accepted as a solution to this problem. Thus, the commercial success of the local Laundromat.
Keeping clothes clean has been a problem since ancient times. Early in the history of this country pioneers washed their clothes by dipping them in the water of the river and rubbing them on rocks near the water. However, a trip outside the home to the local laundry facility was required.
The forerunner of the modern washing machine was a washboard. Using the washboard was somewhat like washing in the river. The user dipped the clothes in a tub of water and rubbed the clothes on the washboard. No longer was a trip to the river necessary. However, the drudgery and dedication of time remained.
The next major break through was the self powered washing machine eliminating the backbreaking work of rubbing the clothes by hand. However, added to the drudgery and dedication of time was the requirement for dedicated space in the home for the washing machine. Suddenly, the useful space in the home became less. The washing machine was always there and in the way.
After that came the automatic washing machine which eliminated the drudgery and the requirement of getting hands wet. However, the dedicated space requirement taking living space from the home remained a problem.
Not all homes have the luxury of extra space to dedicate to a washing machine. Even still, the residents of many homes that have no laundry facilities make the periodic outside trip to the public Laundromat. Still remaining is that long recognized and unfilled need, the need for full sized automatic laundry capability in the home without the requirement of space dedicated to laundry machines.
When people used the river for a Laundromat, wringing out the water was simply a matter of manually applying twisting pressure with the hands. However, that was manual labor.
With the early washing machine came the powered wringer, a device with rollers pressed against the clothes to squeeze the water from the clothes. However, still a human was required to feed each piece into the rollers, sometimes with much pain when long hair would get in with the clothes.
Automatic washing machines came with the advent of water extraction by centrifugal force in a spinning tub. No longer was it necessary to manually remove the clothes from the tub to remove the water from the clothes. The clothes rather than the water remained in the tub throughout the automatic cycle with the water coming and going in the same tub. The disadvantage of the centrifugal extraction machine is the requirement for a perforated washing and spinning tub inside a water containing tub. This results in two heavy metal tubs in addition to the heavy enclosure made of rigid metal surrounding all the other parts results in a big heavy machine that requires a permanent location. With the advent of centrifugal extraction the rollers were removed from the legs of the washing machine. Homemakers have been sharing their homes with the washing machine ever since. Other wringing methods were tried, but did not become popular. This loss of living space in the home has been the standard for decades.
Further, most clothes washing machines are inefficient energy wasters and environment polluters that wash the laundry by utilizing the mechanical force of an agitator and the surface active force of a chemical detergent. Accordingly, in order to improve the washing efficiency, many clothes washing machine makers have utilized various methods including such as improving the agitators ability to agitate the laundry, extending the operating time of the motor during a washing and/or rinsing time period and improving the quality and/or increasing the quantity of detergent used in the washing machine. However, there are limits to improvements in the washing efficiency by the aforementioned methods for the following reasons:
(a) The methods utilizing increased mechanical force to improve the washing efficiency may cause damage to the laundry or to efficiency of the clothes washing machine.
(b) In methods utilizing increased amounts of detergent, a relatively large amount of the detergent which does not react with the laundry is then discharged where it can later cause environmental pollution, and also the remaining detergent sticks to the laundry and thus the laundry is not effectively cleaned.
(c) Also, it is well known that if more than the recommended amount of detergent is used in the clothes washing machine, the washing efficiency of the washing machine is reduced.
Accordingly, inventors created several types of devices to generate surface tension reducing ions for the purpose of reducing the amount of detergent required:
U.S. Pat. No. 5,309,739 to Lee (1994) discloses a device which utilizes the generation of surface-tension-reducing hydroxyl ions for the purpose of reducing the amount of detergent required. However, this device is an add on to the standard automatic washing machine described above.
U.S. Pat. No. 4,066,393 to Morey and Dooley (1978) discloses a device which utilizes a cation exchange resin device to remove calcium and/or magnesium ions from the water for the purpose of reducing the amount of detergent required. However, this device requires a manual step in the washing process and it too is an add on to the standard automatic washing machine described above.
U.S. Pat. No. 5,358,617 to Ibbott (1994) discloses a water treatment devise to use in a standard automatic washing machine which utilizes electrically isolated electrodes of different electrochemical potential to ionize the wash water inside the washing machine for the purpose of reducing the amount of detergent required to little or none depending upon the amount of dissolved solids in the wash water. However, this device requires a standard automatic washing machine described above.
U.S. Pat. No. 2,997,870 to Serra (1961) discloses a washing machine which utilizes friction due to the motion of air, water, and an India rubber vessel in an electrostatic ionic process for the purpose of reducing the amount of detergent required. However, this washing machine is not automatic. It is an attempt to solve the problem of storage out of the way when not in use and has traded off the automatic feature for a more manual system with reduced capacity.
In the prior art there are many patents on collapsible, foldable, portable washing machines with an object to satisfy that long recognized and unfilled need to eliminate the requirement for a dedicated laundry room in living units:
U.S. Patent No. 4,305,265 to Burgas (1981) discloses a washing machine that is to be disassembled when not in use. However, it is not automatic, but hand powered, and complicated to set up.
Other examples of washing machine patents that purport to be space saving are too numerous to mention. Generally they suffer with some or all of the disadvantages of reduced capacity, manually powered, non-automatic, complicated, or inefficient. As a general rule, to make a washing machine lighter, collapsible, foldable, or portable, there is a trade off resulting in inefficiency, and reduced capacity.
The popular automatic washing machines of today are in the way all the time even when not used:
(a) They cannot be stored out of the way.
(b) They cannot be folded into a small space
(c) They cannot be moved or carried around easily.
(d) They are not easily transportable.
The popular automatic washing machines of today contribute significantly to environmental pollution and waste:
(a) Excess, inefficient detergent use contributes to chemical pollution.
(b) Excess energy use wastes our natural resources.
(c) Excess noise disrupts our daily life.
(d) Mechanical agitator causes excess wear and tear on clothing.
OBJECTS AND ADVANTAGES
Accordingly, several objects and advantages of the present invention are:
(a) to provide an automatic washing machine which fills that long recognized and unfilled need for full sized automatic laundry capability in the home without the requirement for dedicated space;
(b) to provide an automatic washing machine which is suitable for use in living units having no area set aside for laundry facilities, such as apartments or mobile homes;
(c) to provide an automatic washing machine which is out of the way when not in use, yet has sufficient capability and convenience such that it will actually be used;
(d) to minimize the drudgery and dedication of time required for hand washing and outside trips to the Laundromat;
(e) to provide an automatic washing machine which will allow the user to reclaim that living space in the home occupied by the washing machine when it is not in use;
(f) to provide an automatic washing machine which painlessly extracts the water from the clothing in a quiet manner without human interaction, without shaking the house, and without the requirement for a large heavy machine;
(g) to provide an automatic washing machine which makes efficient use of energy by eliminating heavy bulky parts which require energy to move;
(h) to provide an automatic washing machine which is gentle to the clothes and reduces the wear and tear of the clothes being washed;
(i) to provide an automatic washing machine which protects our environment from pollution by making efficient use of a minimal amount of detergent;
(j) to provide an automatic washing machine which eliminates the problem of detergent residue in the clean laundry;
(k) to provide an automatic washing machine which utilizes non-polluting ionic methods to increase the cleaning properties of water by reducing the surface tension of water, and does not require a large bulky machine;
Accordingly, the above objects and advantages are to provide an automatic washing machine which can be folded into a small space, which can be easily moved or carried around, which can be stored out of the way, which can be carried as a piece of luggage, which eliminates the excess noise which disrupts our lives, which will conserve rather than waste and pollute our natural resources to a greater extent than heretofore possible.
A further object of the present invention is to provide a unique means for scrubbing laundry employing a cleaning action and a combination of cleaning actions which eliminates the need for many of the heavy bulky parts of a machine of the prior art. The combination provides a superior process of washing without abrasion damage.
A further object of the present invention is to provide a unique means for extracting water from laundry employing a vacuum extraction action in combination with alightweight flexible container which presses the water from the laundry and eliminates the need for many of the heavy bulky parts of a machine of the prior art.
The aforementioned objects and advantages of the invention, will, in part, become obvious from the following more detailed description of the invention, taken in conjunction with the accompanying drawings, which form an integral part thereof.
DRAWING FIGURES
The present invention will be more fully understood by reference to the following detailed description thereof when read in conjunction with the attached drawings, and wherein:
FIG. 1 is a sectional view of a typical automatic washing machine according to the prior art;
FIG. 2 is a sectional view of the first embodiment of an automatic washing machine according to the invention;
FIGS. 3 a and 3 b are side views of a preferred embodiment of an automatic washing machine according to the invention;
FIG. 4 a is a plan view, FIG. 4 b is a side view, FIG. 4 c is an end view, and FIG. 4 d is a perspective view of an alternate preferred embodiment of an automatic washing machine according to the invention;
FIGS. 5 a to 5 c are views of a wall mounted embodiment of an automatic washing machine according to the invention, FIG. 5 a being a view of the front, and FIGS. 5 b and 5 c being side views with the wall cut away;
FIGS. 6 a to 6 d show various views illustrating the water extraction cycle of an automatic washing machine according to the invention;
FIGS. 7 a to 7 g show various views illustrating various scrubbing actions of the washing cycle of an automatic washing machine according to the invention;
FIG. 8 is a sectional view of an embodiment of an automatic washing machine utilizing a combination of at least two scrubbing actions according to the invention;
FIGS. 9 a to 9 e show various views illustrating various water treatment devices of an automatic washing machine according to the invention;
FIGS. 10 a to 10 d are various views of an enclosed bag, front loading, automatic washing machine according to the invention;
FIG. 11 is an overall functional block diagram of the inventive washing method.
DRAWING REFERENCE NUMERALS
20 rigid metal enclosure
22 water containing tub
24 perforated washing and spinning tub
26 transmission
28 motor
30 agitator
32 rigid housing, or base
34 container=bag 36 plus portion of housing 32
36 flexible bag
38 water pump
40 air pump
42 controlling device
44 flow diverter
46 water distribution manifold
52 screen
54 waterjets
58 opening at top of bag
60 drawstring tie
62 hinge
64 clasp
66 seal
68 bag holder
70 clothes retaining rack
72 air
74 dousing water, cleaning solution or fluid
76 items or articles (of laundry)
78 fill hose
80 drain hose
82 power cord with plug connectors on both ends
84 and 84 ′, quick release hose connector
86 water tap
88 sink with drain
90 power cord connector
92 control panel
94 suitcase
96 suitcase lid
98 carrying handle
100 opening handle
102 wall mount bracket
104 backboard
106 backboard hinge
108 support cable
110 sideboard
112 backboard latch
114 vacuum
116 atmospheric pressure
118 air pressure channel
120 outer bag
122 pump assembly
124 electric motor
126 air check valve a
128 air check valve b
130 flow pattern
132 air vent or duct
134 low frequency vibrating disk
136 vibration drive unit
138 reversible rotating disk
140 reversible rotating drive unit
142 tilt
144 flexibly movable portion
146 actuator
148 actuator arm
150 flexjoint
151 pivot or hinge
152 ultrasonic generator
154 ultra sonic vibrator
156 ultrasonic vibration plate
158 sound generator/power amplifier
160 underwater speaker
162 inputjack
164 wide range underwater transducer
166 waveform generator/power amplifier
170 and 170 ′, electrically polarized material
172 water flow
174 electrode containing aluminum
176 electrode containing carbon
178 section of pipe containing electrodes
180 magneticfield
182 and 182 ′, magnet
184 section of pipe containing magnetic field
186 ultra violet light bulb
188 ultra violet light window
190 ultra violet light reflector
192 ultra violet light radiation
194 connecting point
196 neck of container
198 see through door
200 telescoping suitcase
202 left set of water jets
204 right set of water jets
206 functional block diagram of the inventive washing method
208 step a, set up machine
210 step b, load and select cycle
212 step c, fill with water
214 step d, wash
216 step e, extract water
218 step f, fill, rinse, extract
220 step g, notify operator
222 step h, remove clean items
224 step i, store machine
226 block labeled controller
SUMMARY OF THE INVENTION
In accordance with the present invention, an automatic washing machine comprises a container, at least partially constructed in the form of a flexible bag, a filling device, an agitating device, an extracting device, and a controlling device. Alternate embodiments further optionally comprise one or more of the features described in the following “Features of Invention.”
Features of Invention
It may be helpful to the understanding of our automatic washing machine to categorize many of the features. Also included in this list are many features which have been gleaned from the prior art and are listed here as being examples of optional features that would be obvious to one versed in the art and for that reason are not included in the figures.
General Features
A feature of our automatic washing machine is a revolutionary new design based on the use of a flexible container, herein described as a flexible bag, which eliminates many heavy metal parts vital to the design of prior art machines. This elimination of parts drastically reduces the weight and space requirement of our automatic washing machine compared the weight and space requirement of prior art automatic washing machines.
A feature of our automatic washing machine is a collapsible container or vessel at least partially constructed in the form of a flexible bag, to contain a laundry solution such as water, and items of laundry to be washed.
A feature of our automatic washing machine is a flexible bag which is made of material of recent technology so as to be strong, collapsible and durable. An example of such a material is polyurethane coated fabric woven from aramid fiber.
A feature of our automatic washing machine is a scrubbing action for scrubbing items of laundry inside a flexible bag.
A feature of our automatic washing machine is vacuum wringing, which is the application of atmospheric pressure to wring the water from the laundry inside a collapsed flexible container. This vacuum wringing eliminates the vibration of the spin cycle which has been vital to prior art machines.
Scrubbing Features
A feature of our automatic washing machine is a choice of scrubbing actions such as agitation, vibration, rubbing, or other actions obvious to one versed in the art. Examples of such possible actions are: alternating deformation of the bag, injection and extraction of fluid into and out from the bag, motion imparted from a vibrating device inside the bag, motion imparted from a vibrating device outside the bag, circulating fluid inside the bag, circulating air bubbles within the fluid, rapid vibration of the fluid which results in cavitation, and other actions as may be obvious to one versed in the art.
In an embodiment, a method of agitation may be at least one or a combination of at least two scrubbing actions.
In an embodiment, a method of agitation is the use of multiple frequencies. A low frequency of agitation resulting in a sloshing action is augmented by a higher frequency agitating action resulting in cavitation.
In an embodiment, audio frequency vibration in the form of music is used alone or in combination with another frequency of agitating action. Music is from a conventional external source such as a home or portable stereo, fed to our automatic washing machine through an audio cable.
In an embodiment, motion of the laundry items being washed is accomplished by urging a circulating flow of water in the bag, and agitation is accomplished by reversing the flow of water in the bag.
In an embodiment, a manifold with water jets in at least two directions is used for reversing the flow of water. Each of the directions is used independently.
In an embodiment, a conventional reversible pump is used for reversing the flow of water.
In an embodiment, reversing the flow of water is accomplished by conventional automatically operated valves.
In an embodiment, any other washing or cleaning fluid obvious to one versed in the art may be substituted for water.
Space Saving Features
Our automatic washing machine occupies space normally dedicated to living only when in use. When use is finished living space again returns to be used for other activities of living.
Our automatic washing machine easily and conveniently collapses when not in use. With no requirement for a bulky agitator in our automatic washing machine the space occupied by the bag equivalent of a tub is reduced to negligible size for storage.
Our automatic washing machine is energy and space efficient. With no requirement for a steel enclosure, nor a steel water containing tub, nor a steel spinning tub, nor a bulky agitator, the mechanical apparatus of our automatic washing machine is much smaller and lighter. Being much smaller and lighter reduces the power required. With less power required to operate, a smaller motor and auxiliary apparatus are permitted. This further reduces the weight and results in the option to use lighter plastic instead of metal for the supporting structure Less weight and smaller motor result in increased energy efficiency.
Our automatic washing machine is able to be carried by one hand similar to a suitcase. When collapsed the present invention is carried out of the way when not in use. Light as a vacuum cleaner, the present invention is transportable. It can be easily carried as a piece of luggage while traveling.
The present invention stores easily in small space in a closet or on a shelf.
In an embodiment, the washing machine of this invention is produced in a form that can be mounted inside a wall of a house.
Our automatic washing machine enables those living in a house, apartment, or mobile home which is constructed without an area dedicated for the laundry, to enjoy the convenience of having a laundry facility in the home.
Control Features
Still another feature of our automatic washing machine is a controller which controls the various operations of the machine such that the washing proceeds automatically once the machine is loaded and turned on.
In an embodiment, as in prior art machines, a micro processor is used for control and logic means.
In an embodiment, as in prior art machines, a selector is provided for selection among multiple choices of the various phases and timing of the cleaning cycle depending upon the severity of the cleaning desired.
In an embodiment, as in prior art machines, a display is provided to keep the operator informed as to the progress of the cycle, and to alert the operator of any irregularities.
Filling Features
In an embodiment, as in prior art machines, an inlet and an outlet are provided to fill the machine with water and to empty it respectively.
In an embodiment, as in prior art machines, a water level sensing device is provided.
In an embodiment, as in prior art machines, a water pressure sensing device is provided to sense the level of water.
In an embodiment, a sensing device is provided detecting any leakage of the flexible bag before filling it with water. Such a sensing device may utilize air pressure inside the bag.
In an embodiment, a tilt sensor is used to prevent spilling water.
In an embodiment, the bag may be tapered so as to become narrower toward the top than at the bottom to overcome the tendency for the water filled bag to bulge or lean to one side and become unstable.
In an embodiment, as in prior art machines, a means is provided internal to the washing machine for mixing hot and cold water to achieve the desired water temperature.
In another embodiment, as in prior art machines, a means for controlling the water temperature is external in the form of a mixing faucet which supplies the water pre-mixed to the desired temperature.
Environmental Features
A feature of our automatic washing machine is increased efficiency gained by the use of a built in water treating device. Such devices include those utilizing various magnetic, ionic, electrolytic, electronic, cavitation, and radiation physical phenomena and as such are described in the literature and familiar to one versed in the art
In an embodiment, a water treating process is the generating of hydroxyl ions in wash and rinse water by the electrolytic action of water contact with an electrically polarized material of which the washing bag is made, or which is make into the bag. An example of such a material is tourmaline.
In our automatic washing machine a flexible bag muffles the sound of washing and is quieter than the prior art while in operation.
In an embodiment, our automatic washing action generates a pleasant sound of music when operating.
Our automatic washing machine results in less injury to garments by elimination of the requirement for a mechanical agitator.
The present invention results in increased cleaning efficiency due to combined action of low frequency and high frequency agitation.
The aforementioned examples of features of the invention, will, in part, become obvious from the following more detailed description of the invention, taken in conjunction with the accompanying drawings, which form an integral part thereof. Although the list above contains many features, these should not be construed as limiting the scope of the invention but merely as providing illustrations of some of the presently preferred embodiments of the invention. This list is not to be taken as a complete list of the features obvious to one versed in the art, but as examples of many other features of prior art washing machines which are obviously adaptable to our machine.
Theoretical Basis
It may be helpful to understand the theory behind some features of this invention. While we believe this theory to be valid, we do not wish to be limited thereto as other considerations may be pertinent. The validity of the invention has been empirically established.
Overcoming Design Tradeoff Paradox
Conventional automatic washing machines must be big for the following reasons: 1) Automatic washing machines of the prior art use a washing method that requires an agitator to drag the clothes back and forth in the water. This agitator is large and bulky. 2) Automatic washing machines of the prior art use centrifugal force to extract the water between and after the dousing cycles of washing and rinsing. In practical use the load is not balanced and the machine must be heavy to keep the machine in place during the spinning cycle. This spinning cycle and the agitation method result in the requirement for several items which make the machine heavy, large, and non movable. These items include,
(a) a heavy rigid metal enclosure,
(b) a heavy metal tub for containing water,
(c) a heavy metal perforated tub for washing and spinning,
(d) an agitator to drag the clothes back and forth in the water.
(e) a heavy metal transmission,
(f) a heavy large motor with sufficient power to move the heavy moving parts,
Therefore, with the above design requirements, any attempt to make a machine of reduced size or weight is met with the required tradeoff of reduced capacity.
To eliminate this required tradeoff of reduced capacity is the challenge. To design an automatic washing machine with equal or increased capacity and efficiency while having less weight and size requires overcoming this seeming paradox. The revolutionary solution which eliminates the requirements for the tradeoff has several parts and was unobvious.
Steps of the Solution
1. Agitation Method Breakthrough
It has been found that if a plastic grocery bag is tied shut with fruit and water inside, nearly devoid of but including some air, and alternately squeeze it first on one side with one hand and then on the other side with the other hand, causing the water to rush by the fruit, being held in close proximity to the fruit by the plastic bag, the fruit is quickly washed with little abrasion damage to the fruit. Much riper fruit can be washed without damage by this method than by the spraying water method.
This method of washing is adapted to laundering clothes in this invention with the result of superior cleaning and less damage to the clothes being laundered. By experimentation, it been found that if a plastic grocery bag is tied shut with articles of laundry and water inside, nearly devoid of but including some air, and alternately squeezed first on one side with one hand and then on the other side with the other hand, a violent washing action is set up with little energy required. Such washing action is much less damaging to the laundry items. Yet, the laundry items are cleaned as effectively as though they were cleaned by the more destructive method of rubbing.
Of course, eventually the plastic grocery bag breaks and the water spills out. The grocery bag is not practical for that reason. However, with the recent advances in technology, there are much stronger materials available. An example of such a material is polyurethane coated fabric woven from aramid fiber.
A sheath of polyurethane coated fabric woven from aramid fiber may be used for making the flexible bag. However, other types of less expensive materials can obviously be substituted. A list of examples of obvious desirable properties of the material to use for construction of the flexible bag includes but is not limited to:
(a) flexible, such that it will collapse, but not stretch out of shape,
(b) strong, such that it is puncture and stretch resistant,
(c) durable, such that it will last for a thousand washes minimum,
(d) abrasion resistant,
(e) detergent resistant,
(f) bleach resistant,
(g) cleaning fluid resistant,
(h) corrosion resistant,
(i) hot water resistant, such that it will be able to stand up when filled with several gallons of hot water,
(j) mildew resistant,
(k) dimensionally stable, such that it will not stretch with age, such that it will be able to contain air pressure,
(l) non-toxic,
(m) able to withstand ultra sonic energy,
(n) unaffected by dye,
(o) electrically conductive or non conductive as is required by the particular embodiment,
(p) electrically polarized as is required by the particular embodiment,
and other desirable properties as is necessary for the functioning as described herein.
2. Water Extraction Method Breakthrough
It been found that if a plastic grocery bag is tied shut with articles of laundry and water inside, and a vacuum applied inside the bag, the grocery bag collapses due to atmospheric pressure. This collapse presses the water out of the articles of laundry inside the bag. Even more water is extracted by both mechanical and evaporative removal, when air is repeatedly allowed to re-enter the evacuated bag and the bag again evacuated. This method of water extraction is ideal for an automatic washing machine using a flexible bag for the washing container. The reduced atmospheric pressure at higher elevations may require artificial assistance. This reduced atmospheric pressure can be assisted easily by doubling the bag such that one bag is inside the other. Supplemental air pressure could be applied between the two bags to assist the atmospheric pressure in collapsing the inner bag, thus effectively wringing the water from the laundry. This method of supplemental air pressure may be used even at sea level if dryer laundry is desired. Thus, the spin cycle of prior art washing machines is eliminated.
With the spin cycle gone, the heavy parts requirement is gone. It may seem paradoxical that replacing big parts with small parts, metal with plastic and rigid with flexible, will improve the capacity and the cleaning properties of a washing machine. However, the result has been empirically verified. With this invention, less works better.
Water Treatment Theory
There are various water treatment methods in the prior art that empirically have been shown to improve the cleaning effectiveness of water. Water softening methods result in less soap or detergent being required. Magnetic water treatment prevents and removes lime scale. Electrolytic or ionic treatment improves the cleaning properties of water. Hypothetically this improvement is attributed to the reduction of the surface tension due to ion release. Other methods of ion release are found in the prior art, and obviously are adaptable to the present invention.
One method of ion release in the prior art that is easily adapted to the present invention is described in U.S. Pat. No. 5,309,739 to Lee (1994). In his patent, Lee uses tourmaline, an electrically polarized material which has been demonstrated to produce an increase in the effectiveness of the cleaning ability of water when the water is agitated in the immediate vicinity of the electrically polarized material. In our automatic washing machine tourmaline may be used, or alternatively, the bag may be made of a manufactured electrically polarized material. Additionally, the washing action can result in agitation of the water in the immediately vicinity of the surface of the bag which is electrically polarized, resulting in that same increase in washing effectiveness.
The increased cleaning effectiveness described in U.S. Pat. No. 5,309,739 to Lee (1994) is attributed by Lee to ion generation. Other methods of ion generation are described in other patents as mentioned in the prior arts section above. Obviously, any of these methods are adaptable to our inventive automatic washing machine.
U.S. Pat. No. 5,599,455 to Hukai (1997) presents a theoretical basis for the improved cleaning effectiveness of tourmaline treated water which attributes the effect to the generation of hydroxyl ions (H 3 O 2 − ) and hydronium ions (H 3 O + ) both having detergency. Other hypothetical explanations are abundant in the literature. One hypothesis is that the ions improve the washing effectiveness of the clothes washing machine by lowering the surface tension of the wash water due to the ionic surface active effect. It is natural that when the surface tension of the wash water is reduced, the amount of detergent necessary to clean the laundry is also reduced.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As will become obvious, there are multiple preferred embodiments of the present invention. One is a stand alone unit, fully collapsible into a suitcase, another is a unit designed to be built into a wall of a house, others will be obvious adaptations to the environment where the invention will be used or stored. The same part numbers are used for the same functional part in all of the figs even though the shape may be different in different embodiments.
FIG. 1 illustrates an example of an automatic washing machine illustrating the major components necessary in an automatic washing machine design according to the prior art. The machine of the prior art comprises a rigid metal enclosure 20 , a water containing tub 22 , a perforated washing and spinning tub 24 , a heavy transmission 26 , a heavy motor 28 , a bulky agitator 30 , and many other smaller conventional parts such as a control panel (not shown) well known to anyone versed in the art. Motor 28 drives transmission 26 which in turn drives agitator 30 , causing agitator 30 to reciprocate, or drives spinning tub 24 causing it to spin, depending on which cycle is currently in progress. In prior art automatic washing machines these illustrated parts are a necessary part of the design to make the machine automatic.
The prior art design for a washing machine requires agitator 30 for scrubbing the clothes. Motor 28 , and transmission 26 are necessary to drive agitator 30 .
The prior art design for a washing machine to be automatic requires a method of removing the water from the clothes without lifting the clothes from the water. To accomplish this spinning tub 24 is required. Motor 28 , and transmission 26 are necessary to drive spinning tub 24 This design requires the machine to be much heavier than the load of clothes being spun because the load in practical use is never completely balanced. This imbalance causes the machine to move around during the spin cycle unless the machine is heavy enough to stay in place.
In using the prior art machine of FIG. 1, the top is opened, dirty clothes and a little detergent are put inside, the top is closed, the desired cycle is selected, and the power is turned on. The machine automatically begins to fill with water. Later, the operator returns, opens the top, and removes the clean clothes.
FIG. 2 illustrates a first embodiment of the automatic washing machine of the present invention. This automatic washing machine has a rigid housing, or base 32 of which the top portion is the lower portion of a water container 34 . The top portion of container 34 is a flexible bag 36 . Inside the lower portion of housing 32 are a water pump 38 , an air pump 40 , a controlling device 42 , a flow diverter 44 , and a water distribution manifold 46 . Inside container 34 is a screen 52 , and a pair of water jets 54 a and 54 b. A conventional filling hoses 78 , conventional check valve (not shown), conventional fill valves (not shown), a drain hose 80 , and conventional power cord (not shown) complete the apparatus of the automatic washing machine. Flexible bag 36 is collapsible so as to fold down into the top portion of housing 32 for storage. Flexible bag 36 is made of material of recent technology so as to be strong, collapsible and durable. An example of such a material is polyurethane coated fabric woven from aramid fiber. An opening 58 at the top of flexible bag 36 is opened and closed by means of a drawstring tie 60 . Housing 32 and screen 52 are made of conventional plastic having a heat resistance up to over 200 degrees Fahrenheit. Water pump 38 is a conventional water pump of similar size and capacity that would be used on a conventional automatic electric dishwasher. Water pump 38 is connected to pump water from the water container 34 portion of housing 32 to flow diverter 44 , Flow diverter 44 is a series of conventional valves (not shown) controlled by controlling devise 42 . Flow diverter 44 is connected to supply water from water pump 38 through water distribution manifold 46 to waterjets 54 a and 54 b alternately for agitating, or to drain hose 80 for emptying. Air pump 40 is a conventional vacuum cleaner type air pump and is connected to force air from the atmosphere into container 34 or out of container 34 into the drain hose, as controlled by controlling device 42 . A conventional check valve (not shown) is part of air pump 40 to prevent water from flowing out an atmospheric air intake vent (not shown). Controlling device 42 is a standard timing and control device. The wiring and constructional details of timers for operating a machine cycle are so well known to those skilled in the art, that no description of them is contained herein.
The washing and rinsing action, and the water extraction method of the inventive machine are of unique design and are described in detail in FIGS. 6 a to 7 g.
In use, the inventive automatic washing machine of FIG. 2 is quite similar to the use of the automatic washing machine of FIG. 1 of the prior art. In using the prior art machine of FIG. 1, the top is opened, dirty clothes and a little detergent are put inside, the top is closed, the desired cycle is selected, and the power is turned on. The machine automatically begins to fill with water. Later, the operator returns, opens the top, and removes the clean clothes. Likewise, in using the inventive machine of FIG. 2, the top is opened, dirty clothes and a little detergent are put inside, the top is closed, the desired cycle is selected, and the power is turned on. The machine automatically begins to fill with water. Later, the operator returns, opens the top, and removes the clean clothes. Thus from the operators perspective, the operation of the inventive machine of FIG. 2 is identical to the familiar operation of the prior art machine of FIG. 1 .
The inventive automatic washing machine of FIG. 2, however, is much smaller and lighter while still having essentially the same load capacity as the prior art machine of FIG. 1 :
Where the prior art machine of FIG. 1 has a heavy, rigid metal enclosure 20 and a heavy rigid water containing tub 22 , the inventive machine of FIG. 2 has combined the two into a rigid housing, or base 32 of much lower profile and made of a lighter material. An example of the lighter material is plastic. The lower portion of tub 22 in FIG. 1 has been built into the upper portion of housing 32 of FIG. 2 . The upper portion of tub 22 in FIG. 1 has been replaced in FIG. 2 with a flexible bag 36 having opening 58 at the top which is secured by a drawstring tie 60 . In FIG. 2 upper portion of housing 32 and flexible bag 36 together make a container 34 for holding a dousing water 74 for washing or rinsing.
Where the prior art machine of FIG. 1 has a heavy metal perforated washing and spinning tub 24 , the inventive machine of FIG. 2 has none. The water extraction method of the inventive machine of FIG. 2 has eliminated the need for spinning tub 24 of the prior art machine of FIG. 1 .
Where the prior art machine of FIG. 1 has a bulky agitator 30 taking space in tub 22 , the inventive machine of FIG. 2 has a pair of waterjets 54 a and 54 b. In the inventive machine of FIG. 2 no space is taken up inside container 34 with bulky parts.
Elimination of spinning tub 24 and agitator 30 also eliminates the need for transmission 26 and heavy motor 28 of FIG. 1 . The inventive machine of FIG. 2 replaces those heavy parts with a water pump 38 and air pump 40 which are smaller and lighter and fit easily inside housing 32 .
The remaining parts necessary to complete an automatic washing machine are familiar conventional parts which are obvious to one versed in the art, such as mixing and filling valves (not shown), filling hose 78 and drain 80 , a power cord (not shown), a conventional controller (not shown) and other items irrelevant to the invention.
Thus, with the elimination of the need for the six most heavy and bulky parts of the prior art, the inventive machine of FIG. 2 is but a fraction of the size and weight, while still having the same capacity and functionality as the prior art machine.
FIG. 3 a and FIG. 3 b illustrate a preferred embodiment of the automatic washing machine of the present invention. This preferred embodiment is very similar to the embodiment illustrated in FIG. 2, but has no opening in the top of bag 36 . Instead, in this preferred embodiment, container 34 is opened by separating bag 36 portion of container 34 from housing 32 portion of container 34 . There is a bag holder 68 around the bottom opening of bag 36 which holds bag 36 securely against a seal 66 when bag 36 and holder 68 are closed down onto housing 32 . A hinge 62 and a clasp 64 secures holder 68 to seal 66 . A clothes retaining rack 70 is also attached to hinge 62 and snaps into bag holder 68 .
The washing and rinsing action, and the water extraction method of the inventive machine are of unique design and are described in detail in FIGS. 6 a to 7 g.
The use of this embodiment of the automatic washing machine is very similar to the use of the machine illustrated in FIG. 2 . The difference in use is in the opening of bag 36 to insert and remove the articles of laundry. Instead of opening drawstring 60 , to open bag 36 , in the embodiment of FIG. 3 a and FIG. 3 b, the operator opens clasp 64 and raises bag holder 68 including bag 36 in a similar manner as opening the lid on a conventional prior art top loading washing machine. Once bag holder 68 is raised, rack 70 is snapped out of bag holder 68 and the dirty clothes are put into bag 36 . After bag 36 is filled, rack 70 is snapped back into bag holder 68 and bag holder 68 is lowered and attached with clasp 64 , thus insuring a water tight closure against seal 66 on housing 32 .
FIG. 3 b also illustrates the conventional water, drain, and power hookups used in this embodiment. A fill hose 78 with a quick release hose connectors 84 and 84 ′ on either end, and a drain hose 80 with a quick release hose connector 84 on the end connected to housing 32 provide a temporary connection to a water tap 86 and a sink with drain 88 . A power cord 82 with conventional plug connectors on both ends provides a temporary connection to electric power while in use.
The use of the conventional water, drain, and power hookups used in this embodiment is simplified by quick release hose connectors 84 . Water hose 78 , drain hose 80 and power cord 82 are removed from their place of storage. Water hose 78 and drain hose 80 are connected to their respective mating quick release hose connector 84 on housing 32 . The other end of water hose 78 is connected to mating quick release connector 84 ′ previously installed on a convenient water tap. The other end of drain hose 80 is hooked over the edge of a sink with drain such that water from drain hose 80 goes down the drain. Connecting power cord 82 to an appropriate connector 90 on housing 32 and to a conventional electric outlet (not shown) complete the hook-up.
FIGS. 4 a to 4 d illustrate an alternate preferred embodiment of the automatic washing machine of the present invention. FIG. 4 a is a plan view with a suitcase type lid 96 swung open. FIG. 4 b is a side view with lid 96 removed. FIG. 4 c is an end view showing bag 36 and housing 32 to be less tall than wide. FIG. 4 d is a perspective view prepared for storage. This alternate preferred embodiment is very similar to the embodiment illustrated in FIG. 3 a and FIG. 3 b, which has a vertically oriented bag 36 , except the orientation of bag 36 of the embodiment shown in FIGS. 4 a to 4 d is horizontal and bag 36 separates from housing 32 opening to the side (not shown), in the same direction as lid 96 is shown open. Instead of bag 36 setting on housing 32 , this embodiment has bag 36 laying on a horizontal surface (not shown) and housing 32 standing at one end of bag 36 . The arrangement of hinge 62 and clasp 64 are the same. There is no need for rack 70 of FIG. 3, because articles 76 are inserted deeper into bag 36 of this embodiment as the bag of this embodiment is longer. To open this machine housing 32 is swung away from bag 36 . A control panel 92 is conveniently located on the top side of housing 32 . When closed and operating, water 75 inside bag 36 is supported by any horizontal surface such as a floor (not shown) on which bag 36 is laying. Air 72 in bag 36 is in contact with housing 32 making the sensing of the level of water simpler. In this embodiment, the vertical dimension of housing 32 need only be a little greater than the depth of water 74 . This results in housing 32 being smaller and more compact for storage. When in use, bag 36 hangs out the side of housing 32 , which appears like a suitcase with a bag hanging out of it. When not in use, bag 36 collapses conveniently into housing 32 and housing 32 is converted into a suitcase 94 . Suitcase lid 96 swings closed over the bag (and other attachments). A carrying handle 98 on top of housing 32 provides a convenient way to carry the machine into storage.
FIGS. 5 a , to 5 c illustrate a wall mounted embodiment of the automatic washing machine of the present invention. Housing 32 is the door of a front loading automatic washing machine of this invention when the machine is mounted inside a wall. From the front the wall mounting model looks similar to the separate freezing compartment door of a top freezer refrigerator. This is illustrated in FIG. 5 a. This embodiment of the automatic washing machine is very similar to the embodiment illustrated in FIGS. 4 a to 4 d. The machine of FIGS. 4 a to 4 d, as shown in FIG. 5 b, has been modified and fitted with a wall mount bracket 102 and a backboard 104 , that folds down to become the surface on which bag 36 rests. Backboard 104 is connected to wall mount bracket 102 by a backboard hinge 106 . Backboard 104 is normally folded up against the wall on the back side of the wall so as to not use any space out of the room on the back side of the wall. This folded configuration is illustrated in FIG. 5 c. The configuration of hinge 62 is of somewhat different design to accommodate the wall bracket, but serves the same purpose as in the other embodiments. Housing 32 is constructed in the shape of a deep door which nearly fills the depth of the wall. Seal 66 is at the back edge of housing 32 so as to mate with bag holder 68 . Bag holder 68 is permanently affixed to wall bracket 102 near the back side of the wall. Water hose 78 , drain hose 80 , and power cord 82 are permanently affixed to housing 32 with conventional strain relief (not shown), and are permanently affixed to plumbing and power inside the wall as in a conventional washing machine installation (not shown). In this embodiment seal 66 and bag holder 68 are oval or rectangular in shape, as in FIGS. 4 a to 4 d, rather than round as in some other embodiments, otherwise they function the same. When put away, bag 36 is collapsed into housing 32 and covered by backboard 104 . When in use, backboard 104 is lowered down to a nearly horizontal position and bag 36 expands rearward and rests on backboard 104 . A sideboard 110 on each side of backboard 104 and attached to backboard 104 keeps bag 36 from hanging over the side of backboard 104 . Handle 100 serves to open the door which is housing 32 . The door is equipped with a conventional interlock (not shown) to prevent opening the door at the wrong time and spilling water. Such a conventional interlock is common on prior art front loading automatic washing machines.
FIGS. 6 a to 6 d are included to illustrate the water extraction cycle of an automatic washing machine according to the present invention. This water extraction cycle is quite different than the water extraction cycle of the conventional washing machine of the prior art. This water extraction cycle can be visualized as having two phases.
In the first phase, water and air are pumped out. In the second phase, air is pumped in. The two phases are repeated a reasonable number of times to extract as much water as is practical without damage to the clothes.
FIG. 6 a illustrates phase 1 . In Phase 1 air and water is pumped out of container 34 . After water pump 38 (not shown) pumps out all the readily available water, vacuum 114 is applied from air pump 40 (not shown) to evacuate container 34 , causing available atmospheric pressure 116 to collapse bag 36 , pressing articles 76 to screen 52 , thereby wringing water from articles 76 . After a short time of the wringing of phase 1 , phase 2 is started.
FIG. 6 b illustrates phase 2 . In Phase 2 air pressure from air pump 40 is forced into container 34 causing articles 76 to relax and bag 36 to inflate.
Again, after a predetermined short time, phase 1 and phase 2 are repeated a predetermined number of times. This repeated inflating and deflating of bag 36 moves air through articles 76 and results in both mechanical and evaporative removal of water. The final water extraction cycle contains a predetermined greater number of repeats than an extraction cycle that occurs before a rinse cycle. It is not as necessary to get articles 76 as dry when the next step, see FIG. 11, is entering a rinse cycle where they again get wet.
FIG. 6 c illustrates a means for wringing increased amounts of water from articles 76 when drier articles 76 are desired. Atmospheric pressure 116 of phase 1 is assisted by air pressure from a pump assembly 122 , shown in FIG. 6 d. An outer bag 120 in addition to bag 36 is supplied to contain the assisting air pressure. An air pressure channel 118 conducts the additional air pressure from pump assembly 122 into air containing bag 120 . Simultaneously vacuum is applied from pump assembly 122 . This additional air pressure assists the natural atmospheric pressure collapse bag 36 and wrings additional water from the clothes.
FIG. 6 d illustrates air and water pump assembly 122 which is somewhat non-standard and would be suited for this application. Pump assembly 122 replaces three separate pumps with their own electric motors. An electric motor 124 , water pump 38 , air pumps 40 a and 40 b, a check valve a 126 , and a check valve b 128 , are parts of pump assembly 122 . Electric motor 124 is a multi speed motor which speeds up when the load of water pump 38 is gone due to all the water being pumped out. When motor 124 is running at high speed, vacuum is available from air pump 40 a and air pressure is available from air pump 40 b. Check valves 126 and 128 prevent back flow.
FIGS. 7 a to 7 g show various views illustrating the detail of the agitation and scrubbing action of the washing and/or rinsing cycle of an automatic washing machine according to the present invention. The scrubbing action occurs as a result of mechanical agitation. As a result of this scrubbing action, the clothes wash against each other, against the sides of the washing machine, against air bubbles in the water, and against the water itself. This scrubbing accomplishes several things including the loosening of solid material on the surface of and imbedded in the fabric of the clothing, the dissolving of solids, the generation of ions, the emulsification of oil, and the rinsing away of foreign material, be it solid, emulsified, or dissolved. Various embodiments have different methods of inducing agitation.
FIG. 7 a illustrates the water jet method of inducing action. Action is induced in water 74 inside bag 36 by means of water jets 54 a and 54 b through which water is forced by water pump 38 . Flow of water 74 inside bag 36 follows a flow pattern 130 a or a flow pattern 130 b, depending on the predetermined direction and predetermined angle jet 54 a and jet 54 b are mounted, and on which of these jets are currently in use. Flow diverter 44 is connected after water pump 38 and before jets 54 a and 54 b. Flow diverter 40 , under the control of controlling device 42 (not shown), causes flow to be diverted to one or the other, or to both simultaneously. Jets 54 a and 54 b are independently active causing the pattern of flow to be at one time in one direction and at another time in another direction, thus disrupting flow pattern 130 a or 130 b and causing agitation. Different predetermined mounting positions and predetermined numbers of jets 54 are used in different embodiments to achieve the same results as is obvious to one versed in the art.
FIG. 7 b illustrates the water jet plus air bubbles method of inducing action. Action is induced in water 74 inside bag 36 by means of water jets 54 a and 54 b through which water and air are forced by water pump 38 and air pump 40 . This is achieved by locating air pump 40 such that air is introduced in the flow of water between water pump 38 and flow diverter 44 . Excess air rises to the top of the wash water and is allowed to escape via an air vent or duct 132 which recycles the air to air pump 40 . Air bubbles in the water increases the action over water alone. While washing without sudsing detergent or soap, air bubbles would give the pleasing appearance of suds to homemakers who judge cleaning power by the amount of suds. When using sudsing detergent, a control cycle would be selected that did not use the air feature. The vertical embodiment is illustrated in FIG. 7 b. However, implementation in the horizontal, or front loader, embodiment (implementation not shown) would result in a simpler arrangement of duct 132 .
FIG. 7 c illustrates the low frequency vibrating disk method of inducing action. Action is induced in water 74 inside bag 36 by means of a low frequency vibrating disk 134 causing a conventional resonance phenomena (not shown). Disk 134 is driven into vertical vibration by the drive force of a vibrating drive unit 136 . An alternate location for disk 134 is above screen 52 (alternate location not shown).
FIG. 7 d illustrates the reversible rotating disk method of inducing action. Action is induced in water 74 inside bag 36 (shown in FIG. 7 c ) by means of a reversible rotating disk 138 causing a conventional resonance phenomena (not shown) similar to low frequency vibrating disk 134 shown in FIG. 7 c. Disk 138 in FIG. 7 d is rotationally driven by the drive force of a reversible rotating drive unit 140 . Rotating disk 138 differs from vibrating disk 136 in that rotating disk 138 has a predetermined tilt 142 to one side such that when rotating, it moves water up and down on opposite sides of disk 138 . The rotation of disk 138 also sets up a swirling action in the water. The rotation direction of disk 138 reverses every predetermined number of seconds to prevent setting up a violent swirling action in the water. This reversal pattern produces agitation instead of swirling.
FIG. 7 e illustrates the sloshing sideboards or baseboard method of inducing action. Action is induced in water 74 inside bag 36 by means of a portion or portions of sloshing sideboards or baseboard resulting in squeezing, shaking, jiggling, or bumping. This action causes a sloshing movement of the contents of bag 36 . A flexibly movable portion 144 of housing 32 is jostled by the force of an actuator 146 through an actuator arm 148 . Portion 144 is flexibly movable by virtue of a flex joint 150 and a pivot or hinge 151 . In FIG. 7 e one side is shown, however, multiple sides are so equipped resulting in opposing motion.
FIG. 7 f illustrates the ultra sonic vibration method of inducing action. Action is induced in water 74 inside bag 36 by means of inducing ultra sonic vibrations resulting in cavitation, a very effective means of cleaning. An ultrasonic generator 152 is electrically connected to an ultrasonic vibrator 154 . Ultrasonic vibrator 154 and an ultrasonic vibration plate 156 are mounted on housing 32 such that ultrasonic vibrations are induced in water 74 .
FIG. 7 g illustrates the sonic vibration method of inducing action. Action is induced in water 74 inside bag 36 by means of inducing sonic vibrations resulting in cavitation, a very effective means of cleaning. An underwater speaker 160 is mounted inside water container 34 portion of housing 32 . Speaker 160 is electrically driven by a sound generator/power amplifier 158 . Optionally, music or other sound from a conventional external source such as a portable or home stereo (not shown) may be plugged into an input jack 162 on control panel connected to amplifier 158 . When the external source produces music, then music is the waveform of the sonic vibration which produces the cleaning action, and the pleasant sound of music will emanate from the washing machine.
FIG. 8 illustrates a combination of multiple methods of inducing agitation combined in a single embodiment. The water jet method action is induced in water 74 inside bag 36 by means of water jets 54 a and 54 b through which water is forced by water pump 38 as is shown in FIG. 7 a. Or, optionally, by operator selection on control panel 92 , the water jet plus air bubbles action is induced in water 74 inside bag 36 by means of water jets 54 a and 54 b through which water and air are forced by water pump 38 and air pump 40 as shown in FIG. 7 b. Additionally, in the same embodiment, as shown in FIG. 7 g, sonic or ultrasonic vibration action is induced in water 74 inside bag 36 by use of an underwater transducer 164 mounted inside water container 34 portion of housing 32 . Transducer 164 is electrically driven by a waveform generator/power amplifier 166 . Optionally, music or other sound from a conventional external source such as a portable or home stereo (not shown) may be plugged into an input jack 162 connected to amplifier 166 . This combination results in increased cleaning efficiency due to combined action of low frequency sloshing and high frequency vibration agitation.
FIGS. 9 a to 9 e show various views illustrating the detail of several implementations of conventional water treating devices, the inclusion of which is an object of an automatic washing machine according to the present invention.
FIG. 9 a shows a built in water treatment device wherein water 74 interacts with an electrically polarized material 170 to cause electrolysis of water 74 . It has been empirically verified that electrolysis of water 74 has an effect on water 74 which is apparent softening without removing any of the dissolved solids. It has been hypothesized by those versed in the art, that electrolysis generates hydroxyl ions causing a surface active effect, thereby lowering the surface tension of water 74 . This interaction is enhanced by agitation of water 74 in the vicinity of polarized material 170 by ultrasonic vibration plate 156 . An example of electrically polarized material 170 is tourmaline in the form of a tourmaline ceramic coating. Some artificial materials such as some plastics also exhibit this electrically polarized property. In this embodiment, material 170 is a tourmaline ceramic coating on the bottom side of screen 52 .
Water treatment by interaction with an electrically polarized material such as tourmaline is well known by those versed in the art and is adequately described in U.S. Pat. No. 5,309,739 to Lee (1994). Lee describes a device which utilizes the generation of surface-tension-reducing hydroxyl ions for the purpose of reducing the amount of detergent required, and explains the hypothesis behind the effect. That explanation is included herein by reference.
FIG. 9 b shows a built in water treatment device wherein water 74 interacts with an electrically polarized material 170 ′ to cause electrolysis of water 74 . It has been empirically verified that electrolysis of water 74 has an effect on water 74 which is apparent softening without removing any of the dissolved solids. It has been hypothesized by those versed in the art, that electrolysis generates hydroxyl ions causing a surface active effect, thereby lowering the surface tension of water 74 . This interaction is enhanced by agitation of water 74 in the vicinity of polarized material 170 ′, by water jet 54 a and 54 b causing a water flow 172 directed against material 170 ′. In this embodiment, material 170 ′ is an electrically polarized plastic coating on the inside of bag 36 , which becomes more electrically polarized due to the friction of water flow 172 against polarized material 170 ′.
FIG. 9 c shows a built in water treatment device wherein water 74 interacts with an electrode 174 and an electrode 176 which are electrically isolated electrodes of different electrochemical potential resulting in electrolysis of water 74 . It has been empirically verified that electrolysis of water 74 has an effect on water 74 which is apparent softening without removing any of the dissolved solids. It has been hypothesized by those versed in the art, that electrolysis generates hydroxyl ions causing a surface active effect, thereby lowering the surface tension of water 74 . This interaction is enhanced by flow of water 74 in the vicinity of electrodes 174 and 176 . By locating electrodes 174 and 176 inside a section of pipe 178 containing water 74 as water 74 is circulated during agitation. In this embodiment, electrode 174 is made of a material containing aluminum and electrode is 176 is made of a material containing carbon. Other electrically conductive materials having different electrochemical potentials may be used.
Water treatment by interaction with electrically isolated electrodes of different electrochemical potential is well known by those versed in the art and is adequately described in U.S. Pat. No. 5,358,617 to Ibbott (1994). Ibbott describes a device which utilizes electrically isolated electrodes of different electrochemical potential to ionize the wash water inside a prior art washing machine for the purpose of reducing the amount of detergent required. That explanation is included herein by reference.
FIG. 9 d shows a built in water treatment device wherein water 74 interacts with a magnetic field. It has been empirically verified that passing water 74 through a magnetic field 180 causes the deposition of lime scale to cease, and accumulated lime scale to decrease. This is an effect akin to softening of water without physically removing the dissolved metal ions from water 74 . It is well known to those versed in the art that this phenomenon has an effect of reducing the amount of detergent necessary to clean clothes. In this embodiment a magnet 182 is placed on one side of a section of pipe 184 and a magnet 182 ′ is placed on the opposite side of pipe 184 causing magnetic field 180 to occur inside pipe 184 .
FIG. 9 e shows a built in water treatment device wherein water 74 is exposed to ultra violet radiation. It has been empirically verified that exposing laundry water 74 to ultra violet radiation kills bacteria in water 74 . An ultra violet light 186 is installed inside base 32 such that ultra violet light passes through an ultra violet light window 188 into the lower portion of water container 34 , exposing water 74 to an ultra violet radiation 192 . An ultra violet reflector 190 is installed behind ultra violet light 186 to reflect ultra violet radiation 192 into water 74 .
FIGS. 10 a to 10 d illustrate an alternate preferred embodiment of the automatic washing machine of the present invention. FIG. 10 a is a side section view with bag 36 expanded for operation. FIG. 10 b is the same side section view with bag 36 collapsed during the water extraction operation. FIG. 10 c is a rear view of screen 52 showing water jet arrangement. FIG. 10 d is a front view. This alternate preferred embodiment is very similar to the wall mounted embodiment illustrated in FIGS. 5 a to 5 c with the exception that housing 32 , is in the form of a yoke, similar to a donut, around a neck 196 of container 34 , container 34 being made up of bag 36 connected to housing 32 at connecting point 194 . In this arrangement the various components in housing 32 are arranged around neck 196 of container 34 . Screen 52 is a ring around neck 196 of container 34 , curved around housing 32 in a conformable way, spaced a predetermined distance away from housing 32 to provide space for water to flow between screen 52 and housing 32 . With this arrangement, a see through door 198 , permitting a view of the inside of the machine while in operation, is fitted on the opposite side of housing 32 from bag 36 . Articles 76 enter container 34 by passing through neck 196 of container 34 . The embodiment shown here is built into a telescoping suitcase 200 . The side of the suitcase with the door is the front of the machine and appears to the operator very similar to a conventional front loading washing machine of the prior art. The back of the suitcase telescopes out to make room for bag 36 to expand while in use. In the particular embodiment shown, a left set of water jets 202 , in a manner explained for water jet 54 a of FIG. 7 a causes agitation in a clockwise direction. A right set of waterjets 204 , in a manner explained for to water jet 54 b of FIG. 7 a causes agitation in a counterclockwise direction. Water treatment features (not shown) and other means of agitation, either singly or in combination (not shown) are optional features on this embodiment as well as on the others. This embodiment also, is optionally fitted with a flange to be built into a wall similar to the embodiment in FIGS. 5 a to 5 c.
FIG. 11 applies to any of the many embodiments of the inventive automatic washing machine. In FIG. 11 a functional block diagram of the inventive washing method 206 illustrates the overall concepts behind the devices and methods which make up the inventive automatic washing machine, and their usage. Diagram 206 illustrates the process flow of the inventive method of washing clothes. Diagram 206 is to aid in the following explanation of the usage of the inventive automatic washing machine. The accompanying explanation refers to parts shown in the other figures above.
A block labeled controller 226 represents the function of controlling device 42 in FIG. 2 and other Figs. Control of the process is automatically accomplished from a step c 212 through a step g 220 . Steps before and after are under the control of the operator.
A step a 208 is set up machine. Setting up the machine, is accomplished differently depending on the embodiment. Basically the machine is removed from storage, opened if necessary, and connected to water, drain, and power.
Some embodiments are stored in a shape resembling a suitcase. The suitcase is carried from storage, opened, and the connections made as described in the explanation for FIG. 3 .
On some models, the water temperature is adjusted at tap 86 of FIG. 3 .
With the wall mounted embodiment, the water, drain, and power is permanently connected, thus simplifying set up. On this model, the backboard 104 in FIG. 5 is simply unclasped and lowered to complete the set up.
A step b 210 is load and select cycle. Loading the machine and selecting the cycle is accomplished very similar to performing the same function with a conventional automatic washing machine of the prior art. The machine is opened, dirty clothes are put in along with optional laundry products such as detergent, and the machine closed. On control panel 92 (shown in FIGS. 4 and 5 ), the desired cycle pattern is selected, and the power turned on. Control is thereby transferred to controlling device 42 .
A step c 212 is fill with water. Filling the machine with water under the control of controlling device 42 has several unobvious features.
First a leak test is done. As with water beds, when they were first introduced to the consumer, they met with consumer skepticism. There was fear of water spilling all over the house. The same skepticism is anticipated with the washing bag 36 . To overcome this skepticism, the consumer can be assured that a test is performed to check for leaks before filling the machine with water. Such a test is to inflate bag 36 with air to a predetermined pressure, and wait to see if the pressure drops below a predetermined pressure, indicating a leak. If a leak is detected, operation is suspended and controller 42 notifies the operator.
Tip over detection is accomplished. Since most embodiments are portable, and may be tipped over, a conventional tip over detector (not shown) is checked by the controller before each filling. A tip over condition could disrupt the fill level sensor and result in excessive filling. If a tip over is detected, operation is suspended and controller 42 notifies the operator.
Fill to predetermined level is accomplished by using a conventional fill detector/sensor (not shown). Various type devices may be used depending on the embodiment. For the vertical embodiments a conventional water pressure sensing device may be used. In the horizontal embodiments a conventional float level detector may be used.
In an embodiment, as in prior art machines, a conventional device (not shown) is provided internal to the washing machine for mixing hot and cold water to achieve the desired water temperature. In another embodiment, as in prior art machines, a means for controlling the water temperature is external in the form of a mixing faucet which supplies the water pre-mixed to the desired temperature. In this case this function is performed manually in step a 208 , above.
A step d 214 is wash. Washing action, is initiated after filling in step c 212 . Washing action occurs in various ways in different embodiments as illustrated in FIGS. 7 a to 7 g. Simultaneously, any water treatment device as illustrated in FIG. 9 in the particular embodiment is activated. This is a very complex step and is described in detail in FIGS. 7 a to 9 e.
A step e 216 is extract water. Water extraction, is fully illustrated and described in FIGS. 6 a to 6 d.
A step f 218 is fill, rinse, extract. This step 218 , is a predetermined number of repeats of step c 212 , fill with water, step d 214 ,wash, and step e 216 , extract water. Washing action is the same in the wash and the rinse cycles with the exception that any detergent added near the beginning in step b 210 , is rinsed away in the rinse cycles. However, cleaning action continues in the rinse cycles because of the water treatment features built into the machine. The number of repeats of the filling, washing action, and water extraction processes is predetermined, depending on the particular cycle pattern selected on the control panel in step b 210 . The number of repeats of the water extraction process within each repeat of the water extraction step is predetermined, depending on the particular cycle pattern selected on the control panel in step b 210 , and whether the next step is another rinse or removal in step h 222 .
A step g 220 is notify operator. Notification of the operator, is accomplished in the conventional way as in the prior art. It may be by a signal sound, or light, or both. Additionally any malfunctions such as a bag leak would result in some conventional signal appearing on the control panel.
A step h 222 is remove clean items. Removal of clean items, is accomplished in the way familiar to operators of the prior art machines. Simply open the machine and take out the clothes.
A step i 224 is store machine. Putting the machine into storage, is the reverse process of step a 208 . If the embodiment is the wall mounted model, simply raise the backboard to the wall in the other room and secure the clasp. If the embodiment is one of the suitcase models, simply turn off the water and remove the quick disconnect hoses, and power cord. Coil them and place them in the lid. Close the lid. Pick up suitcase and carry it into storage.
In Summary
When it is desired to wash clothes, the machine is removed from it's storage space such as a closet or shelf, and carried to a location in proximity to an electrical outlet and a water tap which has previously been fitted with a quick disconnect water connector. The water inlet/outlet hose assembly of the machine is pulled out of it's storage location of the washing machine and connected to the water tap. The electric supply cord is connected to any electrical outlet. The machine bag is opened and the dirty clothes are put into the machine along with any desired laundry product. The machine is closed. The machine cycle selector is set to the desired automatic cycle, and turned on. The machine automatically goes through the selected cycle and turns off. The machine is opened and the clean clothes are removed. The hoses and power cord are disconnected from the supply and placed into their respective storage locations in the machine. The machine is then carried back to it's storage space out of the way.
When the machine is manually switched on the controlling device 42 causes various functions of filling, agitating, and extraction to occur. At the proper predetermined time the water fills the bag to a predetermined level. Once the predetermined level is reached, a means for agitation is turned on for a predetermined length of time. When the predetermined length of time is expired, the water extraction function is turned on for a predetermined time interval. This cycle is repeated a predetermined number of times and a predetermined duration of each time to wash and rinse the clothes and leave the clothes with the water extracted and ready to be dried.
Within each of the functions of agitation and extraction, the sub functions are controlled by the control means.
Conclusions, Ramifications, and Scope
Accordingly, the reader will see that the automatic washing machine of this invention is made possible without the two tubs, an agitator, and a metal enclosure required by the prior art. Yet, all the features of the prior art are included in the present invention. Beyond the features of the prior art, are several advantages of the present invention. Living space in the home is increased as there is no need for dedication of a room of the house for a wash machine. Homes without dedicated space can have the full capability of a laundry facility in the home. The gentle yet effective washing action saves wear and tear on clothes. The gentle yet effective water extraction method saves wear and tear on clothes. The water treatment methods employed increase the efficiency and reduce the amount of detergent necessary, and therefore reduce pollution of the environment.
The present invention employs a flexible bag and light plastic parts to eliminate the need for those heavy metal parts. The washing action is achieved by water movement interacting with the flexible bag and other plastic parts. The water movement is a pulsating action within the water achieved by pumping, by vibrating or by shaking in or about some part of the bag with the water transmitting the action through the clothes. This not only forces the water through the clothes, but also causes the clothes to rub against each other and the bag. Thus the dirt is loosened and rinsed away.
Surprisingly, the rubbing between the water and the electrically polarized dielectric surface of the plastic parts or flexible bag causes a surprising increase in the washing efficiency due to the generation of ionic action in the water. Further improvement in the cleaning properties of water is accomplished by optional magnetic treatment of the water. A vacuum apparatus is used to extract liquid and air from the bag and the bag thus collapses by atmospheric pressure squeezing the clothes forcing the water out. Repeated cycles of air vacuum out of the bag, and air pressure into the bag will extract more water and fluff the clothes to result in clothes dry enough to put in a clothes dryer or to hang on hangers for final drying. Means to fill and empty the bag with water and means to control the various cycles which are obvious to those versed in the art will complete an automatic washing machine. By virtue of a collapsible bag, and the unobvious benefits it enables, an entire, normal capacity washing machine is reduced into a volume that is suitable to be stored in an out of the way place when not in use. Elimination of the heavy metal parts of the currently popular conventional automatic washing machine of the prior art results in an automatic washing machine that is light enough to be lifted by one hand and carried into storage.
Unlike many other attempts to fill the need for a space saving appliance, this invention operates in the manner to which the homemaker is already accustomed, and little, if any, instruction is needed.
This invention will fill that long recognized and unfilled need for full sized automatic laundry capability in the home without the requirement for space normally dedicated to laundry machines. The automatic washing machine of the present invention has a capacity comparable to a standard automatic washing machine without the disadvantages associated with the space and weight requirements of a standard automatic washing machine according to the prior art. This machine has broken through two major barriers in this area, size and weight. The size of a standard washing machine is over come by the machine of this invention using smaller parts and also by being collapsible. In this invention, the weight of the standard washing machine is overcome not only by the use of lighter materials, but by an unexpected efficiency of the flexible tub washing method which results in a much more energy efficient agitating system. This energy efficiency results in supporting hardware being light enough to be easily carried manually. Using a flexible bag instead of a steel tub, the flexible bag and it's contents can be set in motion at any one area and the motion is transmitted throughout the entire bag by the inter-reaction of the water, the items being washed, and the flexible bag. This eliminates an energy wasting need for an agitator to drag the clothes back and forth.
This flexible bag has another unexpected advantage in that in the pumping out of the water with a vacuum pump, the bag collapses and actually wrings the water out by transmitting the outside atmospheric pressure to the clothes. The previous need for the water to be either wrung out by passing the clothes through rollers, or extracted by the centrifugal force of spinning has been eliminated.
The invention has uses beyond normal home laundry. Dry cleaning, car parts washing, farm produce washing, separation of clay from gold in a mining operation are but a few of the obvious uses.
Many obvious modifications come to mind that have not been included above. Examples of such things that anyone versed in the art would assume to be obvious are:
The size is not limited to that of the standard household washing machine. A much larger or smaller version is obviously within the scope of the invention.
Substitution of various assemblies for individual components, or the addition or deletion of check valves in place of controlled valves are but a few among many of the various options.
Cleaning fluid or other washing solution could be used instead of water.
Water treatment device may be in line, cartridge, or designed into the structure of the apparatus. Water treatment device may be built in or may be a replaceable cartridge. Water treatment device may be an option depending on water condition in users area.
The washing container does not have to be round. It may be oval or some other shape. It may have a rigid side and be only partially collapsible.
The screen does not have to be flat. It could be curved. Many parts that have been shown flat could be curved. Corners could be rounded. The base housing could be smaller than the bag.
The air pump and the vacuum pump may be designed into a single unit using a single motor. The motor may be multi speed, depending on the load, whether it is water or air. The pump unit may even be in combination with control valves.
The closure means of the top opening bag need not be a drawstring. It can be other means such as a water proof zipper, a clamp, or other conventional closing device.
Some embodiments could even be operated in case of a lack of power. the bag could be loaded, massaged by hand or foot, then the clothing removed and hand wrung.
In an alternate design for a horizontal embodiment, the suitcase lid can be the horizontal surface with the hinge on the back (bottom) and the clasp on the top near the handle. The suitcase can be opened in a standing position and the lid lay back on the floor with the bag falling into the lid. The bag and bag holder is then opened away from the housing for clothes to be inserted or removed.
The hoses and power cord can be stored in the lid when not in use.
On models that open other than at the top of the bag, an interlock could be used as in conventional front loader machines, to prevent opening at the wrong time and spilling water.
While plastic has been described, a more rugged embodiment could have many parts made of metal.
The bag may be tapered so that with age, if it swells it will not become unstable.
Many items detailed above are optional, and can be omitted. Many can be changed in size, made of different material, made of a different shape, connected or associated in a different manner, made integrally or in sections, or varied in other ways without departing from the invention in its broader aspects. These items are offered by way of illustration only and not as a limitation.
Since the only difference between sonic and ultrasonic is the frequency range, the sonic and ultrasonic washing actions can be combined by the substitution of a wide range waveform generator/power amplifier instead of the ultrasonic generator and the sound generator/power amplifier, and substitution of a wide range underwater transducer instead of the underwater speaker and the ultrasonic vibrator and plate.
Several alternate scrubbing actions and means of generating those actions have been described. Others too numerous to include are obvious to one versed in the art. Other examples include a bag laying on motion device, rocking, kicking or shoving by any means, motion imparted from a vibrating object inside the bag, motion imparted from a vibrating device outside the bag, any alternating deformation of the bag, injection and extraction of fluid into and out from the bag, friction with sides, friction with items, circulating fluid inside the bag and circulating air bubbles within the fluid. A set of multiple agitating methods could be used simultaneously, or alternatingly.
Many variations on agitation have been presented. Many more are obvious to one versed in the art. A few examples will illustrate the variety. Where agitation is accomplished by reversing the flow of water in the bag, a reversible pump could be used for reversing the flow of water. Conventional automatically operated valves could be used for reversing the flow of water. A manifold with water jets in at least two directions could be used for reversing the flow of water. Each of the directions could be used independently.
Many variations on built in water treatment devices have been presented. Many more are obvious to one versed in the art. A few examples will illustrate the variety. An ion exchange water treating cartridge, could be installed for those with hard water. Rapid vibration of the fluid which results in cavitation, has been presented as a means of agitation. Others versed in the art might argue that it is a means of water treatment. Many physical phenomena result in the improvement of cleaning properties of water. The intent is to include as many as are obvious to one versed in the art. The inclusion of water treatment, whatever form it may take, is an object of the invention.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. For example, where water is mentioned throughout the descriptions, it is obvious that any cleaning solution may be substituted, where textiles or clothes are mentioned throughout the descriptions, other objects could be washed including such diverse items as farm produce or the removal of clay from placer gold. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
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An automatic laundry washing machine that is suitable for use in living units having no area set aside for laundry facilities is achieved by replacing the heavy bulky parts of the currently popular automatic washing machine design with a light flexible bag. A large portion of the volume of any washing machine is the vessel for containing the laundry solution and articles to be washed. That vessel is a flexible bag made of modern durable material so as to be collapsible both while in use and for storage. The method of use includes the complete process of washing, rinsing, and extracting excess water in an automatic cycle analogous to standard automatic washing machines popular today. The vessel containing the items being laundered is a waterproof laundry bag with automatic washing apparatus attached. Items are automatically washed in that bag. The automatic process includes cycles of filling, washing, rinsing and extracting such that the clothes are ready for a drying process such as hanging out to dry or putting into a tumble dryer. The agitating of the washing and rinsing cycles is accomplished without the familiar bulky agitator thereby reducing the volume requirements and the traditional wear and tear on the garments. By eliminating the bulky agitator and the spin water extraction method, the heavy transmission is also eliminated. The water extraction cycle is done in a much less violent way than the conventional spin cycle by allowing atmospheric pressure to collapse the washing vessel and press the water from the articles as the water and air are pumped from the vessel in the draining portion of the cycle. The cleaning ability of the water is enhanced by built in ionic processing of the water thereby reducing the required amount of laundry detergent. The agitating in the non-electrically conductive vessel generates static electric charges in the process and ions thus produced further enhance the cleaning ability of the water. Cavitation produced in a multi-frequency washing action further enhances the washing ability of the water. The washing machine is light, compact and collapsible and is as portable as a piece of luggage. The set up procedure is simple and no assembly is required beyond attaching a quick connect fastener to a water faucet and plugging in a power cord. The washing machine is light and takes little storage space. It can be put in a small closet or on a shelf when not in use. The minimum capacity of the washing machine is a single garment. The normal capacity of the washing machine is comparable to that of a standard household washing machine.
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This application is a continuation of application Ser. No. 08/476,316 filed on Jun. 7, 1995, now abandoned, which was a CIP of 08/178,136, filed Dec. 30, 1993, now U.S. Pat. No. 5,435,417.
FIELD OF THE INVENTION
The present invention relates to elevator machinery for and elevator.
DESCRIPTION OF THE BACKGROUND ART
Depending on the placement of an elevator machinery, its physical dimensions have an influence on the size of the elevator shaft and/or building. When the elevator machinery is placed in the elevator shaft, beside the shaft or in a machine room, the properties and dimensions of the machinery have a significance in respect of the space required.
A conventional elevator machinery has a motor, a gear system and a traction sheave as separate parts. A conventional elevator machinery is well suited for installation in a machine room, because there is a sufficient space reserved for it in the machine room. Solutions are also known in which such a machinery is placed in the counterweight or beside the shaft.
An elevator machinery can also have a gearless construction, based e.g. on a disc-type motor as presented e.g. in FIG. 8 of U.S. Pat. No. 5,018,603. The motors presented in the specification are clearly more compact and also flatter in the axial direction of the motor shaft than conventional geared elevator machineries. However, the machineries described in the specification are clearly designed for installation in an elevator machine room.
When a geared or gearless elevator machinery of known construction is placed in the elevator shaft, their space requirement becomes obvious as they always need an extra space.
SUMMARY OF THE INVENTION
The object of the present invention is to achieve a new solution for the placement of an elevator machinery based on a disc-type motor in which the space required by the machinery when installed in the elevator shaft is as small as possible. The elevator machinery of the invention is characterized by said machinery comprising at least an elevator motor and a traction sheave driving elevator ropes, said elevator motor having a discoidal stator, a discoidal rotor, a motor shaft and at least one bearing between the rotor and the stator, the elevator machinery being mounted on a guide rail for the elevator or counterweight.
The invention provides the advantage that the elevator machinery can be installed in the elevator shaft without substantially requiring any extra space in the shaft. The elevator machinery is mounted on an elevator or counterweight guide rail which is needed in the shaft anyway, and the forces caused by the elevator ropes are transmitted directly to the guide rail. Since the guide rail is designed to receive the large vertical forces generated by the action of the safety gears of the elevator, the guide rails need is not be dimensioned separately to permit the installation of the machinery.
An embodiment of the invention has the advantage that the elevator guide rail is used as a structural part of the elevator machinery to increase its strength. In this case, the elevator machinery itself can have a lighter construction and is therefore cheaper to manufacture.
In another embodiment, the vertical forces generated by the elevator ropes are passed via the rolling center of one of the bearings of the machinery to the guide rail. This provides the advantage that no reinforcement is required in that part of the guide rail to which the elevator machinery is attached to increase the rigidity of the rail, because the machinery permits some bending of the guide rail.
In yet another embodiment, the machinery is provided with means for damping vibrations, placed between the elevator machinery and the guide rail. The damping system in this embodiment ensures that bearing noise and the noise and vibrations generated by the elevator ropes in the rope grooves cannot be transmitted to the guide rail and further to the building.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described by the aid of drawings which are given by way of illustration only, and thus are not limitative of the present invention, and in which
FIG. 1 presents an elevator machinery as defined by the invention, seen from the direction of the motor shaft;
FIG. 2 presents a cross-section of the elevator machinery;
FIG. 3 presents another cross-section of the elevator machinery;
FIG. 4 presents a diagram of a lay-out of the elevator machinery in the elevator shaft;
FIG. 5 presents a diagram of another lay-out of the elevator machinery;
FIG. 6 illustrates the vibration damping system of the elevator machinery; and
FIG. 7 presents the vibration damping elements in a cross-section of the elevator machinery.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a gearless elevator machinery 1 as provided by the invention, mounted on a guide rail 6. The guide rail may be an elevator guide rail or a counterweight guide rail and the point of attachment of the elevator machinery to the guide rail may be e.g. in the upper or lower part of the shaft. The elevator machinery 1 comprises a disc-type elevator motor 2, a brake 3 and a traction sheave 4. The elevator ropes 5 are passed around the traction sheave 4. The elevator machinery is fixed by the edge of the stator 9 to the elevator guide rail 6 by means of clawlike clamps 46 on opposite sides of the machinery. Moreover, the elevator machinery is fixed by its central part to the guide rail by means of fixing elements 35 and a supporting element 34. The vertical forces of the elevator machinery are passed to the supporting element 34 and further via shear bolts 31 to the guide rail 6. The clawlike clamps keep the machinery in place on the guide rail and prevent it from turning. The fixing element 35 supports the elevator machinery by means of the shear bolts 36 and, together with the clamps 34, prevents the machinery from turning and moving sideways in relation to the guide rail. Furthermore, there is a protecting device 33 attached to the guide rail 6 by means of fixing elements 32 to prevent the elevator ropes 5 from coming off the rope groove 19 of the traction sheave 4.
FIG. 2 presents the elevator machinery 1 of FIG. 1 as sectioned along line A--A. The elevator machinery 1 comprises an elevator motor 2, a traction sheave 4 driving the elevator ropes 5 and a brake 3 (shown in FIG. 1). The elevator motor consists of a stator 9, a motor shaft 7 and a rotor 8 and a bearing 10 between the rotor 8 and stator 9. The stator 9 consists of a stator disc 11 formed by an annular stator core packet 12 with a stator winding 13. The stator core packet together with its winding is attached by means of fixing elements 53 to the stator disc 11. The fixing elements are preferably screws. The rotor 8 consists of a rotor disc 14 provided with rotor excitation elements 15 placed opposite to the stator core packet 12. The rotor excitation elements 15 are formed by attaching a number of permanent magnets 23 to the rotor disc 8 in succession so as to form a ringlike circle. The magnetic flux of the rotor flows inside the rotor disc. The portion of the rotor disc lying under the permanent magnets forms part of the magnetic circuit and also contributes to the material strength of the rotor. The permanent magnets may be different in shape and they can be divided into smaller magnets placed side by side or in succession.
Between the permanent magnets 23 and the stator core packet 12 there is an air gap ag which forms a plane 16 essentially perpendicular to the shaft 7. The air gap ag may also have a slightly conical shape (not shown in the figure). In this case, the mid-line of the cone coincides with the mid-line 71 of the shaft 7. The traction sheave 4 and the stator 9 are placed on different sides of the rotor disc 14 in the direction of the shaft 7 of the elevator motor 2.
The elevator motor 2 may be e.g. a synchronous motor or a commutating d.c. motor.
The traction sheave 4 forms an integrated structure with the rotor disc 14, and the shaft 7 is integrated with the stator disc 11, but both could just as well be implemented as separate parts. However, an integrated structure is preferable with regard to manufacturing technology. The elevator machinery is mounted on the guide rail 6 by means of a supporting element 34 fixed to the rail with screws 35. The screws carry the axial (vertical) loads of the elevator machinery. Between the supporting element and the guide rail there are also shear bolts 36 (2 pcs) which receive the vertical loads. The shaft 7 is hollow and the end of the supporting element is inside the hollow shaft. The supporting element is provided with a relatively narrow annular boss 37 of about 10 mm, placed in alignment with the focus of the rope load of the elevator and at the same time with one of the bearings 10. Thus, between supporting elements 38, the elevator machinery is attached to the guide rail by means of clamps 46 holding the machinery horizontally by the stator and by means of supporting element 34 and shear bolts 36 supporting it vertically by its central part, allowing some bending of the guide rail in the region of the narrow boss 37. This arrangement provides the advantage that the guide rail need not be so fixed that it is completely rigid in the region of the machinery, but it suffices for the retainment of the guide rail to fix it to the elevator shaft by means of supporting elements 38 placed on opposite sides of the machinery (FIG. 1) and the guide rail still functions as a structural part reinforcing the elevator machinery. Therefore, the stator of the machinery can be of a light construction, providing an economic advantage.
The stator disc 11 is provided with a cuplike or ring-shaped troughlike cavity 20 formed by a first wall 21 and a second wall 22 joined together, leaving the cavity open on one side. The first wall 21 is attached to the shaft 7. The stator core packet 12 with the stator winding 13 is attached to the first wall by means of fixing elements 53. The second wall 22 is directed towards the rotor disc 14.
The elevator machinery of the invention can also be implemented as an embodiment having a stator disc 11 provided with a cuplike or ring-shaped annular cavity 20 open on one side and formed by a first wall 21 and a second wall 22 joined together, both walls being directed towards the rotor disc 14. The first wall 21 is attached to the shaft 7 by means of bracing ribs and the stator core packet 12 with the stator winding 13 is attached either to the first or the second wall. This second embodiment is suited for elevator motors having a very large diameter. The structure is not shown in the figures because the above description is sufficient for a person skilled in the art.
Mounted between the rotor disc 8 and the second wall 22 directed towards the rotor disc 8 is a sealing 24, which may be a felt gasket, a lap seal or some other type of sealing, e.g. a labyrinth seal. The labyrinth seal may be implemented e.g. by providing the rotor disc 14 with a ridge in the sealing zone 24 and the stator disc with collet-shaped ridges placed in a corresponding location on either side of the first ridge. The sealing prevents detrimental particles from getting into the cavity 20.
The rotor disc is provided with a brake disc 90 for a disc brake, forming an extension of the outer circle of the rotor disc. The brake 3 may also be a shoe brake, in which case the braking surface is the outermost part 39 of the annular brake disc. Thus, the brake disc is substantially an immediate extension of the rotor disc, yet with a narrow annular area for a sealing between the rotor bars and the brake disc.
Moreover, the elevator machinery is provided with an outermost wall 40 which extends over the brake disc and forms a baffle plate shielding the brake plate e.g. from being touched.
Placed between the elevator machinery 1 and the guide rail 6 is a damping means for damping vibrations. The figures do not show the damping means, but it is implemented by placing an element made of a damping material such as rubber between the clamps 46 and the guide rail 6. A corresponding vibration damping element, preferably a tubular one, is also provided between the supporting element 34 and the shaft 7 of the elevator machinery.
FIG. 3 presents section B--B of FIG. 1. The machinery has two brakes 3 float-mounted by means of fixtures 42 and 43 between mounting brackets 47 forming an extension of the stator disc 11 and a bar 41 attached to the stator disc. The braking surfaces 44 of the brake are placed on either side of the brake disc. The figure also shows the projectures 45 placed on opposite sides of the stator disc in the direction of the guide rail and directed towards the guide rail, by which the elevator machinery is fastened to the guide rail by means of fixing elements 46.
FIGS. 4 and 5 present diagrams giving two examples of the placement of the elevator machinery I of the invention on a guide rail 6 in an elevator shaft 51.
In FIG. 4, the elevator machinery is fixed to the top end of the guide rail 6 in the manner illustrated by FIG. 1. The guide rail 6 may be either an elevator guide rail or a counterweight guide rail. One end of the elevator rope 5 is attached to the top 52 of the elevator shaft 51 at point 53, from where the elevator rope is passed via diverting pulleys 56 below the elevator car 54 and up to the traction sheave 4 of the elevator machinery 1, from where it is further passed down to the diverting pulley 57 of the counterweight 55 and then back up to point 58 at the top of the shaft, to which the other end of the elevator rope is fixed.
FIG. 5 illustrates another solution, in which the elevator machinery 1 is fixed to the lower end of the guide rail 6 in the elevator shaft 51. One end of the elevator rope 5 is attached to the top 52 of the elevator shaft 51 at point 53, from where the rope is passed down via diverting pulleys 56 below the elevator car 54 and then over a diverting pulley 59 in the top part of the shaft 51 and back down to the traction sheave 4 of the elevator machinery 1 fixed to the lower end of the guide rail. From here, the rope is passed back up to another diverting pulley 60, then downwards to the diverting pulley 57 of the counterweight 55 and back up to point 58 at the top of the elevator shaft, to which the other end of the elevator rope is fixed.
FIGS. 6 and 7 present an application of the vibration damping system in an elevator machinery 1 as defined by the invention, the machinery being mounted on the rail 6 by means of an auxiliary frame 64.
The auxiliary frame 64 consists of a base plate 66, two side plates 65, a top end plate 67 and a bottom end plate 68, said plates being joined together. The side plates are reinforcing plates extending through about one half of the rail height past the T-back towards the guide surface. This solution enables a small total thickness of the machinery to be achieved. The vibration damping elements 61, 62 and 63 between the elevator machinery 1 and the guide rail 6 are attached to the stator 9 and the guide rail 6 via the auxiliary frame 64 in such manner that the auxiliary frame 64 is fixed to the stator 9 and the damping elements 61, 62 and 63 are between the guide rail 6 and the auxiliary frame 64. In principle, it would be possible to use only one damping element, but technically and economically it is advantageous to divide damping element into smaller parts, preferably three parts, a first 62, a second 62 and a third damper 63. Two dampers 62 and 63 prevent the elevator machinery 1 from substantially turning about the longitudinal axis of the guide rail 6, and similarly two dampers, the first 61 and second 62 and/or the first 61 and third 63 dampers, prevent the elevator machinery 1 from substantially deviating vertically from the direction of the guide rail 6. The first damper 61 at the top edge of the machinery is held between the top end plate 67 and a top cover 69, said top cover being attached to the guide rail 6 by means of a fixing element 73. Correspondingly, the second and third dampers 62 and 63 placed side by side below the machinery are held between the auxiliary frame 64 and a lower supporter 70. The lower supporter is attached to the guide rail 6 by means of fixing elements 74. The top cover 69 and the lower supporter 70 are provided with a fillet to prevent sideways movement of the dampers. The shear forces resisting the rotation and rolling over of the machinery are transmitted by guide pins 72 fixed to the auxiliary frame 64 and passing through the dampers. The auxiliary frame 64 also acts as a structural part increasing the rigidity of the stator 9, the auxiliary frame being attached to the stator 9 at a point in its central part in the region of the shaft 7 by means of the supporting element 34 and fixing screws 35 and at two points on the edge of the stator by means of fixing elements 77. One of the hoisting lugs 76 of the machinery is attached to the guide pin 72 going through the first damper 61. The guide pins 72 are passed through holes 75 in the top and bottom end plates. The guide pins act as safety devices after the occurrence of a possible damper breakage, because in that case the guide pin will remain leaning against the top or bottom end plate.
An alternative way of mounting the dampers is to place each damper between two cuplike structures. The upper cup would have a diameter slightly larger than that of the lower cup and would partly surround the lower cup. In the event of a damper breakage, the cup edges would come into contact with each other, thus preventing the elevator machinery from coming off the auxiliary frame.
It is obvious to a person skilled in the art that different embodiments of the invention are not restricted to the examples described above, but that they may instead be varied within the scope of the claims presented below. 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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An elevator machinery (1) with a disc type motor is mounted on one of the guide rails (6) of the elevator car or counterweight. The guide rail (6) constitutes a part adding to the mechanical strength of the elevator machinery. The vertical forces applied to the traction sheave (4) by the elevator ropes are passed to the guide rail (6) via the rolling center of a bearing. The elevator machinery is provided with a damping system to absorb vibrations and oscillations. The elevator machinery (1) of the invention is light in weight, needs only a small space when mounted and is inexpensive to manufacture.
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TECHNICAL FIELD
The present invention relates to a high pressure fuel supply pump for pumping high pressure fuel to an fuel injection valve of an internal combustion engine, in particular, to a high pressure fuel supply pump equipped with an electromagnetic suction valve for adjusting the volume of discharged fuel.
BACKGROUND ART
In a high pressure fuel supply pump equipped with a conventional electromagnetic suction valve described in JP 2002-48033 A, the electromagnetic suction valve is in a valve-opened state where the suction valve is opened by a biasing force of a spring when an electromagnetic coil is not supplied with current. When the electromagnetic coil is supplied with current, the suction valve is closed by magnetic attractive force generated in the electromagnetic suction valve. Accordingly, the opening-closing motion of the suction valve can be controlled by existence and non-existence of the current in the electromagnetic coil; consequently, the supply amount of high pressure fuel can be controlled.
CITATION LIST
Patent Literature
PTL 1: JP 2002-48033 A
SUMMARY OF INVENTION
Technical Problem
When the electromagnetic coil is supplied with current, magnetic attractive force is generated between a core and an anchor, and the anchor, which is a moving element, starts to move in a valve-closing direction of the suction valve. There has been a problem that the anchor stops when colliding with the core, and a large noise is created due to impact at that time. In particular, the noise has been a problem in an idling operation state of a vehicle in which quietness is required.
An object of the present invention is to reduce collision noise generated in an electromagnetic suction valve in a high pressure fuel supply pump.
Solution to Problem
In the present invention, in order to achieve the object, the mass of a member which makes a collision by magnetic attractive force is made small to reduce the noise to be generated. For this purpose, a configuration is made in which a moving element which moves by magnetic attractive force is divided into two parts (an anchor and a rod), and even if the anchor collides with the core and the anchor stops moving, the rod continues to move. Preferably, kinetic energy of the rod is absorbed by a biasing force of a spring which biases the suction valve in a valve-opening direction.
Advantageous Effects of Invention
The present invention configured in this way provides the following advantageous effects.
The noise created when the core and the anchor collides with each other by magnetic attractive force depends on the magnitude of the kinetic energy of the moving element. The kinetic energy consumed by the collision is only the kinetic energy of the anchor. The kinetic energy of the rod is absorbed by the biasing force of the spring and does not contribute to the noise. Therefore, the energy at the collision between the anchor and the core can be made small, and the noise to be generated can be accordingly reduced.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an example of a diagram of a fuel supply system including a high pressure fuel supply pump according to a first embodiment in which the present invention is practiced.
FIG. 2 is a vertical cross sectional view of a high pressure fuel supply pump according to the first embodiment in which the present invention is practiced.
FIG. 3 is another vertical cross sectional view of a high pressure fuel supply pump according to the first embodiment in which the present invention is practiced.
FIG. 4 is an enlarged cross-sectional view of an electromagnetic suction valve in a high pressure fuel supply pump according to the first embodiment in which the present invention is practiced, and, shows a state where the electromagnetic suction valve is in a valve-opened state.
FIG. 5 is an enlarged cross-sectional view of the electromagnetic suction valve in the high pressure fuel supply pump according to the first embodiment in which the present invention is practiced, and shows a state where the electromagnetic suction valve is in a valve-closed state.
FIG. 6 shows a state before the electromagnetic suction valve of the high pressure fuel supply pump according to the first embodiment in which the present invention is practiced is assembled into a pump main body.
DESCRIPTION OF EMBODIMENTS
Based on an embodiment shown in the drawings, the present invention will be described in detail below.
[First Embodiment]
Based on FIG. 1 to FIG. 6 , a configuration of a high pressure fuel supply pump of an embodiment of the present invention will be described.
In FIG. 1 , the part surrounded by the broken line shows a pump housing 1 of the high pressure fuel supply pump, and shows that mechanisms and components illustrated in the broken line are integrally assembled into the pump housing 1 of the high pressure fuel supply pump.
Fuel in a fuel tank 20 is pumped up by a feed pump 21 based on a signal from an engine control unit 27 (hereinafter, referred to as ECU), is pressurized to an appropriate feed pressure, and is fed to a low pressure fuel suction opening 10 a of the high pressure fuel supply pump through a suction pipe 28 .
In FIG. 2 , on the top of the pump housing 1 is fixed a damper cover 14 . On the damper cover 14 is provided a suction joint 101 , which forms a low pressure fuel suction opening 10 a . The fuel having passed through the low pressure fuel suction opening 10 a passes through a suction filter 102 fixed inside the suction joint 101 , and reaches a suction port 30 a of an electromagnetic suction valve 30 further through a low pressure fuel flow path 10 b , a pressure pulsation reduction mechanism 9 , and a low pressure fuel flow path 10 c.
The suction filter 102 in the suction joint 101 has a function of preventing the foreign matters which reside from the fuel tank 20 to the low pressure fuel suction opening 10 a from being taken into the high pressure fuel supply pump by the flow of the fuel.
In the pump housing 1 , there is formed a convex part 1 A as a compression chamber 11 at the center, and in an suction port 30 a at the entrance of the compression chamber 11 there is provided an electromagnetic suction valve 30 . Inside the electromagnetic suction valve 30 is provided a moving element 31 configured with an anchor 31 b and a rod 31 a . In the electromagnetic suction valve 30 , when an electromagnetic coil 52 is not supplied with current, the moving element 31 is moved leftward in the drawing as shown in FIG. 4 by the difference between the biasing force of an anchor spring 34 and the biasing force of an suction valve spring 38 , and an suction valve 39 is in contact with an suction valve holder 35 to be in a valve-opened state. Thus, the electromagnetic suction valve 30 communicates the suction port 30 a and the compression chamber 11 when the electromagnetic coil 52 is not supplied with current.
The outer periphery of a cylinder 6 is held by a cylindrical fitting part 7 a of a cylinder holder 7 . With a thread 7 g cut in the outer periphery of the cylinder holder 7 being screwed into a thread 1 b cut in the pump housing 1 , the cylinder 6 is fixed to the pump housing 1 . In addition, a plunger seal 13 is held on the lower end of the cylinder holder 7 by a seat holder 16 which is press-fit and fixed to an inner periphery cylindrical surface 7 c of the cylinder holder 7 and by the cylinder holder 7 . Here, the axis of the plunger seal 13 is held coaxially with the axis of the cylindrical fitting part 7 a by the inner periphery cylindrical surface 7 c of the cylinder holder 7 . A plunger 2 and the plunger seal 13 are disposed slidably in contact with each other at the lower end, in the drawing, of the cylinder 6 .
This arrangement prevents the fuel in the circular low pressure seal chamber 10 f from flowing into the side of the tappet 3 , in other words, into the inside of the engine. At the same time, this arrangement prevent lubricant oil (including engine oil) for lubricating sliding parts in an engine housing from flowing into the inside of the pump housing 1 .
Further, on the cylinder holder 7 is provided an outer peripheral cylindrical surface 7 b , and in the outer peripheral cylindrical surface 7 b is provided a groove 7 d , in which an O-ring 61 is to be fit. The O-ring 61 , together with the inner wall of a fitting hole 70 in the engine side and the groove 7 d in the cylinder holder 7 , secludes the cam side and the outside of the engine from each other and thus prevents the engine oil from leaking outside.
The cylinder 6 has a pressure-bonding part 6 a intersecting the direction of a reciprocating motion of the plunger 2 , and the pressure-bonding part 6 a is in pressure contact with a pressure-bonding surface 1 a of the pump housing 1 . The pressure contact is made by the force of a tightened screw. The compression chamber 11 is formed by this pressure contact, and the tightening torque of the screw must be controlled so that the fuel does not leak outside the compression chamber 11 through the pressure-bonding part even if the fuel in the compression chamber 11 is pressurized to a high pressure.
In addition, in order to keep the sliding distance between the plunger 2 and the cylinder 6 in an appropriate range, a configuration is made such that the cylinder 6 is inserted deep into the compression chamber 11 . There is provided a clearance 1 B between the outer periphery of the cylinder 6 and the inner periphery of the pump housing 1 on the side of the compression chamber 11 from the pressure-bonding part 6 a of the cylinder 6 . Since the outer periphery of the cylinder 6 is held by the cylindrical fitting part 7 a of the cylinder holder 7 , it can be possible to prevent the outer periphery of the cylinder 6 and the inner periphery of the pump housing 1 from being in contact with each other by providing the clearance 1 B.
In the manner described above, the cylinder 6 holds the plunger 2 , which performs a back-and-forth motion in the compression chamber 11 , slidably in the direction of the back-and-forth motion.
At the lower end of the plunger 2 , a retainer 15 is fixed to the plunger 2 by fitting. The retainer 15 converts the rotational motion of a cam 5 into an up-and-down motion and transfers the motion to the plunger 2 , and the plunger 2 is pressed through the intermediary of the retainer 15 by a spring 4 against the inner surface of the bottom of a tappet 3 . This arrangement enables the plunger 2 to move up and down with the rotational motion of the cam 5 .
In the case that the cam 5 is a three point cam (having three points of a cam) shown in FIG. 2 , one rotation of a crankshaft or an overhead camshaft makes the plunger 2 reciprocate three times. In the case of a four cycle engine, the crankshaft rotates twice in one combustion stroke. In the case of a three point cam, when the crankshaft rotates the cam 5 , the plunger reciprocates 6 times in one combustion cycle (basically, the fuel injection valve injects fuel into the cylinder once) and pressurizes the fuel 6 times and discharges the fuel from a fuel discharge port 12 .
At an outlet of the compression chamber 11 is provided a discharge valve unit 8 . The discharge valve unit 8 is configured with a discharge valve seat 8 a , a discharge valve 8 b which comes in contact with and separates from the discharge valve seat 8 a , a discharge valve spring 8 c biasing the discharge valve 8 b against the discharge valve seat 8 a , and a discharge valve stopper 8 d containing therein the discharge valve 8 b and the discharge valve seat 8 a ; and the discharge valve seat 8 a and the discharge valve stopper 8 d are bonded at a contact part with a welding 8 e to make an integral unit.
In addition, inside the discharge valve stopper 8 d is provided a stepped part 8 f which limits the stroke of the discharge valve 8 b.
In the state where there is no difference in fuel pressure between in the compression chamber 11 and in the fuel discharge port 12 , the discharge valve 8 b is in a valve-closed state, being pressure-contacted with the discharge valve seat 8 a by a biasing force of the discharge valve spring 8 c . Only after the fuel pressure in the compression chamber 11 becomes higher than the fuel pressure in the fuel discharge port 12 , the discharge valve 8 b is opened against the discharge valve spring 8 c , whereby the fuel in the compression chamber 11 is discharged at high pressure into a common rail 23 through the fuel discharge port 12 . The discharge valve 8 b , when opening, comes in contact with the discharge valve stopper 8 d to limit the stroke. Accordingly, the stroke of the discharge valve 8 b is appropriately determined by the discharge valve stopper 8 d . This arrangement can prevent the fuel discharged at high pressure into the fuel discharge port 12 from flowing back into the compression chamber 11 again because of the delay of closing the discharge valve 8 b because of too large a stroke, whereby the efficiency of the high pressure pump can be prevented from decreasing. Further, so as to allow the discharge valve 8 b to move only in the direction of the stroke when the discharge valve 8 b repeatedly opens and closes, the inner periphery surface of the discharge valve stopper 8 d guides the discharge valve 8 b . With the above described arrangement, the discharge valve unit 8 works as a check valve for limiting the flow direction of the fuel.
With these configurations, the compression chamber 11 is configured with the pump housing 1 , the electromagnetic suction valve 30 , the plunger 2 , the cylinder 6 , and the discharge valve unit 8 .
Thus, of the fuel introduced into the low pressure fuel suction opening 10 a , a required amount is pressurized to a high pressure in the compression chamber 11 of the pump housing 1 , which is a pump main body, by the reciprocating motion of the plunger 2 and is pumped to the common rail 23 from the fuel discharge port 12 .
The common rail 23 is equipped with injectors 24 and a pressure sensor 26 . The injectors 24 are provided in accordance with the number of cylinders in the internal combustion engine, and open and close valves in accordance with a control signal of the ECU 27 to inject the fuel into the cylinders.
The high pressure fuel supply pump is fixed on the engine by using a mounting flange 41 , bolts 42 , and bushes 43 . The mounting flange 41 forms a circular fixing part with a full circumference thereof welded to the pump housing 1 on a welded part 41 a . In this embodiment, laser welding is used.
FIG. 4 is an enlarged view of the electromagnetic suction valve 30 in the non-energized state where the electromagnetic coil 52 is not supplied with current.
FIG. 5 is an enlarged view of the electromagnetic suction valve 30 in the state where the electromagnetic coil 52 is supplied with current.
The moving element 31 is made up of two parts: a rod 31 a and an anchor 31 b . The rod 31 a and the anchor 31 b are separate bodies, and between the rod 31 a and the anchor 31 b is provided a fine clearance. Since the rod 31 a is slidably held also by a sliding part 32 d of a valve seat 32 to be described later, the anchor 31 b is slidably held by the rod 31 a so that the motion is limited in the direction of a valve-opening motion and a valve-closing motion.
The suction valve spring 38 is fit in the suction valve 39 and the suction valve holder 35 as shown in FIG. 4 , and the suction valve spring 38 generates a biasing force in the direction to separate the suction valve 39 and the suction valve holder 35 .
The anchor spring 34 is fit in the anchor inner periphery 31 c and the core inner periphery 33 b as shown in FIG. 4 , and the anchor spring 34 generates a biasing force in the direction to separate the anchor 31 b and the core 33 . Here, the biasing force of the anchor spring 34 is set larger than the biasing force of the suction valve spring 38 . With this arrangement, in the state where the electromagnetic coil 52 is not supplied with current, the difference between the biasing force of the anchor spring 34 and the biasing force of the suction valve spring 38 biases the moving element 31 in the valve-opening direction, leftward in the drawing, as shown in FIG. 4 so that the suction valve 39 is in the valve-opened state.
The valve seat 32 is configured with a suction valve seat 32 a , a suction path part 32 b , a press-fitting part 32 c , and a sliding part 32 d . The press-fitting part 32 c is press-fit and fixed in the core 33 . The suction valve seat 32 a is press-fit and fixed in the suction valve holder 35 , and the suction valve holder 35 is further press-fit and fixed in the pump housing 1 . This arrangement perfectly secludes the compression chamber 11 and the suction port 30 a from each other. The sliding part 32 d slidably holds the rod 31 a.
The core 33 is configured with a first core part 33 a , a magnetic orifice part 33 b , a core inner periphery 33 c , and a second core part 33 d.
When the electromagnetic coil 52 is supplied with current, magnetic flux is generated by the magnetic field created around the electromagnetic coil 52 as shown in FIG. 4 , whereby magnetic attractive force is generated between the anchor 31 b and the core 33 . In this embodiment, the components constituting the magnetic circuit are the anchor 31 b , the core 33 , a yoke 51 as shown in. FIG. 4 , and materials of these components are all magnetic materials. In order to increase the magnetic attractive force, it is only necessary to increase the magnetic flux passing through magnetic attractive surfaces S of the anchor 31 b and the core 33 . For this purpose, between the first core part 33 a and the second core part 33 d is provided a magnetic orifice part 33 b . The magnetic orifice part 33 b is made as thin as possible as far as strength allows, and at the same time the other parts of the core 33 are made to have enough thicknesses. Further, the magnetic orifice part 33 b is provided in the vicinity of the place where the core 33 and the anchor 31 b are in contact with each other. Since this arrangement can decrease the magnetic flux passing through the magnetic orifice part 33 b of the core 33 , most of the magnetic flux passes through the anchor 31 b , whereby the decrease of the magnetic attractive force generated between the core 33 and the anchor 31 b is kept within an allowable range.
If cross-sectional area of the magnetic orifice part 33 b is too large, the magnetic flux directly passes between the first core part 33 a and the second core part 33 d , and the magnetic flux passing through the anchor 31 b is accordingly reduced, thereby decreasing the magnetic attractive force. If the magnetic attractive force is small, the response of the moving element 31 is bad, so that the suction valve is not closed or it takes a longer time for the suction valve to be closed, whereby there arises a problem that the amount of the fuel discharged at high pressure cannot be controlled during high speed operation (during high speed rotation of the camshaft) of the internal combustion engine.
A configuration according to this embodiment does not need to use non-magnetic material for the magnetic orifice part 33 b , and the core 33 can be manufactured as an integral component. As a result, the core 33 does not need to be connected with non-magnetic material by using press-fitting, welding, or the like when assembling the core 33 , and machining and assembling of the components can be simplified.
The core 33 is fixed by welding to the pump housing 1 at the welded part 37 , thereby secluding the suction port 30 a and the outside of the high pressure fuel supply pump.
When the electromagnetic coil 52 is in the non-energized state where the electromagnetic coil 52 is not supplied with current and there is no difference in fluid pressure between in the low pressure fuel flow path 10 c (suction port 30 a ) and in the compression chamber 11 , the moving element 31 comes into a state where the moving element 31 has been moved leftward in the drawing as shown in FIG. 4 by the difference between the biasing forces of the anchor spring 34 and the suction valve spring 38 . At this time, since the suction valve 39 comes in contact with the suction valve holder 35 , the position of the suction valve 39 in the valve-opening direction is limited this state, the suction valve 39 is in the valve-opened state. The gap between the suction valve 39 and the valve seat 32 defines a movable range of the suction valve 39 , and this gap corresponds to the stroke.
If the stroke is too large, it takes a longer time for the suction valve 39 to come in contact with the valve seat 32 and be perfectly closed after the suction valve 39 starts the valve-closing motion upon the energization of the electromagnetic coil 52 . In addition, the distance between the anchor 31 b and the core 33 is accordingly larger, whereby the magnetic attractive force to be generated becomes smaller. As a result, the response will be insufficient during the high speed operation (during the high speed rotation of the camshaft) of the internal combustion engine; thus, the suction valve 39 cannot be closed at a targeted time, thereby creating a problem that the amount of the fuel discharged at high pressure cannot be controlled. If the stroke is too small, an orifice effect is larger at this part, and the pressure loss is higher. For example, in the case that the internal combustion engine is operated at high speed (high speed rotation of the camshaft) at a high fuel temperature such as 60° C., the fuel is vaporized in this part when the fuel flows from the low pressure fuel flow path 10 c into the compression chamber 11 on an suction stroke, whereby the amount of fuel to be pressurized to a high pressure is decreased. As a result, there has been a problem that this issue leads to a decrease in the volume efficiency of the high pressure fuel supply pump. In addition, in the return stroke, when the internal combustion engine is operated at high speed (high speed rotation of the camshaft), the fluid force generated on the suction valve 39 (the force in the valve-closing direction generated by the fuel flowing back from the compression chamber 11 to the low pressure fuel flow path 10 c ) becomes large. Thus, the suction valve 39 is closed at an unexpected time in the return stroke, thereby creating a problem that the amount of the fuel discharged at high pressure cannot be controlled. For these reasons, it is very important to control the stroke of the suction valve 39 .
When a configuration is made as described in this embodiment, the stroke is determined only by the component dimensions of the suction valve holder 35 and the suction valve 39 , whereby the variation of the stroke can be minimized by properly setting the tolerances of these components.
Further, the clearance between the anchor 31 b and the core 33 must be set greater than the stroke between the suction valve 39 and the valve seat 32 . If the clearance is smaller than the stroke, the anchor 31 b collides with the core 33 before the suction valve 39 comes in contact with the valve seat 32 after the suction valve 39 starts the valve-closing motion upon the energization of the electromagnetic coil 52 , whereby there arises a problem that the suction valve 39 does not come in contact with the valve seat 32 , in other words, the suction valve 39 cannot come into the perfect valve-closed state. However, the clearance is too large, even if the electromagnetic coil 52 is supplied with current, sufficient magnetic attractive force is not generated. As a result, the moving element 31 cannot be closed, or the response becomes bad, whereby there arises a problem that the amount of the fuel discharged at high pressure when the internal combustion engine is operated at high speed (high speed rotation of the camshaft).
In a configuration according to this embodiment, the clearance is determined only by the dimensions of the components such as the suction valve holder 35 , the valve seat 32 , the rod 31 a , the core 33 , and the suction valve 39 , whereby the variation of the clearance can be minimized by properly setting the tolerances of these component dimensions.
In the state of a suction stroke (during moving from the top dead center position to the bottom dead center position) where the plunger 2 is moved downward in FIG. 2 by the rotation of the cam 5 , the electromagnetic coil 52 is not supplied with current. At this time, the suction valve 39 is open, whereby the volume of the compression chamber 11 is increased. In this stroke, the fuel flows from the suction port 30 a , through the suction path part 32 b of the valve seat 32 and a suction opening 36 , and into the compression chamber 11 . Here, since the amount of displacement of the suction valve 39 is limited by the suction valve holder 35 , the suction valve 39 is not opened further.
In this state, the plunger 2 finishes the suction stroke, and then goes on to the compression stroke (ascending stroke for moving from the bottom dead center to the top dead center). The volume of the compression chamber 11 is decreased with the compression motion of the plunger 2 ; however, in this state, since the fuel once suctioned into the compression chamber 11 is returned back to the low pressure fuel flow path 10 c (suction port 30 a ) through the suction opening 36 in the valve-opened state, the pressure in the compression chamber is not raised. This stroke is referred to as a return stroke.
At this time, to the suction valve 39 , there are applied forces, one of which is in the valve-opening direction and is based on the difference between the biasing force of the anchor spring 34 and the biasing force of the suction valve spring 38 , and the other of which is in the valve-closing direction and is based on the fluid force generated when the fuel flows from the compression chamber 11 back into the low pressure fuel flow path 10 c . In order to keep the suction valve 39 open during the return stroke, the difference between the biasing forces of the anchor spring 34 and the suction valve spring 38 is set larger than the fluid force.
After the electromagnetic coil 52 in this state is supplied with current, magnetic attractive force is generated between the core 33 and the anchor 31 b so that the core 33 and the anchor 31 b attract each other; and when the magnetic attractive force becomes stronger than the difference between the biasing forces of the anchor spring 34 and the suction valve spring 38 , the anchor 31 b starts to move in the valve-closing direction.
The anchor 31 b and the rod 31 a are different bodies; however, when the anchor 31 b has started in the valve-closing direction, the anchor 31 b is engaged with a stopper part 31 f of the rod 31 a , and the anchor 31 b starts to move with the rod 31 a in the valve-closing direction. When the anchor 31 b collides with the core 33 , the anchor 31 b stops moving and collision noise is created due to the kinetic energy which the anchor 31 b has. Since the anchor 31 b and the rod 31 a are slidably held on each other at an anchor sliding part 31 e , the rod 31 a continues to move in the valve-closing direction even after the anchor 31 b stopped moving upon colliding with core 33 , and the rod 31 a then stops moving with the kinetic energy absorbed by the anchor spring 34 . Therefore, the kinetic energy of the rod 31 a does not contribute to the noise. The configuration as described above can reduce the noise due to the collision with the core 33 .
As described above, when the anchor 31 b and the rod 31 a move in the valve-closing direction, only the biasing force of the suction valve spring 38 is applied to the suction valve 39 . Thus, the suction valve 39 is moved by the biasing force of the suction valve spring 38 in the valve-closing direction, and then comes into contact with the suction valve seat 32 a to come into the valve-closed state, thereby closing the suction opening 36 .
When the suction opening 36 is closed, the fuel pressure in the compression chamber 11 is raised with the ascending motion of the plunger 2 . Then, when the pressure becomes higher than the pressure in the fuel discharge port 12 , the fuel left in the compression chamber 11 is discharged at high pressure through the discharge valve unit (discharge valve mechanism) 8 and supplied to the common rail 23 . This stroke is referred to as a discharge stroke. The compression stroke of the plunger 2 is thus constituted by a return stroke and the discharge stroke.
In a discharge stroke, after the pressurized fuel starts to be supplied, the supply of current to the electromagnetic coil 52 can be removed. This is because, when the pressure in the compression chamber 11 becomes higher than the pressure in the fuel discharge port 12 , the force due to the pressure in the compression chamber 11 is applied to the suction valve 39 in the valve-closing direction, and the force becomes larger than the biasing force of the suction valve spring 38 . Thus, the power consumption in the electromagnetic coil 52 can be reduced.
Further, by controlling the time at which the electromagnetic coil 52 of the electromagnetic suction valve 30 is supplied with current, the amount of the discharged high pressure fuel can be controlled.
When the electromagnetic coil 52 is supplied with current at a sooner time, the portion of the return stroke gets smaller and the portion of the compression stroke gets larger in the discharge stroke.
As a result, the smaller amount of fuel is returned to the low pressure fuel flow path 10 c (suction port 30 a ) and the larger amount of fuel is discharged at high pressure.
Alternatively, when the electromagnetic coil 52 is supplied with current at a later time, the portion of the return stroke gets larger and the portion of the discharge stroke gets smaller in the compression stroke. As a result, the larger amount of fuel is returned to the low pressure fuel flow path 10 c , and the smaller amount of fuel is discharged at high pressure. The time to supply current to the electromagnetic coil 52 is controlled by the instruction from the ECU 27 .
When the plunger 2 finishes the compression stroke and starts the suction stroke, the volume of the compression chamber 11 starts to increase again, and the pressure in the compression chamber 11 decreases. Thus, the fuel flows into the compression chamber 11 from the low pressure fuel flow path 10 c through the suction port 30 a . The suction valve 39 starts the valve-opening motion leftward in the drawing due to the difference between the biasing forces of the anchor spring 34 and the suction valve spring 38 ; then, after having moved by the distance of the stroke, the suction valve 39 collides with the suction valve holder 35 and stops the motion. Since this collision is caused by the difference between the biasing forces of the anchor spring 34 and the suction valve spring 38 , the energy of collision is not so large. Therefore, the collision part does not need to have high hardness. For this reason, this embodiment employs austenite stainless steel as the material for the suction valve holder 35 . In addition, at this time, the anchor 31 b is engaged with the stopper part 31 f of the rod 31 a and performs the valve-opening motion together with the rod 31 a.
By configuring as described above and controlling the time to supply current to the electromagnetic coil 52 , the amount of the fuel discharged at high pressure can be controlled to be the amount which the internal combustion engine requires.
At this time, the moving element 31 repeats the motion in the lateral direction in the drawing with the descending and ascending motion of the plunger 2 , and the suction valve 39 repeats the opening-closing motion of the suction opening 36 . Here, since there are fine clearances between the anchor 31 b and the rod 31 a of the moving element 31 and between the rod 31 a and the valve seat 32 , the moving element 31 is slidably held, with the motion being limited in the direction of the valve-opening motion and the valve-closing motion, thereby repeating a sliding motion. The clearances at the two sliding parts are set as follows. If the clearances are too large, the rod 31 a and the anchor 31 b move in a direction different from the valve-opening motion or the valve-closing motion. Then, the response of the valve-opening motion and the valve-closing motion will be bad, whereby the opening and closing of the suction valve 39 cannot follow during the high speed operation (during the high speed rotation of the camshaft) of the internal combustion engine, and the amount of the discharged high pressure fuel cannot be controlled. Therefore, the clearances need to be set have appropriate values. In addition, the anchor sliding part 31 e and the sliding part 32 d need to have sufficiently low surface roughness so as not to create friction against the valve-opening motion and the valve-closing motion of the moving element 31 .
Further, since high hardness is required from the point of view of durability, martensite stainless steel having high hardness is used as the material for the suction valve 39 , the valve seat 32 and the rod 31 a.
The martensite stainless steel as the material for the rod 31 a and the valve seat 32 is known as magnetic material, which creates magnetic flux therein when located in a magnetic field. Thus, a flow of magnetic flux is created in the rod 31 a and the valve seat 32 through the anchor 31 b , thereby generating magnetic attractive force with which the rod 31 a and the valve seat 32 attract each other. However, in the configuration of this embodiment, most of the magnetic flux flows through only the magnetic attractive surface S between the anchor 31 b and the core 33 , whereby there is no possibility that the suction valve 39 cannot be opened.
In addition, when the moving element 31 repeats the valve-opening motion and the valve-closing motion, the rod 31 a gets in and out of the internal cylindrical part of the core 33 , whereby the volume of the fuel in the internal cylindrical part of the core 33 increases and decreases.
Since the internal cylindrical part of the core 33 is filled with fuel, when the rod 31 a gets in and out of the internal cylindrical part of the core 33 , the fuel displaced by the rod 31 a have to reciprocates right and left in the drawing through a guide part 32 d of the valve seat 32 . However, the clearance between the guide part 32 d and the rod 31 a of the valve seat 32 is so thin that sufficient amount of fuel cannot pass through, thereby impeding the response of the valve-opening motion and the valve-closing motion of the moving element 31 . To address this issue, a communication hole 32 e is provided in the valve seat 32 .
A volume of the space inside the cylindrical part constituted by the inner periphery surface of the anchor 31 b and the inner periphery surface of the core 33 also increases and decreases with the valve-opening motion and the valve-closing motion of the moving element 31 . Further, when the anchor 31 b and the core 33 collides with each other, the space inside the cylindrical part becomes perfectly sealed; thus, there is a problem that at the moment when the anchor 31 b leaves from the core 33 and moves onto the valve-opening motion, the pressure decreases, whereby the valve-opening motion of the moving element 31 becomes unstable. To address this problem, an anchor communication hole 31 d is provided in the anchor 31 b.
The configuration as described above facilitates the fuel to pass through and secures the response of the valve-opening motion and the valve-closing motion of the moving element 31 .
The electromagnetic coil 52 is configured with a lead wire 54 wound about the axis of the moving element 31 . The both ends of the lead wire 54 are welded to the terminals 56 at the lead wire welded part 55 . The terminals are made of conductive material and opened at a connector part 58 , and when a connector from the ECU 27 is connected to the connector part 58 , the terminals come in contact with the corresponding terminals and transfers current to the electromagnetic coil 52 .
In this embodiment, the lead wire welded part 55 is positioned outside the yoke 51 . Since the lead wire welded part 55 is positioned outside the magnetic circuit, the lead wire welded part 55 does not require the space for the lead wire welded part 55 ; therefore, the magnetic circuit can have a short overall length, which arrangement makes it possible to generate sufficient magnetic attractive force between the core 33 and the anchor 31 b.
FIG. 6 shows the state before the electromagnetic suction valve 30 being assembled in the pump housing 1 .
In this embodiment, a suction valve unit 81 and a connector unit 82 are made first as units. Next, the suction valve holder 35 of the suction valve unit 81 is press-fit and fixed to the pump housing 1 , and welding is then performed at the welded part 37 all around the circumference. In this embodiment, laser welding method is used for welding. In this state, the connector unit 82 is press-fit and fixed to the core 33 . With this method, the direction of the connector part 58 can be freely selected.
In the above three strokes of the suction stroke, the return stroke, and the discharge stroke, the fuel gets in and out of the suction port 30 a (low pressure fuel flow path 10 c ) all the time; thus, the fuel pressure has a cyclic pulsation. This pressure pulsation is absorbed and reduced in the pressure pulsation reduction mechanism 9 , and the pressure pulsation is blocked from being transmitted to the suction pipe 28 which communicates from the feed pump 21 to the pump housing 1 , thereby preventing breakage or the like of the suction pipe 28 and enabling the fuel to be supplied to the compression chamber 11 with stable fuel pressure fuel. Since the low pressure fuel flow path 10 b is connected to the low pressure fuel flow path 10 c , the fuel is well supplied to the both sides of the pressure pulsation reduction mechanism 9 , thereby effectively reducing the pressure pulsation of the fuel.
The pressure pulsation reduction mechanism 9 is configured with two metal diaphragms, the outer peripheries of which are fixed by welding at a welded part at all the circumference with the space between the both diaphragms filled with gas. The pressure pulsation reduction mechanism 9 is also configured such that, when the both sides of the pressure pulsation reduction mechanism 9 are loaded with a low pressure pulsation, the pressure pulsation reduction mechanism 9 changes the volume so that the low pressure pulsation is reduced.
The plunger 2 is made up of a large-diameter part 2 a to slide on the cylinder 6 and a small-diameter part 2 b to be slide on the plunger seal 13 . The diameter of the large-diameter part 2 a is set greater than the diameter of the small-diameter part 2 b , and both are set coaxial to each other. Between the lower end of the cylinder 6 and the plunger seal 13 , there is provided a circular low pressure seal chamber 10 f , and the circular low pressure seal chamber 10 f provided in the cylinder holder 7 communicates with the low pressure fuel flow path 10 c through low pressure fuel communication paths 10 d and 10 e , and a circular low-pressure path 10 h . Since a stepped part 2 c between the large-diameter part 2 a and the small-diameter part 2 b is located in the circular low pressure seal chamber 10 f , when the plunger 2 repeats a sliding motion in the cylinder 6 , the stepped part between the large-diameter part 2 a and the small-diameter part 2 b repeats an up-and-down motion in the circular low pressure seal chamber 10 f , hence changing the volume of the circular low pressure seal chamber 10 f . In the suction stroke, the volume of the circular low pressure seal chamber 10 f decreases, and the fuel in the circular low pressure seal chamber 10 f flows to the low pressure fuel flow path 10 c through the low pressure fuel communication paths 10 d and 10 e . In the return stroke and the discharge stroke, the volume of the circular low pressure seal chamber 10 f increases, and the fuel in the low pressure fuel communication path 10 d flows to the circular low pressure seal chamber 10 f through the low pressure fuel communication path 10 e.
In regard to the low pressure fuel flow path 10 c , in the suction stroke, the fuel flows into the compression chamber 11 from the low pressure fuel flow path 10 c , and on the other hand, the fuel flows into the low pressure fuel flow path 10 c from the circular low pressure seal chamber 10 f . In the return stroke, the fuel flows into the low pressure fuel flow path 10 c from the compression chamber 11 , and on the other hand, the fuel flows into the circular low pressure seal chamber 10 f from the low pressure fuel flow path 10 c . In addition, in the discharge stroke, the fuel flows into the circular low pressure seal chamber 10 f from the low pressure fuel flow path 10 c . As described above, since the circular low pressure seal chamber 10 f has a function to help the fuel get in and out of the low pressure fuel flow path 10 c , the circular low pressure seal chamber 10 f is effective to reduce the pressure pulsation of fuel created in the low pressure fuel flow path 10 c.
Reference Signs List
1 pump housing
2 plunger
2 a large-diameter part
2 b small-diameter part
3 tappet
4 cam
6 cylinder
7 cylinder holder
8 discharge valve unit
9 pressure pulsation reduction mechanism
10 a low pressure fuel suction opening
10 b , 10 c low pressure fuel flow path
10 d , 10 e low pressure fuel communication path
10 f circular low pressure seal chamber
11 compression chamber
12 fuel discharge port
13 plunger seal
20 fuel tank
21 feed pump
23 common rail
24 injector
26 pressure sensor
27 engine control unit (ECU)
30 electromagnetic suction valve
31 moving element
31 a rod
31 b anchor
31 c anchor inner periphery
31 d anchor communication hole
31 e anchor sliding part
32 valve seat
33 core
34 anchor spring
35 suction valve holder
38 suction valve spring
39 suction valve
52 electromagnetic coil
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To reduce collision noise created by the operation of an electromagnetic suction valve provided on a high pressure fuel supply pump. In the present invention, in order to achieve the above object, the mass of a member which collides by magnetic attractive force is reduced to reduce the noise to be generated. The thus configured present invention provides the following advantageous effects. The noise generated when a core and an anchor collide with each other by magnetic attractive force depends on the magnitude of the kinetic energy of a moving element. The kinetic energy to be consumed in the collision is only the kinetic energy of the anchor. The kinetic energy of a rod, being absorbed by a spring, does not contribute to the noise; thus, the energy when the anchor and the core collide with each other can be reduced, whereby the noise to be created can be reduced.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus for continuously inspecting the degree of firmness at which an individual bottom stop box is attached to a separable slide fastener, and a separable slide fastener bottom stop box attaching machine, for a separable slide fastener manufacturing system, which is equipped with the inspecting apparatus.
2. Description of the Related Art
U.S. Pat. No. 4,671,122 discloses an apparatus for inspecting the attached state of a separable slide fastener bottom stop box by inserting inspecting projections into notches which are clinched previously to attach the bottom stop box to a box pin and then detecting the depth of insertion after the box pin fixed to one fastener tape and an insertion pin fixed to the other fastener tape are inserted into a metallic box and, at the same time, the notches are clinched.
A method of attaching a thermoplastic synthetic resin box by ultrasonic welding is disclosed in Japanese Patent Publication No. SHO 63-40088. In the attaching method, the welded state of the box and the box pin are inspected in terms of melting and smashing of the projection previously formed on the box surface.
In the method for inspection in terms of depth of clinching notches, since the notches are deformed after the box has been attached, the appearance of the resulting separable bottom stop would be remarkably deteriorated. On the other hand, in the method for inspection in terms of degree of melting and smashing of the projection, partly since the melted projection on the box surface deteriorates the appearance of the separable bottom stop, and partly since the attached state of the box is estimated indirectly from the degree of melting and smashing of the projection, reliable inspection is difficult to achieve.
It is an object of this invention to provide an inspecting apparatus for directly inspecting the degree of firmness of attachment of a separable slide fastener bottom stop box without deteriorating its appearance after attaching the box, and a separable slide fastener bottom stop box attaching machine equipped with the inspecting apparatus for reliably grasping the attached state of the box.
SUMMARY OF THE INVENTION
In order to accomplish the above object, according to a first aspect of the invention, there is provided an apparatus for continuously inspecting the attached states of successive bottom stop boxes attached to separable slide fasteners, comprising a pair of tape grip members movable forwardly and backwardly along a travelling path of a fastener tape to which the individual bottom stop box is attached. The tape grip members are situated upwardly and downwardly of the fastener tape travelling path in confronting relationship, each of the tape grip members being pivotally movable about the horizontal axis extending through its central portion. The tape grip members have urging means for normally urging their upstream ends toward each other, and forced turning means for forcedly turning their downstream ends toward and away from each other. The apparatus further comprises a moving body situated on one side of the grip members for moving forwardly and backwardly together with the grip members, a contact member situated in a fixed position in a path of movement of the moving body and normally urged toward the moving body by a predetermined resilience, and detecting means for detecting an amount of movement of the grip members when the moving body is moved to a predetermined length against the predetermined resilience in contact with the contact member.
According to a second aspect of the invention, there is provided a separate slide fastener bottom stop box attaching machine equipped with an inspecting apparatus as described above, comprising a pair of gripping tips on respective upstream ends of the grip members for gripping the fastener tapes from their upper and lower sides; a movement restricting member for restricting the upstream movement of the grip members; forward feeding means situated downstream of the grip members for forwardly feeding the fastener chain intermittently; a box attaching unit situated near to and upstream of the movement restricting member; backward feeding means situated upstream of the box attaching unit; and controlling means for actuating the forced turning means to cause the gripping tips to forcedly grip the fastener tapes while the box is supplied to the box attaching unit, and also for actuating the backward feeding means and opening the gripping tips when the box is attached to the fastener tapes.
With the separable slide fastener bottom stop box attaching machine, when the forward feeding means is driven to feed the fastener chain forwardly by a length equal to the length of a single slide fastener, the forced turning means of the inspecting apparatus becomes operative to open the upper and lower gripping tips of the grip members so that the fastener chain can freely travel in the inspecting apparatus. With continued feeding of the fastener chain, an element-free space portion to which a box is to be attached is detected and a detection signal is sent to the control unit in order to form cutaways in the tapes with a predetermined time difference. Simultaneously, the forward feeding means is stopped and the forced turning means is operative to close the upper and lower gripping tips of the gripper members to grip the opposite fastener tapes of the fastener chain firmly. Then, a box is supplied to the box attaching position from a box supplying unit and stays in such position. When the box is supplied to the box attaching position, the backward feeding means becomes operative to backwardly feed the fastener chain together with the inspecting apparatus.
When the fastener chain is backwardly fed, the inspecting apparatus firmly gripping the fastener chain is also moved simultaneously. The movement restricting member is situated in such a position that the box can be supplied to the position where the box is attached. When the inspecting apparatus is brought into contact with the movement restricting member, the backward feeding means is stopped with the fastener chain in a predetermined tension. During this backward feeding, the box staying in the waiting position will be threaded onto the fastener tapes from the cutaways, and then an insertion pin and a box pin are inserted into the box. Since the fastener chain has a predetermined tension when the insertion pin and the box pin are inserted into the box, it is possible to enable smooth insertion of the insertion pin and box pin without spreading the opposite tapes at the element-free space portion. Then the box attaching machine will be operative to weld the box and box pin together.
When the box and box pin are welded together, the backward feeding means releases the grippping of the fastener chain and, at the same time, the forced turning means of the inspecting apparatus becomes inoperative so that the fastener tapes are gripped by the upper and lower gripping tips under the resilience of urging means (the spring). This resilience of the spring is determined to such a low degree that the fastener chain can travel between the upper and lower gripping tips when it is fed by the forward feeding means (chain feed rollers). Then the forward feeding means becomes operative to feed the fastener chain. At that time, the fastener chain will slide between the upper and lower gripping tips. During the feeding of the fastener chain, the attached box will come into contact with end surfaces of the grip members between the horizontally opposite gripping tips to move the inspecting apparatus with the fastener chain forwardly. During the moving of the inspecting apparatus, the moving body comes into contact with the contact member and keeps moving forwardly a predetermined distance with the contact member against a predetermined resilience. When the moving body is detected by the displacement-of-grip-member detecting means as it has moved forwardly a predetermined distance, the detecting means will send a detection signal to the control unit to actuate the forced turning means of the inspecting apparatus so that the upper and lower gripping tips of the grip members will spread against the resilience of the spring, thus allowing the box to pass freely between the upper and lower gripping tips. At that time, since the resilient force of the compressed spring exerts on the moving body, the inspecting apparatus is resiliently moved backwardly via the moving body and the fastener chain is fed forwardly. The backwardly moved inspecting apparatus then collides against the movement restricting member and will stay there until the next inspection.
The foregoing is the case where the attaching of the box is complete. Assuming that the attaching of the box is incomplete, when the forward feeding means starts feeding the fastener chain, the fastener tapes slide between the upper and lower gripping tips as described above. During the feeding of the fastener chain, when the box welded to the box pin comes into contact with the end surfaces of the grip members between the horizontally opposite gripping tips, the non-secured box is removed instantly from the fastener chain. If the attachment of the box is not firm enough, the box with the fastener chain will be moved forwardly in contact with the inspecting apparatus, however, when the moving body comes into contact with the contact member during the forward moving of the box, the box is removed from the fastener chain and solely the fastener chain is fed. When the box is thus removed from the fastener chain, it will be detected by a non-illustrated suitable detecting means and marking will be made by a non-illustrated known marking unit before feeding to the next station.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a typical embodiment of a box attaching machine, for successively attaching separable bottom stop boxes to a fastener chain, which is equipped with an apparatus for inspecting the attached state of boxes, according to this invention;
FIG. 2 is a schematic view showing the arrangement of constituent parts of the box attaching machine;
FIG. 3 is a plan view, with parts broken away, of the box attaching machine, showing the manner in which the fastener tapes are gripped by the inspecting apparatus;
FIG. 4 is a plan view, with parts broken away, of the box attaching machine, showing the manner in which the fastener tapes with the inspecting apparatus are moved backwardly;
FIG. 5 is a plan view, with parts broken away, of the box attaching machine, showing the manner in which the inspecting apparatus is moved forwardly as being pushed by the box;
FIG. 6 is a vertical cross-sectional view, with parts broken away, of the box attaching machine, showing the manner in which the inspecting apparatus is moved forwardly as being pushed by the box; and
FIG. 7 is a vertical cross-sectional view, with parts broken away, of the box attaching machine, showing the inspecting apparatus after inspection has been completed.
DETAILED DESCRIPTION
A typical embodiment of this invention will now be described in detail with reference to the accompanying drawings. FIG. 1 is a fragmentary perspective view of a box attaching machine, for continuously attaching separable bottom end boxes to a fastener chain, which is equipped with an inspecting apparatus for inspecting the attached state of the individual separable bottom end box. FIG. 2 is a schematic view showing the arrangement of constituent parts of the box attaching machine. FIGS. 3 through 5 are plan views, with parts broken away, of the box attaching machine, showing the operation of the machine. And FIGS. 6 and 7 are vertical cross-sectional views of the box attaching machine.
The inspecting apparatus 1 comprises upper and lower grip members 4 which are vertically oppositely arranged in a tunnel-shape casing 2 in a travelling path of a pair of horizontally opposed fastener tapes T of a fastener chain C with boxes attached. Each of the grip memers 4 is pivoted at its central portion by a horizontal shaft 3. The inspecting apparatus also comprises a moving body 6 attached to a side portion of the casing 2 parallel to it via a bracket 5, a contact member 8 which is situated in a fixed position in alignment with one end of the moving body 6 and which is normally urged toward the moving body 6 under a predetermined resilience of s compression spring 7, and a detector 9, such as a microswitch or a light detector, for detecting the extent of movement of the grip members 4 at the fixed position when the moving body 6 pushes the contact member 8 and moves a predetermined distance against the resilience of the spring 7.
The casing 2 can be freely movable forwardly and backwardly along the travelling path of the fastener tapes T in a non-illustrated locus. Each of the grip members 4 has on its upstream end a horizontal pair of gripping tips 4a and has a varying thickness decreasing gradually from the central portion to the downstream end in such a manner that confronting surfaces of the grip members 4 are remote from each other gradually toward the downstream end. A compression spring 10 is situated between the upstream end of each grip member 4 and the casing 2. To the downstream end of each grip member 4, the end of a rod of an air cylinder 11 mounted on the casing 2 is fixed. Therefore, when the air cylinder 11 is in a free state, the upper and lower grip members 4 angularly move about the respective horizontal shafts 3 by the respective compression springs 10 to resiliently catch the fastener tapes between the upper and lower gripping tips 4a. When the air cylinder 11 is operative to shrink the rod, the upper and lower gripping tips 4a grips the fastener tapes firmly. If the air cylinder 11 is operative to expand the rod, the upper and lower gripping tips 4a are removed from the fastener tapes to allow the fastener tapes T to travel freely.
The moving body 6 is a bolt, and the position of its head is adjustable by adjusting the extent to which the bolt is threaded into the bracket 5. Reference numeral 6a designates a nut for fixing the head position of the bolt 6. The contact member 8 situated in confronting relationship with the head of the bolt 6 is a bar having a head at each of opposite ends. As shown in FIGS. 3 through 7, the contact member 8 is slidably inserted into a recessed portion 12a having a through hole 12b at a bottom portion and formed on a block body 12 located in a fixed position. The contact member 8 is normally urged toward the head of the bolt 6 under a predetermined resilience of the compression spring 7 received in the recessed portion 12a. The detector 9 for detecting the extent of movement of the grip members 4 sends a detection signal to a non-illustrated drive for the air cylinder 11 to cause the air cylinder 11 to be operative or inoperative as described above.
With even solely the inspecting apparatus of this invention, it is possible to inspect the attached state of each of successive separable bottom stop boxes attached to a fastener chain or a separable slide fastener. The box attaching machine in which the inspecting apparatus 1 is incorporated will now be described with reference to FIG. 2, from which a wide variety of applications of this invention will be understood.
FIG. 2 is a schematic view showing the arrangement of constituent parts of the box attaching machine. In the box attaching machine, a movement restricting member 13 is situated in a fixed position adjacent to the upstream end of the casing 2 for restricting the extent of upstream movement of the casing 2 and the grip members 4 (shown in FIGS. 1, 6 and 7), and an ultrasonic welder 14 composed of an ultrasonic horn 14a and an anvil 14b is situated adjacent to the upstream end of the movement restricting member 13.
A pair of feed rollers 15 for forwardly feeding the fastener chain C intermittently is situated downstream of the inspecting apparatus 1, and a backward feeding unit 16 is situated upstream of the ultrasonic welder 14. The backward feeding unit 16 is located on the travelling path of the fastener tapes T and is composed of a first air cylinder 16b having a tape support member 16a on the rod end, and a second air cylinder 16d having a tape pressure member 16c on the rod end. The second air cylinder 16d is movable forwardly and backwardly on the travelling path of the fastener chain as guided in a non-illustrated locus. With the fastener chain C gripped between the tape support member 16a and the tape pressure member 16c as the second air cylinder 16d is operated, when the first air cylinder 16b is operated to expand its rod, the fastener chain C will be moved backwardly a predetermined distance.
Between the backward feeding unit 16 and the ultrasonic welder 14, there are arranged a space detector 17 for detecting an element-free space portion S to which a box P is to be attached, and a punch unit 18 downstream of the space detector 17 for forming cutaways T-1 at the element-free space portion S of opposed tapes T in order to facilitate the attaching of the box P. At a position adjacent to the ultrasonic welder 14, a box supplying unit 19 is situated for intermittently supplying successive boxes P to a welding portion of the ultrasonic welder 14. Reference numeral 20 in FIG. 2 designates a control unit. These units and devices arc well known in the art, so their detailed description is omitted here. The actuation of these units and device is performed according to the procedure previously stored in the control unit 20, based on command signals from the control 20.
According to the box attaching machine of this embodiment, when the fastener chain C is fed forwardly by a length corresponding to the length of a single slide fastener by the feed rollers 15, the air cylinder 11 of the inspecting apparatus 1 of this invention is operated to expand its rod to open the upper and lower gripping tips 4a of the grip members 4, thus allowing the fastener chain C to freely travel through the inspecting apparatus 1. While the fastener chain C is fed forwardly, the space detector 17 detects an element-free space portion S to which the box is to be attached. As the detection signal is sent to the control unit 20, the punch unit 18 is operated with a predetermined time difference to form cutaways T-1 in the opposed tapes T. At this time, the feed rollers 15 are stopped, and the air cylinder 11 is operated to shrink its rod to close the upper and lower gripping tips 4a of the grip members 4, thus gripping the opposed tapes of the fastener chain C firmly. Then, the anvil 14b and the clamp 14c holding the box P supplied from the box supplying unit 19 are lowered and, at the same time, the ultrasonic horn 14a is raised to a predetermined position so that the box P is set at the welding portion of the ultrasonic welder 14 and stays at that position. When the box P is supplied to the ultrasonic welder 14, the backward feeding unit 16 is operated to backwardly feed the fastener chain C together with the inspecting apparatus 1.
As the fastener chain C is backwardly moved, the inspecting apparatus 1 holding the fastener chain C firmly is also backwardly moved. The movement restricting member 13 is situated at such a position that the box P is supplied to a position where the box pin PB and the box P can be welded together. When the inspecting apparatus 1 comes into contact with the movement restricting member 13, the backward feeding unit 16 is stopped with the fastener chain C in a predetermined tension. During this backward movement of the fastener chain C, the box P in the waiting position is threaded on the fastener tapes from the cutaways T-1 and, at the same time, the insertion pin BB and the box pin PB are inserted into the box P. Since the fastener chain C has a predetermined tension when the insertion pin BB and box pin PB are inserted into the box P, it is possible to facilitate the inserting of the insertion pin BB and box pin PB without spreading the opposed tapes horizontally at the element-free space portion. Then the ultrasonic welder 14 is operated to weld the box P and the box pin PB together.
When the box P and the box pin PB are welded together, the backward feeding unit 16 releases the gripping of the fastener chain C and, at the same time, the air cylinder 11 of the inspecting apparatus 1 becomes inoperative so that the fastener tapes T are resiliently gripped between the upper and lower gripping tips 4a under the resilience of the compression spring 10. This resilience of the spring 10 is set to such a low degree that the fastener chain C can travel between the upper and lower gripping tips 4a as it is fed by the feed rollers 15. Then the feed rollers 15 starts feeding the fastener chain C. At that time, the fastener tapes T slide between the upper and lower gripping tips 4a. During the feeding of the fastener chain C, the box P welded with the box pin PB comes into contact with the end surfaces of the grip members 4 between the horizontally opposed gripping tips 4a, thus moving the inspecting apparatus 1 forwardly together with the fastener chain C. During the moving of the inspecting apparatus 1, the head of the moving body or bolt 6 comes into contact with the head of the contact member 8 and keep moving forwardly a predetermined distance against the resilience of the compression spring 7. When the head of the bolt 6 is detected by the detector 9 as it is moved the predetermined distance, the detector 9 sends a detection signal to the control unit 20 to cause the air cylinder 11 of the inspecting apparatus 1 to expand its rod, thus spreading the upper and lower gripping tips 4a of the grip members 4 against the resilience of the compression spring 10 so that the box P can pass between the upper and lower gripping tips 4a. At that time, since the stored resilience of the compression spring 7 exerts on the head of the bolt 6, the inspecting apparatus 1 is resiliently moved backwardly via the bolt 6 and, at the same time, the fastener chain C keeps moving forwardly. The backwardly moved inspecting apparatus 1 then collides against the movement restricting member 13 and waits at that position until the next inspection.
The foregoing is the case where the attaching of the box P is complete. Assuming that the attaching of the box is incomplete, when the feed rollers 15 starts feeding the fastener chain C forwardly, the fastener tapes T slide between the upper and lower gripping tips 4a. During the feeding of the fastener chain C, when the box P welded with the box pin PB comes into contact with the end surfaces of the grip members 41, between the horizontally opposite gripping tips 4a, the non-secured box P is removed instantly from the fastener chain C. If the attachment of the box P is not firm enough, the box P with the fastener chain C is moved forwardly in contact with the inspecting apparatus 1, however, when the head of the bolt 6 comes into contact with the head of the contact member 8 during the forward moving of the box P, the box P is removed from the fastener chain C and solely the fastener chain C is fed forwardly. When the box P is thus removed from the fastener chain C, it will be detected by a non-illustrated suitable detecting means and marking will be made by a non-illustrated known marking unit before feeding to the next station.
In the above-mentioned embodiment, the box P is made of thermoplastic synthetic resin. This invention can be also applied to the case where the whole separable bottom stop assembly is made of metal. In such a case, instead of the ultrasonic welder, a clinching unit disclosed in the above-mentioned U.S. Pat. No. 4,671,122 may be used, but the clinching notches should be omitted from the box P.
As described above, according to the box attaching machine equipped with the inspect apparatus of this invention, it is possible to continuously inspect the successive boxes attached to the fastener tapes. Further, since the degree of firmness of attaching of the box is directly inspected without causing any deformation on the box surface, unlike the prior art apparatus which inspects it indirectly causing deformation on the box surface, it is possible not only to obtain very reliable inspection results but also to attach the box with excellent appearance.
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An apparatus for continuously inspecting the attached states of successive bottom stop boxes attached to separable slide fasteners, which has a pair of tape grip members movable forwardly and backwardly along a travelling path of a fastener tape to which the individual bottom stop box is attached. The tape grip members are situtated upwardly and downwardly of the fastener tape travelling path in confronting relationship, each of which being pivotally movable about the horizontal axis extending through its central portion. The tape grip members have their upstream ends urged toward each other, and an air cylinder for forcedly turning their downstream ends toward and away from each other. The apparatus has a moving body situated on one side of the grip members for moving forwardly and backwardly together with the grip members, a contact member situated in a fixed position in a path of movement of the moving body and normally urged toward the moving body by a predetermined resilience, and a sensor for detecting an amount of movement of the grip members when the moving body is moved to a predetermined length against the predetermined resilience in contact with the contact member.
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FIELD OF THE INVENTION
The invention relates to a separating device for separating individual container products from a frame assemblage of a plastic material, particularly polypropylene, with at least one punching device which at least partially separates the container product from the frame waste.
BACKGROUND OF THE INVENTION
The prior art (DE 199 26 329 A1) discloses methods and devices for producing container products from plastic, how they are supplied to a generic separating device which is then used to separate these individual container products from a frame assemblage using a cutting or punching device.
To produce the respective container product, first a tube of plasticized plastic material is extruded into a molding device. One end of the tube is closed by heat sealing and by producing a pneumatic pressure which acts on the tube. The tube is expanded forms the container by being placed against the forming wall of the molding device of two opposite molding tools. Then the plastic container is filled under sterile conditions within the molding device by a corresponding filling mandrel. After removing the filling mandrel, it is then hermetically sealed with the formation of a definable head geometry. For the purpose of forming the actual plastic container, in which fluid is later stored, two container forming jaws are moved by a hydraulic driver toward one another to obtain the closed position and are moved in opposite directions away from one another into one of their open positions. In order to achieve very high ejection rates of container products here, DE 103 23 335 A1 describes a multi-station arrangement, where the various molding steps are divided among different stations located in succession on an imaginary circular arc so as to form a type of carousel arrangement which enables very high cycle frequencies for the plastic material to be ejected in the form of container products.
Since the contents to be placed in the respective container product is often very susceptible to ambient media, especially if it is, for example, a highly sensitive pharmaceutical, the prior art focuses on, for example, covering the fill opening of the container tube by a sterile barrier under a sterile space at least from its formation to filling of the pertinent container. Very good results can be achieved here when, as shown in DE 10 2004 004 755 A1, by the barrier when a sterile medium is moved in the direction of the container fill opening using a media conveyance device in order to further improve the sterility. Another or an additional measure to increase sterility is to simply provide higher processing temperatures, for example, when producing the tube for the container product or during the filling process of the fill material. An increased processing temperature finds its limits when the plastic material which is frequently used, such as polyethylene, is temperature-sensitive, but can otherwise be easily processed in the pertinent production devices and is preferred.
Otherwise, in addition to atmospheric oxygen, other gases can also diffuse later into the interior of the container through the thin polyethylene wall during storage and in distribution of the container product which has been produced under sterile conditions, and in this way, can damage the sensitive container contents or even make them unusable.
In order to eliminate this latter disadvantage, prior art production methods for these container products have suggested (DE 103 47 907 A1 and DE 103 47 908 A1) using co-extrusion production methods in which the container is built up from several layers of plastic material, often at least one of the layers being used as a barrier layer. Five and more layers, for example, formed from polyethylene and low-density polyethylene as well as copolymers (ethylene-vinyl alcohol copolymers) can form the multi-layer container wall which in this case then forms an effective barrier layer. These methods are cost-intensive in practical implementation. This makes the respective container product correspondingly more expensive.
If the individual container products arrive filled from the respective production machine, they emerge as ampule blocks in which several ampules or containers located next to one another in the manner of a block assemblage or frame assemblage have a common wall with one another. In order to detach the containers or ampules from the block or frame assemblage, they are cut out or punched out along edge zones. A certain amount of frame waste then is produced which can be recycled with modern techniques. DE-PS 38 31 957 discloses a method for producing hollow container products from plastics which initially emerge as an ampule block or a frame assemblage. In the edge zone of the frame waste, a hollow body is additionally molded in. This hollow body increases the stability of the frame assemblage and also helps facilitate separation of the container product from the frame waste by the separating device used in each case.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved separating device with which the container products, regardless of the plastic material forming them, can be separated from the frame assemblage at high speed, and which in addition to a high degree of operating reliability also has relative low production costs.
This object is basically achieved by a separating device where the punching device can be moved from an initial position into the punching position along a punching axis and vice versa by a ball screw which can be driven by a drive unit, especially in the form of an electric motor. Separation can be done with a very high speed, dictated by the threaded spindle which can be driven by the electric motor. Additional mechanical components for applying a positive force to the punching body in setting up the separation line can be omitted. The ball screw used makes it possible to reduce the energy used correspondingly. This reduced energy usage benefits economical operation of the separating device.
In particular, it has been shown that with the separating device according to the invention, polypropylene as the wall material can be used for the container products, a plastic material which is brittle compared to a polyethylene material and which otherwise can be processed only with difficulty using conventional punching and cutting devices for container separation. To the extent conventional separating devices are used, it has been shown that with respect to the very high processing temperatures of polypropylene it would be necessary to wait several minutes until the punching and cutting process is possible at all. This delay would necessarily lead to very long retention sections and/or require additional cooling for the container products to be separated in order to be able to undertake separation at all without scrap. Due to the punching device which can be triggered by the ball screw, clean separation can take place without these waiting times or additional cooling, simply by the respective container product being knocked out of the still warm or hot frame assemblage at high speed by the spindle drive along the intended punching lines. It is surprising to one with average skill in the art in the field of these separating devices that he will arrive at these clean separating punching lines with the cutting edges of the punching device which are kept relatively blunt and which need not be further reworked (ground) or otherwise maintained. This ability was not possible in the past with devices in the prior art.
The advantage of using polypropylene material instead of polyethylene or a coextruded multilayer composite of LDPE/MDPE is that the polypropylene material at higher temperatures (121° C.) can be autoclaved. The polypropylene material is obtainable from only one extrusion head in a much more favorable manner than the described multilayer system. Thus, ultimately each individual layer to be produced in a multilayer system requires its own extrusion head in the production machine. This requirement increases production cost accordingly also from the control side.
Provided that the separating device according to the invention is used with the punching device which can be driven by the ball screw, this application is not limited thereto. Rather, there are a host of possible applications, and the separating device according to the invention can also be used for other plastic materials such as polypropylene or multilayer plastic systems for separation of the container product as necessary.
In one preferred embodiment of the separating device according to the invention, a damping system prevents overloading of the ball screw in the punching process. The damping system has preferably at least one energy storage (compression spring) which decouples the punching device from the ball screw at least during the punching process. In this way the punching process can be initiated especially carefully and the ball screw is relieved. This arrangement increases its service life.
The separating device according to the invention is made in the form of a column structure with individual guide and adjustment plates which are spaced apart from one another. The column structure in addition to adjustment columns also has guide columns which together with the assignable plates lead to a highly reinforced pedestal construction.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure and which are schematic and not to scale:
FIG. 1 is a top plan view of a frame assemblage of an ampule block and a frame waste;
FIG. 2 is a top plan view of the ampule block of FIG. 1 from which the frame waste has been largely removed, and in which the individual container products are detachably connected to one another with intermediate wall webs as a commercial unit;
FIG. 3 is a front elevational view, partially section of a separating device according to an exemplary embodiment of the invention;
FIG. 4 is a front elevational view of the separating device of FIG. 3 , shown without a punching device and die;
FIG. 5 is a top view of the separating device of FIG. 3 ;
FIG. 6 is a side elevational view of the separating device of FIG. 3 viewed in the direction of arrow X in FIG. 4 ;
FIG. 7 is a top plan view in section of the separating device of FIG. 5 taken along line A-A in FIG. 6 ;
FIG. 8 is a top plan view of the punching die as shown in FIG. 3 with a transport for delivery of the container products to be separated from the frame assemblage.
In some of the figures, components of the overall device are omitted for purposes of clarity of the solution according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The frame assemblage 10 shown in FIG. 1 is formed of a plastic material, in this case of a polypropylene material. The frame assemblage 10 is composed essentially of the actual container products 12 and the frame waste 14 which can be separated from the actual container products 12 . When the container products 12 are separated from the frame waste 14 , an ampule block from which the frame waste 14 has been removed as shown in FIG. 2 results. The individual containers or individual ampules 12 are detachably connected to one another by the remaining intermediate wall webs 16 of the frame waste 14 , the intermediate wall webs 16 making it possible for the respective container product 12 to be separated from the other containers 12 remaining in the block in a twist-off motion.
The respective container product 12 is known in the prior art, with the above-described ampule block solution shown, for example, in DE 38 31 957 C1. The basic form shown in FIGS. 1 and 2 constitutes only one type of one exemplary embodiment. The container geometries in particular can be stipulated by the user within a widely drawn scope. To release the respective container contents, generally in the form of a fluid which has been added beforehand, a twist-off cap 18 is used which likewise can be separated via a corresponding scored site by a twist-off motion from the remaining container product 12 by a handle 20 , with the result that the fluid can be removed via the cleared container opening. Other container opening solutions such as dropper caps, etc., can likewise be implemented.
On the bottom of the frame assemblage 10 as shown in FIG. 1 a type of blind holes 22 are made. Using the pins of a transport (not shown) which engage the blind holes 22 on the lower edge of the frame waste 14 , the frame assemblage 10 of the container products 12 and the frame waste 14 is removed from the tool of a production machine which is not detailed. Due to the higher stability of the frame waste in the form of an inherently closed waste edge zone, removal is easily and reliably possible when the plastic of the frame assemblage 10 has not yet completely cooled. This configuration is conventional and is shown, for example, in EP 0 359 971 A2 so that it will not be further detailed here.
Furthermore, it is also possible to arrange the blind holes 22 or other engagement option for a transport unit, viewed in the direction of looking at FIG. 1 , laterally in a vertical alignment as part of the frame waste 14 on the latter, provided that, instead of the horizontally running transport direction which is shown in FIG. 1 , a direction perpendicular thereto, i.e., in the direction of the longitudinal axes of the container, is desired. How the frame assemblage is suitably placed in the separating device as a cutting or punching device or is retrieved from it again is, for example, the subject matter of DE 38 32 566 C2 in which a moving transport hook engages the transport recesses in the frame waste of the frame assemblage 10 .
For a separating or punching process, viewed in the direction of FIG. 8 , originating from a production machine which is not detailed, the respective frame assemblage 10 moves from right to left into a die 24 , the die 24 shown in FIG. 8 constituting a receiving option for three frame assemblage arrangements 10 next to one another, with five connected container products 12 each. The respective container products 12 originating from the production machine are connected to one another by the frame waste 14 . After the punching or separating process a container assemblage as shown in FIG. 2 , viewed in the direction of FIG. 8 , leaves the die 24 on the left side in order to be then packed into the corresponding packaging units for further transport. Moving the respective frame assemblage 10 with the container products 12 into and out of the die 24 by the transport 26 is prior art so that it will not be further detailed here.
FIG. 3 , viewed in the direction of arrow Y of FIG. 8 , shows a rear view of the die 24 again with three frame assemblage units 10 with five container products 12 each. As furthermore follows from the backward front view as shown in FIG. 3 , the die 24 of a solid metal block is moved upright via support columns 28 extending between a die frame 30 for the die 24 and a lower base plate 32 which a slide 34 reaches through used to remove the plastic waste from the separating device. The lengths of the four support columns 28 are preferably adjustable in order to enable alignment of the die 24 according to given production criteria. The rectangularly made lower base plate 32 allows a modular structure for the entire separating device so that a unit results which is easy to install and which can be easily integrated into the sequence of production machines which are already present.
The separating device shown in FIG. 3 has a punching device 36 which comparably to the die 24 has a solid metal frame block and can be made in several parts. To increase the punching or cutting pressure, a block-like charge weight 38 can be used, whose bottom is joined to individual upper dies 40 which in turn on their bottom have punching blades 42 which enable separation of the frame waste 14 from the container products 12 in order to move from a preliminary product as shown in FIG. 1 to the finished container product assemblage as shown in FIG. 2 . In this respect the strip-like punching blades 42 travel into the intermediate intervals between the container products 12 held in the die 14 for each frame assemblage 10 . This arrangement is only exemplary to the extent one or two units of the frame assemblage 10 or larger units of frame assemblage arrangements with a different number of container products 12 can also be processed. The respective arrangement is dictated by the machine operator and his requirements.
To move the block shaped punching device 36 along a punching axis 44 , a ball screw 46 is used which can be actuated by an electric motor 48 . The electric motor 48 can be especially a conventional servo motor with short operating times relative to the respective switchover direction. The ball screw 46 has a rod shaped ball roller spindle 50 which, guided in a threaded bushing 52 viewed in the direction of FIG. 3 , can be moved down from the raised position shown in FIG. 3 into the punching or separating position along the punching axis 44 . For this purpose, the electric motor 48 drives the threaded bushing 52 by an output pinion (not shown), for example, by a toothed frame drive which is not detailed. The bushing is guided to be able to rotate in a rotary receiver 54 . This belt drive runs within an upper base plate 56 which terminates the separating device as a unit toward the top. The electric motor 48 , the rotary receiver 54 with the threaded bushing 52 , and part of the ball roller spindle 50 project with a definable excess length over the upper base plate 56 , viewed in the direction of FIG. 3 .
To reinforce the overall system, four adjustable columns 58 extend between the lower base plate 32 and the upper base plate 56 . Relative to the punching axis 44 , columns 58 are arranged in pairs diametrically opposite one another (cf. FIG. 7 ). The four adjustable columns 58 as part of an adjustment device 60 extend through a square adjustment plate 62 provided with four adjustable bushings 64 which extend around the respective adjustable column 58 . Another part of the adjustment device 60 on the top of the upper base plate 56 comprises two working cylinders 66 (cf. FIG. 6 ) which, made in the manner of hydraulic or pneumatic cylinders. By adjustable rods 68 fixed with their lower end on the adjustment plate 62 , vertical adjustment is induced along the adjustable columns 58 . For the sake of visual simplicity, FIG. 3 does not show this cylinder arrangement 66 with adjustable rods 68 . For the sake of simplicity FIGS. 4 and 6 have also omitted the punching device 36 . With the indicated adjustment device 60 , depending on the conditions of use on site, the punching plane for the punching device 36 can be adjusted. Viewed in the direction of FIG. 4 , the adjustment plane toward the bottom can be bordered by a stop body 70 .
Furthermore, a damping system 72 , shown in FIG. 3 , also contributes to helping prevent overloading of the ball screw 46 in operation, especially in a punching process itself. For this purpose the damping system 72 has an energy storage in the form of two compression springs 74 which the punching device 36 decouples from the ball screw 46 . For this purpose, the two compression springs 74 with their top which is shown in the direction of FIG. 3 are supported on a stop plate 76 permanently connected to the lower end of the ball roller spindle 50 by a fixing nut 78 . The lower end of the respective compression spring 74 is supported on a guide plate 80 , whose bottom, permanently connected by retaining rods 82 , is adjoined by the punching device 36 . Instead of the compression springs 74 as the energy storage, another solution can be used, for example, in the form of a disk spring or the like.
In the embodiment as shown in FIG. 3 , however, the respective compression spring 74 encompasses a guide pin 84 which forms a guide for the stop plate 76 which in this respect can be moved back and forth between two end positions by the ball roller spindle 50 . The lower possible end position is formed by lower buffer bushings 86 which can be made as an elastomer material and encompass the respective compression spring 74 in addition to the guide pin 84 . In the other stop situation which is pointed upward, the top of the stop plate 76 has annular vibration compensators 88 which are supported on angled boundary strips 90 , provided that the ball roller spindle 50 assumes its nonactuating position assumed in FIG. 3 .
When the electric motor 48 is started and a punching process is to be undertaken, the ball roller spindle 50 is moved down along the punching axis 44 , viewed in the direction of FIG. 3 , and the stop plate 76 is entrained against the action of the two compression springs 74 until it comes into contact with the top of the buffer bushings 86 . In the continuing downward motion the punching process is then induced by the punching device 36 for the respective frame assemblage 10 . If the ball roller spindle 50 is moved up in the reverse sequence, the stop plate 76 is entrained upward until it engages, from underneath, the angular offsets of the two boundary strips 90 as shown in FIG. 3 , this striking motion being cushioned by the vibration compensators 88 .
The guide plate 80 is in turn guided along four guide columns 94 by the corresponding guide bushings 92 . As FIG. 7 shows in particular, these guide column 94 are in turn located diametrically opposite one another to the punching axis 44 and lie within the outer peripheral plane with the four adjustable columns 58 . In order to be able to ensure that the individual components can move smoothly, the block-like punching device 36 as a whole extends through the corresponding rectangular recess in the adjustment plate 62 . The four guide columns 94 are guided on the top of the upper base plate 56 in receivers 96 which are otherwise held on their lower opposite end (cf. FIG. 4 ) in guide receivers 98 on the bottom of the adjustment plate 62 , which guide receivers allow movement for the guide columns 94 in the axial direction parallel to the punching axis 44 . Transversely thereto they enable a defined position in the radial direction. In this way relative adjustment of the adjustment plate 62 to the guide plate 80 is possible.
The punching device 36 is furthermore at least partially encompassed by a hold-down device 100 made as a plate-like hold-down frame. Hold-down device 100 can be raised and lowered by two working cylinders 102 (see FIG. 3 ). In the lowered position the hold-down device 100 is used to press down the frame waste 14 in the direction of the die frame 30 to ensure clean contact of the respective frame assemblage 10 in the pertinent recess of the die 24 . The required working cylinders 102 are preferably driven hydraulically, pneumatically, or servoelectrically, and are permanently connected with their housing parts to the adjustment plate 62 so that the hold-down device 100 can move relative to the adjustment plate 62 . To be able to ensure undisrupted operation for the stop plate 76 in the sense that it can move up and down parallel to the punching axis 44 , as follows especially from FIG. 7 , the stop plate 76 is provided with two U-shaped recesses through which the housing parts of the respective working cylinder 102 extend.
Furthermore, the separating device according to the invention has an ejector 104 ( FIG. 7 ) which ejects the plastic waste of the assemblage 10 which may remain, for example, in the punching device 36 via the slide 34 . For this purpose the ejector 104 preferably has two hydraulically, pneumatically, or servoelectrically actuatable working cylinders 106 which actuate two ejector pins 108 which, viewed in the direction of FIG. 6 , project underneath the adjustment plate 62 . Conversely, the working cylinders 106 are located above the adjustment plate 62 .
For the sake of better understanding, a sequence for a punching process will be described below. The strip of ampules with the three frame assemblage units 10 is transported into the separating device in the manner of a punch by a definable cycle advance. When the respective frame assemblage 10 has advanced to above the die 24 , the block-like punching device 36 is moved into the punching position by vertical lowering within the scope of the cycle advance. Afterwards, the hold-down device 100 , actuated pneumatically, presses from overhead on the strip of ampules and clamps it between the hold-down device 100 and the die 24 . Afterwards, the actual punching stroke is triggered, the electric motor 48 actuating the ball screw 46 in the connected position. The described damping system 72 prevents overly large impacts from being transmitted to the threaded spindle during the punching process, for example, in the form of the ball roller spindle 50 . When the punching stroke has ended, pneumatically actuated ejector pins 108 press the ampules 12 which may have become caught in the punch of the punching device 36 onto a support (slide 34 ). One cycle behind the punching position of the ampules 12 , shortly after punching of the ampules, the waste strip in the form of the frame waste 14 is crushed by pneumatic punching (not shown).
After the punching processes, ejector pins 108 , the punch in the form of a punching device 36 with the punching blades, and the hold-down device 100 and support for the cycle advance move up again and the next cycle can begin. For better accessibility in installation and maintenance, a maintenance stroke can be executed in which the upper structure and therefore the adjustment plate 62 are moved away toward the top. The ball screw 46 with the triggerable threaded spindle allows very prompt feed processes and delivery of very high punching forces via the punching device 36 . This operation had not been achieved in this way to date with the conventional arrangement. So that the punching device 36 does not collide with the lower die 24 , there can be stops, detection sensors, and/or monitoring electronics for the electric motor 48 .
While one embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.
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A separating device for cutting off individual containers ( 12 ) from a frame network made of a plastic material, particularly of polypropylene, has at least one punching device at least partially separating the containers ( 12 ) from a waste frame. Because the punching device can be moved by a ball screw drive ( 46 ) that can be driven by a drive unit, particularly in the form of an eclectic motor ( 48 ), along a punching axis ( 44 ) from a starting position to a punching position and back again, the separation can be done at high speed, determined by the screw shaft that can be driven by the electric motor.
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This application claims priority under 35 U.S.C. § 119(e) to U.S. provisional patent application No. 60/405,106, filed Aug. 21, 2002, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to metallic seals, and more particularly to bellows seals.
(2) Description of the Related Art
A variety of metallic seal configurations exist. Key metallic seals are commonly held under compression between two opposed flanges of the elements being sealed to each other. Such metallic seals may be used in a variety of industrial applications.
Key examples of such metallic seals are of an annular configuration, having a convoluted radial section which permits the seal to act as a spring and maintain engagement with the flanges despite changes or variations in the flange separation. Certain such seals have an S-like section while others have a section similar to the Greek letter ε with diverging base and top portions. Other similar seals are formed with additional convolutions. One exemplary seal is sold by The Advanced Products Company, North Haven, Conn., as the E-RING seal. Such seals are commonly formed as a monolithic piece of stainless steel or superalloy. Such seals are commonly formed from sheet stock into a shape that is effective to provide the seal with a desired range of compressibility from a relaxed condition.
A particular application where a bellows seal cannot easily be used is in horizontally split gas turbine engines. Horizontally split gas turbine engines are formed in two halves and have a lower casing and an upper casing that can be bolted together once the rotating shaft and other components have been installed. Brush seals are well known to those skilled in the art and are used to provide a fluid-tight seal between a high-pressure region of the engine and a low-pressure region of the engine. Brush seals usually include an annular head portion that is coaxial with the shaft. A plurality of bristles extend from the head portion towards the shaft such that the ends of the bristles wipe against the surface of the shaft. For assembly purposes, a brush seal is normally formed from four separate brush seal segments each having ninety degrees of arc. To prevent bypass leakage from the high-pressure region of the engine to the low-pressure region of the engine the brush seals are normally made a tight fit in a groove provided in the lower and upper casings. This makes removal of the brush seals very difficult and leakage between the head portion and the groove is not well controlled. However, the specific construction of horizontally split gas turbines engines is such that it not possible to split the lower and upper casings vertically around the brush seal. This means that a spring seal cannot be used because it would have to be compressed before it could be inserted into a sealing channel provided between the head portion of the brush seal and a wall of the groove provided in the lower and upper casing.
BRIEF SUMMARY OF THE INVENTION
In one aspect, there is a method for providing a seal between two housing walls. A spring seal is provided having an uncompressed length greater than a separation between the two housing walls. An agent is applied to the spring seal, the agent having adhesive and strength properties when cured or set chosen so that it loses at least one of properties under certain predetermined conditions. A compressing force is applied to the spring seal so that it is has a compressed length less than the separation between the two walls. The applied force is maintained for a period effective to cure or set the adhesive sufficiently to permit the applied force to be withdrawn with the agent maintaining the seal in a compressed condition. The compressed spring seal is inserted between the two housings. The certain predetermined conditions are applied to the adhesive so that it loses the property sufficiently to cause the seal to relax and expand into sealing contact the two housing walls.
In various implementations, the adhesive may lose its adhesive properties when it is heated above a predetermined temperature. The predetermined temperature may be between 180 and 220 degrees C. or, more narrowly, 190 and 210 degrees C. The spring seal may be a bellows seal and may have a cross-section of more than 360 degrees of wave between sealing surfaces.
In another aspect, there is a seal. The seal has a metallic body having a convoluted cross-section extending between first and second ends and a first generally interior surface extending between the first and second ends and a second generally exterior surface extending between the first and second ends. An adhesive (e.g., an epoxy) is located in one or more locations on at least one of the surfaces, the adhesive holding the body in a longitudinally contracted condition (e.g., at a length no more than 95% of a relaxed length at like temperature (e.g., room temperature of 21 degrees C.).
In various implementations, the adhesive may have temperature dependent strength and/or adhesion properties such that when placed in an environment at a temperature at or above a threshold temperature the adhesive will permit the body to expand to substantially the relaxed length for such temperature within a predetermined time interval. At an exemplary interval (e.g., 100 seconds or less) and the threshold temperature may be at a convenient range (e.g., 100, 200, 300, 400, or 500 degrees C. ±10 degrees C.). The adhesive may be only on said first surface.
There are related methods of manufacture. In related methods of use, the adhesive is caused to release, allowing the seal to expand toward the relaxed condition, but being stopped in an intermediate sealing condition by engagement with elements to be sealed.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial longitudinal sectional view of an uncompressed seal body.
FIG. 2 is a partial longitudinal view of the uncompressed seal body of FIG. 1 with an adhesive thereon.
FIG. 3 is a partial longitudinal sectional view of the seal of FIG. 2 in a compression fixture.
FIG. 4 is a partial longitudinal sectional view of the seal of FIG. 2 upon release from the fixture.
FIG. 5 is a partial longitudinal sectional view of the seal of FIG. 4 upon insertion between housing members.
FIG. 6 is a partial longitudinal sectional view of the seal of FIG. 5 upon release of the adhesive.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 shows a metallic seal body 20 having symmetry around a central longitudinal axis 500 . The body has first and second surfaces 22 and 24 that, in this internally-pressurized example, are substantially exterior and interior surfaces, respectively. The axis would appear on the opposite side of the cross-section in an externally-pressurized example. The cross-section a would appear rotated by +/−ninety degrees in radial sealing applications. Linear and other sealing applications are also possible.
The surfaces 22 and 24 are separated by first and second end surfaces 26 and 28 . The body is formed having a series of convolutions defining inwardly-directed spaces 30 and outwardly-directed spaces 32 . Along a central portion of the body, the convolutions are regular, of even amplitude (relative to the axis 500 ). Toward the end surfaces 26 and 28 , the body diverges radially inward. The body has first and second longitudinal extremes 40 and 42 , which, in the illustrated embodiment, are annular longitudinally outboard facing portions of the surface 22 relatively close to the ends 26 and 28 . The body has a maximum radius R and a contact radius radius R C at the locations 40 and 42 . The exemplary body has a substantially constant thickness between the surfaces 22 and 24 . The body has a minimum radius R l . The body may be manufactured by myriad known or other techniques. Its convolutions may have various shapes and may be formed of various materials or combinations thereof (e.g., having platings, etc.). An exemplary body is formed of spring steel.
After the body is formed, it is advantageously cut longitudinally into a plurality of segments (e.g., 4×90°, 6×60°, or 8×45°). After this segmenting (or alternatively before) an adhesive agent may be applied to the body segments to ultimately hold the seal in a precompressed condition.
FIG. 2 shows a layer of adhesive 50 applied to one of the surfaces ( 24 in the exemplary embodiment). The adhesive may be applied over substantially the entire subject surface or only a portion or portions thereof. The portion or portions may be longitudinal portions or circumferential portions. In the exemplary embodiment, the adhesive is applied over a portion covering substantially the entire circumferential extent, but only along one of the interior spaces 32 (a space at one longitudinal extreme of the exemplary seal body). Exemplary adhesive is an epoxy. An exemplary epoxy is manufactured by Tra-Con, Inc., Bedford, Mass. under the brand name is Tra-Bond 2151. Tra-Bond 2151 is a thixotropic (smooth paste) heat conductive epoxy system that complies with the NASA Outgassing Specification. It is a two-part adhesive that forms a high strength bond at room temperature, it bonds readily to itself and to metals, silica, stealite, alumina, sapphire, ceramics glass and many other materials. Tra-Bond 2151 provides excellent resistance to salt solutions, mild alkalis, and many other chemicals including petroleum solvents, lubricating oils, and alcohol.
Tra-Bond 2151 Properties:
Color
Blue
Specific gravity, mixed
2.300
Viscosity, cps, mixed
40,000
Operating temperature range ° C.
−70 to 115
Hardness, Shore D
90
Thermal Conductivity W/M*K
9.5E−01
Lap Shear, alum to alum, psi
2,850
Glass Transition (Tg) ° C.
60
Tensile strength, psi
7,500
The adhesive may be dispensed at room temperature (e.g., 21° C.) with the seal in its free uncompressed state.
With the epoxy applied, the seal segments are compressed to a height H 2 (FIG. 3 ), bringing longitudinally adjacent portions of the surface 24 closer together, including portions joined by the adhesive 50 . The compressive force may be applied and maintained by contact of surfaces 200 and 202 of plates 204 and 206 of a fixture with the seal portions 40 and 42 . With the compression maintained, the adhesive is allowed to harden or cure. In the exemplary embodiment, the adhesive is cured at an elevated temperature (e.g., 65° C.±5° C. for 2.5 hours). During this hardening/curing, the height is advantageously maintained at H 2 , although it is possible, depending upon the nature of the fixture, that this could vary (e.g., if the fixture supplied a constant force rather than a constant height). Alternatively, the body may be compressed before adhesive application.
The seal segments are then released from the fixture, whereupon they may expand to a height H 3 (FIG. 4 ). This expansion will be associated with relaxation of the segments along portions not adhered to adjacent portions. At room temperature, this height will be less than the original room temperature height H. The adhered portions of the seal will be held in a compressed, strained condition via the tensile strength of the adhesive. An exemplary seal exerts an outward sealing stress in the region of 1000 lbs/in 2 and a typical tensile bonding strength for the adhesive would be in the region of 4500 lbs/in 2 .
The seal segments are then placed between the elements being sealed. FIG. 5 shows two elements 250 and 252 . In one example, these are housing portions of a horizontally split gas turbine engine. In one example, the element 252 has an annular longitudinally open channel 254 having a base surface 256 facing a surface 258 of the element 250 . The element 252 may be a structural portion of the housing or may be a head portion of a brush seal element being augmented by the precompressed bellows seal. The segments are inserted such as through a longitudinal split or other gap in the channel. After all segments are inserted and any final assembly of the housing, the turbine may be run. Running of the turbine will heat the seal. Once the seal reaches a threshold temperature (or such a threshold temperature for a threshold time), the adhesive will lose its ability to maintain the seal in the precompressed condition. For example, the adhesive may deform such as via plastic flow or may release from portions of the body surface. At this point, the seal will expand and contacting portions 40 and 42 will respectively contact the surfaces 258 and 256 ( FIG. 6 ) to seal the elements 250 and 252 (subject to possible blow-by between the seal segments). Ultimately, the adhesive may be entirely vaporized or burned off.
Gas turbine engines typically have operating temperatures of about 400° C. and above and this will be sufficient to heat the adhesive to a threshold temperature above 200° C. The adhesive will therefore lose its adhesive properties the first time the gas turbine engine approaches its normal operating temperature. Alternatively, to heat the adhesive the complete housing/seal assembly can be placed inside an industrial heating means such as a furnace or oven.
Advantageously, the separation between surfaces 256 and 258 is less than the relaxed seal temperature under all anticipated conditions so that the seal is maintained in compressive engagement maintaining a longitudinal sealing force between the surfaces. For example, if the engine is turned off and allowed to cool to room temperature, the separation will still be less than H.
One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the particular application will influence many of the seal properties. Additionally, other release mechanisms may be possible (e.g., irradiation/light exposure at a particular frequency, sonic exposure at a particular frequency, chemical application (e.g., solvent)). Accordingly, other embodiments are within the scope of the following claims.
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A seal has a metallic body having a convoluted cross-section extending between first and second ends and a first generally interior surface extending between the first and second ends and a second generally exterior surface extending between the first and second ends. An adhesive is located in one or more locations on at least one of the surfaces, the adhesive holding the body in a longitudinally contracted condition. There are related methods of manufacture. In related methods of use, the adhesive is caused to release, allowing the seal to expand toward the relaxed condition.
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BACKGROUND OF THE INVENTION
This invention relates to the production of cyclodimers of dienes, particularly to the inhibition of polymerization of the dienes during production of the cyclodimers (cyclodienes).
Such soluble iron complex catalysts as dicarbonyldinitrosyl iron Fe(NO)2(CO)2] are known to facilitate the dimerization of 1,3-butadiene to produce 4-vinylcyclohexene (VCH). This process is taught in such references as "The Catalytic Dimerization of Dienes by Nitrosylcarbonyl Transition -metal Compounds", J. P. Candlin and W. H. Janes, J. Chem. Soc. (C)., p. 1856 (1968), and "Catalytic Reactions Involving Butadiene. I. Selective Dimerization to 4-vinylcyclohexene With Polymetallic Precursors", 1. Tkatchenko, J. Organometallic Chem., vol 124. pp. c39-c42, (1977).
A. Mortreux and F. Petit ("A New Route to Coordination Catalysis by Electrogeneration of Organometal Transition Reactive Species - A Review", Applied Catalysis vol 24, pp. 1-15, (1986)) have taught that the zero valent dinitrosyliron fragment, "Fe(NO) 2 " is central to the activity of such catalysis. They also discuss a proposed mechanism for the catalysis.
In such a dimerization processes, however, it is noted that there is also some polymerization of the diene to polydiene, e.g. butadiene to polybutadiene. The polymerization and resulting polymer not only consume starting material but also produce by-products which contaminate the vinylcyclohexene and must be removed from it. Additionally, the polymer fouls equipment. Several known inhibitors of butadiene polymerization also can react with the iron complex dimerization catalysts. Such inhibitors which are commonly used include 4-tertiary-butyl catechol (TBC) and N,N-diethylhydroxylamine (DEHA) often in combination with phenylenediamine. (see "Butadiene Polymers", chapter by W. M. Saltman in "Encyclopedia of Polymer Science and Technology", vol 2, p 683 (1965): "Butadiene, General", chapter by T. Reilly in "Encyclopedia of Chemical Processing and Design", vol 5, p 156, (1986): and Japan Patent 61,130,242 (Chemical Abstracts 105:173217). These inhibitors possess active hydrogens capable of being reduced by the low valent iron complexes. Such an oxidation of the iron would render the complex incapable of performing its catalytic task. In addition, the weak acid nature of such inhibitors will leave equilibrium controlled amounts of anions capable of coordinating to the iron and blocking sites of catalytic activity.
It is known to use certain hindered phenols to inhibit certain polymerizations but not polymerization of butadiene.
It would be desirable to have an inhibitor which would not react with the complex, but would inhibit the formation of polybutadiene.
Such polymer inhibition generally involves radical scavenging and chain termination, thought to involve traces of oxygen. Thus, certain compounds commonly referred to as antioxidants can function as polymerization inhibitors. One instance of such inhibitors is the use of 3,5-di-t-butyl-4-hydroxyanisole to inhibit polymerization of acrylamides. (Chemical Abstracts 86:107210)
SUMMARY OF THE INVENTION
In a process of cyclodimerizing a conjugated diene to form a cycloalkene using a soluble iron complex as catalyst, the improvement which comprises using as an inhibitor of diene polymerization, at least one hindered phenol.
These hindered phenols have been found to inhibit the production of polydienes while not interfering undesirably with action of the complex catalyst.
DETAILED DESCRIPTION OF THE INVENTION
The soluble iron complex catalyst is suitably any complex of zero valent iron which is an 18 valance electron complex. Determining the number of valence electrons in an iron complex is within the skill in the art, for instance as described in by F. A. Cotton and G. Wilkinson in "Advanced Inorganic Chemistry", 5th edition, p 37, Wiley Interscience, N.Y., 1988. Preferably, the soluble iron complex catalyst is one which is not undesirably inhibited by the presence of a hindered phenol. More preferably the catalyst is an iron nitrosyl complex catalyst, most preferably an iron nitrosyl catalyst such as [Fe(NO) 2 (CO) 2 ], or compounds wherein the carbonyls are replaced by olefins or diolefins (Fe(NO) 2 (X) y wherein X is CO, an olefin or diolefin and y is 1 or 2 to fill the Fe valence); [Fe(NO) 2 (CO) 2 ] is most preferred for use as a catalyst in the instant invention. By soluble iron complex, it is meant that the iron complex is soluble in common organic solvents such as tetrahydrofuran, diglyme, propylene carbonate, and the like at least to a concentration sufficient to catalyze dimerization of the diene. When X is an olefin or diolefin, it preferably has from about 2 to about 12 carbon atoms, more preferably from about 4 to about 8 carbon atoms.
Preparation of soluble iron complex catalysts is within :he skill in the art. For instance, Gadd, et.al. ("Photochemical Reaction of Fe(CO)2(NO)2 and Co(CO)3NO with 1,3-Butadiene in Liquid Xenon Solution: Possible Intermediates in the Catalytic Dimerization of Dienes", Organmetallics, vol 6, pp. 391-397, (1987)) teach that butadiene will displace the two carbonyl groups in Fe(NO) 2 (CO) 2 to form the 18 electron species. Therefore, compounds such as Fe(NO) 2 (X) y , where X is a neutral ligand should be able to function as catalyst precursors, when X can be displaced by butadiene. The value of y is usually 1 or 2, so that the total number of valence electrons in the complex is 18. Ligands of this type that can be displaced by a diolefin include: carbon monoxide, phosphines (phosphine, trialkylphosphines triphenylphosphines and alkyl-phenyl phosphines), allyl and methylallyl, olefins, such as butenes (including n-butene-1, cis and trans n-butene-2, and other isomers) and VCH, and diolefins such as piperylene, butadiene and isoprene.
An alternative way of preparing the zero valent Fe(NO) 2 moiety involves the chemical or electrochemical reduction of higher valent iron complexes, such as Fe(NO) 2 Cl or its reported dimer (Fe(NO) 2 Cl) 2 , in the presence of suitable ligands such as CO. mono and diolefins to generate an 18 electron Fe(NO) 2 (X)y complex. Examples of such chemical reducing agents are given in U.S. Pat. Nos. 4,234,454; 4,181,707: 4,144,278, 3,481,710: 3,377,397; 3,448,129 and 3,510,533. The last two patents along with an article by Maxfield ("The Reaction of Tetraallyltin With Transition Metal Compounds", Inorg. Nucl. Chem. Lett., vol 6, pp. 707-711 (1970)) teach that when reducing agents such as tin or organotin complexes are used, the final reduced species, containing the Fe(NO)2 may be bridged to a tin complex. Electrochemical reduction is taught in U.S. Pat. No. 4,238,301 and by E. Le Roy and F. Petit, ("Cyclodimerization des Dienes Conjugues par Electrocatalyse", Tetrahedron Letters No. 27, pp. 2403-2406 (1978) and by D. Ballivet-Tkatchenko et al. ("The Electrochemical Reduction of (Fe(NO) 2 Cl) 2 . A Novel Route to the Catalytic Cyclodimerization of Diolefins.", Inorganica Chimica Acta. vol 30, pp. L289-L290 (1978)). Additional processes are taught in copending U.S. Ser. No. 07/348,625 filed May 8, 1989, now U.S. Pat. No. 4,973,568 (Heaton), which is incorporated by reference herein in its entirety and 07/578,110 filed Sept. 5, 1990 (Heaton), and 07/578,109 filed Sept. 5, 1990, (Heaton).
Another approach to the design of a 14 electron zero valent iron species (which will form an 18 electron species upon coordination to the reacting diolefin) is to replace the two 3 electron NO ligands with another ligand or combination of ligands that will supply a total of 6 valence electrons to the iron. Such an approach is taught by H. Tom Dieck, et. al. ("Dimerisierung von Butadien, Codimerisierung von Butadien/1-Buten and Direktverwertung des Raffinerie-C4-Schnitts an einem homogenen Eisen-Katalysator", Chem.-Ing.-Tech., vol 61, pp. 832-833, (1989)) wherein a diazadiene ligand is used in place of two nitrosyl groups in the synthesis of the reduced iron catalyst.
Hindered phenols suitable for use in this invention are any compounds having an aromatic hydroxyl group which inhibit the production of polydiene in the presence of a soluble iron complex catalyst and which do not interfere undesirably with the activity of that catalyst. Preferably, the hindered phenols are those of the formula: ##STR1## wherein each R is independently selected from the group hydrogen, hydroxyl, alkyl, or alkoxy groups, preferably of from 1 to 5 carbon atoms: and wherein, when any R is a hydroxyl group, that R has at least one alkyl or alkoxy group ortho to it: and R' and R" are independently selected from hydrogen, an alkyl or alkoxy group having at least 2 carbon atoms, preferably least 3 carbon atoms, more preferably R' or R" is selected from isopropyl or t-butyl groups, most preferably t-butyl groups: but wherein at least one of R' or R" is such an alkyl group of at least 2 carbon atoms. Preferably, there is no unhindered hydroxyl group on the ring, that is no hydroxyl group not having at least one group of at least 2 carbon atoms ortho to it. Most preferably, there is only one hydroxyl group on the ring. Even more preferably, at least one, preferably both, of R' and R" are t-butyl.
The R, R' and R" groups are unsubstituted or inertly substituted, that is substituted with groups which do not undesirably interfere with the inhibiting effect of the hindered phenol or catalytic activity of the soluble iron complex. Such groups include alkoxy, nitro and phenyl groups.
Suitable hindered phenols include 2,6 di-t-butylphenol, 3,5-di-isopropyl-4-hydroxy-toluene, 3,5-diisopropyl-4-hydroxyanisole and are preferably 3,5-di-t-butyl-4-hydroxy-toluene or 3,5-di-t-butyl-4-hydroxyanisole.
Such compounds are commercially available and may be prepared by methods within the skill in the art such as those described in "Alkyphenols" by H. W. B. Reed, in "Encyclopedia of Chemical Technology" vol 2, pp. 72-96, 3rd Edition, John Wiley & Sons (1978).
Any conjugated diene which can form a cyclic dimer is useful in the practice of the invention. Such dienes include butadiene, isoprene, piperylene, hexadienes and the like and are preferably piperylene. isoprene or butadiene, most preferably butadiene.
Diene streams from 10-100 weight percent can be cyclodimerized with the described iron catalyst system. The amount of catalyst needed should be enough to achieve the desired degree of butadiene conversion. This amount is dependent on reaction temperature, residence time in the reactor, concentration of butadiene and amounts of catalyst poisons such as 1,2 butadiene and acetylenes. The temperature of the reaction can be between about 50° and about 150° C. preferably between about 90° and about 130° C. The catalyst can be run with or without a solvent, with solvent to iron ratios of 0 to 1000 by weight. Solvents that can be used include diethyl ether, butyl ether, tetrahydrofuran, p-dioxane, dimethylformamide, diglyme, acetonitrile, triglyme, ethylene carbonate and propylene carbonate. Diglyme and propylene carbonate are the preferred solvents. The amount of the phenol should be selected to sufficiently inhibit polymer formation. This exact amount depends on the concentration of butadiene and the temperature, but is preferably in the range of 25 to 500 ppm in the process stream, more preferably between 50 and 250 ppm by weight.
The catalyst can be run in a once through mode or recycled and continually used over. Depending on the mode of downstream separation, the inhibitor (hindered phenol) may also be recycled back to the process, with enough fresh inhibitor added to maintain the desired concentration in the reactor section.
The following examples are given to illustrate the invention and should not be interpreted as limiting it in any way. Unless stated otherwise, all parts and percentages are given by weight. Examples (Ex.) are designated numerically while Comparative Samples (CS) which are not examples of the invention are designated alphabetically.
EXAMPLES 1-2 AND COMPARATIVE SAMPLES A AND B.
In a 300 mL autoclave is placed 0.36 g (grams) FeCl 2 (ferrous chloride), 0.19 g NaNO 2 (sodium nitrite), 0.38 g Sn (tin) powder and 18.75 g diglyme as solvent. The reactor is then flushed with CO (carbon monoxide) gas and pressured with CO to 75 psig with stirring. The temperature is maintained at 120° C. with continued stirring for 20 hours, after which, the reactor is vented and the solution filtered.
Ten (10.0) g of the solution (containing 0.15 moles/L of Fe (iron) is added to approximately 150 g of pure 1,3-butadiene at 80° C., containing the amount of inhibitor indicated in Table 1. After 10 hours, the degree of butadiene conversion is measured and is reported in the Table.
TABLE 1______________________________________SAMPLE ppm PercentOR inhibitor by conversion byEXAMPLE INHIBITOR weight moles______________________________________A 4-t-butylcatechol 100 391 3,5-di-t-butyl-4- 100 88 hydroxy-toluene (BHT)2 3,5-di-t-butyl-4- 100 89 hydroxy-anisoleB None 0 93______________________________________
Examples 1-2 and Comparative Samples A and B show that 4-t-butylcatechol (Sample A) severely decreases the catalytic efficiency of Fe(NO) 2 (CO) 2 , while the hindered phenols BHT and 3,5-di-t-butyl-4-hydroxy-anisole (Examples 1 and 2, respectively) do not. Diethylhydroxylamine can not be used as an inhibitor because of formation of insoluble material with unreacted catalyst starting materials.
EXAMPLE 3
In a continuous pilot plant, consisting of two one gallon reactors in series, pure butadiene is flowed at a rate of 12 pounds per hour (lb/hr) and Fe(CO) 2 (NO) 2 catalyst solution is flowed at 0.89 lb/hr (as a 0.5 weight percent Fe solution in diglyme). Sufficient 3,5-di-t-butyl-4-hydroxy anisole is added to maintain 300 ppm by weight in the resulting butadiene/diglyme/catalyst mixture. Reactor temperature is 75° C. No polymer formation is observed after 20 hours of runtime.
COMPARATIVE SAMPLE C
The procedure of Example 3 is repeated with no hindered phenol inhibitor. Polymer formation in control valves and circulation pumps cause plugging and pilot plant shutdown after 6 hours.
EXAMPLE 4
In a continuous pilot plant, consisting of three one-gallon reactors in series, 6 lb/hr of 65 percent by weight butadiene in crude mixture of four carbon hydrocarbons and 1.6 lb/hr of a Fe(NO) 2 (CO) 2 solution (0.86 weight percent in Fe)in propylene carbonate are flowed continuously at temperatures between 90° and 100° C. A concentration of 3.5-di-t-butyl-4-hydroxy-anisole (hindered phenol inhibitor) is maintained at 100 ppm in the hydrocarbon/propylene carbonate mixture. After 150 hours, no evidence of polymer formation is observed.
COMPARATIVE SAMPLE D
The procedure of Example 4 is repeated except that no hindered phenol inhibitor is used. After 12 hours of operation, the pilot plant is shut down due to polymer plugging problems.
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In a process of cyclodimerizing a conjugated diene to form a cycloalkene using a soluble iron complex as catalyst, the improvement comprises using as an inhibitor of diene polymerization, at least one hindered phenol.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for recovering and reusing the solvent in a dry cleaning system.
In conventional dry cleaning systems, the effulent vapors or fumes of the solvent such as perchlorethylene (PERC) emanating from the dry cleaning washing machine and dryers generally are vented directly to the atmosphere and thus pollute the atmosphere. By being so vented, they are also lost for reuse. Thus, the escaping vapors not only produce an environmental hazard, but their loss are extremely costly to the dry cleaning establishment.
Attempt has been made to remove the solvent vapor contained in the air-stream from a dry cleaning machine by passing the solvent laden air-stream through a bed of activated carbon. The carbon adsorbs the solvent vapor or gas held in the air-stream, allowing the thus cleaned air to pass through the carbon bed to atmosphere. See Fuhring et al U.S. Pat. Nos. 3,203,110 and 3,538,615. Unfortunately, the carbon bed will only adsorb approximately one gallon of solvent per 80 lb of carbon before becoming saturated with solvent vapor, and must then be de-adsorbed by passing a "blanket" of steam through the carbon bed in a reverse direction to that of adsorption. The steam and solvent vapors form an azeotrope which must then be condensed, and the resultant water and liquid solvent must be separated according to their specific gravities. Thereafter, the solvent may then be recycled for reuse.
In the foregoing case, expensive and complex equipment is required to provide the carbon, the "steam" cleaning or the cooling condensers, as well as the extensive control equipment necessary for their function. In conventional commercial dry cleaning establishments, the cost for such equipment and for the skilled personnel necessary to operate the equipment is prohibitive.
It is the object of the present invention to economically, simply and with a minimum of equipment and the elimination of attendant personnel, to recapture the cleaning solvent and to reuse the same so that as a result thereof, the solvent is not vented to the atmosphere and thus pollution of the atmosphere is avoided.
It is a further object of the present invention to combine the normally separate dry cleaning washer, and dry cleaning dryer into a closed circulatory system, wherein the heat and cooling necessary to vaporize and condense the solvent are produced in situ without the need for external auxiliary equipment.
It is yet another object of the present invention to provide a closed system for the recovery and reuse of the solvent so that virtually no solvent is vented or lost to atmosphere thereby reducing the threat of any pollution, and the maximization of solvent use.
These objects as well as others will be apparent from the following disclosure.
SUMMARY OF THE INVENTION
According to the present invention, a dry cleaning washer and a dryer are arranged in a closed cycle system so that the effluent solvent vapor from the washer is delivered to an accumulator chamber generally simultaneously with the delivery from the dryer of effluent hot air. The hot air super heats the solvent vapor increasing its vaporization or volitization. The heated and highly volatile solvent vapors are then passed to a condenser which includes the feed coils for supplying clean air to the dryer. In passing through the condenser, the super heated solvent vapor, instantly liquifies giving off its heat to the cool air, thus preheating the clean air prior to its entry into the dryer. The liquified solvent is returned to the washer, or to a storage reservoir.
Preferably the accumulator is a hollow cylinder divided into an upper and a lower chamber. The inlets for the solvent vapor and hot air being in the lower chamber, which is also enlarged to provide a reservoir for any vapor which prematurely liquifies and sufficient space to effect contact between the solvent vapor and the hot air. The upper chamber is provided with a blower which insures flow of vapor and air to the maximum degree for smooth continuous operation.
If desired, the lower chamber may be filled with carbon for adsorbtion of the solvent. However, in this case, the scrubbing of carbon with steam is unnecessary since adsorbed solvent will eventually occur since the solvent is easily vaporized by the hot air from the dryer.
Full details of the present invention are set forth in the following disclosure and are illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a diagram of the recovery and reuse system of the present invention;
FIG. 2 is a vertical section of the accumulator used in the system of FIG. 1;
FIG. 3 is an elevational view of the accumulator rotated about the vertical axis counter clockwise 90 degrees from the view of FIG. 2; and
FIG. 4 is a sectional view of the accumulator taken along line 4--4 of FIG. 2, and rotated about the vertical axis clockwise 90 degrees.
DESCRIPTION OF THE INVENTION
FIG. 1 illustrates schematically the combination of a washer and dryer providing for the simple recovery and reuse of the solvent.
A conventional dry cleaning washer 10 of the tumble or drum type is provided with duct or passage means 12 for cyclically supplying and returning a liquid cleaning solvent such as perchlorethylene (PERC), in the usual and conventional manner, from a reservoir such as a tank 14. Similarly a dryer 16 of the tumble or drum type is provided with a source of heat 18 as, for example, steam or vapor heated water passing through a coil 20 located within the dryer. The dryer is also provided with an inlet, in the form of a condenser coil 22, through which clean cool fresh air may be introduced into the dryer.
During the washing cycle, the solvent, interacting with the clothes or textiles in the washer, and subjected to agitation, emits an effluent of solvent vapor. The solvent vapor effluent passes through a duct or passage 24 into an accumulator 26. Simultaneously, the dryer 16 produces a hot air effluent as a result of the heat and air needed to effect drying of the clothes or textiles. The hot air effluent passes from the dryer 16 through a duct or passage 28 into the accumulator 26, where it comes into contact with solvent vapor. The hot air super heats the solvent vapor increasing its volatility which thereupon passes through a duct 30 into a housing 32 in which the condensor coil 22 passes.
As the heated solvent vapor contacts the cooler coil 22, the vapor liquifies and passes through a duct pipe or passage 34 directly into the solvent reservoir 14 for reuse. Simultaneously the heat from the heated solvent vapor passes into the air, that is moving through the coil 22, thus pre-heating the air fed to the dryer 16 before it even enters the dryer. To insure the proper recovery of any solvent vapor from the dryer, a bypass duct 36 leading from the dryer connects via a T-fitting 38 with the duct 24 leading from the washer, thus mixing the solvent vapor from dryer 16 and washer 14 prior to entry in the accumulator.
As will be explained later, the accumulator 26 preferably comprises a hollow chamber, since it is unnecessary to adsorb the solvent vapor or convert the vapor into droplet or quasi-liquid form at that stage. The accumulator, however, is preferably provided with an enlarged volume at its lower end beneath the inlets from the ducts 24 and 28, so that in the event of a temporary shut-down in operation, or saturation of the solvent vapor, the solvent may liquify and be retained therein. Once, however, effluent hot air from the dryer 16 enters into the accumulator, it will heat and begin to convert the volatile solvent into heat vapor driving the vapor from the accumulator and reducing the solvent which may have liquified therein.
In conventional cleaning and drying installations, the heat emanating from the is at least 180 degrees Fahrenheit. This is sufficient to convert any liquified solvent in the accumulator to vapor driving the liquified solvent from the accumulator.
Since the fresh air fed to the dryer through the coils 22 is preferably at ambient room temperature, a sufficient "delta", or temperature difference between the coil and the super heated solvent vapor exists so that almost instantaneous condensation liquification occurs in housing 32. By regulating the flow of solvent vapor into the housing 32, and fresh air through the coils 22 a sufficiently high flow rate of both media can be effected providing for continuous liquification as well as preheating of the air. Although not shown in the drawings, suitable flow regulating valves, pressure guages and regulators can be employed in conventional manner.
The process of the present invention may be modified if desired to avoid the simple condensation of the solvent vapor in the accumulator where it will lay there overnight or for substantial periods of time. The solvent may be adsorbed in a carbonaceous material such as a charcoal or carbon filter material placed in the accumulator. By adsorbing it in the carbon, the solvent is no longer retained in a liquid form but retained within the solid carbon material and adsorbed to the surfaces thereof.
Normally, the solvent cannot be released from the adsorbing surfaces of the carbon until the carbon becomes fully saturated and then only through the use of steam or super heated water. However, in the present system the solvent is quickly released from the carbon adsorbing surfaces by subjecting such surfaces to the great heat of the dryer exhaust (180 degrees Fahrenheit) which is more than sufficient to drive the solvent off the carbon surfaces as vapor. Thus, the carbon material if and when used functions only as a temporary holder for the solvent when the solvent must remain in the accumulator chamber for such periods as overnight or over a weekend.
In the present invention, no extraneous or external heat is required to treat the solvent in the accumulator to cause the same to vaporize into fumes upon the start up of the day's work. In the morning although the solvent remains accumulated in the chamber, all that is necessary is to start the dryer to the point where its heat is sufficient to cause the solvent to be released from either the bottom of the pool of solvent material lying in the accumulator or from the carbon material that may be contained in the accumulator.
One of the novel features of the invention is that it utilizes the heat of the conventional and in situ system for generating the solvent vaporization or fumes even after the system has been shut down for some period of time and the solvent has has an opportunity to condense and liquify at the bottom of the chamber.
Another of the novel features of the invention resides in the method of treating the solvent laden vapor fumes that emanate from the washer. Unlike the conventional systems which are normally vented to the atmosphere, such fumes are redirected back into the system by way of an accumulator and condenser.
Thus, the method consists of operating a conventional dry cleaning installation in a closed environment proof system in which solvent laden fumes emanating from the dry cleaning machine are heated by the heat of the dryer, and such heater fumes are directed to a condenser at which the fumes are then condensed and liquified and returned to the washing machine tank for reuse. This saves the cost of wasted cleaning fluid and maintains the integrity of the atmosphere.
Another advantage of the present invention lies in providing the dryer with two coils. One is hot, the other is generally considered to be cooler. The solvent laden in the clothes is turned to fumes and blown in the dryer over or through the heated coils of the dryer where they too are super heated and they are thus directed to the accumulator for mixture with the solvent laden vapor fumes from the washer. The cooler fresh air is introduced into the dryer as a scavenging media to cleanse the clothes and dryer of residual solvent vapor, and due to its preheating, reduces the heat source requirements for the dryer.
Illustrated in FIGS. 2-4 is a specific, although not necessarily immutable form of an accumulator capable of functioning in the foregoing system. As seen, the accumulator comprises a generally cylindrical container 40 having a closed bottom 42 and a removable cover cap 44. The hollow interior of the container 40 is provided with a wall 46 extending perpendicularly to the central axis of the container. The wall 46 is sealed or forced fit in contact with the interior wall of the container to divide the container into an upper chamber 48 and a lower chamber 50 distinct from each other. A central hole 52, or series of holes if desired, is formed in the wall 46 establishing communication between the two chambers 48 and 50. Preferably the lower chamber 50 is substantially larger than the upper chamber 48 to provide ample room for retention of a large volume of solvent vapor and hot air.
Entering radially into the lower chamber 50 is a large inlet 54 adapted for connection to the solvent vapor outlet of the washer unit. Offset, at about 90 degrees from the solvent vapor inlet, and of substantially smaller size is a second inlet 56 adapted for connection to the hot air exhaust of the dryer. Exiting from the upper chamber 48 and diametrically opposite from the solvent vapor inlet 54 is an outlet 58 adapted for connection to the housing 32 containing the cool condenser coil 22 (FIG. 1).
The solvent vapor from the washer 10 flows into the lower chamber 50, where it makes contact with the hot air exhaust from the dryer 16. The heated solvent vapor passes through the hole 52 in the wall 46, into the upper chamber 48 and thence through outlet 58 to the condenser. To exhance and control the flow rate through the accumulator, a blower 60 is located in the upper chamber 48, and is driven by a motor 62 mounted on the removable cover cap 44.
The blower aids in the flow of the solvent vapor from their respective machines and pressurizes the flow to the condenser to aid in the rapid movement of solvent vapor from their respective machines to the condenser housing 32. The blower in the accumulator apparatus performs the function of sucking and applying a negative pressure to both the dryer and the washer to positively withdraw the solvent laden vapor fumes into the accumulator and to then blow such fumes to the condenser for liquification.
The inlets 54 and 56 from the washer and dryer respectively are arranged an extent above the bottom wall 44 of the container so as to provide sufficient space to form a reservoir 64 in the bottom of the container for retention of liquid which may result from normal condensation in the accumulator as when the system is shut down or closed overnight.
To facilitate operation and act as a control for the solvent vapor, the lower chamber 50 may be at least partially filled with a bed 66 of activated charcoal adapted to adsorb the solvent. As explained earlier this is not essential but does have certain advantages when used. To contain the charcoal, a filter cup 68 made of open wire mesh is installed concentrically with the opening 52. The bottom of the filter cup 68 is spaced above the bottom 42 of the container to maintain the reservoir space 64.
Should a bed of charcoal or other sorbent material be used, then it is advisable to continue the solvent vapor inlet 54 and the hot air inlet 56 radially into the container toward its center so that they disgorge within the filter cup 68. In this way, the vapor flow and hot air flow will not disturb the charcoal particles in the bed, yet have sufficient contact for vapor volatilization. Only excess vapor and hot air would move outwardly of the filter and penetrate the carbon to be adsorbed thereby and/or stripped therefrom as previously described.
The operation of the described accumulator is fully understandable from the prior description of the system illustrated and described in connection with FIG. 1 without further elaboration here. The form of the accumulator may vary as, for example, the container need not be cylindrical. If carbon is employed, a filter cup may be dispersed with and replaced with a simple filter screen across the hole 52. The blower may be replaced with a vacuum pump or the like.
It is evident that those skilled in the art may now make numerous uses and modifications of the specific embodiments described herein without departing from the inventive concepts disclosed. Consequently, the invention is to be construed as embracing each and every novel feature and novel combination of features present in or possessed by the apparatus and techniques herein disclosed and limited solely by the spirit and scope of the appended claims.
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According to the present invention, a dry cleaning washer and a dryer are arranged in a closed cycle system so that the effluent solvent vapor from the washer is delivered to an accumulator chamber generally simultaneously with the delivery from the dryer of effluent hot air. The hot air super heats the solvent vapor increasing its volitization and the heated and highly volatile solvent vapors are then passed to a condenser which includes the feed coils for supplying clean air to the dryer. In passing through the condenser, the super heated solvent vapor, instantly liquifies giving off its heat to the cool air, thus preheating the clean air prior to its entry into the dryer. The liquified solvent is returned to the washer, or to a storage reservoir.
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FIELD OF THE INVENTION AND RELATED ART
The present invention relates to a charging apparatus for charging a photosensitive member, in particular, a charging apparatus which is employed by an electrophotographic image forming apparatus, for example, a copying machine, a printer, a fax, a multifunction apparatus capable of two or more of the functions of the preceding apparatuses, etc.
There have been known various methods for charging the surface of the photosensitive member of an electrophotographic image forming apparatus. Among these charging methods, the charging method which applies oscillatory voltage made up of DC and AC voltages is superior in terms of the uniformity of charge. Hereafter, the methods for charging a photosensitive member by applying oscillatory voltage to a charging member will be referred to as “AC charging method”.
However, the AC charging method has its own problems. One of the problems is as follows: The AC charging method is greater in the amount of the electrical discharge to a photosensitive member than the DC charging method. Therefore, the AC charging method tends to promote the deterioration, for example, shaving, of a photosensitive member. Further, the employment of the AC charging method sometimes resulted in the formation of abnormal images, for example, images suffering from the appearance of flowing water, because of the byproducts of electrical discharge, in an operational environment in which both temperature and humidity were high.
In order to improve the AC charging method in terms of this problem, it is necessary to minimize in amount the electrical discharge which alternately occurs toward positive and negative sides. In order to minimize in amount the electrical discharge, it is necessary to minimize the amount of voltage necessary to properly charge a photosensitive member.
In reality, however, the relation between voltage and the amount of the electrical discharge caused by the voltage is not always the same. That is, it is affected by the changes in the thickness of the photosensitive layer and inductive layer of a photosensitive member, changes in a charging member, changes of the air attributable to environmental changes, etc. For example, in an environment in which both temperature and humidity are low (L/L), the materials of a photosensitive member are dry, causing thereby the photosensitive member to increase in the resistance value, which in turn makes it difficult for electrical discharge to occur. Thus, in order to uniformly charge a photosensitive member, it is necessary for the peak-to-peak voltage to be higher than a certain value. However, keeping the peak-to-peak voltage higher than a certain value creates the following problem. That is, in a case where a charging operation is carried out in a high temperature-high humidity environment (H/H), with the charge voltage set so that its peak-to-peak voltage is higher than the preset value for ensuring a photosensitive member to be uniformly charged under the low temperature-low humidity (L/L) environment, the charging member causes more electrical discharge than necessary to properly charge the photosensitive member, because in the H/H environment, the materials for a photosensitive member and charging member absorb humidity, and therefore decrease in electrical resistance value. The increase in the amount of the electrical discharge causes various problems. For example, it causes an image forming apparatus to yield images which suffer from the appearance of flowing water, images which appear blurry, and the like. Further, it causes toner particles to melt and adhere to each other. Also, it reduces the service life of a photosensitive member, because it accelerates the deterioration of the peripheral surface of a photosensitive drum, accelerating thereby the shaving of the peripheral surface.
As the methods for preventing the electrical discharge from being made to fluctuate in amount by the environmental changes, there have been proposed the “AC voltage stabilizing controlling method” that keeps constant in value the AC voltage applied to a charge roller, and also, “AC current stabilizing control method” that controls in value the AC current which flows as the AC voltage is applied to a charging member. The AC current stabilizing control method makes it possible to control a charging apparatus so that in the L/L environment, that is, the environment in which the materials increase in electrical resistance, the AC charge voltage increases in the peak-to-peak voltage value, whereas in the H/H environment, that is, the environment in which the materials decrease in electrical resistance, the AC charge voltage decreases in the peak-to-peak voltage. Therefore, the AC current stabilizing control method can more effectively prevent the fluctuation in the amount of the electrical discharge than the AC voltage stabilizing control method.
However, from the standpoint of further prolonging the service life of a photosensitive member, even the AC current stabilizing control method cannot be said to be perfect, because it cannot completely prevent the fluctuation in the amount of electrical discharge, which is attributable to the nonuniformity in properties among charging members, which is attributable to manufacturing processes; charge roller contaminations; change in the electrostatic capacity of a photosensitive member; nonuniformity in properties among high voltage generating apparatuses for the main assembly of an image forming apparatus; etc. Thus, in order to perfectly prevent the electrical discharge between a charging member and a photosensitive member, from fluctuation in amount, various measures have to be taken to improve charging member manufacturing processes so that all charging members will be uniform in properties, to ensure that the operational environment for an image forming apparatus does not change in temperature and humidity, and to come up with a means for preventing a high voltage generating apparatus from fluctuating in output, which results in substantial cost increase.
Thus, there have been proposed various methods for uniformly charging a photosensitive member, which were intended to prevent such problems as the deterioration of a photosensitive member, thermal adhesion of toner particles to each other, formation of images with an appearance of flowing water, etc., by keeping the electrical discharge constant in amount by preventing the occurrence of excessive amount of electrical discharge, regardless of the nonuniformity in electrical resistance value among charging members, which are attributable to charging member manufacturing processes, and the change in electrical resistance value of a charging member, which is attributable to the changes in environmental factors.
For example, disclosed in Japanese Laid-open Patent Application 2000-201921 is the following method for determining the properties of the voltage to be applied to a charging means and the properties of the current to be flowed by the charging means. That is, a DC voltage is applied to a charging member, and discharge start voltage Vth is obtained. Then, a function between AC voltage and AC current is obtained at a point in the non-discharge range, that is, DC voltage range in which voltage is no higher than the charge start voltage Vh, and another function between AC voltage and AC current is obtained at a point in the discharge range, that is, the DC voltage range in which voltage is higher than the charge start voltage Vh. Then, the discharge current amount is obtained as the difference between the two functions, and the charging means is controlled so that the obtained discharge current amount remains stable.
Disclosed in Japanese Laid-open Patent Application 2004-333789 is the following method for obtaining the smallest amount of discharge necessary to uniformly charge a photosensitive member. That is, while applying AC voltage, the amount of DC current is measured to find the DC current saturation point in the AC electric field. Then, the AC voltage value which corresponds to this DC current saturation point is multiplied by a preset ratio, and the product is used as the value for the charge bias for an actual image forming operation.
However, in the case of the above-described method disclosed in Japanese Laid-open Patent Application 2001-201921, unless the discharge start voltage Vth obtained by applying the DC voltage is accurately known, it is impossible to precisely separate the discharge range from the non-discharge range.
FIG. 18 is a graph which shows the relationship between the DC voltage applied to a charging member to charge a photosensitive member A, and the measured amount of surface potential of the photosensitive member A, and the relationship between the DC voltage applied to the charging member to charge a photosensitive member B, which is different in material from the photosensitive member A, and the measured amount of surface potential of the photosensitive member B.
The following is evident from FIG. 18 . That is, in the case of the photosensitive member A, as the DC voltage is increased, the surface potential remained at 0 V until the voltage reached a certain value. Then, from this point on, the surface potential of the photosensitive member A linearly increased. This value is the value of the Vth. On the other hand, in the case of the photosensitive member B, the surface potential gradually increases from the point where the DC voltage was 0 V, although the amount of increase was very small. Then, after the DC voltage reached a certain point, the surface potential of the photosensitive member B linearly increased.
The difference in properties between the two photosensitive members A and B is affected by the electrical resistance, capacity, and materials of the photosensitive members A and B, the electrical resistance, capacity, and materials of the charging member, and the environmental factors. Thus, there occur many situations in which the discharge start point Vth cannot be accurately obtained when DC voltage is applied.
Further, the method used by the apparatus disclosed in Japanese Laid-open Patent Application 2001-201921 is characterized in that the functions between the discharge range and non-discharge range are linear, and the difference between the two functions is calculated. However, the relationship between the peak-to-peak voltage and AC current is not linear at all. That is, referring to FIG. 19 , as the peak-to-peak voltage is continuously increased beyond a certain value, the AC current tends to increase with accelerated rates compared to the rate with which the peak-to-peak voltage is increased. It became evident from the results of intensive studies that this phenomenon occurs because the discharge nip between the charging member and photosensitive member increases in size as the AC voltage is increased in peak-to-peak voltage.
Thus, in order to compare the discharge current amount in the discharge range and that in the non-discharge range in terms of linear function, the value of the peak-to-peak voltage of the AC voltage to obtain the amount of discharge current in the discharge range is desired to be as close as possible the value of the peak-to-peak voltage of the discharge start voltage. Further, using such a value for the peak-to-peak voltage makes it possible to accurately and easily obtain the desired amount of discharge current. Japanese Laid-open Application No. 2001-201921 does not referred to this matter.
FIG. 20 is a graph which shows the relationship between peak-to-peak voltage and AC current, which was obtained, with the use of a combination of a charging member and a photosensitive member, at the time when recording medium began to be conveyed, and that obtained with the use of the same combination of a charging member and a photosensitive member, after a certain number of recording mediums were conveyed, in the case where the discharge start point was accurately found using the method disclosed in Japanese Laid-open Patent Application No. 2004-333789.
In the case where the value of the peak-to-peak voltage at the discharge start point is multiplied with a preset ratio of 1.15, the amount of discharge current was substantially greater after a certain number of recording mediums were conveyed, and therefore the rate of the AC current had substantially increased, than at the time when the recording medium conveyance was started. The relationship between AC voltage and AC current in terms of the rate with which they change is affected by various factors, such as the change in the film thickness of a photosensitive member, change in the operational environment of an image forming apparatus, cumulative image formation count, etc. Therefore, it is difficult to take all of these factors into consideration in order to accurately determine the relationship between the AC voltage and AC current. Therefore, it is difficult to maintain an accurate amount of discharge current with the use of the method which multiplies the peak-to-peak voltage at the discharge start point by a preset ratio.
SUMMARY OF THE INVENTION
One of the primary objects of the present invention is to provide a charging apparatus which is significantly smaller than a conventional charging apparatus, in the amount of the damages to which a photosensitive member is subjected when the photosensitive member is charged by a charging apparatus.
According to an aspect of the present invention, there is provided a charging apparatus, comprising a charging device for electrically charging a photosensitive member; a bias applying device for applying to said charging member a charging bias voltage comprising a DC voltage component and an AC voltage component, wherein said bias applying device effect a constant voltage control with a constant AC component of the charging bias voltage; an AC detector for detecting an AC detected current when said charging member is supplied with a test bias voltage; a DC detector for detecting a DC detected current when said charging member is supplied with the test bias voltage; and a controller for controlling a charging bias voltage to be applied to said charging member; wherein said control means determines a peak-to-peak voltage Vo when a change rate of detected DC current provided by sequentially applying the test bias voltages having different peak-to-peak voltages in order of increasing or decreasing peak-to-peak voltage becomes not more than a predetermined level, and said control means sets a peak-to-peak voltage of the charging bias voltage on the basis of a detected AC current when a peak-to-peak voltage Vp larger than the peak-to-peak voltage Vo and a detected AC current when a peak-to-peak voltage Vq not larger than the peak-to-peak voltage Vo.
According to another aspect of the present invention, there is provided a charging apparatus, comprising a charging device for electrically charging a photosensitive member; a bias applying device for applying to said charging member a charging bias voltage comprising a DC voltage component and an AC voltage component, wherein said bias applying device effects a constant current control with a constant AC component of the charging bias voltage; an AC detector for detecting a peak-to-peak voltage of the AC component when a test bias voltage is applied to said charging member; an AC detector for detecting an AC detected current when said charging member is supplied with the test bias voltage; and a controller for controlling a charging bias voltage to be applied to said charging member; wherein said control means determines an AC current Io when a change rate of detected DC current provided by sequentially applying the test bias voltages having different AC currents in order of increasing or decreasing AC current becomes not more than a predetermined level, and said control means sets an AC current of the charging bias voltage on the basis of a detected peak-to-peak voltage when an AC current Ip larger than the AC current Io and a detected peak-to-peak voltage when an AC current Iq not larger than the AC current Io.
These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of the image forming apparatus in the first preferred embodiment of the present invention, and shows the general structure of the apparatus.
FIG. 2 is a schematic sectional view of the surface layers of the photosensitive drum, and charge roller, in the first embodiment, and shows their laminar structures.
FIG. 3 is a diagram of the operational sequence of the image forming apparatus.
FIG. 4 is a block diagram of the charge bias applying system.
FIG. 5 is a graph showing the results of the measurements of the discharge current amount.
FIG. 6 is a flowchart for describing the charge controlling method in the first preferred embodiment of the present invention.
FIG. 7 is a graph for describing the relationship between peak-to-peak voltage and DC current.
FIG. 8 is a graph for describing the relationship between peak-to-peak voltage and the potential level of the charged object.
FIG. 9 is a drawing for describing the relationship between the peak-to-peak voltage and AC, regarding the charge controlling method in the first embodiment of the present invention.
FIG. 10 is a flowchart for describing the charge controlling method in the second preferred embodiment of the present invention.
FIG. 11 is a drawing for describing the relationship between the peak-to-peak voltage and AC current, regarding the charge controlling method in the second embodiment of the present invention.
FIG. 12 is a flowchart for describing the charge controlling method in the third preferred embodiment of the present invention.
FIG. 13 is a graph showing the relationship between the AC current and DC current.
FIG. 14 is a drawing for describing the relationship between the AC current and the potential level of the charged object.
FIG. 15 is a drawing for describing the relationship between the peak-to-peak voltage and AC current, regarding the charge controlling method in the third embodiment of the present invention.
FIG. 16 is a flowchart for describing the charge controlling method in the fourth preferred embodiment of the present invention.
FIG. 17 is a drawing for describing the relationship between the peak-to-peak voltage and Ac current, regarding the charge controlling method in the fourth embodiment of the present invention.
FIG. 18 is a drawing for describing the relationship between the DC voltage and surface potential of the charged object, regarding one of the conventional DC charging methods.
FIG. 19 is a graph which roughly shows the relationship between the measured amount of discharge current and peak-to-peak voltage, regarding the conventional charging apparatus (charge controlling method).
FIG. 20 is a drawing which describes the relationship between the peak-to-peak voltage and AC current, regarding the conventional charging apparatus (charge controlling method).
FIG. 21 is a drawing for the comparison between the computation in the conventional discharge current controlling method and that in one of the preferred embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, a charging apparatus in accordance with the present invention, and an image forming apparatus which has the charging apparatus in accordance with the present invention, will be described in more detail with reference to the appended drawings.
(Embodiment 1)
FIG. 1 is a vertical sectional view of the image forming apparatus in the first preferred embodiment of the present invention, and shows the general structure of the apparatus. The image forming apparatus 100 in this embodiment is a laser beam printer which uses one of the electrophotographic processes of the transfer type. The laser beam printer uses a charging method of the contact type, and a developing method of the reversal type. The largest sheet of recording medium usable with (passable through) this printer is A3 in size.
The image forming apparatus 100 in this embodiment is provided with an electrophotographic photosensitive member 1 , as an image bearing member, which is in the form of a drum, (which hereafter may be referred to as “photosensitive drum”). The image forming apparatus 100 is also provided with a charge roller 2 , a developing apparatus 4 , a transfer roller 5 , and a cleaning apparatus 7 , which are disposed in the adjacencies of the peripheral surface of the photosensitive drum 1 , listing from the upstream side in terms of the rotational direction R 1 (counterclockwise direction) of the photosensitive drum 1 . The charge roller 2 is a part of a charging apparatus 200 . The transfer roller 5 is a charging member of the contact type. The image forming apparatus 100 is also provided with an exposing apparatus 3 , which is disposed above the roughly mid point between the developing apparatus 4 and charge roller 2 . Further, the image forming apparatus 100 is provided with a fixing apparatus 6 , which is on the downstream side of the transfer portion d (which is interface between photosensitive drum 1 and transfer roller 5 ), in terms of the recording medium conveyance direction.
The photosensitive drum 1 is an organic photosensitive member (OPC). It is 30 mm in external diameter, and is negatively charged. It is rotationally driven by a driving apparatus (unshown) at a process speed (peripheral velocity) of 210 mm in the direction (counterclockwise direction) indicated by an arrow mark R 1 . Referring to FIG. 2 , the photosensitive drum 1 is made up of an aluminum cylinder 1 a (electrically conductive substrate); an undercoat layer 1 b coated on the peripheral surface of the photosensitive drum 1 to prevent the optical interference and to improve the adhesion of the upper layer to the aluminum cylinder 1 a ; an optical charge generation layer 1 c ; and a charge transfer layer 1 d. The three layers are coated in layers in the listed order on the aluminum cylinder 1 a.
The charge roller 2 is rotationally supported at the lengthwise end portions of its metallic core 2 a, by a pair of bearings (unshown), one for one. It is kept pressed toward the center of the photosensitive drum 1 by a pair of compression springs 2 e so that a preset amount of contact pressure is maintained between the peripheral surface of the photosensitive drum 1 and peripheral surface of the charge roller 2 . As the photosensitive drum 1 is rotationally driven, the charge roller 2 is rotated by the rotation of the photosensitive drum 1 in the clockwise direction indicated by an arrow mark R 2 . The contact nip formed between the photosensitive drum 1 and charge roller 2 is the charging portion a (charging nip).
As a charge bias voltage, which is under a specific condition, is applied to the metallic core 2 a of the charge roller 2 from an electrical power source S 1 , the peripheral surface of the photosensitive drum 1 is charged to preset polarity and potential level by the charge roller 2 , which is in contact with the photosensitive drum 1 . In this embodiment, the charge bias voltage applied to the charge roller 2 is an oscillatory voltage which is a combination of a DC voltage (Vdc) and an alternating voltage (AC), more specifically, −1,500 V of DC voltage, and an AC voltage which is 2 kHz in frequency. As a result, the peripheral surface of the photosensitive drum 1 is uniformly charged to −500 V (dark voltage level Vd) by the charge roller 2 , which is in contact with the peripheral surface of the photosensitive drum 1 .
The charge roller 2 is 320 mm in length. It has the metallic core 2 a (substrate), and three layers 2 b (bottom layer), 2 c (intermediary layer), and 2 d (surface layer), which cover the metallic core 2 a in the listed order. The bottom layer 2 b is formed of foamed sponge, and is for reducing the charging noises. The surface layer 2 d is a protective layer provided to prevent leak even if the photosensitive drum 1 has a defect, such as a pin hole or the like.
More concretely, the specifications of the charge roller 2 in this embodiment are as follows:
metallic core 2 a: stainless steel rod with a diameter of 6 mm;
bottom layer 2 b : foamed rubber (NBR) in which carbon particles have been dispersed, and which is 0.5 g/cm 2 in specific gravity, 10 2 -10 9 Ω.cm in volume resistivity; and 3.0 mm in thickness; and
intermediary layer 2 c : fluorinated “Torejin” resin in which tin oxide and carbon particles have been dispersed, and which is 10 7 -10 10 Ω.cm in volume resistivity, 1.5 μm in in surface roughness (10 point average surface roughness Ra in JIS), and 10 μm in thickness.
This embodiment employs such a charging method that charges a photosensitive member by placing a charge roller in contact with the photosensitive drum. However, this is not mandatory. That is, for example, such a method that charges a photosensitive member with the presence of a gap (several tens of micrometers) between a charge roller and a photosensitive member may be employed. In the latter case, all that is necessary is that the gap size falls within the discharge-possible range, which is determined by the gap voltage and the air density (Paschen's law). As long as this requirement is met, the latter can charge a photosensitive drum just as well as the charging method used in this embodiment.
The exposing apparatus 3 in this embodiment is a laser beam scanner which uses a semiconductor laser. The laser beam scanner 3 exposes a portion (point) of the uniformly charged portion of the peripheral surface of the photosensitive drum 1 , at the exposure position (point) b, by outputting a beam of laser light L in a manner to scan the peripheral surface of the photosensitive drum 1 while modulating the beam with the image signals inputted from an unshown host apparatus, such as an image reader or the like. As a given portion (point) of the peripheral surface of the photosensitive drum 1 is exposed to the beam of laser light, this portion (point) reduces in potential. Thus, as the peripheral surface of the photosensitive drum 1 is scanned by the beam of laser light L, an electrostatic latent image, which reflects the image information with which the beam of laser light L is modulated, is formed line by line.
The developing apparatus 4 in this embodiment is such a developing apparatus that develops in reverse the electrostatic latent image with the use of a developing method which uses two-component magnetic brush. It reversely develops the electrostatic latent image on the photosensitive drum 1 ; it deposits toner on the exposed (light) portions (points) of the peripheral surface of the photosensitive drum 1 . That is, the developing apparatus 4 makes the electrostatic latent image visible by supplying the electrostatic latent image with toner.
This developing apparatus 4 is provided with a nonmagnetic development sleeve 4 b , which is rotatably disposed in the developing means container 4 a so that the development sleeve 4 b is exposed through an opening of the container 4 a . The developer 4 e (toner) in the developing means container 4 a is coated in a thin layer on the peripheral surface of the development sleeve 4 b . The coated layer of developer 4 e is conveyed by the rotation of the development sleeve 4 b to the development portion c where the distance between the peripheral surface of the development sleeve 4 b and the peripheral surface of the photosensitive drum 1 is smallest. The developer 4 e in the developing means container 4 a is a mixture of toner and magnetic carrier, and is conveyed toward the development sleeve 4 b by the rotation of two developer stirring members 4 f while being stirred by the stirring members 4 f.
The electrical resistance of the magnetic carrier in this embodiment is roughly 10 13 Ω.cm, and its particle diameter is 40 μm. The toner becomes negatively charged as it is rubbed by the magnetic carrier. The toner density in the developing means container 4 a is detected by a density sensor (unshown), and the toner density in the developing means container 4 a is kept constant by supplying the developing means container 4 a with a proper amount of toner from a toner hopper 4 g , based on the detected toner density in the container 4 a.
The development sleeve 4 b is positioned so that the smallest distance between its peripheral surface and the peripheral surface of the photosensitive drum 1 is 300 μm. It is rotationally driven in the direction indicated by an arrow mark R 4 so that the movement of its peripheral surface in the developing portion c becomes opposite to the rotational direction R 1 (counterclockwise direction) of the peripheral surface of the photosensitive drum 1 in the developing portion c.
A preset development bias is applied to the development sleeve 4 b from an electric power source S 2 . The development bias applied to the development sleeve 4 b in this embodiment is an oscillatory voltage, which is a combination of DC voltage (Vdc) and AC voltage (Vac), more specifically, the combination of −350 V of DC voltage, and an AC voltage which is 8 kV in peak-to-peak voltage.
The transfer roller 5 is kept pressed upon the photosensitive drum 1 , with the application of a preset amount of pressure, forming thereby a transfer portion d. It rotates in the clockwise direction R 5 . To the transfer roller 5 , a transfer bias (which is positive bias, being therefore opposite in polarity to the normal polarity, that is, the negative polarity, to which toner is charged). By the application of this transfer bias, a toner image on the peripheral surface of the photosensitive drum 1 is transferred onto a sheet of recording medium P, such as paper, as the second image bearing member, in the transfer portion d.
The fixing apparatus 6 has a fixation roller 6 a and a pressure roller 6 b , which are rotatable as necessary. After the transfer of the toner image from the photosensitive drum 1 onto the surface of the recording medium P, the recording medium P is conveyed through the fixation nip formed between the fixation roller 6 a and pressure roller 6 b . While the recording medium P is conveyed through the fixation nip, the toner image is thermally fixed with the heat and pressure from the fixation roller 6 a and pressure roller 6 b.
After the transfer of a toner image from the surface of the photosensitive drum 1 onto the recording medium P, the peripheral surface of the photosensitive drum 1 is cleaned by the cleaning apparatus 7 . To describe more concretely, the peripheral surface of the photosensitive drum 1 is rubbed by the cleaning blade 7 a of the cleaning apparatus 7 , in the cleaning portion e, that is, the point of contact between the cleaning blade 7 a and the peripheral surface of the photosensitive drum 1 , being thereby cleared of the toner remaining on the peripheral surface of the peripheral surface of the photosensitive drum 1 . After the cleaning of the peripheral surface of the photosensitive drum 1 , the photosensitive drum 1 is used for forming the next portion of the image, or the next image; the photosensitive drum 1 is repeatedly used for image formation.
A pre-exposing means 8 (charge removing optical means) removes the electric charge remaining on the peripheral surface of the photosensitive drum 1 after the cleaning of the peripheral surface of the photosensitive drum 1 , by irradiating the peripheral surface of the photosensitive drum 1 with light, so that the cleaned portion of the peripheral surface of the photosensitive drum 1 becomes virtually zero in potential before it is charged again.
FIG. 3 is a diagram of the operational sequence of the above described printer.
a. Initial Rotation Step (Preliminary Multiple Rotation Step)
The initial rotation step is the step (warm-up step) which is carried out immediately after the printer is turned on. That is, as the electric power source switch of the printer is turned on, the various processing devices of the printer are made to prepare themselves for image formation; for example, the photosensitive drum 1 is rotationally driven for a preset length of time, and the fixation roller of the fixing apparatus is increased in temperature to a preset level.
b. Preparatory Rotation Step (Preliminary Rotation Step)
The preparatory rotation step is the rotation step between the end of the initial rotation step and when an actual image forming step (printing step) begins to be carried out. In a case where a printing signal is inputted during the initial rotation step, an image forming operation is started as soon as the initialization rotation step ends. In a case where no print signal is inputted during the initialization rotation step, the main motor is temporarily stopped after the ending of the initialization rotation step, and the rotational driving of the photosensitive drum 1 is stopped. Then, the printer is kept on standby until a printing signal is inputted. As a printing signal is inputted, the preparatory rotation is carried out.
In this embodiment, it is in this preparatory rotation step that the program for computing and determining the proper value for the peak-to-peak value (AC current value) for the AC voltage to be applied in the charging step of the image forming operation, is carried out. This subject will be described later in more detail.
c. Printing Step (Image Formation Step)
As soon as the preset preparatory rotation step ends, the printing step, that is, the step for forming an image on the rotating photosensitive drum 1 is started. In the printing step, a toner image is formed on the peripheral surface of the rotating photosensitive drum 1 ; the toner image is transferred onto the recording medium; the toner image is fixed by the fixing apparatus; and the print is discharged from the printer.
When the printer is in the continuous printing mode, the above described printing sequence is repeated until a preset number (n) of prints are outputted.
d. Paper Interval
The paper interval is the period between when the trailing edge of a given sheet of recording medium passes the transfer portion d, and when the leading edge of the following sheet of recording medium reaches the transfer portion d, while the printer is in the continuous recording mode, that is, the period in which no sheet of recording medium is being passed through the transfer portion d.
e. Post-rotation Step
The post-rotation step is the step in which the driving of the main motor is continued for a while to rotationally drive the photosensitive drum 1 , and also, to carry out preset post-operations, after the printing step for the last sheet of recording medium is completed.
f. Standby Step
As soon as the post-rotation step is completed, the rotation of the main motor is stopped, stopping thereby the rotational driving of the photosensitive drum 1 , and then, the printer is kept on standby until the next print start signal is inputted.
In a case where only a single copy is to be made, the printer is put through the post-rotation step after the completion of the printing of the single copy. Then, it is kept on standby after the completion of the post-rotation step.
If it happens that a print start signal is inputted while the printer is kept on standby, the printer begins the pre-rotation step.
The period in which the printer is performing the step c is the image formation period, and the initial rotation step (a), preparatory rotation step (b), paper interval (d), and post-rotation step (e) are the periods in which no image is formed.
FIG. 4 is a block diagram of the circuit for applying the charge voltage to the charge roller 2 , and shows the general structure of the charging apparatus 200 .
As a preset oscillatory voltage (bias voltage (Vdc+Vac)), which is a combination of a DC voltage, and an AC voltage (with a frequency f) is applied to the charge roller 2 through the metallic core 2 a , the peripheral surface of the rotating photosensitive drum 1 is charged to a preset potential level.
An electric power source S 1 , which is the means for applying voltage to the charge roller 2 , has both an electric power source 11 (DC power source) and an electric power source 12 (AC power source).
A control circuit 13 , which is a controlling means, has the function of controlling the abovementioned DC power source 11 and AC power source 12 of the electric power source S 1 so that one of the DC and AC voltage is applied to the charge roller 2 , or both voltages are applied at the same time to the charge roller 2 . The control circuit 13 has also the function of controlling in value the DC voltage applied to the charge roller 2 from the DC power source 11 , and the peak-to-peak voltage of the AC voltage applied to the charge roller 2 from the AC power source 12 .
A measurement circuit 14 is a circuit used as the means for measuring value of the AC component of the AC current which flows to the charge roller 2 from the power source S 1 . The information regarding the AC current value (or peak-to-peak voltage) measured by this circuit 14 is inputted to the above described control circuit 13 .
The measurement circuit 15 is a DC current detecting means for detecting the value of the DC component which flows from the power source S 1 to the charge roller 2 . The information regarding the DC current value detected by this circuit 15 is inputted to the above described control circuit 13 .
The environment sensor 16 is an environment sensor used as the means for detecting the conditions of the environment in which the printer is set up. It is a combination of a thermometer and a hygrometer. The information regarding the operational environment of the printer is inputted to the above-mentioned control circuit 13 from this environment sensor 16 .
That is, the control circuit 13 obtains the information regarding the AC current value (or peak-to-peak voltage value) from the measurement circuit 14 ; the information regarding the DC current value from the DC current measurement circuit 15 ; and the environmental information from the environment sensor 16 . The control circuit 13 has the function of carrying out the program for computing and determining the proper peak-to-peak value for the AC voltage applied to the charge roller 2 in the charging step in the printing step.
Next, the method for controlling the AC bias applied to the charge roller 2 during the printing operation will be described.
The inventors of the present invention discovered through various studies that the discharge current amount numerated according to the following definition can be used as a substitute for the actual amount of AC discharge, and also that there is a strong relationship between this discharge current amount and the shaving of photosensitive drum, formation of an image having the appearance of flowing water, and level of uniformity with which a photosensitive member is charged.
That is, referring to FIG. 5 , when the value of the peak-to-peak voltage Vpp is no more than the discharge start voltage Vth×2 (V) (when peak-to-peak voltage in no discharge range), there is a linear relationship between the value of the peak-to-peak voltage and the value of the AC current Iac. However, as the peak-to-peak voltage value increases past the discharge start voltage Vth×2, that is, as the peak-to-peak voltage increases into the discharge range, the relationship shifts in such a direction that the discharge current Iac increases faster than in the non-discharge range. However, in the case of a similar experiment conducted in the vacuum condition in which electrical discharge does not occur, the linear relationship remains the same even after the increase of the peak-to-peak voltage beyond the discharge start voltage Tth×2 (V). Thus, it is reasonable to think that this difference is the amount of the increase ΔIac in the AC current Iac, which contributes to the discharge.
Hereafter, α stands for the ratio between the current Iac and the peak-to-peak voltage Vpp which is less than the discharge start voltage Vth×2 (V). Thus, the amount of the AC current other than the AC current attributable to discharge, that is, the current which flows through the area of contact (which hereafter will be referred to as “nip current”), etc., is α.Vpp. Thus, the difference between the Iac measured when a voltage, the peak-to-peak voltage of which is higher than the discharge start voltage Vth×2 (V), and α.Vpp, is defined as “discharge current amount ΔIac” which can be used as the substitute for the amount of discharge:
Δ Iac=Iac−α.Vpp.
In a case where the photosensitive drum is charged while the charge voltage or charge current is kept constant, the amount of discharge current is affected by the environmental factors and the cumulative usage of the photosensitive drum and charge roller. This phenomenon occurs because the relationship between the peak-to-peak voltage and discharge current amount, and the relationship between the AC current value and discharge current amount (value), change.
In the case where the charge voltage is controlled so that the AC current remains constant, the charge voltage is controlled so that the total amount of current which flows from a charging member to a member to be charged. As described above, the total amount of current is the sum of the nip current α.Vpp and the amount ΔIac of the current flowed by the discharge which occurs across the area of no contact. Thus, in the case where the charge voltage is controlled so that the AC current remains constant, not only is the discharge current, that is, the very current which is necessary to charge a subject to be charged, but also, the nip current is controlled.
Therefore, the discharge current amount is not actually controlled. That is, even if the charge voltage is controlled so that the charge current remains constant at a preset value, the amount of discharge current naturally reduces if the amount of nip current is increased by the changes caused to the charging member materials by the environmental changes. Further, the reduction in the nip current causes the discharge current to increase. Therefore, even the method for controlling the charge voltage so that the amount of AC current remains constant cannot perfectly prevent the increase or decrease in the amount of the discharge current. Thus, when this method was employed for the longevity of a photosensitive drum, it was difficult to uniformly charge a photosensitive drum while preventing the photosensitive drum from being shaved.
As described above, because of the changes in the electrical resistance, capacity, and materials of an image bearing member, the changes in the electrical resistance, capacity, and materials of a charging member, or the environmental changes, it is difficult to accurately obtain the value of Vth in the discharge start voltage Vth×2 (V). Further, as for the relationship between the peak-to-peak voltage and AC current in the discharge range, as the distance from the discharge start point increases, the discharge current increases in the rate with which it increases, and therefore, the relationship becomes nonlinear.
Based on the discoveries described above, it became evident that it is difficult to precisely obtain the amount ΔIac of the discharge current.
Thus, in order to ensure that the amount of discharge current remains constant at a desired value, the inventors of the present invention controlled a charging apparatus using the following method.
Next, the method for determining the value for the peak-to-peak voltage for a charging apparatus, which keeps the amount of discharge current at a desired amount Ih, will be described.
Referring to FIG. 6 , in this embodiment, multiple test biases, which were different in peak-to-peak voltage, were applied, with preset timing, with the pre-exposure light turned on and the DC voltage kept constant at −500 V, during a period in which no image was formed; the AC voltage was increased (or decreased) in steps, while detecting the DC current value at each voltage level. Then, the AC voltage value, which corresponded to the saturation point of the DC current value, that is, the AC voltage value, above which the rate of change (rate of increase) was below preset value, was defined as the minimum AC voltage value (peak-to-peak voltage V 0 ). Shown in FIG. 7 is the result of the measurements in an environment in which the temperature and humidity were 23° C. and 50%, respectively. As the AC voltage was increased, the DC voltage proportionally increased, reaching −35 μA when the AC voltage was 1,500 Vpp. However, as the AC voltage increased beyond 1,500 Vpp, the rate with which the DC current changed in value suddenly reduced. In this case, the rate with which the DC voltage changed remained at 0.0023=|(DC current value)/AC voltage value)|. In this embodiment, 1,500 Vpp, which was the smallest AC voltage value at which the rate of change fell below 0.0023, was the smallest peak-to-peak voltage V 0 .
Further, as will be evident from FIG. 8 , an AC voltage value (point) above which the DC current remained stable in value, was the AC voltage value (point) to which the potential of the charged photosensitive drum 1 converged, and this voltage value V 0 corresponded to the discharge start point.
Next, a peak-to-peak voltage Vp, which was greater in value than V 0 was selected. In this embodiment, 1,700 V was selected as the value for the peak-to-peak voltage Vp. Then, the AC current value was measured when V 0 =1,500 Vpp, and Vp=1,700 Vpp. Referring to FIG. 9 , the measured AC current values were: (V 0 , I 0 )=(1,500 Vpp, 2,000 μA), (Vp, IP)=(1,700 Vpp, 2,400 μA).
Next, the relationships between the peak-to-peak voltage and AC voltage, more specifically, the mathematical relationships (function) between the peak-to-peak voltage and AC voltage, was obtained from the above-mentioned measured values. One of the functions is F 1 (Vpp) (mathematical relationship between the peak-to-peak and AC current) shows the mathematical relationship between the peak-to-peak voltage level and AC current value when the smallest AC voltage (Vpp), that is, V 0 , was applied to the charging means. Another is F 2 (Vpp), which shows the mathematical relationship between the peak-to-peak voltage level and AC voltage value when a charge voltage which was greater in peak-to-peak value at least by one point than when V 0 is applied to the charging means.
That is, for the discharge range, an approximate linear relationship (F 2 (Vpp)) is calculated based on the two points (V 0 , I 0 ) and (Vp, Ip) (Expression 1). For the non-discharge range, an approximate linear relationship (F 1 (Vpp)) was calculated, based on the two points (point 0) and (V 0 , I 0 ) (Expression 2).
In this embodiment, the relationship between the peak-to-peak voltage and AC current was linearly approximated from the above described measured current values, with the use of the least squares method:
function F 2( Vpp )) Yα=α×α+ A (Expression 1
function F 1( Vpp )) Yβ=β×β (Expression 2
Referring to FIG. 9 , the amount Ih of the discharge current is the difference between the straight line Yα obtained by approximation, and the straight line Yβ in the non-discharge range obtained by approximation.
Ih
=
F
2
(
Vpp
)
-
F
1
(
Vpp
)
=
Y
α
-
Y
β
=
(
αXα
+
A
)
-
(
β
X
β
)
.
Here, assuming that the peak-to-peak voltage value X, which can keep constant the discharge current value Ih, is Vpp, there is the following mathematical relationship:
Ih =(α Vpp+A )−(β Vpp ).
Therefore, the value of the peak-to-peak Vpp, which can keep constant the discharge current amount at Ih, can be calculated with the use of the following Expression 3:
Vpp =( Ih−A )/(α−β) (Expression 3).
Referring to FIG. 9 , in this embodiment, when the desired discharge current amount Ih was set to 50 μA, the peak-to-peak voltage value calculated with the use of Expression 3 given above was 1,575 (Vpp).
The control circuit 13 switches the peak-to-peak voltage to be applied to the charging member, to the obtained Vpp, and made the printer to move onto the above described image formation steps (voltage control at Vpp).
As described above, the peak-to-peak voltage value necessary for keeping the discharge current amount constant at a preset value in actual image forming steps, was calculated during each preparatory rotation step, and during the actual printing steps, the charge voltage was kept constant at the voltage level obtained by calculation during the preparatory rotation step. With the employment of this control method, it was possible to absorb fluctuation in the electrical resistance value of the charge roller 2 , which is attributable to the nonuniformity in manufacturing processes, changes in the properties of the charge roller materials attributable to the changes in the operational environment, high voltage fluctuation of the main assembly of the image forming apparatus. Therefore, it was possible to reliably keep the discharge current amount constant at a desired value.
When the printer in this embodiment was tested for durability while the charge voltage was controlled with the use of the above described method, the deterioration and shaving of the photosensitive member (as image bearing member) did not occur regardless of the changes in the operational environment. More specifically, the service life of the photosensitive drum was extended roughly 10% compared to when the charging apparatus was controlled with the use of the conventional method in which the charge voltage is controlled so that the AC current amount remains constant. Further, this embodiment made it possible to more accurately calculate the relationship between the peak-to-peak voltage and AC current in the discharge range, than the method proposed in Patent Document 1.
FIG. 21 graphically shows the comparison between the conventional method for setting the discharge current amount, and the method, in this embodiment, for setting the discharge current amount.
In the case of the conventional method, the relationship between the peak-to-peak voltage and AC current is nonlinear in the discharge range. Therefore, the discharge start point obtained by calculation is greater in value than that obtained with the use of the method in this embodiment. In other words, even though the conventional method and the method in this embodiment are the same in the necessary amount of discharge current, the former was greater in the value (Vpp) of the AC bias applied as the charge bias.
The necessary AC bias value (Vpp) for obtaining a desired amount of discharge current, which was calculated with the use of the method in this embodiment was better by as much as 30% compared to the conventional method, in terms of the difference from the actual discharge start point.
In this embodiment, the amount of the discharge current was controlled by switching the magnitude of the peak-to-peak voltage of the AC voltage applied to the charge roller 2 . However, this embodiment is not intended to limit the present invention in scope.
For example, the AC current value measurement circuit 14 , as an AC current detecting means, in FIG. 4 , may be replaced with a peak-to-peak voltage measurement circuit as a peak-to-peak voltage detecting means, so that AC current is applied instead. With this replacement, the peak-to-peak of the AC voltage can be measured to control the AC power source in the amount of AC current output by the control circuit 13 so that AC current is always provided by the amount necessary to provide discharge current by a desired amount during the printing steps.
Further, in this embodiment, the discharge current amount Ih, and the value of the peak-to-peak voltage of the AC voltage applied in the preparatory rotation step, are set in anticipation of a specific operational environment. However, in the case of a printing apparatus provided with an environment sensor (combination of thermometer and hygrometer), it is possible to variably set the value for the peak-to-peak voltage and the value for the discharge current amount, in response to the detected environmental variables, so that the photosensitive drum can be even more reliably and uniformly charged.
As described above, in this embodiment, AC voltage was applied during the preparatory rotation step, while increasing in steps the AC voltage in peak-to-peak voltage. Then, the peak-to-peak voltage value was measured at the lowest AC voltage point (value V 0 ), that is, the point at which the AC current virtually stopped increasing (became stable), and at one or more points in the discharge range, while applying the charge voltage to the charge roller 2 . Then, based on the AC current values measured at the above described two or more points, the magnitude for the peak-to-peak voltage of the AC voltage to be applied during the printing steps, was determined, so that the AC voltage, the peak-to-peak voltage of which was suitable for always providing a desired amount of discharge current, or so that the AC current flowed by the AC voltage always supplied the desired amount of discharge current. Thus, not only was it possible to prevent the deterioration and shaving of the photosensitive member, but also, it was possible to uniformly charge the photosensitive member. Therefore, it was possible to prolong the life of the photosensitive member, and also, to improve the printer in image quality.
Further, this embodiment made it possible to absorb the nonuniformity in properties, among charging apparatuses, which was attributable to manufacturing processes. Thus, this embodiment can widen the choice for the materials for a charging apparatus, and also, can lower the level of accuracy with which a charging apparatus is to be manufactured. Thus, this embodiment can reduce the manufacturing cost for a charging apparatus, making it possible to provide a user with a charging apparatus which is substantially lower in cost than a conventional charging apparatus.
(Embodiment 2)
Referring to the flowchart in FIG. 10 , in this embodiment, when the image forming apparatus was on, but not forming an image, the pre-exposure light was turned on, and the DC voltage was kept constant at −500 V, and multiple test biases, which were different in peak-to-peak voltage, were applied. More specifically, the AC voltage was increased (decreased) in steps, and the amount of the DC current was detected at each AC voltage level to find the point beyond which the DC current did not significantly increase (decrease). Then, the AC voltage value corresponding to this point was defined as the smallest value V 0 of the AC voltage.
Also in this embodiment, as in the first embodiment, the DC current value changed in the rate of change (rate of increase) at −35 μA, when the AC voltage was 1,500 V in peak-to-peak value, as is shown in FIG. 7 which shows the results of the measurements made in an operational environment in which temperature and humidity were 23° C. and 50%, respectively. In this case, 1,500 Vpp was the value of V 0 .
Further, as will be evident from FIG. 8 , the point at which the DC current became stable in value was the point which corresponded to the potential level to which the potential of the photosensitive drum 1 converged. This point which corresponded to the V 0 was the discharge start point.
Next, the peak-to-peak voltage Vp, which was greater in value than the peak-to-peak voltage V 0 , was selected. In this embodiment, 1,700 Vpp was selected.
Further, the studies made earnestly by the inventor of the present invention revealed that because of the microscopic nonuniformity in the electrical resistance of the materials of the photosensitive member and/or charging member, discharge (abnormal discharge) sometimes occurs when the AC voltage is in the non-discharge range, but is very close to the discharge start point, and therefore, when the equation for the straight line connecting the discharge start point and Point ( 0 , 0 ) is obtained by approximation, the equation is slightly off in terms of the inclination of the straight line.
Thus, in this embodiment, a peak-to-peak voltage Vq, which is less in value than the peak-to-peak voltage V 0 , was selected, which was 1,400 Vpp.
Next, the AC current value was measured at three points, that is, when the peak-to-peak voltage was V 0 (=1,500 Vpp), Vp (=1,700 Vpp), and Vq (=1,400 Vpp). Referring to FIG. 11 , the measured current values were: (V 0 , I 0 )=(1,500 Vpp, 2,000 μA); (Vp, Ip)=(1,700 Vpp, 2,400 μA); and (Vq, Iq)=(1,400 Vpp, 1,840 μA).
Next, from the measured values mentioned above, the relationship between the peak-to-peak voltage and AC current, more specifically, functions which numerically define the relationship between the peak-to-peak voltage and the amount of AC current, was obtained. One of the functions is F 1 (Vpp), which numerically defines the relationship between the peak-to-peak voltage and the amount of AC current, based on the relationships between the AC voltage and the amount of AC current, which were obtained when two or more AC voltages, which were lower in peak-to-peak voltage than the AC voltage V 0 , were applied to the charging means. Another function is F 2 (Vpp), which numerically defines the relationship between the peak-to-peak voltage and the amount of AC current, based on the relationships between the AC voltage and the amount of AC current, which were obtained when the AC voltage V 0 , and two or more AC voltages, which were higher in peak-to-peak voltage than the AC voltage V 0 , were applied to the charging means.
That is, as for the discharge range, an expression for Function F 2 (Vpp), which corresponds to the straight line between the two points (V 0 , I 0 ) and (Vp, Ip), was approximated (Expression 1). As for the non-discharge range, an expression for Function Fl (Vpp), which corresponds to the straight line approximated from the two p laint points, that is, Point ( 0 , 0 ) and (Vq, Iq) (Expression 2).
In this embodiment, the relationship between the peak-to-peak voltage and AC current were linearly approximated by the control circuit 13 from the measured current values mentioned above, with the use of the least squares method. That is:
Function F 2( Vpp )) Yα=α×α+A (Expression 1
Function F 1( Vpp )) Yβ=β×β. (Expression 2
Referring to FIG. 11 , the amount Ih of the discharge current is the difference between the approximated straight line Yα, and the approximated straight line Yβ in the non-discharge range.
Ih
=
F
2
(
Vpp
)
-
F
1
(
Vpp
)
=
Y
α
-
Y
β
=
(
αXα
+
A
)
-
(
β
X
β
)
.
Here, assuming that the peak-to-peak voltage value, which can keep constant the discharge current value Ih, is Vpp, there is the following mathematical relationship:
Ih =(α Vpp+A )−(β Vpp ).
Therefore, the value of the peak-to-peak Vpp, which can keep constant the discharge current amount at Ih, can be calculated with the use of the following mathematical expression:
Vpp =( Ih−A )/(α−β) (Expression 3).
Referring to FIG. 11 , in this embodiment, when the desired discharge current amount Ih was set to 50 μA, the necessary peak-to-peak voltage value was 1,562 (Vpp).
The control circuit 13 switched the value of the peak-to-peak voltage to be applied to the charging member, to the obtained Vpp, and made the printer to move onto the above described image formation steps (AC voltage was kept constant at Vpp).
By structuring the control circuit 13 so that the charge voltage is controlled as described above, the peak-to-peak voltage value necessary for keeping the discharge current amount constant at a desired value can be precisely obtained regardless of the presence of microscopic nonuniformity in the electrical resistance of the materials of the photosensitive member and/or charging member.
(Embodiment 3)
Referring to the flowchart in FIG. 12 , in this embodiment, when the image forming apparatus was on, but not forming an image, the pre-exposure light was turned on, and the DC voltage was kept constant at —500 V, and multiple test biases, which were different in peak-to-peak voltage, were applied. More specifically, the AC current was increased (decreased) in steps, and the amount of the DC current was detected at each AC current level to find the point beyond (below) which the DC current did not significantly increase (decrease). Then, the DC current value corresponding to this point was defined as the smallest value Io for the AC current.
Referring to FIG. 13 , which shows the results of the measurements made in an operational environment in which temperature and humidity were 23° C. and 50%, respectively, when the AC current value was 2,000 μA, the DC current value became smaller in rate of change after it reached −35 μA. In this case, the rate of change (rate of increase) of the DC current value before the DC current value reached 2,000 μA was 0.0175 (=|(DC current value)/(AC current value)|). In this embodiment, therefore, 2,000 μA, that is, the AC current value (smallest value) above which the rate of change of the DC current value was no more than 0.00175, is the value of I 0 .
Further, as will be evident from FIG. 14 , the point at which the DC current became stable in value is the point which corresponds to the potential level to which the potential of the photosensitive drum 1 converges. This point which corresponds to the I 0 is the discharge start point.
Next, the AC current value Ip, which was greater in value than the AC current value I 0 was selected. In this embodiment, 2,400 μA was selected. Then, the peak-to-peak voltage value was measured when the AC current value was I 0 (=2,000 μA), and Ip (=2,400 μA). Referring to FIG. 15 , the measured peak-to-peak voltage values were: (V 0 , I 0 ) (1,500 Vpp, 2,000 μA), and (Vp, Ip)=(1,700 Vpp, 2,400 μA).
Next, the relationship between the peak-to-peak voltage and AC voltage, more specifically, numerical relationships between the peak-to-peak voltage and AC current were obtained. One of the numerical relationships is F 1 (Vpp) obtained by connecting the point (V 0 , I 0 ) and point (0, 0) with a straight line. Another one is F 2 (Vpp) obtained from the relationship between the AC current value at point (V 0 , I 0 ) and those at two or more points (Vp, Ip) which were greater in AC current value than point (V 0 , I 0 ).
That is, as for the discharge range, an expression for Function F 2 (Vpp), which corresponds to the straight line between the two points (V 0 , J 0 ) and (Vp, Ip), was approximated (Expression 1). As for the non-discharge range, an expression for Function Fl (Vpp) was obtained by approximation based on the two points, that is, point (0, 0) and (Vq, Iq) (Expression 2).
In this embodiment, the relationship between the peak-to-peak voltage and AC current were linearly approximated by the control circuit 13 from the measured current values mentioned above, with the use of the least squares method. That is:
Function F 2( Vpp )) Yα=α×α+A (Expression 1
Function F 1( Vpp )) Yβ=β×β (Expression 2
Here, F 2 (Vpp)=F 1 (Vpp)+Ih.
Here, when an AC current value is Iac 1 , and the corresponding peak-to-peak voltage value is Vpp, Expressions 1 and 2 become:
Iac 1=α Vpp+A (Expression a)
Iac2=β Vpp (Expression b).
Here, Iac 2 stands for the AC current value which corresponds to Vpp on approximated straight line Yβ in non-discharge range.
Since discharge current amount Ih is the difference between Iac 1 and Iac 2 ,
Ih=Iac 1− Iac 2 (Expression c).
From Expressions a and b, AC current value Iac 1 , which provides discharge current amount Ih, is obtained from the following expression:
Iac 1=(α Ih−βA )/(α−β) (Expression 4) ,
Referring to FIG. 15 , in this embodiment, when the desired discharge current amount Ih was set to 50 μA, the necessary amount of AC current was calculated with the use of the equation given above was 2,150 μA.
Then, the control circuit 13 switched the value of the AC current to be supplied to the charging member, to the AC current value Iac 1 , and made the printer to move onto the above described image formation steps (AC current was kept constant at Iac 1 )
(Embodiment 4)
Referring to FIG. 16 , in this embodiment, while no image was being formed, the AC current was increased (decreased) in amount in steps by applying multiple test biases different in peak-to-peak voltage, with the pre-exposure light kept on, and the DC voltage kept at —500 V, and the DC voltage current value was detected at each test bias to find out the smallest value I 0 of the AC current, beyond which the DC current did not significantly change.
Also in this embodiment, as the AC current value was increased beyond 2,000 μA, the DC current value became stable at −35 μA, as shown in FIG. 13 , which shows the results of the measurements in the operational environment in which the temperature and humidity were 23° C. and 50%, respective, as they were in the third embodiment. In this case, 2,000 μA is the value of I 0 .
Further, as will be evident from FIG. 14 , the point which corresponds to the DC current value beyond which the DC current is stable in amount is the point which corresponds to the potential level to which the charge of the photosensitive drum 1 converges. Thus, this Io is the discharge start current value (point).
Further, the studies earnestly made by the inventors of the present invention revealed that even in the non-discharge range, electrical discharge occurs in the adjacencies of the discharge start point, because of the microscopic nonuniformity of the materials of the photosensitive member and/or charging member, in terms of electrical resistance, although the occurrence is very rare. Thus, when approximating the straight line which connects the discharge start point and zero point, there occurs a slight deviation in inclination.
In this embodiment, therefore, AC current value Iq, which is smaller than AC current value I 0 was selected, which was 1,800 μA.
Further, AC current value Ip, which was greater than AC current value I 0 , was selected, which was 2,400 μA.
Then, the peak-to-peak voltage was measured when the AC current value was I 0 (=2,000 μA), Ip (=2,400 μA), and Iq (=1,800 μA). The measured values of the peak-to-peak voltage were (V 0 , I 0 )=(1,500 Vpp, 2,000 μA), (Vp, Ip)=(1,700 Vpp, 2,400 μA), and (Vq, Iq)=(1,370 Vpp, 1,800 μA) as shown in FIG. 17 .
Next, the relationship between the peak-to-peak voltage and AC current, more specifically, numerical relationships between the peak-to-peak voltage and AC current, were obtained from the measured values given above. One is the numerical expression for Function F 1 (Vpp) obtained from the relationship between the values of the peak-to-peak voltage measured at one or more points at which the AC current was smaller in value than when AC current value Io was flowed to the charging means. Another one is the numerical expression for Function F 2 (Vpp) obtained from the relationship between the values of the peak-to-peak voltage measured at the point at which the AC current value was I 0 , and at least one point where the AC current value is greater than I 0 .
That is, in the case of the discharge range, the straight line is approximately calculated based on two points (V 0 , I 0 ) and (Vp, Ip) (F 2 ) (Vpp) (Expression 1). In the case of the non-discharge range, the numerical expression for the straight line was approximated from (0, 0) and (Vq, Iq) (F 1 ) (Expression 2).
In this embodiment, the relationship between the peak-to-peak voltage and AC current was linearly approximated by the control circuit 13 from the two points (V 0 , I 0 ) and (Vp, Ip), with the use of the least squares method. That is:
Function F 2( Vpp )) Yα=α×α+A (Expression 1
Function F 1( Vpp )) Yβ=β×β (Expression 2
Here, F 2 (Vpp)=F 1 (Vpp)+Ih.
Here, when an AC current value is Iac 1 , and the corresponding peak-to-peak voltage value is Vpp, Expressions 1 and 2 become:
Iac 1=α Vpp+A (Expression a)
Iac2=βVpp (Expression b).
Here, Iac 2 stands for the AC current value which corresponds to Vpp on approximated straight line Yβ in non-discharge range.
Since discharge current amount Ih is the difference between Iac 1 and Iac 2 ,
Ih=Iac 1− Iac 2 (Expression c).
From Expressions a and b, AC current value Iac 1 , which provides discharge current amount Ih, is obtained from the following expression:
Iac 1=(α Ih−βA )/(α−β) (Expression 4).
Referring to FIG. 17 , in this embodiment, when the desired discharge current amount Ih was set to 50 μA, the necessary amount of AC current was calculated with the use of the equation given above was 2,123 μA.
Then, the control circuit 13 switched the value of the AC current to be supplied to the charging member, to the AC current value Iac 1 , and made the printer to move onto the above described image formation steps (AC current was kept constant at Iac 1 ).
With the provision of the control structure described above, it was possible to precisely obtain a desired amount of discharge current, regardless of the presence of nonuniformity in microscopic level in the electrical resistance among photosensitive members and/or charging members.
(Miscellanies)
In the preferred embodiments described above, Point ( 0 , 0 ) was used to approximate the straight line in the non-discharge range. However, a point other than Point ( 0 , 0 ) may be used. That is, as long as the amount of the current which flows at a point when the peak-to-peak voltage at this point is Vpp can be known in advance, this point and another point of measurement can be used to obtain the relationship between the peak-to-peak voltage and AC current.
Also in the preferred embodiment, the number of the points (V, I) of measurement, beside the discharge start point, was minimum (one). However, the number of the points of measurement may be two, three, or more. In any case, the discharge current amount can be easily obtained by approximating the linear relationship between the peak-to-peak voltage and discharge current, with the use of the least squares method, for example.
The multiple AC voltages different in peak-to-peak voltage, which were applied to the charging means in the order of the magnitude of their peak-to-peak voltage, to measure the AC current value while no image was formed, may be changed according to the image formation count, operational environment, thickness of the film(s) of an image bearing member, or at least one of the DC current values detected by the DC current detecting means. Similarly, the multiple AC currents different in value, which were flowed through the charging means in the order of their current value, to measure the peak-to-peak voltage values while no image was formed, may be changed according to the image formation count, operational environment, thickness of the film(s) of an image bearing member, or at least one of the DC current values detected by the DC current detecting means.
Further, the amount Ih of the discharge current can be changed according to the image formation count, operational environment, thickness of the film(s) of an image bearing member, or at least one of the DC current values detected by the DC current detecting means. That is, in the preceding embodiments, the discharge current amount Ih, the value of the alternating electric field to which the charging member is subjected during the preparatory rotation step, were variable according to the environmental factors detected by the environment sensor 16 . However, the method for detecting the film thickness of a photosensitive member from the DC current value has been widely known, and it is also effective to design a charging apparatus so that the discharge current amount Ih, and the value of the alternating electric field to be applied during the preparatory rotation step, can be changed according to the detected thickness of the film(s) of a photosensitive member and the detected DC current value. Further, it is also effective to design the charging apparatus so that the cumulative image formation count is stored, and the discharge current amount Ih, and the value of the alternating electric field to be applied during the preparatory rotation step, can be changed according to the stored cumulative image formation count.
Further, in each of the above described preferred embodiments, the programs for determining, by computation, the proper value for the peak-to-peak voltage for the AC voltage to be applied in the charging step of the printing step, were carried out during the preparatory rotation step, that is, one of the steps in which no image was formed by the printer. The steps in which the programs are to be carried out does not need to be limited to the one in the preceding embodiments. That is, the programs may be carried out in any, or two or more, of the steps in which no image is formed, for example, the startup rotation step, paper intervals, or post-rotation step.
Further, in each of the preferred embodiments described above, the image forming apparatus was provided with a cleaning member. However, the present invention is also applicable to the charge process controlling means of a so-called cleaner-less image forming apparatus, that is, an image forming apparatus which has no cleaning member, and cleans its photosensitive member with its developing apparatus at the same time as it develops a latent image with the developing apparatus. Such an application brings forth the same effects as those provided by the preferred embodiments.
Further, the photosensitive drums 1 in each of the preceding embodiments may be replaced with a photosensitive drum of the direct injection type, which is provided with a charge injection layer, the surface electrical resistance of which is in the range of 10 9 -10 14 Ω.cm Even in the case of a photosensitive drum having no charge injection layer, effects similar to those obtainable with the above-mentioned photosensitive member with a charge injection layer can be obtained as long as the electrical resistance of its charge transfer layer is within the abovementioned range. Further, instead of the photosensitive drum 1 in the above-described embodiments, a photosensitive member which is made of amorphous silicon, and the volumetric resistance of the surface layer of which is roughly 10 13 Ω.cm, may be used.
Also in each of the above described embodiments, a charge roller was used as a flexible charging member of the contact type. However, in place of the charge roller, a charging member different in shape and/or material, for example, a fur brush, a piece of felt or fabric, etc., may be used. Further, a charging member, which is better in elasticity, electrical conductivity, surface properties, durability, etc., may be obtained by using in combination various substances as the materials for a charging member.
As for the waveform for the alternating voltage component (AC component: voltage which periodically change in value) to be applied to the charge roller 2 and development sleeve 4 b , any of the sinusoidal form, rectangular form, triangular form, etc., may be used as fit. Further, the alternating component of the AC voltage may be created by periodically turning on and off a DC power source. In such a case, the waveform of the AC component is rectangular.
Also in each of the above described preferred embodiments, the exposing apparatus 3 used as the means (information writing means) for exposing the charged portion of the peripheral surface of the photosensitive drum 1 was a laser scanner. However, the exposing means may be a digital exposing means made up of an array made up of light emitting elements in solid state, for example, LEDs, or an analog image exposing means, the original illuminating light source of which is a halogen lamp, a fluorescent lamp, or the like.
Also in each of the above described preferred embodiments, the first image bearing member was the photosensitive member 1 . However, the first image bearing member may be an electrostatically recordable dielectric member or the like. In the case where the first image bearing member is an electrostatically recordable dielectric member, first, the surface of the electrostatically recordable dielectric member is uniformly charged, and then, an electrostatic latent image which reflects the information of a target image is written by selectively discharging numerous points of the charge surface of the dielectric member with the use of a charge removing means, such as a charge removing needle head, an electron gun, and the like.
Also in each of the above described preferred embodiments, a transfer roller was used as the transferring means. However, the transferring means may be a transfer blade, transfer belt, or any other transferring means of the contact type. Further, it may be of the non-contact type, which uses a corona-based charging device.
Also in each of the above described preferred embodiments, the image forming apparatus was of such a type that directly transfers onto a recording medium, a monochromatic toner image formed on its photosensitive drum. However, the preferred embodiments are not intended to limit the present invention in scope. That is, the present invention is also applicable to a monochromatic image forming apparatus which employs an intermediary transferring member, such as a transfer drum or a transfer belt, and a full-color (multicolor) image forming apparatus which forms a multicolor or a full-color image by transferring in layers multiple monochromatic images.
While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
This application claims priority from Japanese Patent Application No. 178505/2008 filed Jul. 8, 2008 which is hereby incorporated by reference.
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A charging device includes a charging member to charge an image bearing member; an applying device configured to apply to the charging member a charging bias voltage comprising a DC voltage component and an AC voltage component; an AC current detector; a DC current detector; and a controller. The controller determines a saturation peak-to-peak voltage V 0 at which the detected DC current saturates when a peak-to-peak voltage of the AC voltage is increased, calculates a relational expression using only a detected AC current when a peak-to- peak voltage which is not more than the saturation peak-to-peak voltage V 0 is applied, and determines the peak-to-peak voltage of the AC voltage applied to the charging member in an image forming operation on the basis of the relational expression and a detected AC current when a peak-to-peak voltage higher than the saturation peak-to-peak voltage V 0 is applied.
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FIELD OF THE INVENTION
The invention relates generally to intraluminal devices for containing particulate in the vessels of a patient. More particularly, the invention relates to a catheter having a mechanically actuated fluid-column occluder for containing emboli in a blood vessel during an interventional vascular procedure. Furthermore, the invention concerns a mechanically actuated fluid-column occluder mounted on a guidewire that can also be used to direct an interventional catheter to a treatment site within a patient.
BACKGROUND OF THE INVENTION
Catheters have long been used for the treatment of diseases of the cardiovascular system, such as treatment or removal of stenosis. For example, in a percutaneous transluminal coronary angioplasty (PTCA) procedure, a catheter is used to insert a balloon into a patient's cardiovascular system, position the balloon at a narrowed treatment location, inflate the balloon to expand the narrowing, and remove the balloon from the patient. Another example is the placement of a prosthetic stent in the body on a permanent or semi-permanent basis to support weakened or diseased vascular walls to avoid closure or rupture thereof.
These non-surgical interventional procedures often avoid the necessity of major surgical operations. However, one common problem associated with these procedures is the potential release into the bloodstream of atherosclerotic or thrombotic debris that can embolize distal vasculature and cause significant health problems to the patient. For example, during deployment of a stent, it is possible for the metal struts of the stent to cut into the stenosis and shear off pieces of plaque which become embolic debris that can travel downstream and lodge somewhere in the patient's vascular system. Further, particles of clot or plaque material can sometimes dislodge from the stenosis during a balloon angioplasty procedure and become released into the bloodstream.
Medical devices have been developed to attempt to deal with the problem created when debris or fragments enter the circulatory system during vessel treatment. Practitioners have approached prevention of escaped emboli through use of occlusion devices, filters, lysing, and aspiration techniques. For example, it is known to remove the embolic material by capturing emboli in a filter positioned distal of the treatment area.
Alternatively, an occlusion device may be deployed distally or proximally of the treatment area to block the flow of contaminated blood, which can then be aspirated along with the embolic debris contained therein. Known occlusion guidewires include an occluder membrane surrounding an expandable mechanical structure that is actuatable by push-pull action of a core wire through an outer tubular member. However, such expandable mechanical structure can be complex to fabricate and can add undesirably to the overall collapsed profile of the occlusion guidewire.
Other known occlusion catheters or guidewires include an inflatable occlusion balloon located adjacent the distal end of a hollow guidewire. Dilute radiopaque contrast agent is forced through an inflation lumen to inflate and deflate the occlusion balloon. However, operating the balloon may take longer than desired due to the viscosity of the inflation medium, the small size of the inflation lumen, and the requirement to attach, detach and operate one or more inflation accessories at the proximal end of the catheter or guidewire. Accordingly, there is a need for a simplified, low-profile embolic protection device.
BRIEF SUMMARY OF THE INVENTION
The present invention is a protection device for collecting/containing embolic debris in a body lumen. The protection device includes an outer tubular member, an elongate inner member longitudinally slidable within the outer tubular member, and a mechanically actuated occluder The occluder has a proximal end fixedly sealed about a distal end of the outer tubular member, a distal end axially secured to the elongate inner member and a fixed amount of fluid contained therein. In an embodiment of the present invention, a sliding seal accommodates relative sliding movement between the inner and outer members and prevents leakage of occluder fluid from the occluder. In another embodiment, the occluder has an annular cross-section defined by the coaxial arrangement of an inner and an outer tubular wall. The annular space between the inner and outer walls is filled with a fixed amount of occluder fluid. The inner tubular wall isolates the core wire from occluder fluid. Upon positioning of the occluder within the body lumen distally or proximally of the treatment site, proximal movement of the elongate inner member relative to the outer tubular member forces the ends of the occluder toward each other, thus redistributing the occluder fluid radially outward to deploy the occluder into sealing apposition with a wall of the body lumen.
In various embodiments of the present invention, the occluder may be comprised of an impervious elastomeric material filled with a biocompatible fluid.
BRIEF DESCRIPTION OF DRAWINGS
The foregoing and other features and advantages of the invention will be apparent from the following description of the invention as illustrated in the accompanying drawings. The accompanying drawings, which are incorporated herein and form a part of the specification, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. The drawings are not to scale.
FIG. 1 is a side view of a distal protection device in accordance with an embodiment of the present invention.
FIG. 2 is a partial cross-section of a distal end of the distal protection device of FIG. 1 within a patient's vascular anatomy.
FIG. 3 is a partial cross-section of a distal end of the distal protection device of FIG. 1 in accordance with another embodiment of the present invention.
FIG. 3A is a transverse cross-section of the distal protection device of FIG. 3 taken along line A-A.
FIG. 3B is an enlarged view of a distal end of the distal protection device of FIG. 3 in accordance with another embodiment of the present invention.
FIG. 4 illustrates a distal end of the distal protection device of FIG. 1 with the occluder in its deployed configuration within the patient's vascular anatomy.
FIG. 5 is a partial cross-section of a distal end of a protection device within a patient's vascular anatomy according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Specific embodiments of the present invention are now described with reference to the figures, wherein like reference numbers indicate identical or functionally similar elements. The terms “distal” and “proximal” are used in the following description with respect to a position or direction relative to the treating clinician. “Distal” or “distally” are a position distant from or in a direction away from the clinician. “Proximal” and “proximally” are a position near or in a direction toward the clinician.
While the following description generally refers to a distal protection device, it should be understood that the invention is also applicable to a proximal protection device, wherein the occluder may be deployed proximally of a treatment site to block flow upstream of the site. A treatment apparatus, such as a catheter, may be delivered via a through lumen in the proximal protection device to provide therapy at the site. See lumen 509 in FIG. 5 . Debris generated during the therapy will not move downstream to embolize because of the temporary stasis in the vessel. Fluid that may be contaminated with debris can be aspirated via the through lumen before the occluder is contracted to allow fluid flow to resume.
The present invention is a temporary distal protection device for use in minimally invasive procedures, such as vascular interventions or other procedures, where the practitioner desires to capture and remove embolic material that may be dislodged during the procedure. As shown in FIGS. 1 and 2 , distal protection device 100 , viz, occluder system 100 , includes an elongate tubular member, or catheter shaft, 102 , a core wire 108 slidably extending there through, and a hub 110 . Core wire 108 extends within a lumen 207 of tubular member 102 from a proximal end 104 to a distal end 101 thereof. A seal 205 is secured to distal end 101 of tubular member 102 and slidingly seals about core wire 108 to retain fluid on the distal, or occluder side of seal 205 , like a rod-type seal for a hydraulic cylinder. Alternatively, seal 205 may take the form of a cap that sealingly fits over distal end 101 of tubular member 102 . A fluid-column occluder 106 for containing a fixed amount of biocompatible fluid 212 is joined to distal end 101 of tubular member 102 and core wire 108 , as described below.
One alternative to rod-type seal 205 is a seal fixed about core wire 108 to slidingly seal anywhere along the interior surface of tubular member 102 to retain fluid on the distal, or occluder side of the seal, like a piston-type seal (not shown) for a hydraulic cylinder. In another alternative embodiment, a rolling diaphragm-type of seal (not shown) can be disposed between tubular member 102 and core wire 108 . A seal that allows movement between core wire 108 and shaft 102 may be located at distal end 101 , e.g. seal 205 , at proximal end 104 , or anywhere in lumen 207 between shaft ends 101 , 104 . If a seal is located at shaft proximal end 104 or within lumen 207 proximally of shaft distal end 101 , then the portion of lumen 207 distal to the seal will be in fluid communication with the interior of occluder 106 and thus will also contain occluder fluid 212 , which may act as a lubricant between core wire 108 and shaft 102 .
Fluid-column occluder 106 has a proximal end 214 and a distal end 216 . Occluder distal end 216 is axially secured to core wire 108 and occluder proximal end 214 is attached to distal end 101 of tubular member 102 . Occluder ends 214 , 216 may be fixedly attached to tubular member 102 and core wire 108 , respectively, by use of a bonding sleeve, and/or an adhesive, as would be apparent to one of ordinary skilled in the relevant art. Occluder 106 is filled with occluder fluid 212 in the form of gas, liquid, semisolid, i.e. a gel, or combinations thereof. Non-limiting examples of suitable fluids 212 are carbon dioxide gas, saline and silicone oil. Other amorphous, fluid-like substances may be utilized, as long as the substance is biocompatible and is capable of redistributing, deforming or flowing in response to forces applied thereto during push-pull actuation of occluder system 100 . In a further embodiment, fluid 212 may comprise suspended radiopaque particles or a dilute or undiluted x-ray contrast agent to aid in fluoroscopic observation of the occluder in vivo. Optionally and/or in addition to fluoroscopic material within fluid 212 , radiopaque markers (not shown) may be placed on proximal and distal ends 214 , 216 of occluder 106 to aid in fluoroscopic observation during manipulation thereof.
Core wire 108 may be made from a metal, such as nitinol, stainless steel, or cobalt-chromium superalloy wire. In an embodiment of the present invention (not shown), core wire 108 may be tapered at its distal end and/or be comprised of one or more core wire sections of different materials. Core wire 108 may be centerless-ground to have several diameters in its profile in order to provide regions of different stiffnesses with gradual transitions there between. Core wire 108 has a proximal end 109 that extends outside of the patient from proximal end 104 of tubular member 102 . Core wire 108 may also include a coiled tip portion, such as, coiled tip portion 326 shown in FIG. 3 , or may include a flexible coil spring that is formed from a round or flat coil of stainless steel and/or one of various radiopaque alloys, such as platinum, as is well known to those of skill in the art of medical guidewires.
In another embodiment of the present invention, tubular member or catheter shaft 102 may be constructed of multiple shaft components (not shown) of varying flexibility to provide a gradual transition in flexibility. Such a shaft arrangement is disclosed in U.S. Pat. No. 6,706,055, which is incorporated by reference herein in its entirety. In addition, a liner or axial bearings (not shown) as disclosed in the '055 patent may be utilized between core wire 108 and outer shaft 102 in order to facilitate sliding movement there between during expansion and collapse of occluder 106 . In another embodiment, tubular member 102 may be a hollow tube enabling distal protection device 100 to also function as a medical guidewire.
Tubular member 102 may include a thin-walled, tubular structure of a metallic material, such as stainless steel, nitinol, or a cobalt-chromium superalloy. Such metallic tubing is commonly referred to as hypodermic tubing or a hypotube. Metallic tubing formed from other alloys, as disclosed in U.S. Pat. No. 6,168,571, which is incorporated by reference herein in its entirety, may also be used in the tubing of the present invention. In the alternative, outer shaft 102 may include tubing made from a thermoplastic material, such as polyethylene block amide copolymer, polyvinyl chloride, polyethylene, polyethylene terephthalate, polyamide, or a thermoset polymer, such as polyimide.
Fluid-column occluder 106 is comprised of an occluder casing 211 that contains occluder fluid 212 . Occluder casing 211 is comprised of a biocompatible elastic material that is impermeable to bodily fluids, as well as to the contained occluder fluid 212 . In an embodiment of the present invention, occluder casing 211 may be formed from an elastic material such as latex, silicone elastomer, or other viscous forms of natural and synthetic rubbers such as butadiene/acrylonitride copolymers, copolyesters, ethylene vinylacetate (EVA) polymers, ethylene/acrylic copolymers, ethylene/propylene copolymers, polyalkylacrylate polymers, polybutadiene, polybutylene, polyethylene, polyisobutylene, polyisoprene, polyurethane, styrenebutadiene copolymers, and styrene-ethylene/butylene-styrene. Occluder 106 may be made, completely or partially, self-expanding, meaning that occluder 106 may be made to have a mechanical memory to return from the radially contracted or columnar configuration to the radially expanded or deployed configuration, as shown in FIG. 4 . Such mechanical memory can be achieved in occluder 106 by making occluder casing 211 in the shape of the deployed configuration, as by casting or blow molding occluder casing 211 inside a hollow mold, or by forming occluder casing 211 over a removable mandrel, e.g. by dipping or thermoforming.
Occluder 106 is sized and shaped such that when it is deployed, as shown in FIG. 4 , its greatest diameter will be expanded into sealing contact with the inner surface of the blood vessel wall into which it is placed. The inner surface contact is maintained around the expanded circumference to prevent any emboli from escaping past occluder 106 . In the embodiment shown in FIG. 2 , occluder casing 211 is of a substantially cylindrical or columnar, radially contracted shape filled with occluder fluid 212 , as is occluder casing 511 shown in the embodiment of FIG. 5 that is described further below.
Alternatively, as shown in the embodiment of FIGS. 3 , 3 A and 3 B, occluder casing 311 of occluder 306 has an annular cross-section defined by the coaxial arrangement of an inner tubular wall and an outer tubular wall. The annular space between the inner and outer walls is closed at occluder proximal and distal ends 314 , 316 and the fixed internal volume thus defined is filled with a fixed amount of occluder fluid 212 , as measured by volume or mass. The inner tubular wall defines a central lumen 313 that surrounds core wire 108 and isolates core wire 108 from occluder fluid 212 . As in the embodiment of FIG. 2 , occluder distal end 316 is axially secured to core wire 108 and occluder proximal end 314 is attached about distal end 101 of tubular member 102 . However, because occluder fluid 212 is contained within annular occluder casing 311 and does not make contact with the portion of core wire 108 within lumen 313 , no seal or sealing member is needed to seal distal end 101 of tubular member 102 .
In a further embodiment as shown in FIG. 3B , occluder distal end 316 may be axially secured to and rotatable with respect to core wire 108 . Occluder distal end 316 may be affixed to a cylindrical collar or bearing 324 , such that core wire 108 may rotate relative to occluder 306 and tubular member 102 . The bearing may be held in its axial position relative to core wire 108 by proximal and distal stops 320 , 322 , which are fixedly attached to core wire 108 .
Distal protection device 100 is transformable between its radially contracted and deployed configurations by relative movement between proximal and distal ends 214 , 216 of fluid-column occluder 106 . Distal protection device 100 is tracked through a patient's vasculature with occluder 106 in its low profile, contracted form, as shown in FIG. 2 . Once occluder 106 is situated distal of the treatment site, occluder 106 is transformed into its deployed configuration by pulling core wire 108 proximally within tubular member 102 , or by pushing tubular member 102 distally over core wire 108 . This push-pull actuation draws ends 214 , 216 toward each other, thus shortening the length of occluder 106 and redistributing occluder fluid 212 radially outward within occluder casing 211 to thereby bring occluder 106 into contact with the walls of the vessel lumen, as shown in FIG. 4 .
If occluder fluid 212 is a gas, then the initial fixed amount, i.e. fixed mass, of fluid 212 may be compressed from its initial volume to a somewhat smaller volume and corresponding increased internal pressure resulting from shortening the length of occluder 106 during push-pull actuation. However, with proper selection of elastic material and thickness for occluder casing 211 , a gas-filled embodiment of occluder 106 will expand into its deployed configuration in response to push-pull actuation of distal protection device 100 . Occluder 106 is contracted for removal from the body lumen by reversing the push-pull deployment actuation, i.e. by distally advancing core wire 108 relative to tubular member 102 or by proximally drawing tubular member 102 over core wire 108 . As described above, fluid-filled occluder 106 is transformable between contracted and deployed configurations by mechanical actuation, not by adding fluid to, or removing fluid from, the interior of occluder 106 .
FIG. 5 illustrates a further embodiment of the present invention situated within a body lumen, with an embolic occluder 506 in its contracted configuration. Distal protection device 500 includes occluder 506 attached at a proximal end 514 to a distal end 501 of an outer tubular member or shaft 502 and attached at a distal end 516 to an inner tubular member or shaft 503 . Inner tubular member 503 includes a lumen 509 to slidably accommodate a therapy device (not shown) and/or a guidewire 508 therein, whereas outer tubular member 502 includes a lumen 507 to slidably accommodate inner tubular member 503 therein. Occluder ends 514 , 516 may be joined to outer and inner tubular members 502 , 503 , respectively by a bonding sleeve, and/or an adhesive, as would be apparent to one of ordinary skilled in the relevant art. Occluder casing 511 of occluder 506 may be formed from the same elastic materials described above with respect to occluder casing 211 , such that occluder proximal end 514 forms integral seal 505 for accommodating sliding movement of inner tubular member 503 there through without leakage of fluid 512 from occluder 506 . Alternatively, distal protection device 500 may include a seal positioned and secured between inner and outer tubular members 503 , 502 , as described above with reference to seal 205 in the embodiment of FIG. 2 .
Distal protection device 500 is transformable between its deployed and contracted configurations by relative movement between proximal and distal ends 514 , 516 of occluder 506 . Distal protection device 500 is tracked through a patient's vasculature over guidewire 508 with occluder 506 in its contracted or columnar configuration, as shown in FIG. 5 . Once occluder 506 is situated distal of the treatment site, occluder 506 is transformed into its deployed configuration by pulling inner tubular member 503 proximally relative to outer tubular member 502 . This push-pull actuation draws ends 514 , 516 toward each other, thus shortening the length of occluder 506 and redistributing occluder fluid 512 radially outward within occluder casing 511 to thereby bring occluder 506 into contact with the walls of the vessel lumen.
Similarly to the embodiment shown in FIG. 2 , occluder 506 is contracted for removal from the body lumen by distally advancing inner shaft 503 relative to outer shaft 502 . Inner tubular member 503 and outer tubular member 502 may be of any construction or material previously described with reference to tubular member 102 .
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of illustration and example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the appended claims and their equivalents. It will also be understood that each feature of each embodiment discussed herein, and of each reference cited herein, can be used in combination with the features of any other embodiment. All patents and publications discussed herein are incorporated by reference herein in their entirety.
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A flexible elongate device having a distally mounted occluder for collecting particulate debris in a body lumen. The occluder containing a fixed amount of fluid is reversibly expandable by push-pull actuation from a contracted configuration to a deployed configuration wherein the occluder is expanded into sealing engagement with the wall of the body lumen. The occluder has a distal end axially secured to an elongate inner member and a proximal end attached to a distal end of an outer tubular member. The occluder has an impermeable occluder casing for containing the occluder fluid. The elongate inner member is slidable within the outer tubular member such that relative longitudinal movement between the elongate inner member and outer tubular member changes the length of the occluder and thus redistributes the occluder fluid within the occluder casing to transform the occluder between its contracted and deployed configurations.
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RELATED APPLICATION DATA
This application claims the benefit of and priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 60/291,637, filed May 18, 2001, entitled “Offshore Platform,” which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to structural supports. In particular, this invention relates to structural supports for, for example, offshore drilling platforms, or the like.
2. Description of Related Art
Conventional offshore platforms have deck legs that are vertical or are battered outward as they extend downwards. The conventional arrangement provides structurally efficient support for the deck but the associated dimensions of the platform at the water surface result in increased expense for the platform.
SUMMARY OF THE INVENTION
Pile are configured in a “teepee” type configuration, where the piles are arranged to generally form a conical shape with their intersection being approximately at the elevation of, for example, a waterline. The tops of the piles extend pass this intersection to support, for example, a platform or structure, such as a drilling platform. The opposite ends of the piles are proportionally spaced on or below another surface, such as the mudline on an ocean floor.
The basic concept of using conical spaced piles can be extended such that two or more piles can be used to support, for example, a structure at a first end, while also providing support for, for example, a central member, such as a drill pipe, that extends through a central axis of the assembly. However, it is to be appreciated, that three or more piles can be used without a center member to support a structure as discussed above. Furthermore, two or more supports can be used with one or more center members to also support a structure as discussed above.
For example, two piles can be offset substantially 180° from each other, e.g. X shaped, three piles offset substantially 120° from each other, four piles offset substantially 90° from each other, e.g, teepee shaped, or the like. However, it is to be appreciated that the specific offset between the piles, and the number of piles, can be varied depending on, for example, expectant forces on the structure, the topology of the surface the assembly is to be secured to, the weight, structure and anticipated forces of the device that sits on top of the piles, or like.
An aspect of the invention relates to providing a structure support with at least three legs that are positioned in a teepee configuration.
Aspects of the present invention also relate to providing a structure support with four or more legs positioned in a teepee configuration.
Accordingly, an aspect of the invention allows piles to be configured such that the footprint has a greater surface area than the area formed by the opposing ends of piles.
Additional aspects of the invention related to minimizing the bracing required for a structural support in a wave zone.
Aspect of the invention additionally relate to a support structure that reduces lateral wave forces on the structure.
Aspects of the invention additionally relate to providing a structure in which the majority of the components can be installed and welded in-place above a waterline.
Aspects of the invention also relate to reducing drilling platform size.
These any other features and advantages of this invention are described in or are apparent from the following detailed description of the embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the invention will be described in detail, with reference to the following figures, wherein:
FIG. 1 is a view in side elevation Of an offshore platform of according to the present invention;
FIG. 2 is a view in front elevation of the offshore platform according to the present invention;
FIG. 3 is a view in side elevation showing the setting of the deck frame for the offshore platform according to the present invention;
FIG. 4 is a view in side elevation showing the setting of the main deck for the offshore platform according to the present invention;
FIG. 5 is a view in side elevation showing the setting of the helideck for the offshore platform according to the present invention;
FIGS. 6–19 illustrate an exemplary method of assembling a braced caisson according to this invention; and
FIGS. 20–27 illustrate another exemplary method of assembling a caisson according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
The exemplary embodiments of this invention will be described in relation to a support structure, such as drilling platform, supported by three piles and a central vertical member, such as drill pipe. However, to avoid unnecessarily obscuring the present invention, the following description omits well-known structures and devices that may be shown in block diagram form or otherwise summarized. For the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It should be appreciated that the present invention may be practiced in a variety of ways beyond these specific details. For example, the systems and methods of this invention can be generally expanded and applied to support any type of structure. Furthermore, while exemplary distances and scales are shown in the figures, it is to be appreciated the systems and methods of this invention can be varied to fit any particular implementation.
FIGS. 1 and 2 show an inward batter guide offshore platform indicated generally at 10 in which battered bracing piles 12 a–e are arranged so as to minimize platform dimensions at the water surface 14 while maximizing the spacing of the piles as they extend upward from the water surface so that loads from a deck 16 at the top of the piles are transferred directly to the piling. The platform includes a pile guide structure 18 which fits over and is connected to a central vertical member 20 to receive the piles 12 a–e at the water surface. The piles extend angularly through guides 22 of the pile guide structure in such a manner that the distance between piles is minimized at the water surface, but the distances between angled piles is maximized both at the ends supporting the deck 16 as well as at the opposed end buried below the mudline 24 . The pile guide connects the piles to act in unison to restrain lateral movement of the entire offshore platform 10 including the central vertical member 20 . The pile guide 18 also supports appurtenances such as ladders, boat landings, stairs, or the like, so that they can be installed in the field as a unit, thereby, for example, reducing installation expense for the platform. The legs 26 of the deck structure are connected to the tops of the piles. The increased pile spacing at the pile tops provides, for example, more structurally efficient support for the deck, reduced structural vibration periods for the platform and increased resistance to the rotation that results if the deck mass is eccentric to the central vertical member 20 than if the deck is supported by the central member. All field connections can be made above the water surface where structural integrity of the connections can be more easily verified than if the connections were made below the water surface.
With reference to FIG. 3 , once the piles 12 are in place, the deck frame 28 can be set on top of the piles and connected to the upper ends of the piles. Then, as shown in FIG. 4 , the main deck 16 is set on the deck frame, and finally, as shown by FIG. 5 , a helideck 30 is set in place.
FIGS. 6–19 illustrate an exemplary method for assembling a structure in accordance with an exemplary embodiment of this invention with, for example, a barge boat, around a SSC 50 (Self Sustaining Caisson). In this exemplary embodiment, the SSC has been installed by a drilling rig, such as a rig drilling an exploration well. In FIG. 6 , the position, and orientation of the legs are determined and a lift boat 55 anchored and jacked-up relative to the installation point of the SSC. Next, as illustrated in FIG. 7 , the jack-up orientation of the liftboat relative to the SSC is shown. Next, as illustrated in FIG. 8 , the guide structure 65 is unloaded from the barge 60 . Then, as illustrated in FIG. 9 , the legs or piles 70 , are unloaded, placed in the guide structure, and in FIG. 10 , installed via the guide structure into, for example, the ocean floor with the aid of a hydraulic hammer. As can be seen from this illustration, the piles 70 intersect at a point just above the water line. This allows, for example, the piles and all associated connection to be made above water.
In FIG. 11 , the barge 60 is relocated and the deck frame 75 is unloaded. In FIG. 12 the deck frame 75 installed on the piles. Next, in FIGS. 13–16 , the southskid 80 , northskid and ventroom 85 , and helideck 90 , respectfully, are unloaded from the barge and installed on the piles. In particular, FIG. 16 illustrates how the various portions of the rig are installed at an end of the piles above the intersection point, and thus above the water line. Then, in FIGS. 17–18 , the main deck 95 unloaded and installed.
FIG. 19 illustrates the completed rig where the barge has been unloaded and the vent boom 100 rotated into position.
FIGS. 20–27 illustrate exemplary steps for constructing a structure support according to an alternative exemplary embodiment of this invention where a SSC is not initially present at a well head. In particular, this exemplary method utilizes a jack-up drilling rig and derrick barge to construct the rig. Specifically, in FIG. 20 , a jack-up drilling rig is mobilized and the first conductor with a mudline suspension is drilled. Next, as illustrated in FIG. 21 , the jack-up rig installs a sub-sea template 200 that is used as a guide structure for the well head and the subsequent installation of the SSC. Then, in FIG. 22 , a second conductor with a mudline suspension is drilled and installed via the sub-sea template 200 .
FIG. 23 illustrates the installation of the caisson by, for example, a derrick barge 210 . Next as illustrated in FIG. 24 , for example, the derrick barge 210 installs the inward batter guide structure 220 . Then, as illustrated in FIG. 25 , the piles 70 are installed. FIG. 26 illustrates the installation of the deck frame 230 and FIG. 27 the helideck 240 .
It is, therefore, apparent that there has been provided, in accordance with the present invention, a support and method for assembling the support to support a structure. While this invention has been described in conjunction with a number of illustrative embodiments, it is evident that many alternatives, modifications, and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, the disclosure is intended to embrace all such alternatives, modifications, equivalents and variations that are within in the spirit and scope of this invention.
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A pile based braced caisson structural support device includes a number of legs. These legs are configured in a teepee type configuration such that the footprint of the base is larger than the footprint of the opposing end. This structural support can be used as a base for an offshore drilling platform in that the support reduces the lateral forces on the support caused by wave action.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional patent application No. 60/471,299 filed May 16, 2003, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to devices and methods for improved near-field transmission of electromagnetic waves. More specifically, it relates to resonant transmission through sub-wavelength apertures to provide high spatial resolution and high power throughput in the near field.
BACKGROUND OF THE INVENTION
[0003] In many technological areas it is desirable to be able to transmit electromagnetic energy with very high spatial resolution. At far-field distances from an electromagnetic wave source, the spatial resolution of the radiation is theoretically limited by the diffraction limit. Specifically, an electromagnetic wave of wavelength λ can resolve two objects in the far field only if they are spatially separated by at least λ/(2n sin(θ)), where n is the refractive index of the medium in which the objects are embedded and θ is the maximum power collection angle of the imaging system. This theoretical limit, however, only applies to far-field distances from the source, i.e., at distances greater than about λ/2. At near-field distances, it is theoretically possible for the spatial resolution to exceed the diffraction limit.
[0004] One approach to achieve high spatial resolution beyond the diffraction limit is shown in FIG. 1 . This approach uses a circular aperture 100 in a thin metallic plate 102 exposed to incident linearly polarized light 104 , where the aperture width w is much smaller than the wavelength λ of the light. Although this aperture can provide sub-wavelength resolution at near-field distances, it suffers from extremely low power transmission. In contrast to large apertures (w>>λ) where the power throughput (PT) is almost 100%, these sub-wavelength apertures (w<<λ) have a power throughput proportional to the fourth power of the aperture size, i.e., PT∞(W/λ) 4 . Consequently, these conventional circular sub-wavelength apertures suffer from a trade-off between spatial resolution (small w) and power throughput (large PT). Other known probe designs, such as tapered fiber probes, also suffer from this problem with low power transmission.
[0005] A new sub-wavelength aperture design having improved performance is described in international publication WO 01/17079 A1, which is incorporated herein by reference. This publication describes an aperture geometry having at least one protrusion extending into the aperture. For example, a single protrusion creates a C-shaped aperture. It is generally stated that, preferably, the geometry is adjusted to maximize desirable properties such as total field intensity and near field localization of optical power. No specific teachings are provided, however, regarding how such an optimization can be performed. The joint maximization of two or more parameters with respect to unlimited geometric possibilities is an extremely complex problem, even with computational simulations. Clearly, it would be an advance in the art to provide a single criterion for simultaneously maximizing both spatial resolution and power throughput, and to provide more exact methods for optimizing C-aperture geometries. It would also be an advance in the art to provide entirely new features in addition to geometrical aperture shape that provide additional improvements in performance.
SUMMARY OF THE INVENTION
[0006] Building on the initial discovery of C-apertures, the present invention provides improvements in the design and function of C-apertures, as well as a deeper understanding of their properties. The present inventors have developed a numerical method for C-aperture optimization. These optimized C-apertures have improved performance in both transmission efficiency and spatial resolution as compared to prior C-aperture designs. In one aspect of the invention, these optimized C-apertures are designed by selecting the aperture geometry so that it resonates at a larger normalized resonant wavelength. The normalized resonant wavelength is defined as the ratio of the resonant wavelength to the aperture size. The inventors have also discovered that filling the aperture with high refractive index material can red-shift the resonant wavelength of the aperture and thus can achieve even higher spatial resolution.
[0007] In another aspect, the inventors have discovered that, unlike other very small apertures, the high transmission through the C-aperture does not decay with aperture metal thickness. This means that, in the case of a metal film with thickness not negligible compared to wavelength, the transmission enhancement through the C-aperture is even higher than the factor of 1000 enhancement in a very thin metal plate case. Furthermore, the resonant transmission may be further enhanced when the aperture metal thickness is designed properly to achieve a Fabry-Perot-like resonance from constructive front and back interface reflections.
[0008] The inventors have also discovered that, for metals with finite losses, the high transmission performance may be maintained by reducing the corresponding aperture size to compensate for the finite penetration depth of the metal.
[0009] Those skilled in the art will appreciate that, while the C-apertures may be designed and described for optical frequency ranges, the principles of the invention are of general application to other frequencies. For example, the same aperture geometry can be applied to other electromagnetic frequencies such as microwave, THz, and infrared ranges. The aperture geometry in each case is simply scaled according to the corresponding application wavelength. Thus, the scope of the invention is not limited to apertures for use in optical frequency ranges.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a conventional sub-wavelength circular aperture in a thin metallic plate exposed to linearly polarized light.
[0011] FIG. 2 shows the parameters defining the geometry of a C-aperture according to an embodiment of the present invention.
[0012] FIG. 3 is a graph illustrating the power throughput of square, rectangular, and C-apertures, illustrating the principle that higher performance apertures have higher normalized resonant wavelength.
[0013] FIG. 4 is a graph showing how the spectral response of C-apertures changes as the thickness of the aperture metal plate increases.
[0014] FIG. 5 is a graph illustrating the presence of a transmission resonance with periodic peaks at different values of the metal thickness.
[0015] FIG. 6 is a cross-section of an aperture in a plate of thickness t, illustrating the principle behind the transmission resonance effect shown in FIG. 5 .
[0016] FIG. 7 illustrates an aperture filled with a high index material according to an embodiment of the invention.
[0017] FIG. 8 is a graph showing the frequency response curves for a C-aperture with a glass filling and without a glass filling.
[0018] FIG. 9 shows a C-aperture design that includes a substrate medium upon which the metal and aperture filling layers are deposited.
[0019] FIG. 10 illustrates a C-aperture that is tapered in the thickness dimension t to provide impedance matching, according to an embodiment of the invention.
[0020] FIG. 11 illustrates an aperture design according to an embodiment of the present invention, including two back-to-back C-apertures.
[0021] FIG. 12 illustrates the compound aperture of FIG. 11 being used to trap a small particle of diameter d.
[0022] FIG. 13 shows a tapered fiber probe fabricated with a C-aperture at the output end, according to an embodiment of the present invention.
[0023] FIG. 14 shows a very small aperture laser fabricated with a C-aperture for use in a high density optical data storage device, according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0024] The description of the present invention and its various embodiments is best understood by first defining certain technical terms that pertain generally to sub-wavelength apertures, such as the aperture shown in FIG. 1 . An planar aperture is defined as an opening 100 in a locally planar surface 102 that allows radiation 104 incident on one side of the surface to pass from one side of the surface to the other, resulting in the transmission of radiation 106 through the aperture. The transmission cross-section σ 1 is defined as the ratio of the total transmitted power P trans to the incident power flux density S inc , i.e., σ 1 =P trans /S inc . The power throughput is defined as PT=σ 1 /A, where A is the aperture area. Without loss of generality, the coordinate system used in this description is selected so that the radiation 104 incident on the aperture propagates in the z direction, the x-y plane coincides with the plane 102 of the aperture, and the origin is located at the center of the aperture 100 . The wavelength of incident radiation is denoted λ, and the aperture width is denoted w for circular or square apertures. A large aperture refers to the case where w>5λ. A small aperture refers to the case where w<<λ/2. An resonant aperture refers to an intermediate aperture size between these two extremes. A sub-wavelength aperture refers to an aperture where w<λ. For sub-wavelength apertures, the very near field region refers to the region where z<λ/2, the far field region refers to the region where z>λ/2, and the intermediate field region refers to the region between these extremes where w/2<z<λ/2. In the very near field region the electromagnetic field intensity is confined to a size about equal to the aperture size. In the far field region the field intensity drops as 1/z 2 .
[0025] In one aspect of the invention, computational simulations are used to study the near-field transmission of electromagnetic waves through apertures, and to optimize aperture design. In one embodiment, the computational simulation uses the finite difference time domain (FDTD) method, which is a well-known numerical method for rigorously solving Maxwell's equations. Given a characterization of the incident radiation field and the geometric and material properties of the interacting structures in the environment, the FDTD method accurately provides complete information about the electric and magnetic field components at any point in space and time. The commercially available software package XFDTD pro, for example, may be used to implement to FDTD method. To reduce numerical errors, it is preferred to 1) select the time step Δt to satisfy the Courant condition, (cΔt) 2 ≦(1/Δx) 2 +(1/Δy) 2 +(1/Δz) 2 , where Δx, Δy, Δz are the grid sizes in the x, y, z directions, and 2) select Δx, Δy, Δz≦L/20, where L is the smaller of the wavelength in the highest index medium present and the smallest length defined in the interacting structure. In the FDTD method, metals may be simulated using four parameters (ε dc , ε ∞ , σ, τ). These parameters specify the static permittivity, the infinite frequency permittivity, the conductivity, and the relaxation time, respectively, of the metal.
[0026] The simulations preferably model incident light as a plane wave or Gaussian mode wave linearly polarized in the x-direction, i.e., polarized in the horizontal direction when the aperture is oriented to appear like the upright letter C. To determine an aperture's resonant transmission wavelength, it is preferred to model the incident radiation as a short plane wave pulse. During the simulation process, electromagnetic field values in the transmission region are recorded at several locations. Fourier transforms are performed for both the incident pulse and the measured transmission fields to obtain both the incident field spectrum and the transmission field spectrum. By normalizing the transmission field spectrum to the incident field spectrum, a response spectrum is obtained at each location. The peak location in the response spectrum determines the resonant transmission frequency. The resonant transmission wavelength λ reso can be calculated from this frequency. The resonant transmission power throughput can be obtained by performing another simulation using an incident monochromatic wave at the resonant wavelength λ reso , The advantage of using an incident pulse in the initial simulation is that the resonant transmission wavelength can be determined from a single simulation, which is more computationally efficient than performing a simulation at each wavelength.
[0027] Prior understanding of conventional square apertures was limited to the very small and very large aperture cases (i.e., w<<λ and w>>λ). The inventors have discovered surprising properties of apertures whose width is an intermediate size between these extremes.
[heading-0028] Geometry Effect
[0029] Changes in aperture geometry profoundly affect transmission efficiency through the aperture. However, it is not initially obvious how to select a geometry to optimize power throughput and localization of high intensity peaks (i.e., spatial resolution). Further investigation with square and rectangular apertures shows that aperture transmission is strongly correlated with aperture size in the direction perpendicular to the incident polarization and is much less correlated with aperture size in the direction parallel to the incident polarization. Increasing an aperture's size in the direction perpendicular to the incident light polarization increases its transmission efficiency and its near field intensity. Reducing an aperture's size in the direction parallel to the incident light polarization helps to reduce the near field spot size and does not affect its transmission efficiency much. For near field applications, vertically oriented rectangular apertures are better than square apertures. These observations provide guidance in optimizing aperture geometry, such as an aperture whose geometry has the shape of a letter C, i.e., a C-aperture.
[0030] As shown in FIG. 2 , geometrical parameters of a C-aperture can be defined by four linear lengths: the total horizontal extent W a , the total vertical extent H t , the vertical gap H b between the two arms, and the horizontal width W b of the vertical waist connecting the two arms. A known C-aperture design has the following relative dimensions: W b =H b , W a =2.2W b , and H t =3H b . The arms in this design have equal height (H t −H b )/2. This C-aperture design (called C 1 ) has resonant transmission at a wavelength λ=10W b =10H b . For example, to design such a C-aperture that resonates at λ=1000 nm, one sets W b =H b =100 nm, W a =220 nm, and H t =300 nm. A high intensity field is produced at about z=50 nm=λ/20 from the aperture plane, centered along the inner vertical edge of the C with a full width half maximum (FWHM) of 128 nm in the x-direction and 136 nm in the y-direction. The power throughput is 4.41, which is about 1000 times larger than that of a square aperture with w=100 nm.
[0031] The inventors have discovered even higher performance C-aperture designs. In particular, simulations were used to find the geometric dimensions for a C-aperture that optimizes its performance. This optimization is based in part on the following novel insights. Apertures with the same area but different geometries may resonate at different wavelengths. Thus, for an aperture with area A, we define the normalized resonant wavelength to be the resonant wavelength normalized by the aperture size, i.e., λ reso,N =λ reso /A 1/2 . For apertures with a same resonant wavelength, the near field spatial resolution is proportional to the corresponding normalized resonant wavelength, i.e., the higher the normalized resonant wavelength, the higher the near-field spatial resolution. Comparing square, rectangular, and C-apertures, it is found that the aperture geometries with higher power throughput also have higher normalized resonant wavelength, as illustrated in FIG. 3 . Thus, preferred aperture geometries correspond to apertures with high normalized resonant wavelength. This provides a criterion to guide a search for optimal aperture designs for high transmission, high spatial resolution applications. (It should be noted that the polarization effect mentioned earlier is also illustrated in FIG. 3 by the power throughput difference between the two rectangular apertures.)
[0032] Moreover, there are several other important observations that provide guidance for “C”-aperture design optimization.
[0033] 1. The near field spot size. The near field spot from a C-aperture is mostly concentrated along the inner edge of the aperture waist around the C-aperture center. This implies that a smaller near field spot size may be achieved (at a closer distance from the aperture) by reducing the waist height and width.
[0034] 2. The resonant transmission wavelength. An aperture with a longer resonant transmission wavelength may provide both higher spatial resolution and higher resonant transmission efficiency.
[0035] 3. The resonant wavelength curve. A C-aperture's resonant wavelength changes as the aperture's geometry is tuned. The resonant wavelength of a C-aperture ( FIG. 2 ) is much more sensitive to changes of W a and W b than that of H b and H t . By increasing W a or decreasing W b , the resonant wavelength can be red-shifted.
[0036] Combining these guidelines, reducing the relative lengths of both H b and W b is beneficial for achieving both higher spatial resolution and a longer resonant wavelength. With this insight, a second C-aperture design (called C 2 ) was developed. The relative dimensions of the C 2 design are: H b =W b , H t =4.2H b , W a =4.4W b . For example, with H b =W b =50 nm, the other parameters are H t =210 nm and W a =220 mm. At 48 nm away from the aperture, C 2 shows a more than two times higher near field intensity than that of C 1 . In addition C 2 has a spot size about 30 nm smaller than that of C 1 in the y-direction. The spot size in the x-direction is about the same. For C 2 , a fairly well-defined spot is formed at 24 nm away from the aperture. The field intensity at this location is about 4 times higher than that at 48 nm away. The near field spot size at 24 nm away is greatly reduced as well, which is about 50 nm smaller in the x-direction and about 25 nm smaller in the y-direction than that at 48 nm away.
[0037] The C 2 design suggests that reducing the C-aperture's relative dimensions in the y-direction is helpful for achieving higher spatial resolution. Based on this observation, another C-aperture design (called C 3 ) was developed. The relative dimensions of the C 2 design are: H b =W b , H t =3H b , W a =5W b . For example, with H b =W b =48 nm, the other parameters are H t =144 nm and W a =240 nm. At 48 nm away from this aperture, there is more than three times higher peak intensity than that of C 1 , and it is also higher than that of C 2 . The spot size from C 3 is significantly smaller than that of C 1 as well and it is also a little smaller than C 2 in the y-direction. Similar to C 2 , at 24 nm away from the aperture, C 3 has a well-defined spot. At this location, the spot size is smaller in the y-direction but a little larger in the x-direction than that of C 2 . The size reduction in the y-direction seems related to a shorter total aperture height H t . A little increase in x might be related to a longer W a in C 3 . A further spot size reduction in the x dimension may be achieved by reducing W b . Of course, in the C 3 case, at a closer distance to the aperture, an even smaller spot size should be expected.
[0038] In comparing C 1 , C 2 and C 3 , it is interesting to observe that the aperture physical area is decreasing while the resonance power throughput is increasing, the resonance width is decreasing, and the transmission resonance is getting sharper and sharper. This is a further demonstration of the general guideline for aperture optimization: the higher the normalized resonant wavelength, the higher the spatial resolution and the power throughput. (In general, the upper limit of a resonant transmission cross-section σ t is about (λ reso ) 2 .)
[0039] Thus, in general the following numerical method for C-aperture optimization may be used. To find the optimal C-aperture geometry, the normalized resonant wavelength λ reso,N can be maximized with respect to the four geometric parameters W a , H t , H b , and W b . Optimizing the normalized resonant wavelength for a specific application will result in a C-aperture geometry that has high performance in terms of both spatial resolution and power throughput. The single normalized resonant wavelength variable thus provides an efficient way to simultaneously optimize two desirable C-aperture properties.
[heading-0040] Thickness Effect
[0041] Prior theoretical models of sub-wavelength apertures assume the metal plate thickness t is negligible compared to the wavelength (i.e., t<<λ). At optical wavelengths, however, this approximation is not always practical to realize. Consequently, prior knowledge of transmission through apertures in plates with non-negligible thickness has been limited. For example, it has been assumed that, for small apertures, both power throughput and near field intensity drop as thickness increases. The present inventors have verified this assumption for small square apertures. Surprisingly, however, for C-apertures the inventors have discovered that the power throughput remains high as thickness increases, and there is also a slight blue-shifting and a narrowing of the spectral response, as shown in FIG. 4 . In fact, the peak spectral response is higher as thickness increases.
[0042] Moreover, simulations of transmission of polarized radiation through narrow slits oriented perpendicular to the polarization direction show that additional transmission resonance associated with the metal thickness may be produced. As shown in FIG. 5 , this kind of resonance appears periodically as the metal thickness continuously increases, with the resonance becoming weaker and weaker as thickness increases due to power losses in the metal. The resonant peaks appear at multiple thicknesses separated by about half the wavelength. Thus, longitudinal resonance happens when t is an integral multiple of λ reso /2. For example, a 100 nm slit exposed to 658 nm incident radiation has transmission resonance peaks at thicknesses of 220 nm and 550 nm. A 50 nm slit exposed to 658 nm incident radiation exhibits a very strong transmission resonance peak at thickness t=250 nm with power throughput over 4. The resonance effect for larger slits is not as significant. This transmission resonance effect is presumably due to constructive interference between front and back scattering fields, analogous to a Fabry-Perot effect. FIG. 6 is a cross-section of an aperture in a plate of thickness t, illustrating the principle behind this effect. As the incident radiation 640 enters the aperture 620 at the front surface plane 600 of the metal plate 630 there is front scattering. The wave then experiences mode propagation through the interior of the aperture 620 , which behaves like a waveguide of length t. At the back surface plane 610 of the plate 630 the wave exits the aperture 620 and experiences back scattering. Interference between the front and back scattering in the longitudinal direction produces periodic longitudinal resonance of period equal to about λ/2.
[heading-0043] Finite Conductivity Effects
[0044] At microwave and infrared wavelengths, metals are well approximated as perfect conductors. At optical wavelengths, however, the finite conductivity can have a significant effect. In particular, because the waves penetrate into the metal by roughly a skin depth, the aperture is effectively larger than its physical size, resulting in an increase in the spot size. The C-aperture geometry can still be appropriately optimized using the optimization techniques discussed earlier. In general, the optimized C-aperture in a lossy metal has a geometry smaller than its perfect conductor counterpart by roughly a size of the skin depth. For example, a fourth C-aperture design (called C 4 ) was developed with H b =W b =60 nm, H t =260=m, and W a =100 nm to have resonant transmission at 1 μm in a silver plate. The power throughput from this C-aperture is 2.2, the near field spot size (FWHM) is 115 nm by 130 nm, near field peak intensity is 7.42, as measured at 50 nm away from the aperture.
[0045] Because metallic nano-structures show plasmon resonance at optical frequencies, a further enhancement of transmission may be realized by aligning the resonance wavelength of the local surface plasmon with the resonance wavelength of the aperture transmission.
[heading-0046] Refractive Index Effect
[0047] In addition to geometry, the inventors have discovered another way to achieve a higher spatial resolution: inserting a high refractive index material in the aperture. In a medium with refractive index n, the light wavelength is reduced by a factor of n. Therefore, the aperture size could be scaled down by the same factor and the near-field spot size can be scaled down (i.e., near-field spatial resolution is scaled up) as well. FIG. 7 illustrates an aperture 710 in a metal plate 700 , where the aperture 710 is filled with a high index material (e.g., glass or other dielectric). Incident radiation 720 of wavelength λ enters the aperture and its wavelength is effectively reduced by a factor n. Consequently, the aperture optimization in this case will result in smaller dimensions and a higher spatial resolution. For example, as shown in FIG. 8 , for the C 3 design filled with glass (n=1.5), the resonant transmission wavelength red-shifts by a factor of about 1.4, which is close to the glass refractive index. The red-shift of the resonant wavelength implies that higher spatial resolution can be achieved using this modification. FIG. 8 also shows that the frequency response increases. Because the resonant wavelength increases, the normalized resonant wavelength also increases, which implies increased overall performance.
[heading-0048] Media Effect
[0049] In optical applications, it can be difficult to fabricate a free-standing metal aperture plate whose thickness is smaller than the wavelength. Thus, as shown in FIG. 9 , it can be of practical benefit to include a substrate medium 900 upon which the metal 910 and aperture filling 920 is deposited. In such aperture designs, the substrate is on the incident radiation side of the aperture, providing free space in front of the aperture for the radiation 930 to usefully interact with target objects 940 . The presence of the substrate medium results, however, in a media effect on the transmission. The effect of the media is to effectively decrease the wavelength of the radiation from λ to λ/n, where n is the refractive index of the medium. To compensate for this effect, the aperture geometry can be scaled down by a factor of approximately n and its parameters optimized. The apertures of the present invention may also be fabricated in dielectric media or nonlinear media.
[0050] FIG. 10 illustrates a C-aperture that is tapered in the thickness dimension t, while maintaining its geometry in the transverse dimensions. (Note that this cross-sectional view does not show the C-aperture shape that would be seen in a top view.) This tapering can modify the effective impedance of the aperture through the thickness. This provides a way to impedance match the aperture with its front, back interface materials (if they have different index) and its filling material to further improve the power throughput efficiency. As the effective wavelength is decreased in a high refractive index material, in general, the aperture size should be scaled down at the end where the interface material has a higher index and should be scaled up at the end where the interface material has a lower index. Thus, FIG. 10 shows a tapering of the aperture 1040 in the metal layer 1010 outward from a high index substrate 1020 to the lower index air 1030 .
[heading-0051] Multiple C-Apertures
[0052] Multiple apertures of the present invention may be used together for producing multiple spots at separated distances, or to produce a compound aperture of mutually interacting single apertures. For example, a 1D or 2D array of C-apertures of similar size and geometry arranged with the same or differing orientations can be used for parallel nano-lithography applications. As another example, FIG. 11 illustrates an aperture design including two back-to-back C-apertures 1100 and 1110 separated by a distance Ax. This type of compound aperture can be used for three-dimensional sub-diffraction limited optical trapping (compared to two-dimensional sub-diffraction limited trapping from a single C-aperture) of very small particles, e.g., particles having diameters from 50 nm to 600 nm. FIG. 12 illustrates such an aperture 1200 formed in a metal plate 1210 of thickness t used to trap a small particle 1220 of diameter d. This strong local field of the C-aperture makes its particle trap force more than 100 times greater than the force of a trap using a conventional square aperture. Thus, it is strong enough to overcome the Brownian random motion of the particle.
[heading-0053] C-APERTURES WITH TAPERED FIBERS
[0054] Another type of sub-wavelength aperture design is the tapered fiber aperture. Such a device can be fabricated with a C-aperture at the output end, as illustrated in FIG. 13 , which provides enhanced convenience and flexibility for applications such as high resolution optical endoscopes, near-field data storage, or as an efficiency power coupler for photonic crystal devices. The fiber 1300 may have a metal coating 1310 and may be tapered toward the aperture end, as with a conventional tapered fiber probe. At the output end, however, a C-aperture 1320 is fabricated. The taper and the metal coating around the probe sides may not be necessary if the probe head size and positioning control is not a concern. Transmission power can be improved without the taper and the metal coating at the side. Similarly, a C-aperture may be fabricated at the output of a pyramid probe tip with similar transmission performance improvement.
[heading-0055] Data Storage Applications
[0056] The improved C-apertures of the present invention are valuable for various near field optical applications such as high density optical data storage, nano-scale particle manipulation, and near field optical microscopy and spectroscopy. For example, an aperture of the invention may be used in a high density optical data storage device, as illustrated in FIG. 14 . A vertical small aperture laser (VSAL) is fabricated with a nano-sized C-aperture 1400 just beyond its small aperture output. A dielectric spacer 1410 is positioned between the laser cavity and the C-aperture 1400 . The C-aperture preferably is filled with a high index material to increase performance. In the illustrated embodiment, the laser has an N-side contact 1420 , P-side contact 1430 , GaAs substrate 1440 , Bragg mirror 1450 , and an oxide mode confinement layer 1460 . A data storage medium 1470 is positioned in the near-field region just beyond the C-aperture 1400 . Because current near field probes suffer from low power transmission, they suffer from low signal to noise ratios and hence slow data transfer speeds. The performance of this data storage device is dramatically improved compared to conventional devices by using the C-aperture designs of the present invention. For examples of such small aperture lasers, see S. Shinada, F. Koyama, K. Suzuki, N. Nishiyama, K. Goto, and K. Iga, “Microaperture surface emitting laser for near field optical data storage”, in Technical Digest . CLEO/Pacific Rim '99, 30 Aug.-3 September 1999, Seoul, South Korea, (Piscataway, N. J., USA: IEEE, 1999), p.618. Also see A. Partovi, D. Peale, M. Wuttig, C. Murray, G. Zydzik, L. Hopkins, K. Baldwin, W. Hobson, J. Wynn, J. Lopata, L. Dhar, R. Chichester, and J.-J. Yeh, “Highpower laser light source for near-field optics and its application to high-density optical data storage”, Applied Physics Letters 75, 1515 (1999). It is also important to note that a C-aperture can also be used for optically assisted magnetic data storage. Another possibility is to create dynamically a C-aperture (instead of a circular aperture) in Super-RENS type of near-field data storage to enhance the light transmission through the aperture (see J. Tominaga, T. Nakano, and N. Atoda, “An approach for recording and readout beyond the diffraction limit with an Sb thin film”, in Applied Physics Letters 73, 2078 (1998)).
[heading-0057] Fabrication Methods
[0058] C-apertures can be fabricated with focused ion beam technology or other nano-fabrication technologies (E-beam lithography, nano-imprint technology, etc). Compared with a coaxial probe or a dimple-hole array, the C-aperture is clearly easier to fabricate since it is a single planar structure. Other aperture geometries, such as doughnut-shapes, appear to be inferior to the C-aperture in both transmission efficiency and spatial confinement. I- or H-shaped apertures provide performance similar to a C-shaped aperture. A high-performance C-aperture is expected to significantly improve near-field optical applications such as optical data storage, nanolithography, and nanomicroscopy.
[heading-0059] Other Applications
[0060] C-aperture can be used for ultra-high resolution laser machining, cutting, laser surgery. This is potentially very useful for operation on single molecules such as DNA chains, proteins, bio-tissues, etc. The highly localized and strong intensity field can also be used for local field enhanced Raman spectroscopy, local field enhanced two-photon excitation, which are extremely important for biosensor and chemical sensor applications to enhance the signal level by orders of magnitude. The high local field is also very useful for enhanced nonlinear optical efficiencies. The strong local field can also be used as a high resolution optical tweezers to manipulate single molecules. The high transmission high resolution aperture metal layer can be deposited on a medium within photonic crystal devices or other devices and used as an efficiency power coupler. A C-aperture also provides a good polarization selectivity about 1:20 at deep sub-wavelength scale, which could be very useful in an integrated optical devices within which a C-aperture is fabricated as an integrated component. A C-aperture layer may also be fabricated upon an electro-optic medium to produce an electro-optic switch. The index tuning of the electro-optic medium makes the C-aperture function as a switch due to the transmission resonance shift.
[0061] The C-apertures and their resonant-transmission properties can be scaled to other electromagnetic wavelengths. For applications in the visible spectrum, the C-apertures can be fabricated using focused ion-beam lithography or electron-beam lithography, which can provide a spatial resolution as high as about 25 nm. The C-aperture does not require any other surface structures to support resonant transmission, and the high power-transmission efficiency does not require an extended beam illumination. This makes the C-aperture highly efficient in terms of photon usage. The C-aperture can also be arranged in an array format for parallel operations. Compared with the transmission enhancement through a hole array, the single C-aperture geometry makes it much more flexible in regard to the array periodicity and array pattern. Therefore we expect C-apertures, and other single sub-wavelength apertures, to be very useful for various applications such as ultrahigh-density optical data storage, nanolithography, near-field optical probes, and nano-optical tweezers.
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Near-field sub-wavelength C-apertures provide enhanced spatial resolution and power throughput by increasing the normalized resonant wavelength of the aperture. These improved apertures are characterized by the use of improved geometric proportions for C-apertures, filling the aperture with high-index material, designing aperture thickness to produce longitudinal transmission resonance, and/or tapering the aperture in the longitudinal direction to achieve impedance matching. Apertures according to the present invention may be used for many technological applications in various portions of the electromagnetic spectrum. Exemplary applications to high density optical data storage and optical particle trapping and manipulation are described.
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BACKGROUND OF THE INVENTION
The present invention pertains to speaker recognition system and more particularly to discriminative speaker recognition systems.
Modern methods in digital signal and speech processing have made it possible to assess identity of an individual through audio characteristics of individuals voices. This speaker recognition process makes possible the recognition of each individual from the voice of the person speaking. The end result is the capability to identify the person with a unique identifier or name of the individual.
A typical system for speaker recognition extracts audio features from speech. It then applies a pattern classifier to the features to perform the recognition. The pattern recognition system is either unsupervised or supervised (discriminative).
Previous state of the art methods for discriminative recognition training required large amounts of data transferring and computation for classifying a speaker.
Unsupervised classifiers model the features of an individual person or speaker without reference to features of others. Discriminative pattern classifiers, in contrast, are trained to discriminate between different speakers.
In general, supervised classifiers are more accurate than unsupervised classifiers because they focus on many specific differences between various speakers.
A drawback of supervised classifiers is that they traditionally require large amounts of computation capability to adequately train the processor to recognize a speaker.
Accordingly, it is advantageous to have a means of implementing discriminative speaker recognition that is less complex and less costly than previous methods.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram depicting a speaker recognition training system.
FIG. 2 is a block diagram depicting the polynomial pattern classifier used in the computer to discriminate between speakers in accordance with the present invention.
FIG. 3 is a flowchart for adding an additional speaker to the database in accordance with the present invention.
FIG. 4 is a flowchart for reinforcing the model for a particular person for training in accordance with the present invention for a speaker recognition system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the present invention, a novel method and apparatus for training, reinforcement, and retraining of a speaker recognition system is shown.
The basic system accepts an audio input from a person' speech. An analog to digital (A/D) converter then converts the audio input to a digital form. Next, a digital signal processor (DSP) processes the digitized audio signal.
This digitized audio signal becomes a differentiating factor that describes the person speaking. This information is then stored and processed for training a pattern recognition system. Computation for retraining is reduced dramatically over previous speaker recognition methods.
Storage is also significantly reduced since the original speech data does not need to be stored. The novel classifier structure also reduces the storage requirements. Previous state of the art methods require large amounts of data transferring and computation for retraining. The present invention reduces data handling so it can be readily performed over a data link, if desired.
Referring to FIG. 1, a block diagram is shown of a system to implement the training process for a speaker recognition system. In this configuration, an audio input 10 is entered into the speech system. This could be from a recorded medium or a communication system. The system starts by converting the audio signal into a digital format through an analog-to-digital (A/D) converter 20 to produce a digitized audio signal.
The digital signal processor (DSP) 30 then processes the digitized audio signal. DSP 30 produces a differentiating factor (r) describing the speaker voice input.
This set of differentiating factors (r) is then processed directly by computer 50 or by sending a set of differentiating factors (r) to a database computer 50, by a data link 40, if desired.
The differentiating factor (r) is stored and processed in the computer 50. This becomes a digital audio signature (w) that describes the person speaking. The first digital audio signature (w) is then stored and processed for training in a pattern recognition system.
In order to understand the speaker recognition process, refer to the FIG. 2 block diagram. FIG. 2 illustrates the incorporation of the polynomial pattern classification system 60, which includes software resident in computer 50. FIG. 3 illustrates the flow chart for the data as it flows through the block diagram hardware of the present invention. FIG. 4 shows the parallel flowchart for retraining or reinforcement of a speaker in the data base.
Computation for retraining is reduced dramatically over previous recognition methods. Storage is significantly reduced since the original speech data does not need to be stored. The classifier structure also reduces the storage requirements.
The converted input audio speech 10 is read in from the A/D converter 20 and are block 21. The converted input audio signal is processed by the DSP 30 and the speech parameters are block 31. The data rate of the sampled speech is usually around 128 kbits / sec. The sampling rate is usually around an 8 kHz rate and 16 bit data.
The DSP 30 is extracting audio spectral features that are used to derive the speaker model used in the polynomial classifier. The speaker model is referred to as the audio print or voice signature. The basic features being used are the frequency domain representation of the short-time power spectra of the speech, termed cepstra and the transitional or dynamic information of the cepstra, termed the delta-cepstra.
Alternate similar spectral features can also be used that have similar performance. These include linear-predictive coefficients, or LPC, and non-linearly processed filter bank outputs termed mel-frequency cepstra coefficients (MFCC) known to those skilled in the art.. The DSP is used to produce a sequence of feature vectors denoted as X 1 , X 2 , . . . , X M using some speech recognition representation.
These are the audio features used by the polynomial classifier 60 in the pattern recognition system. An example of a polynomial classifier can be found in the U.S. Pat. No. 5,390,136: "Artificial Neuron and Method of Using Same".
Each feature vector, X i , is expanded in the well known set of polynomial basis terms up to a maximum order of K. For this application, the standard canonical basis of polynomials for variables X 1 , X 2 , . . . , X N is used; the constant 1; the first order terms X 1 , X 2 , . . . , X N ; the second order terms X 1 X 2 , X 1 X 3 , . . . , X N X N ; the third order terms, etc., up to the order K.
The vector of polynomial basis terms for a given vector can be denoted X by p(X) or p(X)= 1 X 1 X 2 X N X 1 X 2 . . . ! . In order to discriminate between inputs form different speakers, the polynomial classifier must be trained. First, only two speakers will be classified. A first speaker can be specified as having features X 1 , X 2 , . . . , X M and a second speaker, as having features Y 1 , Y 2 , . . . , Y M .
To discriminate between each of the two speakers, a classifier is trained for each speaker. For the first speaker, polynomial fitting or training can be done in the 2-norm to an ideal output of 1 for the features of the first speaker and an ideal output of 0 for the second speaker. This can be represented in matrix form.
First define M i to be the matrix whose rows are the polynomial expansions of speaker i's features; i.e., ##EQU1## Also, let ##EQU2## and let o 1 be the column vector of length 2M whose first M entries are 1 and remaining entries are 0, and o 2 =1-o 1 . The resulting training problems for the first and second speaker are respectively ##EQU3##
First a basic method of solving the equations above will be presented. By solving the equation for a speaker the digital audio signature (r) for that speaker is produced.
This method involves improvement in storage and computation because of the unique structure of the polynomial classifier. Next the solution of the equations in the framework of training over a data link is presented.
First consider only the training for speaker 1. To solve Equation 1, the method of normal equations can be used. Suppose that the rows in M corresponding to the speaker 1's and speaker 2's data are denoted as M 1 and M 2 respectively.
Then using the method of normal equations:
M.sup.t Mw.sub.1 =M.sup.t o.sub.1
(M.sub.1.sup.t M.sub.1 +M.sub.2.sup.t M.sub.2)w.sub.1 =M.sub.1.sup.t 1Equation 2
(R.sub.1 +R.sub.2)w.sub.1 =M.sub.1.sup.t 1
where 1 is a vector of all ones.
Equation 2 shows the basic idea of training, which could be directly coupled to a processor or over a data link. The matrix R i relies only upon data from speaker i and can be computed from the input speech data; further this matrix needs to be computed only once per speaker.
After the matrix is computed, it can be stored for future retraining. Finally, it is noted that M i t 1 can be obtained from the entries of R 1 ; we let a i =M i t 1.
Next consider the compression and computation of the R i matrix. Because the rows of M i are polynomial basis terms, significant structure exists in the R i matrix.
The distinct terms of the matrix R i are exactly the sums of polynomial basis terms of order less or equal to 2K. This property can be seen by noting that ##EQU4##
The number of entries in the matrix R i is significantly greater than the number of polynomial terms of order less than or equal to 2K. Significant compression therefore results from storing only the polynomial terms. A mapping between the polynomial terms and the matrix can be found using ordering relations. Next, denote the sum of the vector of polynomial terms for each speaker, r i ; and denote the vector polynomial terms of order 2K for a feature vector x by p 2 (x).
Referring to FIG. 3, block 21 reads in the speech parameters from the analog to digital converter. Block 31 extracts the speech parameters from the input speech. The calculate r step stores only the polynomial terms, block 61. The polynomial terms may be sent over a data link, block 63. The polynomial terms may also be stored on a central computer, block 65. Block 68 then finds the speaker recognition using the polynomial classifier. This is called the digital audio signature (w). Thus FIG. 3 has shown the novel flowchart for addition of a speaker to the speaker database in accordance with the present invention.
The novel training/retraining method for the database follows: First set R=0. For i=1 to the <number of speakers>, map r i to R i and R=R+Ri. Find the Cholesky decomposition of R=L t L. For i=1 to the <number of speakers>, solve L t Lw i=a i using back substitution. Note that the matrix R does not have to be computed every time a retraining or enrollment occurs if all speakers in the database are included in the training.
Referring to FIG. 4, the calculate r steps stores the polynomial terms, block 62. The polynomial terms may be sent over a data link, block 64. The polynomial terms may also be stored on a central computer, block 66. Means for adding a new set of differentiating factors is included. Block 70 then finds the speaker recognition using the classifier. The comparison with a stored signature results in recognition for permitting access to the speaker.
FIG. 4 has shown the flowchart for extracting, iterating and adding speech parameters for reinforcement of a speaker in the database in accordance with the present invention using well known matrix methods. The improvement in this invention over the prior technology includes three main areas of the art: computation, storage, and scalability.
Computation for retraining has been reduced dramatically over previous methods. In addition, training is now structured with the current invention such that it can also be performed over a data link. The prior art had the drawback that retraining and reinforcement times were computationally complex.
Retraining is performed every time a new individual is introduced into the speaker verification system. The present invention has a specific apparatus, storage method, and computation method to reduce retraining so that it can be performed with extremely low complexity. For example, training and retraining can be performed on a laptop computer.
In addition to the retraining feature, the system has the advantage that it is not traditional artificial neural network technology, but a technology that is usually used in an "unsupervised" mode. The present invention classifier is "supervised" which means that the training takes advantage of any impostors to improve speaker recognition performance.
Previous state of the art methods such as recursive least squares (RLS) or the pseudo-inverse method require large amounts of computation and data transfer for retraining. Storage has been reduced dramatically by the present invention over previous art since the original audio data does not need to be stored.
Further reductions in storage were achieved because of the structure of the classifier. Finally, the system is readily scaleable by those skilled in the art. Because of efficient management of computation and storage, the present invention can be used with large numbers of speakers. This can be used to deny or permit communication access by a speaker by recognition of their differentiating factors. The present invention will reduce the cost, computing capability and storage required to implement speaker audio recognition systems.
Although the current preferred embodiment of the invention has been illustrated, and that form described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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A method and apparatus for training a system to assess the identity of a person through the audio characteristics of their voice. The system inserts an audio input (10) into an A/D Converter (20) for processing in a digital signal processor (30). The system then applies Neural network type processing by using a polynomial pattern classifier (60) for training the speaker recognition system.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method and a system for identifying a fault in an electrical machine.
BACKGROUND OF THE INVENTION
[0002] Like any technical device, electrical machines may suffer from different kind of faults, either of mechanical or electrical character. Since electrical machines have a moving element in form of a rotor, many of the most common fault conditions cause vibrations to the machine. It is known that different fault conditions cause different kind of vibrations. In turn, it follows that by knowing what kind of vibration a certain fault condition causes, it is possible to detect the fault by monitoring the vibration characteristics of the machine.
[0003] Vibration monitoring has been conventionally used to detect mechanical faults in electrical machines. This monitoring method has been successful e.g. in detecting bearing defects. However, one has not been able to detect electrical faults in a satisfactory way by means of vibration monitoring, even if attempts into this direction have been taken. For example, the conference paper “An analytical approach to solving motor vibration problems” from Finley, W. R. et al. 1999 (D1) discloses a table (Table I) with indicators for identifying both mechanical and electrical faults in an induction motor. The main fault indicators are the frequencies of the vibrations and their sidebands. It requires a lot of empirical interpretation to determine the root source of the vibration with the help of D1, and it is not possible to distinguish between different fault conditions in a satisfactory manner.
SUMMARY OF THE INVENTION
[0004] One object of the invention is to provide a method which enables an improved identification of a fault in an electrical machine.
[0005] A further object of the invention is to provide a monitoring system which enables an improved identification of a fault in an electrical machine.
[0006] These objects are achieved by the method according to the claimed invention.
[0007] The invention is based on the realization that a mode shape of a vibration at a particular frequency is an important indicator for many fault conditions. In the prior art, a mode shape of certain vibration has not been considered as a fault indicator. For example, with the measurement setup disclosed in D1, FIG. 15 it is not even possible to determine the mode shapes of the different vibration frequencies.
[0008] According to a first aspect of the invention, there is provided a method for identifying a fault in an electrical machine having a rotor and a stator. The method comprising the steps of: carrying out a first vibration measurement in a first radial direction of the stator; carrying out a second vibration measurement in a second radial direction of the stator; determining, on the basis of at least one of the first vibration measurement and the second vibration measurement, a first vibration frequency; determining, on the basis of the first vibration measurement and the second vibration measurement, a mode shape of the vibration at the first vibration frequency; and using a combination of the first vibration frequency and the mode shape to identify a fault condition of the electrical machine.
[0009] By using a combination of the first vibration frequency and the mode shape as a fault indicator, a more reliable identification of a fault condition is achieved.
[0010] According to one embodiment of the invention the method comprises the steps of: carrying out a plurality of vibration measurements in at least three different radial directions of the stator, such as at least four, at least six or at least eight different radial directions of the stator; determining, on the basis of at least one of the plurality of vibration measurements, a first vibration frequency; and determining, on the basis of the plurality of vibration measurements, a mode shape of the vibration at the first vibration frequency. The more measurements there are at different radial directions of the stator, the higher mode numbers can be detected and the better is the reliability of this detection.
[0011] According to one embodiment of the invention the fault condition is identified when a vibration amplitude at the first vibration frequency exceeds a predetermined threshold value. It is reasonable to determine a threshold value for the vibration amplitude since very small amplitude vibration is not harmful for the machine, and a false fault condition diagnosis can be thereby avoided.
[0012] According to one embodiment of the invention the method comprises the steps of: carrying out vibration measurements with a first load and with a second load of the machine; determining a difference in vibration amplitudes with a first load and with a second load at the first vibration frequency; and using a combination of the first vibration frequency, the mode shape and the difference in vibration amplitudes to identify a fault condition of the electrical machine. By using the difference in vibration amplitudes as an additional fault indicator, distinctions between further fault conditions are enabled and a more reliable identification of a fault condition is achieved.
[0013] According to one embodiment of the invention the fault condition is one of the following: a broken rotor bar, dynamic eccentricity, static eccentricity, inter-turn short circuit, inter-coil short circuit. The present method is particularly suitable for identifying the listed fault conditions as clear correlations between the vibration characteristics and the fault conditions can be found.
[0014] According to one embodiment of the invention the method comprises the step of: determining, on the basis that the first vibration frequency ƒ and the mode shape m fulfil one of the following conditions: ƒ=n·ƒ r or ƒ=n·ƒ r ±2·s·ƒ s and m=n, wherein n=(1, 3, 5, . . . ), ƒ r =rotation frequency of the motor, s=rotor slip and ƒ s =supply frequency, that a rotor bar is broken. It has been discovered that the mentioned conditions are a reliable fault indicator for a broken rotor bar.
[0015] According to one embodiment of the invention the method comprises the step of: determining, on the basis that the first vibration frequency ƒ and the mode shape m fulfil one of the following conditions: ƒ=2·ƒ r and m=2; ƒ=2·ƒ s −ƒ r and m=2·p−1; ƒ=2·ƒ s +ƒ r and m=2·p+1, wherein ƒ r =rotation frequency of the motor, ƒ s =supply frequency and p=number of stator pole pairs, that the rotor is dynamically eccentric. It has been discovered that the mentioned conditions are a reliable fault indicator for a dynamic eccentricity of a rotor.
[0016] According to one embodiment of the invention the method comprises the step of: determining, on the basis that the first vibration frequency ƒ and the mode shape m fulfil the following conditions: ƒ=2·ƒ s and m=2·p+1 or m=2·p−1, wherein ƒ s =supply frequency and p=number of stator pole pairs, that the rotor is statically eccentric. It has been discovered that the mentioned conditions are a reliable fault indicator for a static eccentricity of a rotor.
[0017] According to one embodiment of the invention the method comprises the step of: determining, on the basis that the first vibration frequency ƒ and the mode shape m fulfil one of the following conditions: ƒ=2·k·ƒ s and m=(2, 4, 6, . . . ), wherein k=(1, 2, 3, . . . ) and ƒ s =supply frequency, that the stator coils have either an inter-turn short circuit or an inter-coil short circuit. It has been discovered that the mentioned conditions are a reliable fault indicator for either an inter-turn short circuit or an inter-coil short circuit.
[0018] According to one embodiment of the invention the method comprises the steps of: carrying out vibration measurements with a first load and with a second load of the machine, the a first load being smaller that the second load; determining a difference in vibration amplitudes with a first load and with a second load at the first vibration frequency; and determining, on the basis that the vibration amplitude increases with an increasing load and that the increase of the vibration amplitude exceeds a predetermined threshold value, that the stator coils have an inter-turn short circuit. It has been discovered that an increasing vibration amplitude with an increasing load is a reliable fault indicator for distinguishing between an inter-turn short circuit and an inter-coil short circuit.
[0019] According to one embodiment of the invention the electrical machine is an induction motor. The present method is particularly suitable for identifying fault conditions in induction motors wherein clear correlations between the vibration characteristics and the fault conditions can be found.
[0020] According to a second aspect of the invention, there is provided a monitoring system for identifying a fault in an electrical machine having a rotor and a stator. The monitoring system comprises a first sensor arranged to measure vibration in a first radial direction of the stator, and a second sensor arranged to measure vibration in a second radial direction of the stator. A processor receives measurement signals from the first sensor and the second sensor. The processor comprises a first algorithm for detecting from the measurement signals a first vibration frequency and a mode shape of the vibration at the first vibration frequency. The processor further comprises a second algorithm for identifying a fault condition of the electrical machine from the combination of the first vibration frequency and the mode shape. With a monitoring system capable of using a combination of the first vibration frequency and the mode shape as a fault indicator, a more reliable identification of a fault condition is achieved.
[0021] According to one embodiment of the invention the monitoring system comprises a plurality of sensors arranged to measure vibration in at least three radial directions of the stator, such as in at least four, in at least six or in at least eight different radial directions of the stator, and the processor receives measurement signals from the plurality of sensors. High number of measurements at different radial directions of the stator allow high mode numbers to be detected with a good reliability.
[0022] According to one embodiment of the invention the sensors are accelerometers. Accelerometers are preferable vibration sensors because of their small size and low price.
[0023] According to one embodiment of the invention, there is provided an induction motor comprising a monitoring system according to the description hereinabove.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will be explained in greater detail with reference to the accompanying drawings, wherein
[0025] FIG. 1 shows a physical installation according to an embodiment of the invention;
[0026] FIG. 2 shows the first four mode shapes of vibration; and
[0027] FIG. 3 shows a table listing correlations between certain vibration characteristics and certain fault conditions.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring to FIG. 1 , a measurement installation 10 for measuring vibrations in an electrical machine is shown. There are eight accelerometers 20 evenly distributed about the circumference of a stator 30 . A great number of accelerometers 20 enables the detection of high number modes, so the more accelerometers 20 the better fault identification ability the measurement installation 10 has. However, since we are mainly interested in low number modes (from 1 to 4), eight accelerometers 20 or even less should be enough. The accelerometers 20 are connected by measurement cables 40 to an amplifier 50 , and further to an A/D converter 60 . The accelerometers 20 give the vibration information in time space i.e. the acceleration as a function of time. In addition, angular position of each accelerometer 20 is known. The measurement results are finally stored in digital form in a computer memory 70 for further processing.
[0029] A processor 80 receives and processes the measurement results from the computer memory 70 . The processor 80 comprises a first algorithm 90 for detecting from the measurement signals a first vibration frequency and a mode shape of the vibration at the first vibration frequency. The first algorithm 90 comprises a two dimensions Fourier transform explained in more detail below. The processor 80 further comprises a second algorithm 100 for identifying a fault condition of the electrical machine from the combination of the first vibration frequency and the mode shape.
[0030] Two dimensions Fourier transform, with respect of position (defined by the sensor location) and with respect of time, is applied to the measurement results in order to reveal the mode shapes and the frequencies of the vibrations. Equation for the Fourier transform can be written as:
[0000]
a
(
θ
,
t
)
=
∑
m
=
0
∞
∑
n
=
0
∞
[
A
1
·
cos
(
m
·
θ
+
n
·
ω
·
t
)
+
A
2
·
cos
(
-
m
·
θ
+
n
·
ω
·
t
)
]
[0000] wherein a=measured acceleration, θ=angular position along the stator perimeter, t=time, A=calculated coefficients of the acceleration and ω=supply frequency, and wherein m determines the mode shape and n determines the vibration frequency. It is to be understood that detecting indefinite high number modes is not possible since theoretically an indefinite number of accelerometers 20 would be required. In practice, however, only the lowest number modes are of interest, and the number of required accelerometers 20 is respectively low. It is assumed that a skilled person is able to determine the number of accelerometers 20 required for detecting a certain mode shape. Eight accelerometers 20 are considered sufficient for detecting mode shapes up to mode number four. The first four mode shapes 1 to 4 are illustrated in FIG. 2 .
[0031] Summarizing the detailed description so far, the disclosed measurement installation 10 together with the known mathematical theory enables not only the detection of the vibration frequencies but also the detection of the vibration shapes, the so called mode shapes. These mode shapes are further utilized for identifying fault conditions in the electrical machine.
[0032] FIG. 3 shows a table wherein characteristics of certain vibrations in terms of vibration frequencies and mode shapes are listed for certain fault conditions. For example, detecting a vibration at frequency ƒ=2·ƒ s would not allow distinguishing between the fault conditions “static eccentricity” and “inter-turn short circuit”/“inter-coil short circuit” since all the three fault conditions exhibit vibration at this frequency. After determining the mode shape of the vibration, however, such distinction would be possible since the shape of the vibration caused by “static eccentricity” is different from that caused by “inter-turn short circuit” or “inter-coil short circuit”.
[0033] Distinction between “inter-turn short circuit” and “inter-coil short circuit” can further be made by monitoring the behaviour of the vibration amplitude with load of the machine. Namely, it has been discovered that the vibration amplitude increases proportionally with an increasing load in the case of “inter-turn short circuit”. Consequently, by measuring the vibration amplitude with two different loads, distinction between the two fault conditions can be made. If the vibration amplitude increases by certain predetermined threshold value, the fault condition will be identified as “inter-turn short circuit”. Otherwise, the fault condition will be identified as “inter-coil short circuit”.
[0034] Descriptions about the fault conditions listed in the table of FIG. 3 are given in the following:
Broken bar—A conductor bar running at a periphery of a rotor in axial direction is broken. Dynamic eccentricity—The rotor periphery is eccentric in relation to the axis of rotation. The eccentricity varies when the rotor is rotating. Static eccentricity—The rotor periphery is eccentric in relation to the axis of rotation. The eccentricity remains constant even when the rotor is rotating. Inter-turn short circuit—A stator coil is short circuited between two turns within one and the same stator coil. Inter-coil short circuit−Two stator coils are short circuited between each other.
[0040] The correlations between vibration characteristics and the fault conditions listed in the table of FIG. 3 are to be considered as examples of such correlations so far discovered by the inventor. It is to be respected that other correlations between the listed vibrations and fault conditions may exist, and that other vibrations and fault conditions than those listed certainly exist with many correlations between them. The disclosed method may therefore be used for identifying the listed fault conditions using an alternative combination of frequency and mode shape of a vibration, and further fault conditions may be identified by using the listed or alternative combinations of frequency and mode shape.
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For identifying a fault in an electrical machine vibration is measured in a plurality of radial directions of the stator. On the basis of the vibration measurements a vibration frequency and a mode shape of the vibration at this frequency is determined. Characteristics of the vibration in terms of both the vibration frequency and the mode shape are used to identify a fault condition of the electrical machine.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a heterojunction bipolar transistor.
2. Related Art
There is continuing and increasing interest in improving the operating speed of bipolar transistors in microcircuits, particularly in the context of VLSI circuits for high-speed and ultra high-speed logic applications.
One route to such speed improvements, which has been relentlessly pursued to the practical limits of existing technology, is the reduction in feature size of the devices. In connection with this, new self-aligned processes, which remove the need to provide for alignment tolerances, continue to be developed.
An alternative route to achieving higher operating speeds is to use gallium arsenide (GaAs) or other related III-V compound semiconductors in place of silicon, since the electron mobility and saturation velocity are higher in GaAs and the other III-Vs than in silicon. Unfortunately, although at first sight it appears possible to achieve a respectable speed increase by producing GaAs versions of bipolar transistors which are conventionally made of silicon, such an approach does not in fact give rise to any significant improvement in performance. The problem is that, in such devices, it is necessary to keep the base width small, and use only low levels of base doping, with the result that the base resistance tends to be high. In order to keep the base resistance acceptably low, high hole mobility is needed. Unfortunately, although electron mobility in GaAs is high (which is useful for giving short emitter-collector transit times), hole mobility is less than half that of silicon, resulting in excessive base resistance.
An approach to making high speed bipolar devices in GaAs which gets round the limitation of poor hole mobility is to produce the device as a heterojunction bipolar transistor (HBT) using aluminium gallium arsenide (AlGaAs) and gallium arsenide (GaAs).
In an HBT, the emitter is formed of a material having a larger energy gap than the base, whereby injection of holes from the base into the emitter is prevented and it becomes possible to use heavy base doping, and hence very thin (1,000 Å) base widths, without excessive base resistance.
Unfortunately, although HBTs theoretically offer quite exceptional performance (for more details of which see the review paper by Herbert Kroemer in PROC.IEEE, Vol. 70, No. 1, Jan. 1982), they have proved exceedingly difficult to make.
The bulk of the work done on HBTs has involved the use of AlGaAs and GaAs, in part because of the superior electronic properties of GaAs, but also because it is possible to make very high quality AlGaAs-GaAs heterojunctions. Unfortunately, fabrication of GaAs HBTs is very complex because of the difficulties inherent in GaAs processing. In particular, the absence of a native oxide means that processing is limited to etching and non-selective deposition, which in turn means that GaAs devices are essentially non-planar. It can be seen, therefore, that there are appreciable costs associated with the speed advantages offered by GaAs. It is to the reduction of these costs, while realising the benefits of improved speed, that work on HBTs has been directed in recent years.
The comparative ease with which silicon can be processed and the ubiquitous nature of silicon processing together provide a strong incentive for the development of an HBT which is compatible with existing silicon technology. A few silicon based wide-gap emitter transistors have been reported. For example, gallium phosphide-silicon has been tried with disappointing results; and, with a heavily-doped "semi-insulating polycrystalline" silicon emitter on a silicon base (the polycrystalline/amorphous silicon having a wider band gap than that of the single crystal silicon of the base), the results achieved have been better, but are still a long way short of those obtained with AlGaAs/GaAs. Consequently, research on HBTs continues to be centered on the use of GaAs.
SUMMARY OF THE INVENTION
The aim of the invention is to provide a method of fabricating HBTs which is largely compatible with known silicon processing techniques.
The present invention provides a heterojunction bipolar transistor having an emitter which comprises an epitaxial layer of silicon grown on a silicon and germanium base layer, the active region of the transistor comprising a semiconductor having a silicon/silicon and germanium strained lattice, and the lattice strain being such as to produce a predetermined valence band offset at the emitter/base junction while maintaining commensurate growth, wherein the base comprises an alloy of silicon and germanium, the alloy being grown on a {100} plane of silicon.
Advantageously, the lattice strain is such as to enhance the effective mobility of electrons in the base. Preferably, the lattice strain is tailored throughout the base depth such that the energy separation between the low mobility and high mobility conduction bands is increased towards the collector.
In a preferred embodiment, the germanium content of the silicon and germanium base layer lies within the range of from 12% to 20%, and is preferably at least 15%.
Using a silicon germanium alloy base, it is possible to produce devices which, apart from the growth of the heterolayers, are made using conventional silicon processing steps. The heterolayers may be grown using molecular beam epitaxy (MBE).
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described with reference to the accompanying drawings in which:
FIG. 1 shows six-fold degeneracy of the silicon conduction band;
FIG. 2a shows the four-fold degeneracy of the conduction band of strained {100} Si-Ge layers;
FIG. 2b shows the two-fold degeneracy of the conduction band of strained silicon;
FIGS. 3a and 3b shows the band discontinuity in {100} Si:Si-Ge;
FIG. 4 shows the band structure of a conventional silicon bipolar transistor;
FIG. 5 shows the doping levels of the same conventional silicon transistor;
FIG. 6 shows the band structure of an HBT using Si:Si-Ge;
FIG. 7 shows the doping levels for a HBT with 15% germanium content in the base; and
FIG. 8 shows a simple mesa etched HBT.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Since silicon and germanium have different lattice constants, it is possible to tailor lattice strains by adjusting the relative proportions of silicon and germanium in the alloy layers. In this way, it is possible to engineer band structures and band offsets, so that charge carrier transport can be modified. However, layer thickness is limited, since dislocations result from excessive thickness, the critical thickness being dependent upon the germanium content.
In unstrained SiGe, the conduction band remains Si-like until the molar Ge content exceeds about 85%. It has a six-fold degeneracy with a conduction band minimum lying in each of the <100> directions (see FIG. 1). Thus, for an electron travelling in a given direction, the effective mass is averaged over all six minima since these are approximately equally occupied. In the <100> direction, this requires averaging over two heavy longitudinal masses (0.98 m o ) and four light transverse masses (0.19 m o ), and gives 0.45 m o , where m o is the stationary electron mass. But, for SiGe grown on a {100} Si plane, the unit cell is distorted from the cubic system into the orthorhombic, by forcing the atoms closer together in the plane. This breaks the six-fold conduction band degeneracy, and forces two minima up in energy (by about 150-170 meV when the Ge content is 20%) and four down (see FIG. 2). Thus, the lowest conduction band consists only of the four lobes which lie in the plane, and an electron traversing this layer experiences mainly the light transverse electron mass. The effective mass is, therefore, lowered to that of the transverse mass which is similar to that of silicon. Thus, in the strained layer, the electron's effective mass is reduced, and its mobility increased over that of unstrained alloys of the same composition. However, the mobility will not scale directly with effective mass.
If the heterostructure were to be grown on a {111} plane, the distortion would be from the cubic into the hexagonal system. As the six-fold symmetry of the resulting crystal would remain, the degeneracy of the conduction band would not be split, and the effective mass of the electron would not be significantly altered.
In addition to the mobility changes associated with the heterostructure, the layers of differing composition have different band-gaps and offsets. If a SiGe layer is grown on a {100} Si substrate, there is a small discontinuity in the conduction band, but a major discontinuity in the valence band. Following growth on a SiGe substrate (which may simply be a thick SiGe buffer layer grown on Si), there is a discontinuity in both bands, as shown in FIGS. 3a and 3b. This discontinuity varies with both strain and composition.
In the <111> direction, valence band offsets are similar to those in the <100> direction, but the conduction band in the Si is lower than in the SiGe for all substrates.
FIG. 4 shows a schematic band structure of a conventional npn silicon transistor under normal bias conditions. Because the emitter has to be very heavily doped, it suffers bandgap narrowing, and there is a smaller barrier to holes than to electrons at the base-emitter junction. As the current gain in a well-designed transistor is given largely by the ratio of electrons and holes crossing this junction, the base must have a much lower doping than the emitter. This also prevents breakdown. For high frequency operation, the base must be narrow, because the electrons drift across this (with a low effective acceleration voltage of kT/q, where k in Boltzmann's constant, T is the thermodynamic temperature, and q is the charge). Consequently, the collector must have a low doping, so that the depletion layer is in the collector rather than in the base. Otherwise the base would punch through at too low a collector voltage. This gives a large depletion region, and a large contribution to the transit time, even though the electrons traverse it at saturated drift velocity. A compromise is usually made between punch-through voltage, collector transit time and collector capacitance, whereby the collector doping is increased deeper into the transistor. A typical doping regime is shown in FIG. 5.
As well as the time taken for the electrons to traverse the base and the collector, there is a component of transit time given by the product of the emitter resistance and the sum of base-emitter and base-collector capacitance. As the emitter resistance is the slope resistance of the diode, its value falls as emitter current increases. The transistor must, therefore, be operated at the highest possible value of current density to get the best speed. However, when the density of electrons injected into the base from the emitter becomes too large, the base-collector junction is pushed into the collector (the Kirk effect), and the time taken for electrons to drift across the base increases sharply. Thus, there is a natural maximum operating current which is related to the base doping.
The effects of these individual time constants are summed into one figure of merit, the transit frequency f t , which is inversely proportional to the sum of the transit times. Clearly, the larger this parameter is, the faster circuits can operate. However, when a real transistor is made, the circuit is also slowed down by the time constant of the base resistance and the collector-base capacitor. A second figure of merit f max is applied which takes account of this effect. As the base is low-doped, the base resistance is high, and only by using very fine dimensions (particular layer-layer tolerances) can f max be made reasonably large. Self-aligned bipolar transistors are under development, and these promise very large values of f max , such that f t once again becomes the limiting factor. Values of f t in excess of 10-15 GHz are extremely difficult to achieve with a conventional device.
Because there is an energy barrier preventing hole injection into the emitter, the wide-gap emitter HBT allows gain to be high, even for a heavily-doped base. Thus base resistance can be very low. More importantly, the base does not widen (as a result of the Kirk effect) until a much higher injection level, and the transistor may be operated at a significantly higher current density, thus reducing the emitter charging time. Also, the collector doping can be increased, without pushing the depletion region into the base, and the collector transit time is also reduced. Since the base width is less sensitive to operating voltage, it can be made somewhat smaller, to reduce its transit time. Finally, if a strained SiGe {100} layer is used for the base, the predicted mobility will reduce the base transit time even further.
Thus the silicon-germanium HBT offers a way to increase f t substantially above the values available with silicon bipolar transistors. A value of 20 GHz should be feasible for a 0.15-0.2 μm base width, with further improvement possible at even narrower dimensions.
The foregoing theory suggests the use of a Si emitter with a SiGe base grown commensurately on {100} Si. FIG. 6 shows the band structure of a suitable layer arrangement.
An example of a Si-Ge HBT of a very simple construction is shown in FIG. 8. The relevant doping profiles are shown in FIG. 7. This simple structure is readily formed using molecular beam epitaxy (MBE) and mesa etching.
At a base width of between 0.15 and 0.2 μm, the germanium content in the SiGe layer can be up to 20%, giving a bandgap discontinuity in the valence band of about 150 meV, whilst maintaining commensurate growth of the SiGe layer 10 on the Si substrate 12. Preferably, the germanium content of the SiGe layer 10 is at least 15%, though useful results are obtained with a lower germanium content. Assuming equal Gummel numbers in the base 10 and the emitter 14, a germanium content of 20% would give a gain of ˜300, and this allows the base Gummel number to exceed that of the emitter 14. With a high base doping of 1E19, and an emitter doping of around 1E18, a gain of ˜100 is obtained. This is an ideal value to give the required 3-5 V emitter-base breakdown voltage. To make contact to the emitter 14, this doping level is inadequate, but it can safely be increased at the surface, at a distance of at least 0.15-0.2 μm from the base 10. The collector can be doped at 1E16 to 2E16 to give a fairly short transmit time, and ample breakdown voltage, but should rise to a buried layer of 1E19 at a distance of about 0.2-0.5 μm. With this doping profile, the collector 16 must be silicon to ensure that the bandgap difference at the emitter junction appears in the valence band rather than the conduction band. The band discontinuity at the collector 16 junction has little effect, as it is swamped by the applied bias.
For a simple structure, such as that shown in FIG. 8, the collector 18 contact can be made to the back of the wafer 12, and the emitter area 14 can be defined by a mesa etching technique. Mesa etching right through the base layer 10, to reduce the base/collector contact area may be beneficial, but this etch need not be controlled accurately. FIG. 8 shows the structure formed in this manner, and FIG. 7 shows the required doping profiles.
For integrated devices, it is of course necessary to deposit dielectric and metal layers. This can be done using the techniques used in silicon processing. For high performance devices, selective epitaxy offers a method of reducing base area and also permits the introduction of heteroepitaxy after initial processing. This avoids problems with temperature cycling of strained materials.
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A heterojunction bipolar transistor has an emitter which comprises an expitaxial layer of silicon grown on a silicon and germanium base layer. The active region of the transistor comprises a semiconductor having a silicon/silicon and germanium strained lattice and the silicon and germanium base layer is grown on a silicon substrate while maintaining commensurate growth. The lattice strain is such as to produce a predetermined valence band offset at the emitter/base junction. The mobility in the base is also enhanced over that of an unstrained alloy of the same composition.
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The invention relates to an apparatus for lengthening a person's own hair using artificial and/or genuine hair and for permanently fastening artificial and/or genuine hair; the invention also relates to the method applied in this regard when using the above apparatus.
BACKGROUND OF THE INVENTION
Biosynthetic achievements including the extension of and permanent attachment to tufts of a person's own hair, i.e. hair that is growing naturally out of the scalp, using genuine and/or artificial hair. Such techniques are used on the one hand for medical applications, though primarily for cosmetic applications. A person's own hair can be lengthened, not to mention thickened, in that a person's own hair and the genuine and/or artificial hair fastened thereto is cut to the same length. In technical fields, a great many systems are known for lengthening and thickening a person's own hair; such systems are described in the 21/94 edition of the "Top Hair Special" magazine. In accordance therewith, a person's own hair can be extended by using artificial or genuine hair by means of special binding and knotting techniques and by various adhesive techniques.
U.S. Pat. No. 5,107,867 describes a hair extension method in which strands of the hair to be extended are joined using a heat-resistant adhesive in order to form a graft on a strand of extension hair, whereupon a coating consisting of a plastic material that is fusible when heat is introduced is applied to this graft. Strands of the person's own natural hair are then threaded through a shrinkable tube portion, the graft of extension hair pretreated in the above-described manner is also inserted into the shrinkable tube and this shrinkable tube treated by application of heat. Either a heating iron, which is described in further detail, or another suitable device can be used. On the one hand, the application of heat causes the tube to shrink, on the other hand the fusible adhesive melts and produces a permanent connection between the natural genuine hair and the strand of extension hair. The tube is intended to protect the connection from environmental influences, but it is also intended to act as a hair care product. If heat is re-applied to the shrinkable tube, the hair extension can be removed once again.
This and other techniques in which adhesives are used make it necessary for a person to after-treat his/her own hair once the hair extension has been removed. Residual adhesive sticking in a person's own hair has to be removed by using a suitable solvent, usually acetone. This results in damage to a person's own hair, particularly as the hair extension methods need to be repeated at regular intervals, approximately every 6 weeks. When solvents are used for such a frequent treatment of the natural hair of the head, a person's own hair may be destroyed at the connecting points.
SUMMARY OF THE INVENTION
The present invention aims to develop an apparatus of the aforementioned type for lengthening a person's own hair and for permanently fastening artificial and/or genuine hair; such an apparatus allows a person's own hair to be lengthened or an extension strand or a hair-piece to be permanently fastened in a simple and inexpensive manner without damaging a person's own hair in the process.
The invention's object is solved in that in the aforementioned type of apparatus, a tube which can be shrunk when energy is applied is disposed around a positionally secured, thickened portion, particularly a knot in a strand of a person's own hair, and around a strand of artificial or genuine hair; and energy means transfers energy, particularly heat, to the shrinkable tube.
The advantage of this invention lies in the fact that without applying adhesive, the mechanical connection between a person's own hair and an extension strand of artificial or genuine hair occurs by means of shrinking the tube on an area where there is a positionally secured, thickened portion, such as a knot in a person's own hair.
This knot makes an important contribution toward the connection's stability because it is located roughly in the center of the shrinkable tube--when heat acts thereon--is constricted on both sides of the knot over a smaller cross section than is possible in the area of the knot. This achieves an additional holding function which is brought about in the prior art by the application of adhesives.
The method to be applied so as to lengthen a person's own hair is characterized by the following steps:
Knotting a strand of a person's own hair, sliding a fastening element, particularly a tube, which can be shrunk when energy is applied, onto the knot of a person's own strands of hair; sliding a strand of artificial and/or genuine hair into the tube; and shrinking the shrinkable fastening element by applying energy.
The method according to the invention enjoys the advantage that the connection produced therein between a person's own hair and the artificial or genuine hair is detachable without residue, thus preventing a person's own hair from being damaged even when this technique is frequently applied. The application is without pain and the tractive forces that arise are kept to a minimum, thereby avoiding instances of disturbed blood supply in the area of the scalp. Because of the connecting elements' low weight and high flexibility, the extension strands are not felt to be inconvenient by the wearer.
According to a preferred embodiment, that end of the strand of artificial or genuine hair which is disposed within the shrinkable tube is embedded in a heat-resistant adhesive. In consequence, the extension hair strand is lent a good hold, thus facilitating the insertion of this strand of extension hair into the shrinkable tube as part of the method according to the invention. The strands of artificial or genuine hair being used in the apparatus and method according to the invention can furthermore be used several times, so that the removal and storage of the strand of extension hair is considerably improved as a result of bonding the end.
According to a further embodiment, the energy application means is constituted by a heating iron which has two profiled jaws directed toward one another, at least one profiled jaw of which is heatable.
The use of a heating iron has the advantage that the thermal energy to be expended so as to shrink the tube can be transferred very conveniently to the shrinkable tube. Heat transfer also takes place in a highly systematic manner, i.e. the thermal energy to be expended to shrink the tube is transferred by bringing the heating iron into direct contact with the shrinkable tube. As a result, the total amount of energy expended can be reduced, though the generation of heat in the area surrounding the shrinkable tube is also kept very low. This is extremely important because the connecting sites between a person's own hair and the extension strand of artificial or genuine hair are usually located very close to the scalp and a development of pain can therefore be avoided.
According to another embodiment, the heating iron has either a stationary or a pivotable shank or two pivotable shanks to which the profiled jaws are respectively attached. The heating iron can then be moved from an opened position into a closed position in which the profiled jaws are slightly spaced apart from one another or are in contact with one another.
By providing one or two pivotable shanks it is possible to open the heating iron, to dispose between the profiled jaws the shrinkable tube to be treated and containing the knotted strand of a person's own hair and the extension strand or to insert the tube into one of the profiled jaws and then to move the heating iron into a closed position in which the two profiled jaws come into contact with the shrinkable tube.
In this regard, it is advantageous for one or both profiled jaws to have a groove into which the shrinkable tube can be inserted. Furthermore, so as to cause the shrinkable tube to be constricted on both sides of the knot located in the shrinkable tube, it is advantageous for one or both profiled jaws to have an indentation into which the positionally secured thickened portion, for example the knot, can be inserted.
According to a preferred embodiment, the two profiled jaws are heatable. This causes heat to be evenly applied to the shrinkable tube, making it possible to reduce the treatment duration for producing a connecting element both heatable profiled jaws are preferably heatable to a temperature ranging between 100° C. and 350° C. Both profiled jaws can be heatable to the same temperature; but it is preferable for one profiled jaw to be heatable to a lower temperature than the other profiled jaw. This has the advantage that it is possible to work in direct proximity to the scalp in that the heating irons are held such that the profiled jaw facing toward the scalp has a lower temperature than the profiled jaw facing away from the scalp. This likewise makes it possible to work in direct proximity to the scalp without causing any pain on account of the high generation of heat or without damaging the hair in close proximity.
According to a preferred embodiment, one or both profiled jaws is/are fitted with a temperature sensor.
This has the advantage that the temperature of the one or of both profiled jaws can be monitored, thus enabling the occurrence of interference to be identified in good time, whereby on the one hand, the risk of a nondurable connection between the person's own hair and the extension strand can be avoided when the temperature is too low, while on the other hand, the risk of damaging the hair can be avoided when the temperature is too high.
The temperature of one or both profiled jaws is/are preferably controllable. Depending on the particular application and the use of different materials for the shrinkable tube, this makes it possible to set those temperatures best suited for this purpose and to check that such temperatures are adhered to.
In a preferred embodiment, one or both profiled jaws is/are provided with a heat insulation element. As already mentioned, application frequently takes place in direct proximity to the scalp, with the result that the provision of a heat insulation element avoids a possible development of pain, particularly if that profiled jaw of the heating irons which faces toward the scalp accidentally comes into contact with the scalp. The heat insulation element is preferably made from a material, particularly plastic, that sheathes that profiled jaw and has poor thermal conductivity.
When actuated, the heating iron can, according to another embodiment, remain in the closed position for an adjustable interval of time. In consequence, the contact time between the shrinkable tube and the profiled jaws that is best suited to the application of heat to the shrinkable tube can be set and the heating iron automatically remain in the closed position for this preselected interval of time. This makes it possible to rule out operating errors which may result in an inadequate mechanical connection between the extension strand and the person's own hair, but which may also cause pain to take effect an undesirable extent.
The present invention will be described as follows purely by way of example on the basis of the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of the hair extension apparatus according to the invention;
FIG. 2 shows a schematic section of the hair connection in the region of the shrinkable tube;
FIG. 3 shows an embodiment of an energy application device in the form of heating irons;
FIG. 4 shows an embodiment of a profiled jaw depicted as an exploded diagram;
FIG. 4A shows a horizontal projection of the heating surface of the profiled jaw according to FIG. 4; and
FIG. 5 shows another embodiment of a profiled jaw depicted as an exploded diagram.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a schematic view of the apparatus for lengthening and permanently fastening a person's own hair using artificial and/or genuine hair, this apparatus being designated in general by the reference number 10. The apparatus comprises a shrinkable tube 12 which in proximity to the head 14, is fitted onto a strand 16 of the person's hair and onto an extension strand 18 of artificial and/or genuine hair. As will be subsequently depicted by FIG. 2, a knot is present in the strand 16 of the person's own hair. Energy application means, in this particular instance in the form of heating iron 20, transfers thermal energy to the shrinkable tube 12.
Various other technical versions of an energy application device are feasible instead of the heating irons 20. Apart from generating thermal energy by a suitable heat carrier medium or by using a resistor wire, the application of energy may for instance take place by means of laser treatment or by ultrasonic emission.
The heating iron 20 is preferably heated via a resistor wire and connected by a connecting cable 22 to a controlled 24 which is in turn battery-powered, or may be connected via a mains lead 26 to the mains power supply.
In the simplest of cases, the controller can supply energy to one or both of the profiled jaws 30 of the heating iron 20, but is also able to assume responsibility for more extensive display or control duties. For example, the controller 24 can process the temperature registered via temperature sensors on the profiled jaws as part of a control loop and hence ensure that the temperature of one or both profiled jaws is kept constant, but the controller can also display merely the temperature or temperatures or--if the heating iron 20 are automatically closed--it can drive the movement of one or both shanks of the heating iron 20 such that these shanks remain in the closed position for a present interval of time.
FIG. 2 shows a schematic view of how a strand 16 of a person's own hair and an extension strand 18 are connected to a shrinkable tube 12. For the purpose of simpler explanation, just a single strand 16 of a person's own hair is shown on the head 14. The stand of a person's own hair consists of about ten to fifty hairs, depending on the client's hair thickness and bearing the client's specific wishes in mind. Having been adapted to the thickness of these hair strands, shrinkable tubes are available in various gradations of diameter. The strand 16 of a person's own hair is preferably knotted close to the head 14, with various techniques being known for this purpose. An entwinement is preferably produced in the hair by using a crochet needle.
In FIG. 2, the strand 16 of a person's own hair ends just after the pint where it emerges from the shrinkable tube 12. The method according to the invention for lengthening a person's own hair may, however, also be used when it is intended to bridge a transitional period between hair that has been cut short and hair that has been deliberately left to grow long. In this instance, the strand of a person's own hair and the extension strand are also preferably connected together in direct proximity to the head 14; the strand 16 of a person's own hair may nevertheless be grown long, for example shoulder length.
When, after the strand 16 of a person's own hair has been knotted, the method according to the invention is performed, the shrinkable tube 12 is slid over the strand 16 of a person's own hair so that the knot 17 in relation to the axial length of the shrinkable tube is approximately in the middle of same. The extension strand 18 is then likewise slid into the shrinkable tube, whereby attention must be paid to the fact that after insertion, the extension strand 18 extends across the entire length of the shrinkable tube 12 or a large proportion of the length of the shrinkable tube 12. For the purpose of anchorage behind the knot 17, the extension strand 18 has an adhesive site 19 composed of a thermally non-fusible adhesive and which ends up situated within the shrinkable tube 12. The adhesive site 19 advantageously makes it easier to insert the extension strand 18.
The adhesive site 19 is applied to the extension strand 18 in an upstream procedural step and is used to render this strand more easily manageable. The extension strand can be re-used several times, with the result that a secure hold of the strand is extremely advantageous for insertion into the shrinkage tube, for removal from the shrinkage tube and for any interim storage of the extension strand.
The hair combined in the extension strand is preferably turned helically within the region of the adhesive site 19, thereby forming a very good connection to the closely fitting shrinkable tube 12 and the strand 16 of a person's own hair in the region of the knots 17.
The shrinkage tube is manufactured from plastic and is about 15 mm in length. As depicted in FIG. 2, the shrinkable tube 12 is shrunk onto the connection of the two strands of hair under the action of heat, thus forming a bulge in the region of the knot 17.
FIG. 3 shows an embodiment of the heating iron 20 according to the present invention.
The heating iron 20 essentially comprises a handle 32, shanks 34, profiled jaws 30 and the connecting cable 22. The handle 32 consists of an insulating enclosure, preferably made of plastic, within which are located the power supply via the connecting cable 22, the attachment of the shanks 34 in the form of a stationary and a pivotable shank or in the form of two pivotable shanks, the transfer of the measurement signal or signals of one or more temperature sensors and, in a feasible embodiment, a mechanism for automatically closing the heating irons by moving the shanks 34 toward one another.
The heat generating means, which is for example designed to resemble that of a soldering iron, may be located within the shanks 34. The shanks 34 are preferably surrounded by an insulating enclosure 36.
The profiled jaws 30 are attached to the ends, remote from the handle 32, of the shanks 34. The profiled jaws consist of a material that conducts heat well, preferably a metal that conducts heat well. It is particularly preferable to design the profiled jaws in aluminum or bronze because on the one hand, these metals have good thermal conductivity, and on the other, they can be easily machined.
The profiled jaws 30 can be attached to the shanks 34 in any manner, and when the heating iron 20 is actuated, these jaws are moved toward one another with the heating surfaces 31, as shown in FIG. 3 by means of arrow A. The arrangement of the profiled jaws 30 represented in FIG. 3 in relation to one another at a greater distance is to be designated as an opened position of the heating iron 20, whereas pivoting the shank 34 in the direction of arrow A is designated as the heating iron's closed position, as is the associated act of bringing the heating surfaces 31 of the profiled jaws 30 into contact or of virtually bringing them into contact.
The heating surfaces 31 of the profiled jaws 30 may have a random shape, but are preferably profiled such that a shrinkable tube 12 that is disposed perpendicular to the plane of projection in FIG. 3 between the heating surfaces 31 can be inserted into corresponding grooves of the heating surfaces 31. This entails the advantage that the shrinkable tube can be fitted or inserted onto one of the two heating surfaces 31 and is secured in position to a certain degree before the other heating surface pivots in the direction of the shrinkable tube when the heating iron is moved into the closed position.
One or both of the profiled jaws can be connected to a heat insulation element 38 that completely or partially surrounds the profiled jaw beyond the heating surface. The heat insulation element is preferably formed from a material that has poor thermal conductivity, as exhibited by a great many plastics, such as Teflon.
With the help of the actuating switch 40 which moves the heating iron from the opened to the closed position, the heating iron 20 can be operated via various active mechanisms known in technical fields.
One of the profiled jaws, or both profiled jaws, can be heated electrically. Both the profiled jaws are preferably heatable, with either the tow profiled jaws being heatable to the same, rigidly predetermined temperature, or with the two profiled jaws being heatable to a rigidly predetermined but different temperature, or with both profiled jaws being heatable to a temperature that can be jointly set for both jaws or separately for each individual jaw. The two profiled jaws are preferably heatable to a temperature varying between 100° C. and 350° C. The provision of different temperatures was found to be particularly advantageous, with one profiled jaw being heatable to 120° C. and the other to 220° C.
To check the temperatures of the profiled jaws, as well as to regulate them, one or more temperature sensors may be located on one or both profiled jaws. All the temperature sensors known in the field of technology, such as resistance temperature sensors or bimetallic thermocouples, can be used here. In particular, it is important to adhere accurately to the temperature, it being particularly important to avoid exceeding the temperature, at the profiled jaw facing toward the head. For this reason, a heat insulation element is also preferably disposed on this so-called head-end profiled jaw.
FIG. 4 shows the layout of an embodiment of a profiled jaw for use on heating iron. The profiled jaw 30 consists of two members, an upper member 46 and a lower member 48, which can be securely connected together in a suitable manner, for example by using screws 47. The upper member and the lower member preferably comprise a material which conducts heat well and which at the same time can be easily machined, such as aluminum or bronze.
The face 53 of the upper member 46 has a concavely formed curvature designed to correspond to the 35 convex curvature of the face 54 of the lower member 48. Slots 51, through which the attachment screws 47 are fitted, are formed in the upper member 46; these attachment screws 47 can be screwed into the threads 52. As a result, the profiled jaw 30 composed of the upper member 46 and the lower member 47 can be adjusted, in terms of its inclination, relative to the attachment rod 56 which in turn is suitably connected to the shank 34 of the profiled jaw 30.
The lower member 48 may have a notch 58 into which a temperature sensor can be inserted. The lower member 48 also has a recess 60 which is disposed in the region of groove 62 for inserting the shrinkable tube and serves to increase the distance of the heated upper member 48 from the exposed artificial or genuine hair. This is intended to avoid damaging the artificial or genuine hair.
FIG. 4A shows a horizontal projection of the heating surface 31 of the profiled jaw 30 according to FIG. 4. An indentation 64 which serves to receive the thickened portion of the shrinkable tube in the region of the knot 17 is depicted in addition to the groove 62.
FIG. 5 shows another embodiment of a profiled jaw of ruse on heating irons 20 according to the present invention.
The profiled jaw 30 consists of a trough 70 produced from a material that conducts well, particularly aluminum or bronze. As already explained by means of the profiled jaw shown in FIG. 4 and FIG. 4a, the trough 70 has an attachment rod 56 and a groove 62 for inserting the shrinkable tube 12. In the same way, as described on the basis of FIG. 4, the trough 70 may possess recesses (not depicted) for receiving that portion of shrinkage tube which is thickened in the region of the knot 17, as well as on one or both sides for increasing the distance of the heated trough from the exposed artificial or genuine hair.
A plurality of lugs 66 which serve to connect the trough 70 to the heat insulation element 38 are disposed on the trough 70. The heat insulation element 38 is attached to the trough 70 in that the lugs 66 pass through corresponding apertures 68 within the heat insulation element.
In the embodiment illustrated, it is possible to assemble the two members 70 and 38 since the heat insulation element is preferably produced from a plastic that insulates heat well, such as Teflon, and which is sufficiently elastic to be elongated to such an extend that the lugs 66 can be inserted into the apertures 68 on both sides.
The heat insulation element 38 is preferably shaped such that there exists an air gap between the upper surface 71 of the trough 70 and that surface of the heat insulation element 38 which covers same. A free convection flow of air may occur within this air gap, with the convection slots 72 serving to remove heat systematically. This causes the temperature to drop by about 30 Kelvin across the thickness of the air gap.
A step 74 which serves to receive a temperature sensor is also disposed in the surface 71 of the trough 70. The recess 76 within the heat insulation element 38 serves to receive the attachment rod 56.
While heating iron 20 is feasible, the two profiled jaws of which are formed according to the embodiment depicted in FIG. 4 or according to the embodiment depicted in FIG. 5, an advantageous embodiment is to have that profiled jaw of the heating iron which faces toward the scalp designed according to the embodiment in FIG. 5 and to have the other profiled jaw designed according to FIG. 4.
The method according to the invention for lengthening a person's own hair with artificial and/or genuine hair and for permanently fastening artificial and/or genuine hair is constituted by the following steps.
The extension strand of artificial and/or genuine hair is pretreated in an upstream step in that the hairs of that end of the extension strand to be inserted into the shrinkable tube are joined using a thermally stable adhesive. A rapid thermosetting adhesive can be used here, for example a cyanoacrylate-based adhesive. The extension strand pretreated by using an adhesive is advantageously twisted helically within the region of the affixed end.
A strand of a person's own hair consisting of ten to fifty hairs is then combined, and the strand of a person's own hair is knotted such that the knot is very close to the scalp, preferably about 5 mm therefrom. A preferred manner of forming this knot is to entwine the strand of hair using a crochet needle.
A shrinkable tube is then slid onto the knot of the strand of a person's own hair such that the knot of the strand of a person's own hair ends up being located roughly in the middle of the shrinkable tube in relation to its axial length.
The strand of artificial and/or genuine hair pretreated in the aforementioned manner is then slid into the tube so that as far as possible, this strand fills the entire axial length of the shrinkable tube. Finally, the shrinkable tube is shrunk by applying energy and the mechanically secure connection is produced. Alternatively, the shrinkable fastening element, which is preferably tubular in shape, may also exhibit a different geometry provided that an equally stable mechanical attachment can thereby be produced.
The advantage of the method according to the invention is that no adhesive is used and an easily securable and detachable connection between a strand of a person's own hair and an extension strand can be produced; moreover, this connection does not cause any damage to the person's own hair and can be re-used several times.
The method is used both for lengthening and thickening a person's own hair as well as for fastening hair-pieces.
While there have been illustrated and described particular embodiments of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention.
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The invention concerns a device for lengthening a person's own hair using artificial and/or genuine hair and for the permanent fastening of artificial and/or genuine hair. The invention is characterized in that a tube (12), which can be shrunk when energy is applied, is disposed above a thickened portion, secured in position, in particular a knot in a strand of a person's own hair (16) and above an extension piece of artificial and/or genuine hair. An energy-application device, in particular in the form of heating irons (20), transfers thermal energy in a deliberate manner to the shrinkable tube (12). The method in which the device is used is characterized by the following steps: knotting a strand of the person's own hair, sliding onto the knot in the hair strand a fastening element which can shrink when energy is applied; sliding an extension strand of artificial and/or genuine hair into the tube; and shrinking the shrinkable fastening element by the application of energy.
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FIELD OF THE INVENTION
The present invention relates to a salicide (Self Aligned Silicide) layer of CMOSFET and a method of manufacturing the same.
BACKGROUND OF THE INVENTION
In the manufacture of CMOS (complementary insulation gate type) integrated circuits, more concretely in the formation of CMOS-FET (electric field effect transistor) on the semiconductor substrate, it is indispensable to form an extremely thin diffused layer of a source region and a drain region of FET in order to restrict short channel effect that will become conspicuous along with microstructure for high integration and high speed. As a consequence, the diffused layer of the source region and the drain region becomes highly resistant, causing the deterioration in transistor driving power and the increase of delay time.
To solve the above problems, technologies to make the diffused layer resistance low by forming a metallic layer on the diffused layer of the source region and the drain region have been proposed heretofore, one of which is so called Salicide process.
One example of Salicide process is explained hereinafter in reference to FIGS. 1(a) and (b).
In FIG. 1(a), a separation region 51 is formed on a semiconductor substrate 50, and a gate electrode 53 (generally polysilicon) is formed via a gate insulating film 52 on the partial surface of the element region separated by the above separation region 51, and further nitrided silicon (SiN) 54 film is formed on a side-wall insulation layer of the above gate electrode 53.
In the next place, a diffused layer 55 of source region and drain region is formed by the ion implantation method well known to those skilled in the art, a Ti target is sputtered by use of Ar plasma, thereby Ti film 56 is accumulated.
Further, a cap film comprising nitrided titanium (TiN) film 57 is formed so as to restrict the roughness of titanium silicide surface at the formation of titanium silicide described later. At this moment, normally, titanium target is sputtered by use of plasma of mixture gas of argon and nitrogen, thereby nitriding reaction of titanium is induced on the titanium-target surface, and TiN film 57 is accumulated on the abovementioned Ti film 56.
Heat treatment is carried out on the multi layer film formed as shown above, under nitrogenous atmosphere, and as shown in FIG. 1(b), titanium silicide (TiSi 2 ) film 58a and 58b are formed by solid phase reaction of titanium in the TiN film 56 and silicon in the diffused layer 55 and silicon in the gate electrode 53. Then TiN film 57 and unreacted Ti film 56 are removed by etching by use of mixture solution of sulfuric acid and hydrogen peroxide.
According to the above process, self aligned metal layers, i.e., TiSi 2 film 58a and 58b can be formed only on the diffused layer 55 and the gate electrode 53. By the way, after this, insulating film is accumulated on the whole surface, a contact ball is formed, and wiring line is arranged so as to connect TiSi 2 films 58a and 58b.
TiSi 2 films 58a and 58b formed in the above manner reduce the sheet resistance at the region of the diffused layer 55 and the gate electrode 53, for example, the formation of TiSi 2 film 58a with film thickness 80 nm reduces the sheet resistance of the diffused layer 55 with juncton depth 250 nm from 50 Ω/□ to 3 Ω/□.
On the other hand, in the silicon MOSFET as mentioned above, it is indispensable to form an extremely thin diffused layer of a source region and a drain region in order to restrict short channel affect that will become conspicuous along with microstructure for high integration and high speed. As a result, there is a tendency where the clearance between the interface of PN junction of the diffused layer 55 and the interface of substrate silicon of TiSi 2 film 58a will become small. And it has been found that the small clearance causes the juncton leak current of PN juncton of the diffused layer 55 to become conspicuous.
To avoid this phenomenon, it has become necessary to make thin film thickness of TiSi 2 film 58a as well as the depth of the diffused layer in accordance with Scale rule, further, it has become necessary make a thin width of the source region and the drain region-electrode in accordance with scale rule from the viewpoint of reduction of juncton capacity.
However, in the case using the thin silicide film as mentioned above, it has been found that there will be the following problems (1) and (2), becoming large factors to prevent microstructure that is indispensable for high integration and high speed of elements.
(1) The rise of the specific resistance of TiSi 2 itself was observed by making the TiSi 2 film thin. In concrete, it was found that when TiSi 2 58a was formed in thickness 55 nm on the diffused layer 55 with as rather shallow a juncton depth as 180 nm, and than formed by Rapid Thermal Annealing (RTA) for 30 seconds at 750° C. and for 30 seconds at 850° C., the specific resistance of TiSi 2 58a showing 13 μΩcm increased by 30% in bulk TiSi 2 , becoming a large factor to prevent the realization of microstructure of elements. This phenomenon becomes more conspicuous as TiSi 2 film is made thinner, for instance, in the case when TiSi 2 58a with film thickness 30 nm is formed on the diffused layer 55 with as rather shallow a juncton depth as 180 nm, the specific resistance increases by about 100%. The above is a problem owing to the reduction of TiSi 2 in its film thickness direction.
(2) It has been found that the electrode sheet resistance increases abnormally as FET is made into microstructure in accordance with scale rule and the width of gate and source and drain electrode becomes narrow. For instance, in the case when TiSi 2 58a with film thickness 55 nm is attached to source and drain electrode with thickness lam, the sheet resistance appears 3 Ω/□, while in the when TiSi 2 58a with film thickness 55 nm is attached to source and drain electrode with thickness 1 μm, the sheet resistance becomes 12 Ω/□.
And the increase of the sheet resistance of TiSi 2 in such a micro fine shape becomes more conspicuous as the thickness of TiSi 2 gets thinner, for instance, when the thickness of TiSi 2 58a is 30 nm, the sheet resistance of source and drain electrode of 2 μm is 40 Ω/□, while the sheet resistance becomes 2 Ω/□ in source and drain electrode of 5 μm.
The main possible cause for the increase in resistance mentioned above may be understood as shown below. In the case where the region of the reaction portion between titanium in Ti film 56 and silicon in the diffused layer 55 is a micro fine shape, the contribution of the surface to unit mass naturally increases, and interface energy affects largely upon mophology, i.e., TiSi 2 will easily aggregate in order to reduce interface energy.
As a result, for example, as shown in FIG. 2, TiSi 2 58a in the diffused layer 55 becomes partially thinner or gets into island shape, therefore, it has been impossible to realize desired low resistance.
As mentioned heretofore, in the formation of CMOSFET in prior art, there has been a problem that when salicide process was adopted to make electrode portion react with transition metal and make it into metal with low resistance in order to prevent the increase of incidental resistance accompanying with microstructure, if the region of the reaction portion was of a micro fine shape, transition metal chemical aggregated owing to heat process and resistance increased, therefore, it was impossible to realize a desired low resistance.
The above discussion is also true of the silicide process adopted to make the resistance of bipolar base electrode low.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a semiconductor device and a method of manufacturing the same that enable to prevent transition metal chemical from aggregating owing to heat process and resistance from increasing even if the region of reaction portion is of a micro fine shape in the case to apply salicide process to the formation of CMOSFET gate electrode, source and drain electrode, or bipolar base electrode.
To achieve the above object, the present invention provides a semiconductor device which comprises a semiconductor substrate, and a salicide (Self Aligned Silicide) layer on the semiconductor substrate, including boron so,that a morphology of a surface of the salicide layer is improved.
The present invention also provides a method of manufacturing the semiconductor device which comprises the steps of preparing a semiconductor substrate, forming a metal layer on the semiconductor substrate, forming a metal silicide on a surface of the semiconductor substrate, by a reaction on the semiconductor substrate and the metal layer, and implanting boron so that a concentration of the boron included in the metal silicide is 1×10 19 cm -3 .
Other objects, features, and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF DRAWINGS
A more complete appreciation of the present invention and many of its attendant advantages will be readily obtained by reference to the following detailed description considered in connection with the accompanying drawings, in which:
FIGS. 1(a), 1(b) are cross sectional diagram showing an example of MOSFET forming process by applying one example of the conventional salicide process;
FIG. 2 is a cross sectional diagram showing an example where TiSi 2 becomes partially thinner or gets into island shape in the case where the region of the reaction portion between titanium in metal titanium film and silicon in diffused layer is a micro fine shape;
FIGS. 3(a)-3(d) are cross sectional diagrams showing an example of the process regarding an Embodiment 1.
FIG. 4 is a diagram showing an example of the condition setting in the process in FIG. 3;
FIG. 5 is a diagram showing an example of boron depth distribution in boron implementation immediately after the formation of TiSi 2 film in the process in FIG. 3; and
FIG. 6 is a diagram to compare the diffused layer width dependency of the sheet resistance of the metal chemical film formed by a semiconductor device formed by the manufacturing method in FIG. 3, and that formed by the conventional technology.
FIGS. 7(a)-7(e) are cross sectional diagrams showing an example of the process regarding embodiment 2 according to the present invention;
FIGS. 8(a)-8(d) are cross sectional diagrams showing an example of the process regarding embodiment 3 according to the present invention;
FIGS. 9(a)-9(d) are cross sectional diagrams showing an example of the process regarding embodiment 4 according to the present invention, and
FIGS. 10(a), 10(b) are cross sectional diagrams showing an example of the process regarding embodiment 5 according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention will be described in detail with reference to the drawings.
Embodiment 1
FIGS. 3(a) throughout (d) are schematic diagrams showing a process flow using salicide process in the formation of CMOSFET regarding an embodiment of the manufacturing method of a semiconductor device according to the present invention. And FIG. 4 shows an example of the condition setting in the process shown in FIG. 3.
In the first place, as shown in FIG. 3(a), a separation region 11 is formed on a semiconductor substrate 10, and a gate electrode 13 (generally, non-dope polysilicon) is formed via a gate insulating film 12 on the partial surface of the element region.
In the next place, by the ion implantation method well known to those skilled in the art, As + ion is implemented into the region of NMOSFET under the conditions 30 KeV, 1×10 14 cm -2 , while BF 2 + ion is implanted into the region of PMOSFET under the conditions 20 KeV, 1×10 14 cm -2 , thereby impurities are added to gate electrode 13 and impurity diffused region for source region and drain region is formed on substrate surface portion in self aligned manner.
Then, in order to prevent short-circuit between the source-region and the drain region and the gate electrode 13, a side-wall insulating layer 14 is formed on the side surface of the gate electrode by use of the known technology. Namely, the side-wall insulating layer 14 is formed by dry etching without using mask after accumulation of an insulating layer that does not react in the silicide process of the gate and source and drain regions described later, for example, nitrided silicon (SiN) film.
Further, by the ion implantation method once again As + ion is implanted into the region of NMOSFET under the conditions 600 KeV, 3×10 15 cm -2 , while BF 2 + ion is implanted into the region of PMOSFET under the conditions 40 KeV, 5×10 14 cm -2 , thereby impurity diffused regions at high concentration are formed in a predetermined region where the source and drain regions are formed. These conditions are shown in FIG. 4. Then, heat treatment is carried out in nitrogenous (N 2 ) atmosphere at 950° C. for 30 seconds to activate impurities, thereby, LDD (lightly-doped drain) layer 151 directly under the side-wall insulating layer 14 is formed in depth 65 nm, while the high impurity diffused region 152 of the source and drain regions is formed in depth 180 nm.
After the above, as shown in FIG. 3(b), Ti target is sputtered by use of Ar plasma, thereby metal titanium film (Ti film) 16 is accumulated 30 nm. Then, a cap film 17 comprising nitrided titanium (TiN) film is accumulated 70 nm so as to restrict the roughness of titanium silicide surface at the formation of titanium silicide described later. At this moment, normally, titanium target (metal titanium film) 16 is sputtered by use of plasma of mixture gas of argon and nitrogen, thereby nitriding reaction of titanium is induced on the titanium target surface, and TiN film 17 is accumulated on the abovementioned metal titanium film 16.
Heat treatment is carried out on the multi layer film formed as shown above, at 750° C. to 800° C. under nitrogenous atmosphere for 30 seconds, and titanium silicide (TiSi 2 ) films 18a and 18b are formed by solid phase reaction of titanium and silicon in the metal titanium film 16 on the source and drain regions and the gate electrode 13 contacting the metal titanium film 16.
Then TiN film 17 and unreacted Ti film 16 are removed by etching by use of mixture solution of sulfuric acid and hydrogen peroxide, and then as shown in FIG. 3(c), boron (B) is added under the conditions 10 KeV, 2×10 15 cm -2 by use of ion implantation method.
FIG. 5 shows an example of the depth distribution of boron obtained by the ion implantation under the above conditions, wherein boron stays in TiSi 2 films 18a and 18b, and does not thrust out substrate.
Through the optimization in this manner, the increase of the contact resistance with TiSi 2 film also on the diffused layer of N type MOSFET and on the gate electrode of N type MOSFET is avoided, therefore, the above process is completely compatible with CMOS technology.
Then, through heat treatment under nitrogenous atmosphere at temperature over 800° C. (preferably, about 850° C., they are changed completely into TiSi 2 films 18a and 18b having a C54 crystal structure that is stable at high temperatures. Also through this heat treatment, boron forms titanium boride in TiSi 2 films 18a and 18b and gets to exist stably.
According to the above process, TiSi 2 films 18a and 18b can be formed only on the high impurity diffused layer 152 of source and drain regions, and the gate electrode 13, however, TiSi 2 film may be formed only on the gate electrode 13, or only on the high impurity diffused layer 152.
After the above, interlayer insulating layer 21 is accumulated on the whole surface, and contact hole is opened, and a wiring line 23 of a first layer is arranged so that TiSi 2 films 18a and 18b are connected via a contact plug 22.
The solid line in the graph shown in FIG. 6 shows the measurement results of the diffused layer width dependency of the sheet resistance of TiSi 2 films 18a and 18b formed according to the above process. By the way, the dot line in the graph shown in FIG. 6 shows the diffused layer width dependency of the sheet resistance of TiSi 2 films 18a and 18b formed according to the prior art as for comparison.
The specific resistance of TiSi 2 films 18a and 18b formed according to the above process appears to be about 13 μΩcm though the film thickness of TiSi 2 films 18a and 18b is as thin as 55 nm, thus it has been found that the specific resistance is extremely low as well as bulk value.
Moreover, in the prior art, the rapid increase of the specific resistance of diffused layer was observed at the width of diffused layer below 1 μm, on the other hand, in accordance with the above embodiment, even when the width of the high impurity diffused layer 152 was made to 0.4 μm, the specific resistance of TiSi 2 film formed on the high impurity diffused layer 152 could be made extremely low, therefore, the sheet resistance of diffused layer could be reduced to 3 Ω/□, that is, 1/3 of that in the case formed by the conventional art. As a result, TiSi 2 film formed in accordance with the above embodiment has enabled to overcome the defect in the prior art where increase of resistance was to be observed on micro regions.
Namely, according to the manufacturing method of a semiconductor device as mentioned above, salicide process is adopted so as to reduce the incidental resistance on an extremely thin diffused layer accompanying with high integration and high speed of CMOSFET. In this case, at the formation of TiSi 2 film as the metal chemical of the transition metal and the element configuring semiconductor substrate (silicon) formed on the diffused layer of NMOSFET and on that of PMOSFET respectively, as shown in FIG. 5, boron is implemented so that the concentration of boron in TiSi 2 film should be 1×10 19 cm -3 . And boron does not thrust out semiconductor substrate and added in only TiSi 2 film, facilitating thermally stable titanium boriding.
With respect to this point, it can be explained crystallographically as shown below. Namely, the solid phase reaction between the silicon atom and the transition metal in semiconductor substrate causes a phase transition.
Then, since there is a difference between the thermodynamic energy before solid phase reaction (free energy) and the thermodynamic energy after solid phase reaction (free energy), i.e., since the free energy after the reaction is smaller, the above phase transition becomes a heat generating reaction. Because TiSi 2 has a large interface energy, it receives thermal energy (the abovementioned temperature increase) and transforms in the direction where surface area becomes smaller. Therefore, the convexes and concaves on the surface of TiSi 2 film become larger, causing the increase of sheet resistance.
Therefore, the inventors of the present patent application have make the most of the fact that titanium boride is a thermodynamically stable chemical, and put a large amount of titanium boride in TiSi 2 to make the convexes and concaves on the surface of TiSi 2 film small, thereby succeeded in making the sheet resistance of TiSi 2 film small.
In this manner, the formation of boride of thermodynamically stable transition metal improves the aggregation resistance of TiSi 2 by heat treatment off post process, as a consequence, it is possible to realize low resistance of electrode irrespective of the size of reaction portion.
Thereby, even in the case where the region of reaction portion is of a micro fine shape, it is possible to restrict the resistance increase owing to the aggregation of transition metal chemical. For instance, even in the case when the film thickness of TiSi 2 film 9 is made as thin as below 55 nm and the width of the region of the diffused layer is made as fine as below 0.4 μm, it is possible to realize CMOSFET where the specific resistance of TiSi 2 film does not increase, and further the improvement and high speed of the driving power of CMOSFET can be attained.
Namely, the process in this case comprises a first step to accumulate transition metal onto a silicon semiconductor substrate, a second step to add boron into only the above transition metal by ion implantation so as for boron not to thrust out the silicon semiconductor substrate, a third step to form self aligned metal silicide on the electrode portion of MOSFET by solid phase reaction between the above transition metal and silicon through heat treatment, and a fourth step to remove unreacted metal in the above third step.
Embodiment 2
The second embodiment of the present invention is described in detail hereinafter with reference to FIGS. 7(a) throughout (e).
FIGS. 7(a) throughout (e) are schematic diagrams showing a process flow using salicide process in the formation of CMOSFET regarding an embodiment of the manufacturing method of a semiconductor device according to the present invention.
In the first place, as shown in FIG. 7(a), a separation region 11 is formed on a semiconductor substrate 10, and a gate electrode 13 (generally, non-dope polysilicon) is formed via a gate insulating film 12 on the partial surface of the element region.
In the next place, by the ion implantation method well known to those skilled in the art, As + ion is implanted into the region of NMOSFET under the conditions 30 KeV, 1×10 14 cm -2 , while BF 2 + ion is implanted into the region of PMOSFET under the conditions 20 KeV, 1×10 14 cm -2 , thereby impurities are added to gate electrode 13 and LDD (lightly-doped drain) layer 151 for source region and drain region is formed on substrate surface portion in self aligned manner.
Then, in order to prevent short-circuit between the source region and the drain region and the gate electrode 13, a side-wall insulating layer 14 is formed on the side surface of the gate electrode by use of the known technology. Namely, the side-wall insulating layer 14 is formed by dry etching without using mask after accumulation of an insulating layer that does not react in the silicide process of the gate and source and drain regions described later, for example, nitrided silicon (SiN) film.
Further, by the ion implantation method once again As + ion is implanted into the region of NMOSFET under the conditions 60 KeV, 3×10 15 cm -2 , while BF 2 30 ion is implanted into the region of PMOSFET under the conditions 40 KeV, 5×10 14 cm -2 , thereby impurity diffused regions 152 at high concentration are formed in a predetermined region where the source and drain regions are formed. Then, heat treatment is carried out in nitrogenous (N 2 ) atmosphere at 950° C. for 30 seconds to activate impurities, thereby, LDD (lightly-doped drain) layer 151 is formed in depth 65 nm, while the high impurity diffused region 152 is formed in depth 180 nm.
After the above, as shown in FIG. 7(d), Ti target is sputtered by use of Ar plasma, thereby metal titanium film (Ti film) 16 is accumulated 30 nm. Then, boron (B) is added under the conditions 10 KeV, 2×10 15 cm -2 by use of ion implementation. In this case, even if nitrided titanium (TiN) is formed on surface, the principle of the present invention will not be changed at all.
Then, as shown in FIG. 7(c), heat treatment is carried out on the titanium film to which boron has been added, at 750° C. to 800° C. under nitrogenous atmosphere for 30 seconds, and titanium silicide (TiSi 2 ) film 18a and 18b are formed by solid phase reaction of titanium and silicon in the metal titanium film 16 on the source and drain regions and the gate electrode 13 contacting the metal titanium film 16. In the silicide film, boron added by ion implementation combines with titanium by the above annealing, and exists stably as titanium boride. And since litanium silicide consumes silicon and is formed on substrate side, even if boron should thrust out substrate by the above ion, boron is taken in all inside of silicide, accordingly, the increase of contact resistance with TiSi 2 film both on the diffused layer of N type MOSFET and the gate electrode of N type MOSFET is avoided, therefore, the above process is completely compatible with CMOS technology.
Then, as shown in FIG. 7(d), TiN film 17 and unreacted Ti film 16 are removed by etching by use of mixture solution of sulfuric acid and hydrogen peroxide.
Then, through heat treatment under nitrogenous atmosphere at temperature over 800° C. (preferably, about 850° C.), they are changed completely into TiSi films 18a and 18b having a C54 crystal structure that is stable at high temperatures.
According to the above process, TiSi 2 films 18a and 18b can be formed only on the high impurity diffused layer 152 of source and drain regions, and the gate electrode 13, however, TiSi 2 film may be formed only on the gate electrode 13, or only on the high impurity diffused layer 152.
After the above, as shown in FIG. 7(e), interlayer insulating layer 21 is accumulated on the whole surface, and contact hole is opened, and a wiring line 23 of a first layer is arranged so that TiSi 2 films 18a and 18b are connected via a contact plug 22.
According to the method described above, with respect to the boron-added silicide film as well as the silicide film shown in the previous embodiment 1, the formation of boride of thermodynamically stable transition metal improves the aggregation resistance of TiSi 2 by heat treatment of post process, as a consequence, it is possible to realize low resistance of electrode irrespective of the size of reaction portion.
Embodiment 3
In the next place, the third embodiment of the present invention is described in detail hereinafter with reference to FIGS. 8(a) throughout (d).
FIGS. 8(a) throughout (d) are schematic diagrams showing a process flow using salicide process in the formation of CMOSFET regarding an embodiment of the manufacturing method of a semiconductor device according to the present invention.
In the first place, as shown in FIG.8(a), a separation region 11 is formed on a semiconductor substrate 10, and a gate electrode 13 (generally, non-dope polysilicon) is formed via a gate insulating film 12 on the partial surface of the element region.
In the next place, by the ion implantation method well known to those skilled in the art, As + ion is implanted into the region of NMOSFET under the conditions 30 KeV, 1×10 14 cm -2 , while BF 2 + ion is implanted into the region of PMOSFET under the conditions 20 KeV, 1×10 14 cm -2 , thereby impurities are added to gate electrode 13 and LDD (lightly-doped drain) layer 151 for source region and drain region is formed on substrate surface portion in self aligned manner.
Then, in order to prevent short-circuit between the source region and the drain region and the gate electrode 13, a side-wall insulating layer 14 is formed on the side surface of the gate electrode by use of the known technology. Namely, the side-wall insulating layer 14 is formed by dry etching without using mask after accumulation of an insulating layer that does not react in the silicide process of the gate and source and drain regions described later, foe example, nitrided silicon (SiN) film.
Further, by the ion implantation method once again As + ion is implemented into the region of NMOSFET under the conditions 60 KeV, 3×10 15 cm -2 , while BF 2 + ion is implanted into the region of PMOSFET under the conditions 40 KeV, 5×10 14 cm -2 , thereby impurity diffused regions 152 at high concentration are formed in a predetermined region where the source and drain regions are formed. Then, heat treatment is carried out in nitrogenous (N 2 ) atmosphere at 950° C. for 30 seconds to activate impurities, thereby, LDD (lightly-doped drain) layer 151 is formed in depth 65 nm, while the high impurity diffused region 152 is formed in depth 180 nm.
After the above, as shown in FIG. 8(b), Ti target is sputtered by use of Ar plasma, thereby metal titanium film (Ti film) 16 is accumulated 30 nm.
Then, heat treatment is carried out at 750° C. to 800° C. under nitrogenous atmosphere for 30 seconds, and titanium silicide (TiSi 2 ) film 18a and 18b are formed by solid phase reaction of titanium and silicon in the metal titanium film 16 on the source and drain regions and the gate electrode 13 contacting the metal titanium film 16.
Next, boron (B) is added under the conditions 10 KeV, 2×10 15 cm -2 by use of ion implementation.
Then, as shown in FIG. 8(a), TiN film 17 and unreacted Ti film 16 are removed by etching by use of mixture solution of sulfuric acid and hydrogen peroxide.
Then, through heat treatment under nitrogenous atmosphere at temperature over 800° C. (preferably, about 850°C.), they are changed completely into TiSi films 18a and 18b having a C54 crystal structure that is stable at high temperatures.
In the silicide film, boron added by ion implementation combines with titanium by the above annealing, and exists stably as titan boride.
According to the above process, TiSi 2 films 18a and 18b can be formed only on the high impurity diffused layer 152 of source and drain regions, and the gate electrode 13, however, TiSi 2 film may be formed only on the gate electrode 13, or only on the high impurity diffused layer 152.
According to the method described above, with respect to the boron-added silicide film as well as the silicide film shown in the previous embodiment 1, the formation of boride of thermodynamically stable transition metal improves the aggregation resistance of TiSi 2 by heat treatment of post process, as a consequence, it is possible to realize low resistance of electrode irrespective of the size of reaction portion.
Embodiment 4
In the next place, the fourth embodiment of the present invention is described in detail hereinafter with reference to FIGS. 9(a) throughout (d).
FIGS. 9(a) throughout (d) are schematic diagrams showing a process flow using salicide process where to attach silicide only to the source and drain electrode in self aligned manner in the formation of CMOSFET regarding an embodiment of the manufacturing method of a semiconductor device according to the present invention.
In the first place, as shown in FIG. 9(a), a separation region 71 is formed on a semiconductor substrate 70, and impurity ion implementation is carried out and a well is formed by diffusion, and a polysilicon film 13' (generally, non-dope polysilicon) is formed via a gate insulating film 72 on the partial surface of the element region.
In the next place, by the ion implantation method well known to those skilled in the art, As + ion is implanted under the conditions 30 KeV, 1×10 15 cm -2 , while BF 2 + ion is implanted under the conditions 20 KeV, 1×10 15 cm -2 respectively, thereby impurities are added to the polysilicon film 13'. Then, a metal film 73 comprising tungsten silicide is accumulated by PVD such as sputtering or CVD, and insulation film is accumulated directly on it. By the way, the above metal film 73 may be titanium silicide or cobalt silicide. And a gate protection film 74 is accumulated directly on it.
Then, as shown in FIG. 7(b), patterning is carried out on a gate electrode by lithography technology, and the gate protection film 74, the metal film 73, and the polysilicon film 13' are processed by reactive etching (RIE), and thereby a gate electrode 13 is formed Following the above, by the ion implantation method, As + ion is implanted into the region of NMOSFET under the conditions 35 KeV, 1×10 14 cm -2 , while BF 2 + ion is implanted into the region of PMOSFET under the conditions 20 KeV, 1×10 14 cm -2 , thereby the known LDD (lightly-doped drain) layer 76 is formed, and after this, the side-wall insulating layer 75 is formed by the known technology on the side surface of the gate electrode for the purpose of preventing the short-circuit between the source region and drain region and the gate electrode 13. Namely, the side-wall insulating layer 75 is formed by dry etching without using mask after accumulation of an insulating layer that does not react in the silicide process or the gate and source and drain regions described later, foe example, nitrided silicon (SiN) film.
Further, with regard to substrate surface portion, by the ion implantation method, As + ion is implemented into the region of NMOSFET under the conditions 60 KeV, 3×10 15 cm -2 , while BF 2 + ion is implanted into the region of PMOSFET under the conditions 40 KeV, 5×10 14 cm -2 , thereby impurity diffused regions 77 at high concentration are formed in a predetermined region where the source and drain regions are formed. Then, heat treatment is carried out in nitrogenous (N 2 ) atmosphere at 950° C. for 30 seconds to activate impurities, thereby, LDD (lightly-doped drain) layer 76 is formed in depth 65 nm, while the high impurity diffused region 77 is formed in depth 180 nm.
After the above, as shown in FIG. 9(a), Ti target is sputtered by use of Ar plasma, thereby metal titanium film (Ti film) 78 is accumulated 30 nm. Following this, a cap film 79 comprising nitrided titanium (TiN) film is accumulated 70 nm so as to restrict the roughness of titanium silicide surface at the formation of titanium silicide described later. At this moment, normally, titanium target (metal titanium film) 16 is sputtered by use of plasma of mixture gas of argon and nitrogen, thereby nitriding reaction of titanium is induced on the titanium target surface, and TiN film 79 is accumulated on the abovementioned metal titanium film 78.
Heat treatment is carried out on the multi layer film formed as shown above, at 750° C. to 800° C. under nitrogenous atmosphere for 30 seconds, and titanium silicide (TiSi 2 ) film 80 is formed by solid phase reaction of titanium and silicon in the metal titanium film 78 on the source and drain regions contacting the metal titanium film 78.
Then, as shown in FIG. 9(d), TiN film 79 and unreacted Ti film 78 are removed by etching by use of mixture solution of sulfuric acid and hydrogen peroxide, and then, boron (B) is added under the conditions 10 KeV, 2×10 15 cm -2 by use of ion implementation method.
FIG. 5 shows an example of the depth distribution of boron obtained by the ion implementation under the above conditions, wherein boron stays in TiSi 2 film 80, and does not thrust out substrate.
Through the optimization in this manner, the increase of the contact resistance with TiSi 2 film also on the diffused layer of N type MOSFET and on the gate electrode of N type MOSFET is avoided, therefore, the above process is completely compatible with CMOS technology.
Then, through heat treatment under nitrogenous atmosphere at temperature over 800° C. (preferably, about 850° C.), it is changed completely into TiSi film 80 having a C54 crystal structure that is stable at high temperatures. Also through this heat treatment, boron forms titan boride in TiSi 2 film 80 and gets to exist stably.
According to the above process, TiSi 2 film 80 can be formed on the high impurity diffused layer 77 of source and drain regions.
After the above, interlayer insulating layer is accumulated on the whole surface, and contact hole is opened, and a wiring line of a first layer is arranged so as to connect TiSi 2 film 80 via a contact plug.
The specific resistance of TiSi 2 film 80 formed according to the above process appears to be about 13 μΩcm though the film thickness of TiSi 2 film 80 is as thin as 55 nm, thus it has been found that the specific resistance is extremely low as well as bulk value.
Moreover, in the prior art, the rapid increase of the specific resistance of diffused layer was observed at the width of diffused layer below 1 μm, on the other hand, in accordance with the above embodiment, even when the width of the high impurity diffused layer 152 was made to 0.4 μm, the specific resistance of TiSi 2 film formed on the high impurity diffused layer 77 could be made extremely low, therefore, the sheet resistance of diffused layer could be reduced to 3 Ω/□, that is, 1/3 of that in the case formed by the conventional art. As a result, TiSi 2 film formed in accordance with the above embodiment has enabled to overcome the defect in the prior art where increase of resistance was to be observed on micro regions.
Namely, according to the manufacturing method of a semiconductor device as mentioned above, salicide process is adopted so as to reduce the incidental resistance on an extremely thin diffused layer accompanying with high integration and high speed of CMOSFET. In this case, at the formation of TiSi 2 film as the metal chemical of the transition metal and the element configuring semiconductor substrate (silicon) formed on the diffused layer of NMOSFET and on that of PMOSFET respectively, as shown in FIG. 5, boron is implemented so that the concentration of boron in TiSi 2 film should be 1×10 19 cm -3 . And boron does not thrust out semiconductor substrate and added in only TiSi 2 film, facilitating thermally stable titanium boriding.
By the way, in the embodiment mentioned above, when a metal silicide is formed in self aligned manner on silicon substrate by accumulating transition metal and by the solid phase reaction of transition metal and silicon, metal silicide is formed in self aligned manner on the electrode portion by heat treatment immediately after accumulating transition metal, and unreacted metal is removed, then boron is added only into metal silicide by ion implementation with boron not thrusting out semiconductor substrate, however, the order of processes may be changed as shown in the following (1) and (2);
(1) Immediately after a metal chemical is formed in self aligned manner on the electrode portion just after accumulation of transition metal (immediately before the removal of unreacted metal), boron may be added into only metal silicide by ion implementation with boron not thrusting out semiconductor substrate.
Namely, the process in this case comprises a first step to form metal silicide in self aligned manner an the electrode portion of MOSFET by the solid phase reaction of transition metal and silicon by heat treatment by accumulating transition metal on a silicon semiconductor substrate, and a second step to add boron into only the above metal silicide so that boron should not thrust out the silicon semiconductor substrate by ion implementation, and a third step to remove unreacted metal in the above first step.
(2) Immediately after accumulation of transition metal, boron may be added into only transition metal by ion implementation so that boron should not thrust out the semiconductor substrate so as for the final concentration to become as shown in the figure.
Namely, the process in this case comprises a first step to accumulate transition metal onto a silicon semiconductor substrate, a second step to add boron into only the above transaction metal by ion implementation so as for boron not to thrust out the silicon semiconductor substrate, a third step to form self aligned metal silicide on the electrode portion of MOSFET by solid phase reaction between the above transition metal and silicon through heat treatment, and a fourth step to remove unreacted metal in the above third step.
Embodiment 5
The embodiments described heretofore are concerned with CMOSFET, however, the present invention may be applied to not only CMOSFET but also silicide attachment to the electrode of transistor base resistance.
FIG. 10(a) shows a salicide process to a bipolar transistor base resistance by a known method, First, a separation region 102 and a N-well 101 are formed on a semiconductor substrate 100. An insulating film is formed on the N-well 101, and the insulating film at the portion where a base electrode is formed is removed so that the surface of the semiconductor substrate 100 should be exposed. A base electrode 103 is formed on this removed portion by epitaxial growth.
In the next place, a polysilicon film is formed on the whole surface of the semiconductor substrate 101, and the polysilicon film at the emitter region forming portion in the base electrode 103 is removed. Thereby, a base drawer electrode 104 is formed. Then, an insulation film is formed on the side surface and the front surface of this base drawer electrode 104 is formed. Anisotropic etching is carried out on this insulating film so that part of this insulating film should be left on the side surface of the base drawer electrode 104. In this manner, a first insulating film side wall 105 is formed.
Following the above, an insulating film 106 is formed on the surface of the base drawer electrode 104. Polysilicon is accumulated on the slot just above the base electrode 103, from which an emitter electrode 107 is formed by ion implantation process. Then, an emitter drawer electrode 108 comprising polysilicon is formed on the surface of the insulating film 106.
Then, a second insulating film side wall 109 is formed, and a metal titanium film is accumulated on the whole surface, and a rapid thermal annealing (RTA) is carried out at 700° C. to 800° C. in nitrogenous atmosphere. Thereby, titanium silicide (TiSi 2 ) film 110 is formed by solid phase reaction of titanium and silicon in the metal titanium film on the emitter electrode 107, the base drawer electrode 104, and the surface of the semiconductor substrate 101 to become a collector drawer electrode contacting the metal titanium film 16.
Then TiN film and unreacted metal titanium film are removed by etching by use of mixture solution of sulfuric acid and hydrogen peroxide, and then boron (B) is added under the conditions 10 KeV, 2×10 15 cm -2 by use of ion implementation method.
Then, through heat treatment under nitrogenous atmosphere at temperature over 800° C. (preferably, about 850° C.), it is changed completely into TiSi film 110 having a C54 crystal structure that is stable at high temperatures. Also through this heat treatment, boron forms titan boride in TiSi 2 film 110 and gets to exist stably.
According to the above process, as shown in FIG. 10(b), TiSi 2 film 110 can be formed on the emitter drawer electrode 107, the base drawer electrode 104, and the surface of the semiconductor substrate to become a collector drawer substrate 101.
After the above, interlayer insulating layer is accumulated on the whole surface, and contact hole is opened, and a wiring line of a first layer is arranged so that TiSi 2 film 110 is connected via a contact plug.
The specific resistance of TiSi 2 film 110 formed according to the above process appears to be about 13 μΩcm though the film thickness of TiSi 2 film is as thin as 55 nm, thus it has been found that the specific resistance is extremely low as well as bulk value.
According to the present invention mentioned heretofore, it is possible to provide a semiconductor device and a method of manufacturing the same that enable to prevent transition metal chemical from aggregating owing to heat process and resistance from increasing even if the region of reaction portion is of a micro fine shape in the case to apply salicide process to the formation of CMOSFET.
While there has been illustrated and described what are presently considered to be preferred embodiments of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for devices thereof without departing from the true scope of the invention. In addition many modifications may be made to adapt a particular situation or material to the teaching of the present invention without departing from the central scope thereof. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention include all embodiments falling within the scope of the appended claims.
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A semiconductor device has a metal silicide on silicon conductor formed using a salicide process. The metal silicide layer of the conductor includes boron which improves the morphology and conductivity of the metal silicide layer. Implanting boron into the metal silicide layer or the metal to be silicided prevents the metal silicide from aggregating during a subsequent annealing or other heating process. This process allows narrower conductors to be formed without undesirable increases in the resistance of the metal silicide layer. The boron incorporating salicide process is compatible with CMOS processes.
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[0001] The invention relates to an electromotive drive system, to a thermal shielding device, to an electric and/or hybrid vehicle, and to a production method.
BACKGROUND
[0002] Electric motors generally have heat-sensitive components. Thus, the rotor and the stator, especially the rotor, can react sensitively to excessive heat input.
[0003] The actuation of a friction brake, for example, can generate a great deal of heat.
[0004] A special embodiment of an electric motor is an electric wheel hub drive. A wheel hub drive comprises an electric motor that is installed directly into a wheel of a vehicle and that, at the same time, supports the wheel hub so that part of the motor rotates with the wheel. Wheel hub drives have a high integration density, which is why heat transfer from a friction brake to heat-sensitive components of the electric motor cannot be countered by increasing the distance between the friction brake and the heat-sensitive components.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide thermal shielding for heat-sensitive components of electric motors that reduces heat transfer, especially in the form of thermal radiation, to the component that is to be shielded, even in case of a large amount of heat caused, for example, by a friction brake.
[0006] The present invention provides a motor with a rotor and a stator, a friction brake and a shielding device for thermally shielding at least one component of the electric motor against heat input, especially thermal radiation, stemming from the friction brake. The shielding device comprises at least one coolant line for cooling the shielding device with a coolant.
[0007] Owing to the coolant line, the shielding device has a high heat capacity. Moreover, the coolant line makes it possible to dissipate excess heat. Thus, it is advantageous that a temperature rise and a heat transfer to the electric motor component that is to be shielded can be prevented and a particularly effective shielding of active parts of the electric motor, especially the rotor, can be achieved. In addition to shielding thermal radiation, the shielding device can also advantageously carry convection heat out of the drive system.
[0008] In particular, the drive system or the electric motor can be an electric wheel hub drive, for example, for an electric and/or hybrid vehicle. Preferably, the electric motor can be operated as a motor and as a generator.
[0009] The friction brake can especially comprise a rotating friction element and at least one brake element that can be pressed against the friction element. For example, the friction brake can be a drum brake or a disc brake. The friction element can be, for instance, a brake drum or a brake disc. Accordingly, the brake element can comprise a brake lining or brake pad or it can be a brake lining or brake pad. The brake element can be pressed against the friction element, for instance, by a brake shoe or by a brake caliper.
[0010] Water, for example, can be used as the coolant.
[0011] Within the scope of one embodiment, the shielding device has a ring-shaped body. In particular, the coolant line can be integrated into the ring-shaped body.
[0012] The term “ring-shaped body” refers to an essentially hollow-cylindrical body. In particular, the essentially hollow-cylindrical body can have an essentially round, for example, circular or ovaloid, base area. In this context, the term “essentially hollow-cylindrical” encompasses conventional hollow cylinders that have a closed circumferential surface (closed ring) as well as bodies that differ from a conventional hollow cylinder in that the circumferential surface is interrupted (open ring).
[0013] The ring-shaped body can be arranged especially at a radial distance between the friction element—for example, the brake drum or the brake disc, especially the outer circumferential surface of the brake drum or the brake disc—and the rotor, especially the inner circumferential surface of the rotor.
[0014] In particular, the body can be configured in the form of a closed ring. Owing to the design of the body in the form of a closed ring, the mechanical stability of the body can advantageously be increased.
[0015] Aside from having the ring-shaped body, the shielding device can also have at least one shielding device fastening element, especially on an end face of the ring-shaped body, for purposes of attaching the shielding device, especially to a stationary part of the drive system, especially of the electric motor. In particular, the ring-shaped body can be joined, for instance, on an end face, to the shielding device fastening element(s). In this case, the shielding device fastening element(s) can extend radially inwards, for example, on the end face.
[0016] The ring-shaped body and the shielding device fastening element(s) can be configured in one piece or in multiple pieces. All in all, the shielding device can have a pot-like structure, similar to a brake drum. Within the scope of one embodiment, the ring-shaped body and the shielding device fastening element(s) are configured in one piece, for example, in that the otherwise ring-shaped body has one or more sections on one end face that serve as shielding device fastening element(s).
[0017] The coolant line can run around the body, especially circumferentially, or it can be integrated into the body so as to run circumferentially around it.
[0018] The term “runs circumferentially around” means that the coolant line runs completely around the body in one or more coils and also that the coolant line partially runs around the body in one or more coils. For example, in a first coil, the coolant line can run around most of the circumference, optionally up to an interruption of the ring-shaped body, it can then be reversed and can once again run around most of the circumference in a second coil that runs counter to the first coil, etc.
[0019] Fundamentally, the coolant line can be configured to be partially or completely, straight, especially helical and/or meander-like. It is also possible for the coolant line to be reversed one or more times. In particular, the coolant line can have at least one meander-like section and/or at least one straight section and/or at least one reversing section.
[0020] The term “straight”, especially with reference to a straight coolant line section of a ring-shaped body, should not be construed in the strict sense of the word. Instead, a straight section of the coolant line can refer to a section that results in a ring within the scope of the production method (explained below) when a metal strip is bent with a straight (in the strict sense of the word) fluted indentation section. The resulting section, referred to as a straight section, can thus have a curvature that corresponds to the curvature of the ring-shaped body.
[0021] Within the scope of one embodiment, the coolant line alternatingly has meander-like and straight sections. Here, a reversing section can be formed between a meander-like section and a straight section. This can achieve that the coolant has a different flow direction in the meander-like sections than it does in the straight sections.
[0022] In particular, the coolant line can have a helical configuration. For example, the coolant line can be configured in the shape of a double helix or a multiple helix. The individual helix strands can be connected to each other by means of a reversing section. The helix strands as such can have a straight configuration as well as a meander-like configuration.
[0023] The coolant line can have an essentially round as well as a polygonal cross sectional surface area. In particular, the coolant line can have a circular or ovaloid, for example, elliptical or semi-circular or semi-ovoidal, for instance, semi-elliptical, cross sectional surface area.
[0024] The ring-shaped body and the coolant line can especially be formed by at least two ring-shaped metal strips that are joined to each other. Here, especially at least one of the metal strips can have a fluted indentation that forms the coolant line. Consequently, the shielding device can advantageously be produced very easily, cost-effectively and with a low weight.
[0025] Within the scope of one embodiment, only one of the metal strips has a fluted indentation that forms the coolant line, whereby the fluted indentation that forms the coolant line is covered by a second metal strip that does not have an indentation. In this manner, the coolant line can be produced very easily and with a narrow manufacturing tolerance.
[0026] Within the scope of another embodiment, two metal strips have fluted indentations, whereby the fluted indentations are configured in such a way that, when the two metal strips are laid onto each other and joined, they each form part, for example, half, of the coolant line. In this manner, the coolant flow rate can advantageously be increased and consequently, the shielding effect can be improved.
[0027] Within the scope of another embodiment, the coolant line has a coolant feed line and a coolant drain line. In particular, the coolant line can have a coolant feed line connection and a coolant drain line connection. Preferably, the coolant feed line and the coolant drain line, or the coolant feed line connection and the coolant drain line connection are arranged adjacent to each other. Preferably, the coolant feed line and the coolant drain line or the coolant feed line connection and the coolant drain line connection are laid in such a way that they come to lie close to each other along the circumference. For other configurations, however, it is likewise possible for the coolant feed line and the coolant drain line or the coolant feed line connection and the coolant drain line connection to be arranged offset. The coolant feed line and the coolant drain line or the coolant feed line connection and the coolant drain line connection can especially be connected to a cooling circuit of the drive system. In this manner, multiple benefits and a very high integration density can be achieved.
[0028] Within the scope of another embodiment, the shielding device is arranged between the friction brake and the electric motor component that is to be shielded. Preferably, the shielding device is arranged at a distance from the friction brake and/or from the electric motor component that is to be shielded.
[0029] Within the scope of another embodiment, the electric motor component that is to be shielded is the rotor and/or the stator, especially the rotor.
[0030] Within the scope of another embodiment, the friction brake is a drum brake or a disc brake. In particular, the shielding device can be arranged between the brake drum or the brake disc and the electric motor component that is to be shielded, for example, the rotor and/or the stator, especially the rotor. Here, the shielding device can especially be arranged at a distance from the brake drum or brake disc and/or from the electric motor component that is to be shielded.
[0031] For instance, the shielding device can be arranged between the brake drum and the rotor or the rotor support, especially whereby the shielding device is arranged at a distance from the brake drum as well as from the rotor or the rotor support. For example, the ring-shaped body of the shielding device can circumferentially run around the brake drum at a radial distance. The rotor or the rotor support can, in turn, circumferentially run around the ring-shaped body of the shielding device at a radial distance. A radial distance from the rotor or from the rotor support is advantageous in order not to detrimentally affect the magnetic circuit.
[0032] Within the scope of another embodiment, the shielding device is attached to a stationary component of the drive system, especially to the electric motor. In this way, the coolant line can advantageously be connected very easily to a cooling circuit of the drive system.
[0033] Another subject matter of the present invention is a shielding device for thermally shielding at least one component of an electric motor against heat input, especially thermal radiation, said shielding device comprising at least one coolant line for cooling the shielding device with a coolant. In particular, the coolant line can be integrated into the ring-shaped body.
[0034] Thanks to such a shielding device, the active parts of an electric motor, especially the rotor and/or stator, can be shielded with respect to a heat-generating structure, for example, a friction brake. In particular, the shielding device according to the invention is suitable for a drive system according to the invention. As far as additional advantages and features as well as definitions are concerned, reference is hereby made to the explanations pertaining to the drive system, to the production method and to the figures.
[0035] Within the scope of one embodiment, the body and the coolant line are made up of at least two ring-shaped metal strips that are joined to each other. Preferably, at least one of the metal strips has a fluted indentation that forms the coolant line. In this manner, the shielding device can advantageously be produced very easily, cost-effectively and with a low weight.
[0036] Within the scope of one version of this embodiment, only one of the metal strips has a fluted indentation that forms the coolant line, whereby the fluted indentation that forms the coolant line is covered by a second metal strip that does not have an indentation. In this manner, the coolant line can be produced very easily and with a narrow manufacturing tolerance.
[0037] Within the scope of another version of this embodiment, two metal strips have fluted indentations, whereby the fluted indentations are configured in such a way that, when the two metal strips are laid onto each other and joined, they each form part, for example, half, of the coolant line. In this manner, the flow rate of the coolant can advantageously be increased and consequently, the shielding effect can be improved.
[0038] Within the scope of another embodiment, the body is configured in the form of a closed ring. Owing to the design of the body in the form of a closed ring, the mechanical stability of the body can advantageously be increased.
[0039] Aside from the ring-shaped body, the shielding device can have at least one shielding device fastening element, especially on one end face of the ring-shaped body, for purposes of attaching the shielding device, especially to a stationary component of the drive system, especially of the electric motor. In particular, the ring-shaped body can be joined, for instance, on one end face, to the shielding device fastening element(s). In this case, the shielding device fastening element(s) can extend radially inwards, for example, on the end face.
[0040] The ring-shaped body and the shielding device fastening element(s) can be configured in one piece or in multiple pieces. All in all, the shielding device can have a pot-like structure, similar to a brake drum. Within the scope of one embodiment, the ring-shaped body and the shielding device fastening element(s) are configured in one piece, for example, in that the otherwise ring-shaped body has one or more sections on one end face that serve as shielding device fastening element(s).
[0041] The coolant line can run around the body, especially circumferentially.
[0042] Within the scope of another embodiment, the coolant line can be integrated into the body so as to circumferentially run around it.
[0043] Fundamentally, the coolant line can be configured to be partially or completely straight, especially helical and/or meander-like. It is also possible for the coolant line to be reversed one or more times.
[0044] Within the scope of another embodiment, the coolant line has at least one meander-like section and/or at least one straight section and/or at least one reversing section.
[0045] Within the scope of another embodiment, the coolant line alternatingly has meander-like and straight sections. In particular, a reversing section can be formed (in each case) between a meander-like section and a straight section. Meander-like sections can have a large surface area and, associated with this, good cooling properties. However, meander-like sections can increase the flow resistance. Straight sections can entail less flow resistance than meander-like sections. A combination of meander-like sections and straight sections can be particularly advantageous in this context.
[0046] Within the scope of another embodiment, the coolant line can have a helical configuration. For example, the coolant line can be configured in the shape of a double helix or a multiple helix. The individual helix strands can be connected to each other by means of a reversing section. The helix strands as such can have a straight configuration as well as a meander-like configuration.
[0047] The coolant line can have an essentially round as well as a polygonal cross sectional surface area.
[0048] Within the scope of another embodiment, the coolant line has a circular or ovaloid, for example, elliptical or semi-circular or semi-ovoidal, for example, semi-elliptical, cross sectional surface area. An ovaloid cross sectional surface area—at the same height—can have a larger cross section than a circular cross sectional surface area, as a result of which a greater quantity of coolant can be made available for heat absorption.
[0049] Moreover, the coolant line can have a coolant feed line and a coolant drain line. In particular, the coolant line can have a coolant feed line connection and a coolant drain line connection. Preferably, the coolant feed line and the coolant drain line or the coolant feed line connection and the coolant drain line connection are arranged adjacent to each other. Preferably, the coolant feed line and the coolant drain line or the coolant feed line connection and the coolant drain line connection are laid in such a way that they come to lie close to each other along the circumference. For other configurations, however, it is likewise possible for the coolant feed line and the coolant drain line or the coolant feed line connection and the coolant drain line connection to be arranged offset.
[0050] Another subject matter of the present invention is a method for the production of a shielding device according to the invention, comprising the following method steps:
a) providing a first metal strip with a fluted indentation that forms the coolant line and providing a second metal strip; and b) joining, especially welding, the first metal strip to the second metal strip.
[0053] In this manner, the shielding device according to the invention and thus the drive system according to the invention can advantageously be produced very easily, cost-effectively and with a low weight. As far as additional advantages and features are concerned, reference is hereby made to the explanations pertaining to the drive system, to the shielding device and to the figures.
[0054] In method step a), the second metal strip can be configured without an indentation as well as with a fluted indentation that forms the coolant line.
[0055] In method step a), especially the first and the second metal strips can have the same width. In contrast, in method step a), the first and the second metal strips can have a different length. In particular, the length difference between the two metal strips can be selected here in such a way that the metal strips can be bent to form two concentric rings that are in contact with each other.
[0056] The metal strips can be made, for example, by a stamping or cutting process from a metal sheet, for instance, from a stainless steel sheet. The fluted indentations can be made in the metal, for instance, by deep-drawing, embossing or by a metal-removal process. Here, it is possible to make the fluted indentations before as well as after the metal strips are cut.
[0057] Within the scope of one embodiment, the method also comprises the following method steps:
a1) bending the first metal strip to form a ring and joining, especially welding, the two end faces of the first metal strip to each other; and a2) bending the second metal strip to form a ring and joining, especially welding, the two end faces of the second metal strip to each other; and a3) concentrically arranging the rings formed from the first and second metal strips.
[0061] In method step b), particularly the side edges of the rings formed from the first and second metal strips are joined, especially welded, to each other. The joining or welding can be carried out within the scope of method steps a1), a2) and/or b), especially by means of laser welding.
[0062] Another subject matter of the present invention is an electric and/or hybrid vehicle comprising a drive system according to the invention and/or a shielding device according to the invention or a shielding device produced according to the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0063] Below, the invention will be explained in greater detail with reference to the accompanying drawings. The drawings and their description serve to illustrate the subject matters according to the invention and are not to be construed to limit the invention in any manner whatsoever. The following is shown:
[0064] FIGS. 1 a - c schematic views of a first embodiment of a shielding device having a meander-like coolant line with a circular cross sectional surface area;
[0065] FIGS. 2 a -c schematic views of a second embodiment of a shielding device having a meander-like coolant line with an ovaloid cross sectional surface area;
[0066] FIGS. 3 a -c schematic views of a third embodiment of a shielding device having a meander-like coolant line with a semi-ovaloid cross sectional surface area;
[0067] FIGS. 4 a -c schematic views of a fourth embodiment of a shielding device having a helical coolant line in the form of a double helix and with a circular cross sectional surface area;
[0068] FIGS. 5 a -c schematic views of a fifth embodiment of a shielding device having a coolant line with alternating meander-like and straight sections and with a circular cross sectional surface area.
DETAILED DESCRIPTION
[0069] FIGS. 1 a to 1 c show a first embodiment of a shielding device 1 for thermally shielding at least one component of an electric motor, for example, the rotor, against heat input stemming, for example, from a friction brake. FIGS. 1 a to 1 c illustrate that, within the scope of this embodiment, the shielding device 1 has a ring-shaped body 3 , 3 a, 3 b and a coolant line 2 , 2 a, 2 b integrated into the ring-shaped body 3 , 3 a, 3 b for cooling the shielding device 1 with a coolant. FIG. 1 a illustrates that, within the scope of this embodiment, the ring-shaped body 3 , 3 a, 3 b is an essentially hollow-cylindrical body with a closed circumferential surface (closed ring) and with a circular base area.
[0070] FIG. 1 a particularly shows that the ring-shaped body 3 , 3 a, 3 b and the coolant line 2 , 2 a, 2 b are formed by two ring-shaped metal strips 3 a, 3 b that have fluted indentations 2 a, 2 b that form the coolant line 2 , 2 a, 2 b, whereby their side edges are joined to each other by means of a weld seam 6 . Moreover, FIG. 1 a shows that the fluted indentations 2 a, 2 b are formed in the metal strips 3 a, 3 b in such a way that, when the two metal strips 3 a, 3 b are laid onto each other and joined, they each form part, especially half, of the coolant line 2 , 2 a, 2 b.
[0071] FIGS. 1 a to 1 c also illustrate that the coolant line 2 , 2 a, 2 b is integrated into the ring-shaped body 3 , 3 a, 3 b so as to circumferentially run around it meander-like, and that it has a circular cross sectional surface area.
[0072] Moreover, FIGS. 1 a to 1 c show that the coolant line 2 , 2 a, 2 b has a coolant feed line 4 and a coolant drain line 5 , especially a coolant feed line connection 4 and a coolant drain line connection 5 . Within the scope of the embodiment shown, the coolant feed line 4 and a coolant drain line 5 are arranged adjacent to each other and they are laid in such a way that they come to lie close to each other along the circumference.
[0073] The second embodiment shown in FIGS. 2 a to 2 c differs from the first embodiment shown in FIGS. 1 a to 1 c essentially in that the coolant line 2 , 2 a, 2 b has an ovaloid cross sectional surface area.
[0074] The third embodiment shown in FIGS. 3 a to 3 c differs from the second embodiment shown in FIGS. 2 a to 2 c essentially in that only one of the two metal strips 3 a has a fluted indentation 2 a that forms the coolant line 2 , 2 a, 2 b, whereby the fluted indentation 2 a that forms the coolant line 2 , 2 a, 2 b is covered by a second metal strip 3 b that does not have an indentation. Accordingly, the coolant line 2 , 2 a, 2 b has only a semi-ovaloid cross sectional surface area.
[0075] The fourth embodiment shown in FIGS. 4 a to 4 c differs from the first embodiment shown in FIGS. 1 a to 1 c essentially in that the coolant line 2 , 2 a, 2 b has a helical configuration, and the coolant feed line 4 and the coolant drain line 5 are arranged offset relative to each other. In particular, in this embodiment, the coolant line 2 , 2 a, 2 b is configured in the form of a double helix, whereby the individual helix strands H 1 , H 2 , which are straight as such, are joined to each other by means of a reversing section U. A uniform temperature distribution can advantageously be achieved with a coolant line 5 that is configured in this manner. FIGS. 4 a to 4 c —like FIGS. 5 a to 5 c explained below—illustrate that, in conjunction with the coolant line 2 , 2 a, 2 b, the term “straight” should not be construed in the strict sense of the word but rather, it means that the section of the coolant line referred to as “straight” does not have any bends within the circumferential surface of the ring-shaped body 3 , 3 a, 3 b, but all in all, can have a curvature that corresponds to the curvature of the ring-shaped body 3 , 3 a, 3 b.
[0076] The fifth embodiment shown in FIGS. 5 a to 5 c differs from the first embodiment shown in FIGS. 1 a to 1 c essentially in that the coolant line 2 , 2 a, 2 b alternatingly has meander-like sections M and straight sections G, whereby a reversing section U is formed between a meander-like section M and a straight section G. Moreover, within the scope of this embodiment, the coolant line 2 , 2 a, 2 b only partially runs around the body 3 , 3 a, 3 b. In particular, in a first coil in the form of a straight section G, the coolant line 2 , 2 a, 2 b runs around only most of the circumference, it is then reversed in a reversing section U so that, in a second coil in the form of a meander-like section M running counter to the first coil, it once again runs around most of the circumference until, in another reversing section U, it is reversed into a third coil in the form of a straight section G running counter to the second coil, etc. A temperature distribution that is uniform over the circumference can advantageously be achieved with a coolant line 5 that is configured in this manner.
List of Reference Numerals
[0000]
1 shielding device
2 coolant line
2 a fluted indentation that forms the coolant line
2 b fluted indentation that forms the coolant line
3 ring-shaped body
3 a first metal strip that forms the body
3 b second metal strip that forms the body
4 coolant feed line
5 coolant drain line
6 weld seam of the side edges
M meander-like section of the coolant line
G straight section of the coolant line
U reversing section of the coolant line
H 1 first helix strand
H 2 second helix strand
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An electromotive drive system, especially an electric wheel hub drive, for example, for an electric and/or hybrid vehicle. In order to protect heat-sensitive components of the electric motor against heat input stemming from a friction brake, the drive system includes a shielding device ( 1 ) having a coolant line ( 2, 2 a, 2 b ) for cooling the shielding device ( 1 ) with a coolant. A shielding device ( 1 ), to an electric and/or hybrid vehicle as well as to a production method.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention generally relate to video-over-networks, e.g., video-over-Internet Protocol (IP) networks that utilize digital rights management functions for securely communicating content to network components. More specifically, the present invention relates to a method and apparatus for delivering a certificate revocation list (CRL) to a one-way client device over a broadcast one-way network.
[0003] 2. Description of the Related Art
[0004] Digital content information has recently gained wide acceptance in the public. Such content includes, but is not limited to: movies, videos, music, and the like. Consequently, many consumers and businesses employ various digital media devices or systems that enable the delivery of such digital multimedia content via several different communication channels (e.g., a wireless satellite link or a wired cable connection). Similarly, the communication channel may be a telephony based connection, such as DSL and the like.
[0005] In addition to being used to deliver digital content, a communication channel may be used to distribute a certificate revocation list (CRL) to one-way client devices (e.g., a set top box (STB) that receives a broadcast and does not have an interactive connection to the infrastructure) located in a local network. Typically, a CRL is delivered over an IP network as a communication message that is distinguished from digital content information. This manner of distribution may be an inefficient use of network resources. Furthermore, two-way interactive communications are not available to all receivers, e.g., digital TV set-top boxes without a return channel. Additionally, CRLs may grow to be very large over time while a receiving client device may possess a limited amount of memory. Consequently, the memory may be quickly consumed in the attempt to handle such large CRL objects. Although an attempt to keep the CRLs small could be made, the overall effectiveness of the CRL distribution system may be compromised. For example, in an effort to minimize the size of CRLs, only Certificate Authority (CA) certificates are revoked. Therefore, when a CA certificate is revoked, all device certificates (compromised and uncompromised device certificates alike) issued by that CA are effectively invalidated.
[0006] Thus, there is a need in the art for a method and apparatus for delivering a CRL to a one-way client device to a local network.
SUMMARY OF THE INVENTION
[0007] In one embodiment, the present invention discloses an apparatus and method for delivering a revocation list. Specifically, the revocation list is partitioned to form a first certificate revocation list (CRL) sequence if the number of entries in the revocation list exceeds a predetermined value. Individual identification numbers belonging to a first identification number series are subsequently assigned to partitions of the first CRL sequence. Afterwards, the first CRL sequence is interleaved into a first content transport stream.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0009] FIG. 1 depicts a block diagram of a system for facilitating the streaming of digital content over a communications network in accordance with the present invention;
[0010] FIG. 2 depicts an Intellectual Property Management and Protection (IPMP) tool that carries an encapsulated CRL;
[0011] FIG. 3 depicts a method for delivering a certificate revocation list in accordance with the present invention; and
[0012] FIG. 4 is a block diagram depicting an exemplary embodiment of a computer suitable for implementing the processes and methods described herein.
[0013] To facilitate understanding, identical reference numerals have been used, wherever possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
[0014] FIG. 1 is a block diagram of a content distribution system 100 (e.g., an Internet Protocol rights management (IPRM) system) that utilizes an authenticated key management protocol (e.g., MOTOROLA ESBroker™ protocol) to facilitate the secure transfer of digital rights and content. In general, any secure content distribution system where the delivered content is persistently stored and consumed on one or more devices within the end user's network can be utilized.
[0015] In the event the content distribution system used by a content provider utilizes digital certificates, there is a need for end user devices to verify the revocation status of the digital certificates belonging to the content provider's servers. Furthermore, end user devices may legally exchange content in a protected manner, which commonly requires the local devices to verify each device's digital certificate. Therefore, end user devices also need to verify the revocation status of each device's certificate (e.g., deliver CRLs to those end user devices).
[0016] In one embodiment, the system 100 comprises a content provider 108 (e.g., a streaming server), a communications network 112 (e.g., the Internet), a certificate revocation license (CRL) server 114 , and a local network 102 . Although only one content provider 108 , one CRL server 114 , and one local network 102 are depicted, those skilled in the art realize that any number of content providers, CRL servers, or local networks may be included in the system 100 .
[0017] The local network 102 may comprise a home network that includes a Home key distribution center (Home KDC) 104 and a plurality of client devices 106 1 . . . N . The devices 106 1 . . . N may each comprise a set top box (STB), a digital video recorder (DVR), and the like. These devices may be used to provide digital content to viewing devices, such as a television, computer monitor, and the like. In one embodiment, client devices are one-way, although not limited to being one-way. That is, a one-way client device is capable of receiving communication messages (e.g., broadcast) but does not have an interactive connection to the infrastructure. For example, the infrastructure equipment may be responsible for generating a one-way MPEG-2 transport stream that is delivered as a digital broadcast over cable, satellite or a terrestrial network. While the infrastructure may support two-way communications for some client devices with a return channel capability, cheaper devices do not have the return channel and are only capable of receiving a one-way broadcast transport stream. At present, this is the scenario with most cable and satellite digital television networks. In addition, some two-way client devices may not use their interactive capability for all functions, and may instead process broadcast messages, particularly in a hybrid network consisting of both one-way and two-way devices.
[0018] The Home KDC 104 is typically a single device (e.g., a STB, a DVR, etc.) in a home network that is designated to function as a media gateway. The Home KDC 104 facilitates communication between the local network 102 and the other components of the system 100 . In addition, the Home KDC 104 exchanges messages with the devices 106 1 . . . N in order to register a client device 106 , provide tickets needed to obtain content from a content provider 122 , and the like. Similarly, the Home KDC 104 in an IPRM-protected domain is configured to process CRLs after an updated CRL sequence is received via broadcast from the CRL server 114 .
[0019] The content provider 108 may comprise a streaming server that provides the digital content requested by the client devices 106 1 . . . N (or the Home KDC 104 ). More specifically, the content provider 108 distributes encrypted content to the Home KDC 104 positioned in the local network 102 where the content is ultimately provided to the appropriate client device 106 . In one embodiment, the content provider 108 may be configured to utilize caching servers (not shown) throughout the system 100 to distribute content to the local network(s).
[0020] The CRL server 114 may comprise a stand-alone server that obtains signed CRL files from a certificate authority (CA) server 110 . Specifically, a Certificate Authority 110 is responsible for recording the serial number of a client device that is deemed to be compromised or when a client device's certificate is revoked for any reason. Specifically, the serial number of the device is recorded to a CRL 116 . Once a CRL has been created and signed by a Certificate Authority, it can be safely transferred to a CRL server 114 with no additional security necessary. The CRL server 114 is capable of storing a plurality of CRLs in a database or other storage medium. Upon being notified that the CRL needs to be modified, the Certificate Authority updates the CRL sequence to include the additional compromised devices (or remove authorized devices). The updated CRL sequence is subsequently transferred to the CRL server 114 and broadcast to the local network 102 .
[0021] A CRL sequence is repeated periodically at a configurable interval, e.g., once every few hours. The client devices 106 1 . . . N are required to remain tuned in to the broadcast of the CRL. If the previously obtained CRL has expired and a new one has not been obtained within a pre-defined interval (e.g., 1 day), a client device 106 temporarily loses its ability to transfer any content to other devices. After an updated CRL has been acquired, the ability to transmit content is regained. In one embodiment, each CRL is an X.509 CRL that conforms to the IETF RFC 3280 standard. A client device 106 inspects the CRL Number parameter and determines if that particular CRL has already been received, so that the CRL does not have to be downloaded again. Because the X.509 CRL encoding positions the CRL Number extension near the end of the CRL, each DER-encoded X.509 CRL is also prefixed by a 4-byte CRL Number at the beginning of the CRL for the sake of efficiency (i.e., easier detection for client device).
[0022] FIG. 2 depicts an exemplary IPMP Tool Container 200 that is used to encapsulate a CRL. IPMP protocol is defined by MPEG-2 Part 11 in order to carry DRM-related information in an MPEG-2 broadcast stream. IPMP defines a set of MPEG-2 tables that can be included in an MPEG-2 multiplex and can include a construct called an IPMP Container, which may be used to include CRLs. Other standards-based and proprietary containers for broadcasting CRLs are also possible. In one embodiment, the IPMP Tool Container 200 may be used to distribute CRLs in-band over a video transport stream, such as a moving picture experts group (MPEG) broadcast stream (e.g., MPEG-2 broadcast stream) utilizing a specific PID (e.g., PID 3). Each CRL is separated into sections 206 1 . . . M (e.g., IPMP_Control_Info sections), which are carried by the IPMP Tool Container 200 . A single IPMP_Control_Info section can hold up to 4093 bytes of data. Because a memory-constrained device may run out of memory processing large CRL objects, IPRM protocol limits the size of a single CRL to a maximum of 1024 entries, which amounts to approximately 40 kilobytes. Consequently, a CRL may have to be separated into a maximum of 10 sections (i.e., 40 kilobytes divided by 4093 bytes). The IPMP Tool Container 200 comprises a CRL issuer name 202 , a CRL Number parameter 204 , the CRL itself and a signature 212 . The CRL issuer name 202 is a field that identifies the CRL issuer that signed the CRL, which is commonly a Certificate Authority (and is not the CRL Server). The CRL Number parameter 204 and issuer 202 are fields that a client device may inspect in order to determine if the corresponding CRL has been previously received. The signature 212 is normally included as part of each CRL to validate that the CRL has not been modified after being generated by a legitimate CRL issuer named in the CRL.
[0023] In order to support a CRL that contains more than 1024 entries, a CRL can be represented as a sequence of CRLs (i.e., CRL “partitions”) that are individually signed (i.e., each individual CRL partition contains its own unique signature that is only associated with that one CRL partition). Notably, a sequence of CRLs may be characterized by a number of factors. In one embodiment, all the CRLs in a given sequence must have the same validity period (i.e., the CRLs expire at the same time). Also, the first CRL in a sequence includes an identification number (e.g., a CRL Number extension) with a value that is a multiple of a number such as 0×10000 (65536). Similarly, each successive CRL in the same CRL sequence includes a CRL Number that is incremented by the same constant value (e.g., “1”). Furthermore, the last CRL in a given sequence must have less than the maximum 1024 entries. If the number of revoked certificates is an exact multiple of 1024, then the last CRL in the sequence must be empty. The present invention utilizes the CRL Numbers to signify the grouping of a particular CRL sequence as well as an indicator of an updated revocation list.
[0024] For example, in one embodiment, a particular CRL sequence may use a specific “series” of numbers to be used as CRL Numbers. A first sequence of CRLs may employ a 0×10000 series representation wherein the first CRL in the sequence possesses an identification number of 0×10001. Similarly, the second CRL in the sequence would be incremented have an identification number of 0×10002. This method of numbering the identification numbers would continue in like fashion for all the CRLs in a given sequence. However, when a CRL server 114 needs to modify the current revocation list, a new sequence of CRLs is assigned a second series of numbers. For example, the CRL server 114 may assign a 0×20000 series representation to the second sequence of CRLs, wherein the first CRL in the sequence would be numbered 0×20001, the second CRL would be numbered 0×20002, and so on. By changing the entire series of numbers used to identify a modified CRL sequence, the Home KDC 104 and the client devices 106 1 . . . N in the local network 102 are able to detect an updated CRL. Notably, the device compares the identification number in Section 0 to the last identification number(s) stored in memory and initiates a download of the CRL sequence if a change is detected.
[0025] The ESB protocol defines the types of messages in which a CRL may be included. During client provisioning with a Home-KDC, the Init Principal Reply message includes a CRL of Home-KDC certificates (i.e., a list of compromised) Home KDCs and like devices. Similarly, a client device may utilize an AS Request message to request that a CRL be included in a corresponding AS Reply from the Home KDC. Client devices need to request a new CRL if the old revocation list has already expired or is about to expire. In one embodiment, each Home-KDC is required to obtain two types of CRLs: (1) client CRL so that the KDC can verify client certificates, and (2) a Home-KDC CRL that is provided to clients within a local network. In one embodiment, CRLs are distributed to each Home-KDC over an MPEG-2 multiplex using an in-band method. For example, when a client sends a request message such as AS Request to the Home-KDC, it first checks the timestamp on its copy of a Home-KDC CRL to see if it is expired. If that CRL appears to be expired, then the client sets a flag in the request message to indicate to the Home-KDC that it needs a fresh CRL. When preparing a normal response message to the client (e.g., AS Reply), the Home-KDC will also include the latest and non-expired copy of the Home-KDC that it obtained from a CRL Server. Once the client receives the reply from the Home-KDC with an updated CRL, it will use it to verify the status of the Home-KDC certificate.
[0026] After detecting an updated revocation list, the Home KDC (or client device) downloads the new CRL and processes the data. Notably, the Home KDC 104 determines if any client device in the local network 102 is listed on the downloaded CRL. If so, the Home KDC records the id of the client device on a “to-be-revoked” list. When a client device with “to-be-revoked” status contacts the Home-KDC, the Home-KDC may be configured to reject any request from such clients. Consequently, the client device will be denied access to all content in the IPRM-protected domain that is not already stored locally.
[0027] FIG. 3 illustrates a method 300 for delivering a CRL to a client device in accordance with the present invention. Method 300 begins at step 302 and proceeds to step 304 where a CRL is generated. In one embodiment, the CRL server 114 creates a revocation list after receiving a list of compromised client devices (and/or Home KDCs) from network operators, equipment manufacturers, or some other reporting entity.
[0028] At step 306 , a determination is made as to whether the CRL contains a number of entries that exceeds a threshold value. In one embodiment, the CRL server 114 ascertains if the compromised devices entries on the revocation list exceeds 1024. If the threshold value is not exceeded, then the method 300 proceeds to step 312 . If the threshold value is exceeded then the method 300 continues to step 308 where a CRL sequence is generated. In one embodiment, the CRL server 114 divides the oversized revocation list into separate CRL “partitions” that contain a maximum of 1024 device entries.
[0029] At step 310 , identification numbers are assigned to the CRL sequence. Notably, the CRL server 114 assigns each sequence “partition” an identification number that belongs to an identification number series. In one embodiment, the first CRL partition has an identification number that is a multiple of 0×10000 (i.e., 65536). Similarly each sequence CRL in the same sequence has an identification number that increments by 1.
[0030] At step 312 , the CRL sequence is transmitted. In one embodiment, the CRL server 114 interleaves the CRL sequence into a content transport in-band to a local network. For example, the CRL sequence may be inserted into an MPEG transport stream. Typically, a Home KDC in the local network receives the digital content and CRL sequence. At step 314 , a determination is made as to whether the transmitted CRL sequence has been previously received. Notably, the Home KDC 104 ascertains if the CRL is either a previously received CRL or a new and/or modified CRL. In one embodiment, the Home KDC accomplishes this by inspecting the identification number series of the CRL sequence and comparing the value(s) to a recorded value (i.e., a previously received identification number series). If the CRL sequence has already been received on a prior occasion, the method 300 continues to step 322 , where the Home KDC will ignore the CRL sequence. Alternatively, the method 300 continues to step 316 where the CRL sequence is downloaded.
[0031] At step 318 , a determination is made as to whether the CRL sequence contains a client device in the local network. In one embodiment, the Home KDC compares the certificate(s) of the client devices in the local network 102 with the CRL sequence entries. If a match is not found, the method 300 continues to step 324 and ends. If a match is found, the method proceeds to step 320 where the device certificate is revoked. In one embodiment, the Home KDC 104 places the compromised client device on a “to-be-revoked” list that is stored locally. If the Home KDC 104 receives any content requests from the client device in question, the requests will be ignored. The method 300 ends at step 324 .
[0032] FIG. 4 depicts a high level block diagram of a Home KDC or general purpose computer suitable for use in performing the functions described herein. As depicted in FIG. 4 , the system 400 comprises a processor element 402 (e.g., a CPU), a memory 404 , e.g., random access memory (RAM) and/or read only memory (ROM) and/or persistent memory (Flash), a CRL delivery module 405 , and various input/output devices 406 (e.g., storage devices, including but not limited to, a tape drive, a floppy drive, a hard disk drive, a compact disk drive, a receiver, a transmitter, a speaker, a display, a speech synthesizer, an output port, and a user input device (such as a keyboard, a keypad, a mouse, etc.) and the like.
[0033] It should be noted that the present invention can be implemented in software and/or in a combination of software and hardware, e.g., using application specific integrated circuits (ASIC), a general purpose computer or any other hardware equivalents. In one embodiment, the CRL delivery module or process 405 can be loaded into memory 404 and executed by processor 402 to implement the functions as discussed above. As such, the present CRL delivery module 405 (including associated data structures) of the present invention can be stored on a computer readable medium or carrier, e.g., RAM memory, magnetic or optical drive or diskette and the like.
[0034] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
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The present invention discloses an apparatus and method for delivering a revocation list over a one-way broadcast network to receivers with limited memory capabilities. In one example, the revocation list is partitioned to form a first certificate revocation list (CRL) sequence if the number of entries in the revocation list exceeds a predetermined value. Individual identification numbers belonging to a first identification number series are subsequently assigned to partitions of the first CRL sequence. Afterwards, the first CRL sequence is interleaved into a first content transport stream.
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BACKGROUND OF THE INVENTION
The present invention relates generally to a dozer blade mounting assembly and more specifically to a mounting assembly which allows the pitch of a dozer blade to be adjusted independently of the blade tilt angle.
There are many known techniques for adjusting the pitch and tilt of a dozer blade. For example, FIG. 1 depicts a well-known technique for effecting dozer blade tilt and pitch. In FIG. 1, dozer blade 10 is supported along its back surface 12 by push beams 14, 16. Push beams 14, 16 are fastened to back surface 12 by way of pivot hinges 18, 20. Hydraulic cylinder 22 is fastened to back surface 12 of dozer blade 10 by way of joint 23 and to push beam 14 by way of joint 27. Adjustable strut 24 is fastened to back surface 12 of dozer blade 10 by joint 25 and to push beam 16 by joint 29. Adjustable strut 24 is typically comprised of a turnbuckle, jack screw or the like which can be manually adjusted to change the overall length of strut 24. Hydraulic cylinder 22 is typically attached to the appropriate hydraulic circuit (not shown) which allows the length of cylinder 22 to be adjusted from a remote position. The conventional design depicted in FIG. 1 allows the pitch angle 26 of dozer blade 10 to be adjusted by setting the appropriate length of strut 24 and adjusting cylinder 22 to a comparable length. Thus, it can be appreciated that the greater the pitch angle between vertical axis 28 and back surface 12 of dozer blade 10, the greater cylinder 22 and strut 24 must deviate from a neutral (or center) position.
To effect tilt 30 of dozer blade 10, cylinder 22 is lengthened or shortened while strut 24 maintains a fixed length. For example, if cylinder 22 is lengthened (while strut 24 remained fixed), left corner 32 of dozer blade 10 will rise while right corner 34 of dozer blade 10 will remain substantially unaltered. Similarly, if cylinder 22 is shortened (while strut 24 remains fixed), left corner 32 of dozer blade 10 will lower while right corner 34 of blade 10 will remain substantially unaltered. Thus, it will be appreciated that the conventional design depicted in FIG. 1 can be used to alter the pitch 26 and tilt 30 of dozer blade 10.
Although the conventional design depicted in FIG. 1 is desirable because of its low cost and mechanical simplicity, it is not without its drawbacks. For example, it can be seen that there is an interdependence between setting pitch 26 and tilt 30. For example, if tilt 30 of blade 10 is set to its desired angle and thereafter pitch 26 is set, initial tilt angle 30 will be effected by virtue of the above-mentioned interaction between the pitch and tilt of blade 10. This interaction necessitates several interations between tilt and pitch adjustment before tilt and pitch can be adjusted to their desired set points.
Thus, in bulldozer designs which support the bulldozer blade via two main push beams, it can be seen that conventional designs which have kept the tilt/pitch mechanisms simple have not been altogether satisfactory in providing independently controllable pitch and tilt of the dozer blade.
Accordingly, it is an object of this invention to provide a simple mechanism for controlling the pitch and tilt of a dozer blade independent of one another. It is a feature of this invention to have the dozer blade joined to a support arm by way of a cam.
It is an advantage of this invention that when the cam is rotated about its rotational axis, the pitch of the dozer blade is changed independent of the tilt angle of the dozer blade.
SUMMARY OF THE INVENTION
In light of the foregoing objects, the present invention provides an apparatus for setting the pitch of a bulldozer blade which is mounted to a bulldozer by two spaced, forwardly extending push beams, each beam being pivotally attached to a respective side of the blade, thereby permitting the blade to pivot about an axis. The apparatus includes a support strut and a cam. The support strut has one end pivotally attached to the bulldozer and the remaining end attached to one surface of the cam. The cam has two rotational surfaces and a rotational axis. One of the rotational surfaces of the cam is concentric to the cam's rotational axis, and the other rotational surface of the cam is eccentric to the cam's rotational axis. One of the rotational surfaces is rotationally mounted to the strut, and the remaining rotational surface is rotationally engaged to the dozer blade. The cam is rotatably engaged to the dozer blade spaced from the first axis of the blade. When the cam is rotated, the movement of the eccentric surface in relation to the concentric surface causes the blade to move relative to the support strut end, thereby changing the pitch of the blade by causing the blade to rotate about the blade's first axis. The movement of the cam thus allows the pitch of the blade to be adjusted regardless of the tilt of the blade.
In a preferred embodiment, the disclosed apparatus further includes a slave cam, a coupling shaft and a second support strut. The slave cam has a rotational axis, a surface concentric to the rotational axis and a surface eccentric to the rotational axis. The second support strut has one end pivotally attached to one of the push beams, and its second end is rotatably fastened to one of the surfaces of the slave cam. The remaining surface of the slave cam is rotatably fastened to the blade generally in vertical alignment with the end of the second strut which is attached to its respective push beam. The first strut has one end pivotally fastened to the remaining push beam, and its remaining end is rotatably fastened to one of the surfaces of the cam. The cam is fastened to the blade generally in vertical alignment with the end of the first strut which is attached to its respective push beam. The coupling shaft is joined to the cam and the slave cam generally in coaxial alignment with each cam's rotational axis. When the coupling shaft is rotated, the first and second cams rotate about their rotational axis, thereby causing the blade to rotate about its first axis and thereby changing the pitch of the blade.
Other advantages and meritorious features of the present invention will become more fully understood from the following description of the preferred embodiments, the appended claims and the drawings, a brief description of which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a conventional bulldozer blade and the associated apparatus for tilting and pitching the blade.
FIG. 2 is an isometric view of one embodiment of the apparatus of the present invention.
FIG. 3 is a partial top view of the cam assembly of the present invention taken substantially along lines 3--3 of FIG. 2.
FIG. 4 is an exploded view of the cam assembly of FIG. 3.
FIG. 5 is a side view of the cam assembly of the present invention taken substantially along lines 5--5 of FIG. 3.
FIG. 6 is a diagrammatic view of the apparatus of the present invention showing its ability to pitch the blade at various inclines.
FIG. 7 is a partial isometric view of the apparatus of the present invention depicting how it could be utilized for manually adjusting blade pitch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to the drawing of FIG. 2, dozer blade 10 is supported by push beams 14, 16. Push beams 14, 16 are attached to dozer blade 10 by way of conventional pivot hinges 18, 20. Hinges 18, 20 are preferably coaxially aligned, thereby permitting blade 10 to pivot about their common axis 36 through pivot pins 21. Structs 22, 24 have respectively associated first and second ends. The first end of each strut 38, 40 is respectively pivotally attached to beams 14, 16. The second end of each strut 42, 44 is respectively associated with cams 46, 48.
Cams 46, 48 are joined by virtue of coupling shaft 50. Cams 46, 48 each have a rotational axis and two rotational surfaces, one rotational surface being concentric with the rotational axis and the remaining surface being eccentric with the rotational axis. Coupling shaft 50 is joined to each cam such that the longitudinal axis of shaft 50 is coaxial with the rotational axis of cams 46, 48. Means for rotating shaft 50 is provided by cylinder 52. Having discussed the elements of the disclosed apparatus, its operation to accomplish tilt and pitch of dozer blade 10 will now be explained.
As is generally known by those skilled in the art, blade tilt is the ability to adjust one corner 32 of dozer blade 10 above or below opposite corner 34 of blade 10. This adjustment would generally result in movement of blade 10 as depicted by arc line 54. Likewise, the pitch of blade 10 is generally set by rotating blade 10 about axis 36. Rotation of blade 10 about axis 36 would generally result in movement as depicted by arc line 56. When it is desired to tilt blade 10, hydraulic cylinder 22 is extended or contracted relative to strut 24. If, for example, cylinder 22 is extended, corner 32 would rise in relation to corner 34, thereby sloping blade 10 downwardly to the right (as viewed by the vehicle operator). Conversely, if cylinder 22 were contracted relative to strut 24, left corner 32 of blade 10 would drop, thereby causing dozer blade 10 to slope downwardly from right to left. In addition to controlling tilt 54 of blade 10, pitch 56 can be set independently of tilt. Setting the pitch 56 of blade 10 is accomplished with the disclosed apparatus by simply lengthening or shortening the stroke of hydraulic cylinder 52. When the stroke of cylinder 52 is changed, coupling shaft 50 rotates, thereby causing cams 46, 48 to rotate also. Because the two rotational surfaces of each cam 46, 48 do not share a common rotational axis, rotating each cam 46, 48 causes blade 10 to rotate about axis 36 whenever shaft 50 rotates. Thus, cylinder 52 can effect the pitch of blade 10. It is important to note in the disclosed embodiment of FIG. 2 that pitch adjustment is accomplished independent of tilt adjustment. This is accomplished by virtue of cams 46, 48 being identical in design and synchronized in their stroke so as to provide uniform indexing between second ends 42, 44 and blade 10. Thus, it can be appreciated that the embodiment disclosed in FIG. 2 provides a simple apparatus for adjusting the pitch of a dozer blade independent of the tilt setting of the blade.
Now referring to the drawing of FIG. 3, cam 46 includes a rotational axis 58, a rotational surface 60 eccentric to axis 58 and two rotational surfaces 62, 64 concentric with rotational axis 58. Concentric surfaces 62, 64 are rotationally engaged to blade 10 by respective mounting ears 66, 68. Concentric surfaces 62, 64 are adapted to freely rotate within respective ears 66, 68 and can be fitted therein by way of any suitable bearing means well known to those skilled in the art. Second end 42 of hydraulic cylinder 22 is rotationally engaged to eccentric surface 60 by way of ball joint 70. Ball joint 70 allows three degrees of freedom between eccentric surface 60 and end 42 (although in this embodiment a simple sleeve bearing will suffice). Three degrees of freedom are necessary at the points where push beams 14, 16 are mounted to the dozer frame (dozer frame not shown) because of the twisting experienced by one beam about the other during tilting. Cam 46 is fastened to shaft 50 in an orientation whereby the longitudinal axis 72 of shaft 50 is coaxial with rotational axis 58 of cam 46. By arranging the axes of these two members to coincide, any rotational forces exerted on shaft 50 will be impressed upon cam 46 in a way which causes cam 46 to rotate about its rotational axis 58. Cam 46 is fitted with an arm 74 to provide a lever arm for turning cam 46 and shaft 50. Arm 74 is attached to cylinder 52, thereby providing a means for rotating cam 46 and shaft 50. It can be easily seen from the drawing of FIG. 3 that when cylinder 52 is extended or contracted, arm 74 causes cam 46 to rotate about axis 58, and correspondingly, arm 74 causes shaft 50 to rotate about axis 72. Because surface 60 is eccentric to surfaces 62, 64, distance 76 will change depending upon the setting of cylinder 52. By varying distance 76, the pitch of blade 10 is altered. Inasmuch as the arrangement surrounding cam 48 is identical to the arrangement described in conjunction with FIG. 3, the rotation of shaft 50 imparts equal pitching motion on each respective corner 32, 34 of blade 10.
Now referring to the drawing of FIG. 4, mounting ears 66, 68 respectively engage concentric surfaces 62, 64 for providing a means for rotationally coupling cam 46 to blade 10. Second end 42 of cylinder 22 receives within its inner opening 82 ball joint 70. Ball joint 70 receives within its inner opening 84 eccentric surface 60 of cam 46. Spacers 78, 80 keep ball joint 70 centered between mounting ears 66, 68. Arm 74 is mounted to cam 46 via conventional fastening means such as bolts, rivets and the like. Arm 74 is fitted with hole 86 for providing a means of joining arm 74 to cylinder 52. It is not necessary to show the assembly and mounting of cam 48 inasmuch as it is identical to that of cam 46 as shown in FIG. 4.
Now referring to the drawing of FIG. 5, mounting ear 68 is shown fastened to blade 10 via welds 88 or any other conventional fastening means known to those skilled in the art. Cam 46 is shown exhibiting eccentric surface 60 and concentric surface 64. Arm 74 is attached to cam 46 via bolts 90. Shaft axis 72 is displaced from the center 92 of eccentric rotational surface 60 as evidenced by reference numeral 94. This difference 94 between axis 72 and center 92 is what permits relative motion between second end 42 of cylinder 22 and blade 10.
Now referring to the drawing of FIG. 6, dozer blade 10 is shown in relation to mounting ear 66, cam 46 and second end 42 of cylinder 52 as heretofore described. By rotating cam 46, dozer blade 10 assumes a new position 10'. Other surfaces are translated during the rotation of cam 46, such as eccentric rotational surface 60 which moves to 60', mounting ear 66 which moves to position 66' and second end 42 of cylinder 52 which moves to 42'. Reference numeral 96 depicts the relative horizontal motion of a fixed point located on second end 42 of cylinder 52.
Now referring to the drawing of FIG. 7, in an alternative embodiment of the present invention, cylinder 52 can be eliminated, thereby reducing the cost of the disclosed apparatus. Mechanical means can be employed for rotating shaft 50, such as a wrench 110 or the like. If the disclosed invention is to be used without cylinder 52, bolts 98, 100 or some similar fastening means must be used to prevent cams 46, 48 (not shown) from rotating once they have been placed in the proper orientation. One method of achieving this fixation is to place a plurality of holes 102-108 (holes 106 and 108 are not visible because bolt heads 98 and 100 are blocking their view) in arm 74 and at least two holes in ear 66 (holes in ear 66 not visible from this view). If adjustment of pitch is desired, bolts 98, 100 are simply removed, and wrench 110 is used to rotate shaft 50 until blade 10 (not shown) is set at its desired pitch. Once the desired blade pitch is set, shaft 50 is rotated until two of the four holes 102-108 are properly aligned against the two holes in ear 66 to receive bolts 98, 100. It is contemplated that four holes 102-108 spaced ninety degrees apart should give sufficient resolution for most pitch adjustment needs. If four holes do not give sufficient resolution, additional hole sets can be made to accommodate greater pitch resolution settings.
The foregoing detailed description shows that the preferred embodiments of the present invention are well suited to fulfill the objects of the invention. It is recognized that those skilled in the art may make various modifications or additions to the preferred embodiments chosen here to illustrate the present invention, without departing from the spirit of the present invention. For example, cylinder 22 and 52 can be replaced by any manual means such as a turnbuckle, jack screw or the like. It is also contemplated that sufficient structure could be developed such that only one cam is necessary to achieve the disclosed pitching motion independent of blade tilt. For example, cylinder 22 could be mounted to the center of a beam which traverses push beams 14, 16. One end of cylinder 22 would be pivotally mounted intermediate this traversing beam, and the remaining end of cylinder 22 would be mounted to the disclosed cam assembly which would be mounted to the middle of blade 10. Accordingly, it is to be understood that the sought to be afforded hereby should be deemed to extend to the subject matter defined in the appended claims, including all fair equivalents thereof.
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An apparatus adapted to permit independent setting of pitch and tilt of dozer blades without necessitating complex hydraulic circuitry or mechanical linkage. The blade is pivotally supported by two forwardly extending push beams. A strut is connected at one end to one of the push beams and is connected at its other end to the dozer blade via a cam assembly. The cam assembly permits dozer blade pitching to take place without interacting with the dozer blade tilt angle. In a preferred embodiment, two struts are used at opposite ends of the blade and are each connected to their respective side of the blade by a respective cam. The two cams are linked together and synchronized so that their stroke equally pitches the sides of the dozer blade.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 126,838 filed Mar. 3, 1980, U.S. Pat. No. 4,287,341, which in turn is a continuation-in-part of application Ser. No. 90,313, filed Nov. 1, 1979, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to certain 2,4-diaminoquinazolines. Particularly, the invention relates to certain 7-alkoxy-2,4-diaminoquinazolines which are further substituted by a 6-chloro group and/or an 8-alkoxy group, their use as antihypertensive agents, pharmaceutical compositions thereof and intermediates for their production.
2. Description of the Prior Art
U.S. Pat. Nos. 3,511,836; 3,635,979 and 3,663,706 disclose 6,7-dimethoxy-2,4-diaminoquinazolines of the formula ##STR2## where Z is a nitrogen-containing heterocyclic group. One of these compounds, 2-[4-(2-furoyl)piperazin-1-yl]-4-amino-6,7-dimethoxyquinazoline, is a clinically useful antihypertensive agent and is marketed under the generic name "prazosin," the pharmacology of which is discussed in Constantine et al., "Hypertension: Mechanisms and Management," edited by Onesti, Kin and Moyer, Grune and Stratton, 1973, pp. 429-444.
U.S. Pat. No. 3,669,968 and U.S. Pat. No. 3,769,286 disclose 6,7,8-trialkoxy-2,4-diaminoquinazolines in which the 2-amino group is substituted by certain alkyl and hydroxy substituted alkyl groups or is a heterocyclic group such as piperidino or 4-substituted piperazino. One of these compounds is known by the generic name "trimazosin" and has the formula ##STR3## Trimazosin is also an active antihypertensive agent, see e.g., Vlachikis et al., Current Therapeutic Research, 17, 564 (1975). However, it is less potent than prazosin. Althuis et al., J. Med. Chem., 20, 146 (1977) have shown the 6-O-demethyl derivative is a major metabolite of prazosin of considerably lower blood pressure lowering activity. The 7-O-demethyl derivative is a less prevalent metabolite.
U.S. Pat. No. 3,920,636 and U.S. Pat. No. 4,044,135 disclose homopiperazinoquinazoline compounds as antihypertensive agents.
Several patents have issued which disclose antihypertensive compounds of the general formula ##STR4## U.S. Pat. No. 4,001,237 claims compounds wherein R a is an oxazole, isoxazole, thiazole or isothiazole radical.
In U.S. Pat. No. 4,001,238, such compounds are disclosed wherein R a is of the formula ##STR5##
U.S. Pat. No. 3,780,040 discloses 3,4-dihydroquinazoline analogs of the above formula wherein R a is 2-thienyl.
In U.S. Pat. No. 4,026,894 and U.S. Pat. No. 4,112,097, R a is a 2-tetrahydrofuryl or 2-tetrahydropyranyl moiety. U.S. Pat. No. 4,060,615 claims compounds in which R a is cycloalkyl having 3 to 8 carbon atoms and cycloalkenyl having 4 to 8 carbon atoms. U.S. Pat. No. 4,101,548 is concerned with 1,2,3-thiadiazole amides of the above formula wherein R a is ##STR6## and R b is hydrogen, lower alkyl, NH 2 or NHCO 2 R c in which R c is lower alkyl.
6,7-Dimethoxy-2-(4-thiomorpholin-1-yl) 4-aminoquinazolines and derivatives in which the 2-substituent is ##STR7## are disclosed as antihypertensive agents in U.S. Pat. No. 4,115,565.
British Pat. No. 1,530,768 discloses prazosin analogs in which the 2-amino group is of the formula ##STR8## where R e is phenyl, substituted phenyl, furyl, thienyl or 5-alkylthio-1,3,4-oxadiazol-2-yl.
French Pat. No. 2,321,890 discloses analogs of prazosin in which the 2-amino substituent is a piperidino or piperazino group substituted in the 3 or 4 position.
The compounds of the invention are highly potent antihypertensive agents having improved duration of action since they are not susceptible to metabolic demethylation at the 6-position with resultant loss of activity as is the case with prazosin. In addition, the invention compounds have improved water solubility when compared to prazosin. They can therefore be administered intraveneously, particularly for emergency purposes and are uniformly absorbed by all patients.
SUMMARY OF THE INVENTION
The present invention discloses new 2,4-diaminoquinazoline compounds and processes for their production. The new 2,4-diaminoquinazolines possess valuable pharmacological properties and other aspects of the invention relate to pharmaceutical compositions for oral or parenteral administration to a mammal comprising one or more of said new compounds and a pharmaceutically acceptable carrier, as well as a method for treating hypertension which comprises orally or parenterally administering to mammals in need of such treatment an antihypertensive effective amount of a compound of the invention.
The compounds of the invention are also useful for their vasodilation properties, as antiglaucoma agents and in the treatment of congestive heart failure.
The novel compounds disclosed are of the formula ##STR9## wherein Y 1 is hydrogen or chloro, Y 2 is OR and Y 3 is hydrogen or OR such that when Y 1 is hydrogen, Y 3 is OR and when Y 1 is chloro, Y 3 is hydrogen or OR, and the pharmaceutically acceptable acid addition salts thereof;
R is alkyl having from one to three carbon atoms;
R 1 and R 2 are the same or different and when taken separately are each a member selected from the group consisting of hydrogen, alkyl having from 1 to 5 carbon atoms, cycloalkyl having from 3 to 8 carbon atoms; alkenyl having from 3 to 5 carbon atoms, alkynyl having from 3 to 5 carbon atoms, hydroxy substituted alkyl having from 2 to 5 carbon atoms and when taken together with the nitrogen atom to which they are attached R 1 and R 2 form ##STR10## where X 1 is a member selected from the group consisting of S(O) t , CHOR 6 , --(CH 2 ) p -- and CHR 7 , and X 2 is a member selected from the group consisting of X 1 , O, NR 3 , NCOR 4 and NCOOR 5 , where
m is 2 or 3,
n is 2 or 3,
p is 1 to 3,
t is 0, 1 or 2;
R 3 is a member selected from the group consisting of hydrogen, alkyl having from 1 to 6 carbon atoms, alkenyl from 3 to 5 carbon atoms, alkynyl having from 3 to 5 carbon atoms, hydroxy substituted alkyl having from 2 to 5 carbon atoms, cycloalkyl having from 3 to 8 carbon atons, --(CH 2 ) q C 6 H 4 R 8 and --(CH 2 ) q C 10 H 6 R 8 where q is 0 or 1;
R 4 is a member selected from the group consisting of hydrogen, alkyl having from 1 to 6 carbon atoms, alkenyl having from 3 to 5 carbon atoms, cycloalkyl and cycloalkylmethyl wherein said cycloalkyl has from 3 to 8 carbon atoms, ##STR11## R 10 , CH 2 R 10 and (CH 2 ) q C 6 H 4 R 8 where A is S or O, q as defined above and R 10 is a member selected from the group consisting of ##STR12## where r is 1 or 2;
R 5 is a member selected from the group consisting of alkyl having from 1 to 7 carbon atoms, alkenyl having 3 to 5 carbon atoms, cycloalkyl having from 3 to 8 carbon atoms, hydroxy substituted alkyl having from 2 to 5 carbon atoms, CH 2 C 6 H 4 R 8 , CH 2 C 10 H 6 R 8 , CH 2 R 10 and CH 2 O-pyridyl;
R 6 is a member selected from the group consisting of hydrogen, C 6 H 4 R 8 , --(CH 2 ) p ZR 15 , alkyl having from 1 to 6 carbon atoms, and said alkyl substituted by a member selected from the group consisting of Cl, F, Br, OH, CH 3 O, SO 2 CH 3 and NHSO 2 CH 3 , where p and A are as previously defined and Z is a member selected from the group consisting of O, S, SO, SO 2 , NH and NR 16 ;
R 7 is a member selected from the group consisting of alkyl having from one to six carbon atoms, hydroxyalkyl having from one to five carbon atoms, --(CH 2 ) q C 6 H 4 R 8 and COC 6 H 4 R 8 ;
R 8 is a member selected from the group consisting of H, Cl, Br, F, CH 3 , CH 3 O, CF 3 , OH, SO 2 CH 3 and NHSO 2 CH 3 ;
R 9 is a member selected from the group consisting of H, Cl, CH 3 , C 2 H 5 and phenyl;
R 11 is hydrogen or methylthio and
R 12 is a member selected from the group consisting of H, NH 2 alkyl having from one to four carbon atoms and NHCO 2 R 14 ;
R 14 is alkyl having from one to four carbon atoms;
R 15 is a member selected from the group consisting of alkyl having from one to four carbon atoms, C 6 H 4 R 8 and C 10 H 6 R 8 ; and R 16 is hydrogen or alkyl having from one to four carbon atoms.
Preferred compounds of the invention include the compounds of formula (I) wherein Y 1 , Y 2 and Y 3 are as defined above and NR 1 R 2 is ##STR13## where R 4 is a member selected from the group consisting of ##STR14## and cycloalkyl having from 3 to 8 carbon atoms and A, r and R 11 are as previously defined. Also preferred are the compounds of formula (I) wherein Y 1 , Y 2 and Y 3 are as defined above and NR 1 R 2 is ##STR15## where R 5 is hydroxy substituted alkyl having from 2 to 5 carbon atoms.
Particularly preferred compounds of the invention are:
2-[4-(2-furoyl)piperazin-1-yl]-4-amino-7,8-dimethoxyquinazoline,
2-[4-(2-furoyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline,
2-[4-(2-furoyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline,
2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-7,8-dimethoxyquinazoline,
2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline and
2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline, and their hydrochloride salts.
The invention further provides certain intermediates useful in the preparation of the compounds of formula (I). These intermediates are of the formula ##STR16## where Y 1 , Y 2 and Y 3 are as defined above.
The term "pharmaceutically acceptable" used herein to describe an acid addition salt of a compound of formula (I) refers to those salts having anionic species of a variety of relatively non-toxic inorganic or organic acids. The anion does not contribute appreciably to the toxicity of the salt or to its pharmacological activity. Illustrative of such salts are those formed with acetic, lactic, succinic, maleic, tartaric, citric, gluconic, ascorbic, benzoic, cinnamic, fumaric, sulfuric, phosphoric, hydrochloric, hydrobromic, hydroiodic, sulfamic, sulfonic acids such as methanesulfonic, benzenesulfonic, p-toluenesulfonic, and related acids. Preparation of the mono-acid addition salts may be carried out in conventional manner by treating a solution or suspension of the free base in a reaction inert organic solvent with one chemical equivalent of the acid or if the di-acid addition salt is desired, at least two chemical equivalents of the acid. Conventional concentration or crystallization techniques are employed in isolating the salts.
The compounds of formula (I) are especially useful as antihypertensive agents having significant advantages over the prior art. The Y 1 substituent, at the 6-position of the invention compounds, is either hydrogen or chloro, groups which are not prone to metabolic attack. Consequently, the invention compounds are not subject to facile metabolic demethylation with resultant loss of activity, as has been shown for prazosin. Accordingly, the compounds of formula (I) have greater duration of action than prazosin and other 6,7-dimethoxy- and 6,7,8-trimethoxyquinazoline antihypertensive agents known in the art.
The invention compounds also have significantly greater water solubility than prazosin and as a result of their improved solubility, are uniformly absorbed by all patients. Furthermore, they can be administered in time release form, as well as parenterally, including intraveneously.
DETAILED DESCRIPTION OF THE INVENTION
The antihypertensive compounds of the invention are represented by either of the formulae ##STR17## wherein Y 1 , Y 2 , Y 3 , R, R 1 and R 2 are as previously defined. They are prepared by synthetic methods described below.
Scheme I, below, outlines a preferred reaction sequence. In the first step a 4-alkoxyanthranilic acid of formula (IX) containing the desired substituents Y 1 and Y 3 as defined above is cyclized to the corresponding 2,4-dioxoquinazoline of formula (X). The cyclization is brought about by reacting the compound (IX) with sodium or potassium cyanate or urea according to the procedure of Curd et al., Jour. Chem. Soc., 777 (1947) for the corresponding 6,7-dimethoxyquinazolinediones. Of course, as will be apparent to one skilled in the art, the anthranilic acids of formula (IX) may be replaced in this reaction by the corresponding compounds in which the carboxylic acid moiety is replaced by a CONH 2 , CN, or carboxylic ester group with satisfactory results. The cyclized compounds of formula (X) are novel compounds, of value as intermediates for preparing the antihypertensive compounds of the invention. As will be recognized by one skilled in the art, they may also be represented as the corresponding tautomeric 2,4-dihydroxyquinazolines. ##STR18##
In preparing the intermediates of formula (X), the starting material (IX) is suspended in a polar solvent in the presence of acid, preferably water-acetic acid, and a 2-4 molar excess of the cyanate salt, e.g., potassium cyanate or urea added. The resulting mixture is then heated at a temperature of from about room temperature up to the reflux temperature of the solvent until reaction is substantially complete. Typical reaction times are from about 1 to 24 hours. The mixture is then cooled, made alkaline with sodium hydroxide or potassium hydroxide and the alkaline mixture heated again at a temperature of from about 70° to 100° C. for 1 to 5 hours. The resulting sodium salt of the product (X) is then acidified and isolated by standard methods known in the art.
The intermediate of formula (X) is then reacted with a mixture of phosphorous pentachloride and phosphorous oxychloride or the corresponding phosphorous bromides to prepare the corresponding 2,4-dihaloquinazolines. The preferred embodiment, in which the above phosphorous chlorides are employed, is depicted in Scheme I to provide the intermediates of formula (XI) in which R, Y 1 and Y 3 are as defined above. Typically the dione (X) and a 2 to 4 molar excess each of phosphorous pentachloride and phosphorous oxychloride are heated at reflux for 2 to 6 hours, the residual phosphorous oxychloride evaporated and the residue slurried in a reaction inert organic solvent, for example, chloroform or dichoromethane, and poured into ice-water. Insoluble material is removed and the product isolated from the organic layer by evaporation or precipitation by addition of a non-solvent, for example, hexane, to precipitate the dichloro compound of formula (XI).
The key 2-chloro-4-aminoquinazoline intermediates of formula (XII) are provided by reacting equimolar amounts of ammonia and 2,4-dichloroquinazoline (XI) in the presence of a reaction inert organic solvent. Examples of suitable reaction inert solvents are ethyl ether, tetrahydrofuran, chloroform and benzene. A preferred solvent is tetrahydrofuran. In ordinary practice a preferred excess of ammonia of from one to ten moles would be used in order to shift the reaction toward completion. The temperature at which this reaction can be carried out is from about 25° to 200° C. for a period of from one to 48 hours. A preferred reaction temperature and time for this reaction would be about 25° to 60° C. for about five hours. Upon completion of the reaction the product is recovered by conventional means. For instance, the solvent can be evaporated and the crude solid can be triturated with water or precipitated from dilute aqueous acid in crystalline form and subsequently recrystallized from any number of organic solvents such as methanol, dimethylformamide or their mixtures with water.
Conversion of the 2-chloroquinazoline intermediate of formula (XII) to the desired compound of formula (III) is accomplished by contacting the intermediate (XII) with an equimolar amount of an amine of the formula R 1 R 2 NH in the presence of an aqueous or an organic solvent. A small molar excess of amine is generally employed. Preferred organic solvents for this reaction include polar solvents like tetrahydrofuran, dioxane, dimethylacetamide, dimethylformamide; alcohols such as methanol, ethanol and isoamyl alcohol and ketones such as methylethylketone and methylisobutylketone. Particularly preferred solvents are isoamyl alcohol and methylisobutylketone. The reaction mixture is heated preferably at a temperature of from about 60° to 160° C. for from one to 65 hours. Particularly preferred reaction temperatures are from about 100° to 140° C. and temperatures in this range are conveniently obtained by maintaining the reaction mixture at the reflux temperature of the particularly preferred solvents. At such temperature the reaction is ordinarily complete in from about two hours to two days.
Alternate procedures for preparing the compounds of the invention may also be used with satisfactory results. For example, the alternate methods disclosed in U.S. Pat. No. 3,511,836 for preparation of prazosin and its analogs can also be used with the appropriate starting materials to provide the invention compounds of formula (I). These methods are enumerated and discussed briefly below.
1. 2-Amino-4-chloroquinazolines (XXIX) prepared by methods analogous to those described in U.S. Pat. No. 3,511,836 for the corresponding 6,7-dialkoxy- compounds may be reacted with ammonia under conditions described above for the conversion of compounds (XI) to (XII) with resultant formation of the desired product of formula (I) where Y 1 , Y 2 , Y 3 , R 1 and R 2 are as defined above. ##STR19##
2. The quinazolinedione of formula (X) can be reacted with a reagent such as phosphorous pentasulfide or the like to form the corresponding 2,4-quinazolinedithione which are in turn reacted with an alkyl or benzyl halide to form the corresponding 2,4-dithioalkylquinazoline or 2,4-dithiobenzylquinazoline. This is then reacted with ammonia by the procedure previously described for the reaction of the 2,4-dichloroquinazolines (XI) to provide the corresponding 4-amino-2-thioalkyl (or thiobenzyl) quinazoline (XX). The latter compound is then converted to the desired compound (I) by employing conditions previously described for the formation of compound (I) from 2-chloro compounds of formula (XII). ##STR20## where Y 1 , Y 2 , Y 3 , R 1 and R 2 are as previously defined.
3. Compounds of formula (I) wherein NR 1 R 2 forms a heterocyclic moiety of the formula ##STR21## where X 2 is NR 3 , NCOR 4 or NCOOR 5 and m, n, R 3 , R 4 and R 5 are as previously defined, but R 3 is other than hydrogen, can also be prepared from the compound wherein X 2 is NH, for example NR 1 R 2 is piperazino, by acylation, alkylation or carbonyloxylation. ##STR22## The compound (XXI) is reacted with a compound of formula R 3 --X 3 , R 4 COX 3 or X 3 COOR 5 , where R 3 , R 4 and R 5 are as defined above and X 3 is a leaving group, preferably the halides, Cl or Br. When the preferred halides are employed it is advantageous to use at least a slight molar excess to ensure complete reaction. The intermediate (XXI) and reagent of formula R 3 X 3 , R 4 COX 3 or X 3 COOR 5 are contacted in the presence of a reaction inert organic solvent, for example, benzene, tetrahydrofuran, acetone methylethyl ketone, methylisobutyl ketone, 1,2-dimethoxyethane or diethyleneglycol dimethylether. A preferred such solvent is methylisobutyl ketone. The reaction may be carried out successfully over a wide range of temperatures. However, a temperature in the range of about 0° C. up to the reflux temperature of the solvent is preferred for reasons of efficiency and convenience. At such a preferred temperature the reaction is ordinarily complete in from about 30 minutes to six hours. The resulting solid product is then isolated as either the hydrohalide or the free base by conventional methods and purified, if desired, by crystallization, column chromatography or the like.
4. In this method the 2-aminobenzonitrile intermediate of formula (XIV) is reacted with a guanidine of the formula ##STR23## where R 1 and R 2 are as defined above. The benzonitrile (XIV) and an equivalent amount, but preferably a molar excess, of the guanidine are contacted in the presence of a reaction inert organic solvent, for example, ethylene glycol, diethyleneglycol, dimethylformamide, dimethylsulfoxide or diethyleneglycol dimethylether, at a temperature of from about 120°-180° C. for from about four to 15 hours. The desired product of formula (I) is then isolated by well known methods, for example, the solvent is evaporated, the residue contacted with water and the precipitated product is filtered, recrystallized and dried. The reaction is illustrated as follows: ##STR24##
The guanidine starting materials are prepared by methods well known in the art. For example, the amine of formula R 1 R 2 NH is reacted with cyanogen bromide to form the corresponding N-cyano-compound which, in turn, is reacted with hydroxylamine, followed by catalytic hydrogenation using the methods and conditions of Carrington, Jour. Chem. Soc., London, 2527 (1955) for the conversion of anthranilonitrile into 2-aminobenzamidine.
Variations of the above method can also be carried out employing either of the following starting materials in place of the 2-aminobenzonitrile (XIV). ##STR25## The 2-chlorobenzonitriles are obtained, for example, by diazotization of (XIV) in the presence of cuprous chloride. The 2-aminobenzamidines are obtained, for example, by the method of Carrington, above.
5. 2-Chloro-4-alkoxy-7,8-disubstituted quinazolines, which are prepared by methods described by Curd et al., Jour. Chem. Soc., 775 (1974) for the isomeric 2-chloro-4-alkoxy-6,7-disubstituted quinazolines, can be reacted with an amine, R 1 R 2 NH, to obtain the corresponding 2-aminoquinazolines. The 4-alkoxy substituent is then replaced by NH 2 by reaction with ammonia as described above for the 4-chloro compounds of formula (XXIX). This reaction sequence is exemplified below for a 2-chloro-4-ethoxyquinazoline starting material. ##STR26## Y 1 , Y 2 , Y 3 , R 1 and R 2 are as previously defined. The 4-thioalkylquinazolines corresponding to the above 4-alkoxy compounds can also be employed as starting materials in this sequence.
6. The compounds of the invention are also provided by methods disclosed in U.S. Pat. No. 3,935,213 for prazosin, trimazosin and analogs thereof as set forth below where Y 1 , Y 2 , Y 3 , R 1 and R 2 are as previously defined; ##STR27## A 1 is selected from the group consisting of CN and C(═NH)XR 3 wherein X is O or S and R 3 is alkyl having from one to six carbon atoms; and Q is CN or --C(═NH)NH 2 . Preferably the reaction is carried out in the presence of from about 0.5 to 5 molar equivalents of a basic catalyst, e.g., sodium hydride, potassium ethoxide or triethylamine, and at a temperature in the range of from about 50° to 180° C. The products of formula (I) are isolated by well known methods, for example, those described in U.S. Pat. No. 3,935,213.
7. Compounds of formula (I) are also obtained by employing the appropriate starting material of formula (XIV) in the process described in Belgian Pat. Nos. 861,821 and 861,822 for synthesis of prazosin. The method is outlined in Scheme II. The o-aminobenzonitrile (XIV) wherein Y 1 , Y 2 and Y 3 are as defined above is reacted with at least an equimolar amount of thiophosgene in a reaction inert organic solvent, e.g., 1,2-dichloroethane. ##STR28## To the mixture is added a base, e.g. calcium carbonate, water and the mixture stirred typically at about 0°-5° C., then warmed to about room temperature until reaction is substantially complete. The o-isothiocyanatobenzonitrile (XV) produced is isolated in crude form for use in the next step. The intermediate (XV), dissolved in a reaction inert organic solvent, typically ethyl acetate, is contacted with the amine of formula R 1 R 2 NH, where R 1 and R 2 are as defined above, at a temperature below 0° C., preferably at about -30° to -5° C. to obtain the o-thioureidobenzonitrile (XVI). This is then contacted with a methylating agent, for example methyl iodide or methyl bromide, and the resulting S-methyl hydrohalide salt treated with a mild base to obtain the S-methylthioformamidate of formula (XVII) which is cyclized by reaction with anhydrous ammonia in the presence of a polar solvent and an alkali metal amide to provide the desired compounds of formula (I). Preferred polar solvents for the cyclization are formamide or N,N-dimethylformamide. Also preferred for the final step are use of from 1 to 3 equivalents of alkali metal amide, especially sodium amide and a temperature of from about 100° to 150° C.
8. In U.S. Pat. No. 4,138,561 a novel process for preparing prazosin and trimazosin is disclosed. This method is also suitable for preparation of the compounds of the present invention as shown below. ##STR29##
The starting materials of formula (XXXIII) wherein Y 1 , Y 2 and Y 3 are as previously defined are known compounds [see, for example, Gibson et al., J. Chem. Soc., 111, 79 (1917); Munavalli et al., Bull. Soc. Chim., France, 3311 (1966); Chem. Abstr., 66, 46303s (1967); and German Offenlegungsschrift 1,959,577; Chem. Abstr., 75, 63397d (1971)]. The starting material (XXXIII) is converted to the isothiocyanate (XXXIV) as described above for intermediate (XV) and this is reacted with an amine R 1 R 2 NH wherein R 1 and R 2 are as defined above to provide the substituted thiourea (XXXV) by the method described above for intermediate (XVI). The intermediate (XXXV), in turn, is reacted with an alkylating agent, Y 4 X 4 to obtain an intermediate of formula (XXXVI) in which Y 4 is alkyl having from one to four carbon atoms or an aryl derivative containing electron withdrawing groups, for example, 2,4-dinitrophenyl, and X 4 is a member selected from the group Cl, Br, I, alkyl-SO 4 having from one to four carbon atoms, C 6 H 5 SO 2 , F 3 CSO 2 and FSO 3 . An especially preferred alkylating agent, Y 4 X 4 , is methyl iodide. Alternatively, as disclosed in U.S. Pat. No. 4,138,561, phosgene may be used in the first step in the above reaction sequence of Scheme III, wherein each of the intermediates (XXXIV) to (XXXVI) is the corresponding compound in which an atom of oxygen replaces the sulfur atom shown therein. The intermediate of formula (XXXVI) is then reacted with cyanamide to provide the corresponding carboxamidine intermediate of formula (XXXVII).
Alkylation of thiourea derivatives (XXXV) and subsequent reaction with cyanamide is normally carried out in a reaction inert organic solvent. Suitable solvents include dioxane, tetrahydrofuran, dimethyl sulfoxide, and the alkanols having from one to five carbon atoms. These reactions are preferably carried out at a temperature of from about 25° to 100° C. for a period of about 0.5 to 24 hours. The intermediate of formula (XXXVII) may also be obtained by alternate procedures described in U.S. Pat. No. 4,138,561.
The conversion of carboxamidine intermediates (XXXVII) to the desired quinazolines of formula (I) is carried out by reaction with cyclizing reagents such as phosphorus trichloride or phosphorus pentachloride in a solvent amount of phosphorus oxychloride. Other phosphorus halides and phosphorous oxyhalides such as phosphorus tribromide and phosphorus pentabromide in a solvent amount of phosphorus oxybromide may be employed. The ring closure may also be carried out by reacting the intermediate (XXXVII) with acidic reagents such as aqueous hydrogen chloride, hydrogen chloride in phosphorus oxychloride, trichloroacetic acid or Lewis acid catalysts such as ZnCl 2 , FeCl 3 , AlCl 3 , AlBr 3 , and the like.
With respect to carrying out the reaction with phosphorus halides, approximately equimolar amounts of the carboxamidine (XXXVII) and phosphorus halides are employed with a convenient amount of phosphorus oxyhalide relative to the amount of starting material (XXXVII). The term "solvent amount" as used herein refers to a quantity of phosphorus oxychloride or phosphorous oxybromide sufficient to provide good mixing and handling characteristics with respect to the reaction mixtures. For this purpose a ratio of from about 2 to 15 ml. of the phosphorus oxyhalide for each gram of carboxamidine reactant of formula (XXXVII) is generally preferred.
Commonly used temperatures for carrying out the cyclization reaction range from about 25° to 125° C. with a preferred temperature of from about 70° to 100° C. As will be appreciated by those skilled in the art, reaction times and conditions required for cyclization of intermediates (XXXVII) to form the desired products of formula (I) vary according to several factors such as temperature and reaction time. For example, at lower temperatures, longer reaction periods are needed, while at higher temperatures, the cyclization reaction is completed in a shorter time. Reaction periods of from about 0.5 to 24 hours can be used, however a period of from about 1 to 3 hours is preferred at the above mentioned preferred reaction temperatures.
The required starting materials of formula (IX) for the procedure of Scheme I, above are obtained by the reaction sequences illustrated in Schemes IV, V and VI below, for the case where R is CH 3 . ##STR30##
In the reaction schemes above and below, for the sake of convenience, the lower case letters a, b and c are used after the Roman numerals for the compounds shown to denote the following:
a. Y 1 =H, Y 2 =Y 3 =OR where R is alkyl having from one to three carbon atoms.
b. Y 1 =Cl, Y 2 =Y 3 =OR, R is as defined above.
c. Y 1 =Cl, Y 2 =OR as defined above, Y 3 =H. ##STR31##
In the reaction sequence of Scheme IV vanillin is acetylated with, for example acetic anhydride or acetyl chloride by well known methods and the acetylated intermediate nitrated to obtain 4-acetoxy-3-methoxy-2-nitrobenzaldehyde (V). The acetyl group is removed by hydrolysis, for example by treatment with an aqueous strong base such as sodium hydroxide, followed by acidification to provide the 4-hydroxy-3-methoxy-2-nitrobenzaldehyde intermediate of formula (VI). This intermediate is then alkylated with one of the well known alkylating agents commonly employed for the conversion of phenolic groups to the corresponding alkyl ethers. Examples of such alkylating agents are dimethylsulfate, diethyl sulfate, methyl bromide, n-propyl iodide and ethyl iodide. In the case illustrated in Scheme IV a methylating agent is employed to provide 3,4-dimethoxy-2-nitrobenzaldehyde, (VII). Compounds in which the two ether groups are different are obtained by use of, for example, diethyl sulfate or n-propyl iodide as the alkylating agent. When ethyl vanillin or n-propyl vanillin are employed in place of vanillin as starting material in this reaction sequence the corresponding compounds are likewise obtained wherein the corresponding alkoxy groups are 4,5-diethoxy, 4,5-dipropoxy, 4-ethoxy-5-methoxy, 4-ethoxy-5-n-propoxy, 4-n-proproxy-5-methoxy and 4-n-propoxy-5-ethoxy.
The dialkoxy intermediate of formula VII, e.g., is then oxidized to the corresponding carboxylic acid. While a wide variety of oxidizing agents and conditions are known in the art to bring about oxidation of aromatic aldehydes to the corresponding carboxylic acids, preferred oxidizing conditions are those employing potassium permanganate in aqueous acetone at the reflux temperature of the mixture. The 2-nitro-4,5-dialkoxy-benzoic acid intermediate, e.g. the compound of formula (VIII) is isolated by known means and reduced to the corresponding 2-amino acid, for example, the compound of formula (IXa, R=CH 3 ), by well known means, e.g. by catalytic hydrogenation employing a noble metal hydrogenation catalyst. A preferred catalyst is palladium.
The intermediate of formula (IXa) is useful as a starting material in the reaction sequence shown in Scheme I, above, to provide the corresponding invention compounds of formula (Ia) or (IIIa). Alternatively, as shown in Scheme IV, the intermediates (IXa) serve as a starting material for the corresponding 5-chloro intermediates of formula (IXb). The carboxylic acid is first esterified to form an alkyl ester, e.g. the methyl or ethyl ester, by well known means. The ester is then chlorinated employing, for example chlorine or sulfuryl chloride and the latter reagent is preferred for reasons of efficiency and ease of handling. Typically a slight molar excess, e.g. a 20% molar excess, of sulfuryl chloride is added to a cooled solution of the intermediate carboxylate ester of the acid (IXa) in a chlorinated hydrocarbon solvent, e.g. chloroform, methylene chloride or 1,2-dichloroethane, the resulting mixture is allowed to warm to room temperature, then heated at reflux until reaction is substantially complete, e.g. from one hour to 24 hours. The crude 5-chloro ester is then hydrolyzed, e.g. by means of sodium hydroxide as described above to provide the corresponding 5-chloro acid of formula (IXb).
The starting 5-chloro-5-alkoxyanthranilic acids of formula (IXc) are obtained as shown in Scheme V. 4-Methoxy-2-nitroaniline (XVIII) is treated with sodium nitrite in concentrated hydrochloric acid under conditions well known to those skilled in the art, to form an intermediate diazonium salt to which is then added an aqueous solution containing an equimolar amount of cuprous cyanide and a molar excess, typically a 50% excess, of potassium cyanide while warming the reaction mixture on a steam bath. The product 4-cyano-3-nitroanisole (XIX) is then isolated and then hydrolyzed, e.g. in the presence of aqueous sulfuric or hydrochloric acid to obtain the carboxylic acid of formula (XXI). This, in turn, is hydrogenated as described above for the conversion of compound (VIII) to (IXa) to provide 4-methoxy anthranilic acid (XXII) and the latter chlorinated to provide the desired compound (IXc, R=CH 3 ) employing the conditions described above for the conversion of compounds of formula (IXa) to 5-chloro compounds (IXb).
As shown in Scheme V, other synthetic routes may be employed to provide the desired starting material of formula (IXc). In one such alternate method the 4-cyano-3-nitroanisole (XIX) is hydrogenated as previously defined for conversion of compound (VIII) to compound (IXa) to provide the aminonitrile of formula (XX). This is chlorinated as described above for the conversion of compounds (IXa) to (IXb) and the resulting 5-chloro nitrile (XIVc, R=CH 3 ) is hydrolyzed as described for the preparation of compound (XXI) from nitrile (XIX), to provide the desired compound (IXc, R=CH 3 ).
Another route shown in Scheme V involves oxidation of the starting material 4-methyl-3-nitroanisole with potassium permanganate to provide the intermediate (XXI) which is converted to compound (IXc) as previously described.
As will be obvious to those skilled in the art when the methoxy group present in the starting materials of formula (XVIII) and (XXIII) employed in Scheme V is replaced by an ethoxy or n-propoxy group, the corresponding compounds of formula (IXc) are obtained wherein R is C 2 H 5 or n-C 3 H 7 , respectively.
Similarly, replacement of either one or both of the methoxy groups present in the starting material of formula (XXV) employed in Scheme VI by ethoxy or n-propoxy provides the corresponding compounds of formula (IXa) or (IXb).
The starting materials of formula (XIV) employed in the reaction sequence illustrated in Scheme II for the preparation of the compounds of the invention, are prepared as shown in Scheme V for compounds (XIVc) and in Scheme VI for compounds (XIVa) and (XIVb), and as described above.
Many of the requisite amines of formula R 1 R 2 NH wherein R 1 and R 2 are as previously defined are known compounds, see for example, the references mentioned above as prior art. Those that are new are prepared by methods which will be apparent to those skilled in the art. For example, the amines of formula ##STR32## where a is 1, 2, or 3, n is 2, or 3 and R 6 is as defined above are obtained by reacting the appropriate corresponding N-protected amine wherein R 6 is hydrogen with, for example, a compound of the formula (R 6 )'--Hal where (R 6 )' has any of the values assigned above for R 6 except hydrogen and Hal is Cl, Br, I or other known leaving groups such as SO 3 CH 3 . The reaction is typically carried out employing an equimolar amount of a metal hydride, for example sodium hydride and in the presence of a reaction inert organic solvent, e.g. dimethylformamide. The N-protecting group is then removed to provide the desired amine of the above formula. Typically, protecting groups such as acetyl or benzyl are employed. The former being removed by hydrolysis and the latter by catalytic hydrogenation, e.g., employing a palladium catalyst.
Alternatively, the above compounds wherein R 6 contains an ether moiety can be obtained by the reaction sequence below which illustrates the preparation of 4-(ethoxy-n-propoxy)piperidine. ##STR33##
Many of the requisite amines of formula ##STR34## wherein a, n and R 7 are as defined above are known compounds. Those that are not known are prepared by well known methods. For example, the R 7 -substituted piperidines may be obtained by catalytic hydrogenation of the corresponding R 7 -substituted pyridines. The cyclic amines of the above formula wherein R 7 is alkyl having from one to six carbon atoms are provided by reacting the appropriate N-protected aminoketone with an alkyl Grignard reagent, for example, as outlined below. ##STR35## The catalytic hydrogenolysis of the tertiary hydroxy group is often facilitated by prior acetylation.
The desired cyclic amines wherein R 7 is hydroxyalkyl having from two to five carbon atoms are obtained, for example by methods outlined below. ##STR36## The compounds of formula (XXXVIII) wherein R 7 is hydroxymethyl are obtained by e.g. lithium aluminum hydride reduction of the corresponding aldehydes or carboxylic acid esters.
The compounds of formula (XXXVIII) wherein R 7 is R 8 C 6 H 4 (CH 2 ) 8 wherein q is 0 or 1 and R 8 is as previously defined may also be obtained via a Grignard reaction as shown below, for example. ##STR37##
The starting materials of formula (XXXVIII) wherein R 7 is R 8 C 6 H 4 CO may be obtained, for example, by Friedel-Crafts acylation of R 8 C 6 H 5 by an N-protected carboxylic acid halide as illustrated below. ##STR38## The piperidine derivatives of the latter formula are also obtained by employing the corresponding pyridine carboxylic acid halides and compound of formula R 8 C 6 H 5 in the Friedel-Crafts acylation followed by hydrogenation of the pyridine moiety.
The cyclic aminocarboxylic acid precursors of the above N-protected cyclic aminoacid halides are either readily available or may be obtained by the well known Dieckmann reaction followed by hydrolysis and decarboxylation of the resulting alpha-keto-ester to provide a cyclic ketone intermediate which can be converted to the desired carboxylic acid by a variety of methods, e.g. ##STR39##
In the above reaction sequence a and n are as defined above and R 13 is a suitable amino protecting group, e.g. benzyl or acetyl. As will be recognized by one skilled in the art, in the above reaction sequence when R 13 is benzyl the ketone reduction step is preferably carried out by a metal hydride, e.g. sodium borohydride or lithium aluminum hydride, and removal of the benzyl group is accomplished by hydrogenolysis.
Use of a longer chain R 13 -protected iminodicarboxylate esters in the above Dieckmann reaction can be employed to provide the corresponding R 13 -protected amino ketones of the formula ##STR40## which upon Wolff-Kishner reduction and deprotection provides starting materials of formula ##STR41## where a, n and p are as defined above.
The antihypertensive activity of the compounds of the invention is shown by their ability to lower the blood pressure of conscious spontaneously hypertensive rats and conscious renally hypertensive dogs, when administered orally at doses of up to 30 mg./kg.
For instance, 2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline, a typical and preferred compound of the invention, has been found to lower blood pressure in renally hypertensive dogs to a statistically significant degree, e.g., when this compound is administered orally at doses as low as 0.2 mg./kg., it effected a decrease of 30 mm. Hg after 4 hours with no significant change in heart rate or other side effect. Similarly, at the same dosage 2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline, a particularly preferred compound of the invention, caused a reduction of 40 mm. Hg after one hour which increased only by 20 mm. Hg 6 hours after administration; and another particularly preferred compound: 2-[4-(2-furoyl)-1-piperazinyl]-4-amino-6-chloro-7-methoxyquinazoline effected a reduction in blood pressure of 40 mm. Hg which increased by only 5 mm. Hg six hours after the oral dose (0.2 mg./hg.) had been administered. Again, no significant heart rate change or other unwanted side effect was noted with the latter two compounds.
In addition to their useful antihypertensive activity, the compounds of the invention also demonstrate activity in standard tests designed to show vasodilator activity, antiglaucoma activity and utility in the treatment of congestive heart failure.
The compounds of the invention can be administered alone, but will generally be administered in admixture with a pharmaceutical carrier selected with regard to the intended route of administration and standard pharmaceutical practice. For example, they can be administered orally in the form of tablets containing such excipients as starch or lactose, or in capsules either alone or in admixture with excipients, or in the form of elixirs or suspensions containing flavoring or coloring agents. They can be injected parenterally, for example, intramuscularly, intravenously or subcutaneously. For parenteral administration, they are best used in the form of a sterile aqueous solution which can contain other solutes, for example, enough salt or glucose to make the solution isotonic. For treatment of glaucoma, they can be administered topically as well as by the above mentioned routes of administration. For topical application, a compound of the invention is admixed under sterile conditions with a pharmaceutically-acceptable liquid carrier or solvent such as water, a glycol or mixtures thereof, and toxicity adjustors, preservatives and buffers added as required. The resulting solution or dispersion is then sterilely filtered and used to fill sterile bottles.
The invention also provides a pharmaceutical composition comprising an antihypertensive effective amount of a compound of the formula (I) or pharmaceutically acceptable acid addition salts thereof together with a pharmaceutically acceptable diluent or carrier.
The compounds of the invention can be administered to humans for the treatment of hypertension or congestive heart failure by either the oral or parenteral routes, and may be administered orally at dosage levels approximately within the range 1 to 500 mg./day for an average adult patient (70 kg.), given in a single dose or up to 3 divided doses. Intravenous dosage levels would be expected to be about one-half to one-tenth of the daily oral dose. Thus for an average adult patient, individual oral doses in the tablet or capsule form will be approximately in the range from 0.5 to 250 mg. of the active compound. Variations will necessarily occur depending on the weight and condition of the subject being treated and the particular route of administration chosen as will be known to those skilled in the art.
The invention yet further provides a method of treating an animal, including a human being, having hypertension, which comprises administering to the animal an antihypertensive effective amount of a compound of the formula (I) or pharmaceutically acceptable acid addition salt thereof or pharmaceutical composition as defined above.
The following Examples illustrate the invention.
EXAMPLE 1
7,8-Dimethoxyquinazoline-2,4-dione (Xa)
Acetic acid (177.4 ml., 3.1 moles) was added to a vigorously stirred suspension of 3,4-dimethoxyanthranilic acid (436.5 g., 2.21 moles) in 10 liters of water. Then 2.24 liters of 20% potassium cyanate (5.53 moles) solution was gradually added and the mixture was stirred for one hour at 40° C. After cooling the reaction mixture to 20° C., 3.54 kg. sodium hydroxide pellets were added maintaining the temperature below 40° C. The reaction mixture was heated to 90° C. for 45 minutes and then slowly cooled in an ice bath. The sodium salt of the product was filtered, resuspended in 6 liters of water, acidified with concentrated hydrochloric acid (370 ml.), cooled and filtered to yield 404 grams (82%) of the product. Recrystallization from dimethylformamide gave colorless crystals, M.P. 314°-6° C.
Analysis, Percent Calcd. for C 10 H 10 N 2 O 4 : C, 54.05; H, 4.54; N, 12.61. Found: C, 53.96; H, 4.57; N, 12.63.
EXAMPLE 2
2,4-Dichloro-7,8-dimethoxyquinazoline (XIa)
A mixture of 7,8-dimethoxyquinazoline-2,4-dione (400 g., 1.80 moles), phosphorous pentachloride (750 g., 3.60 moles) and phosphorous oxychloride (4 liters) was refluxed under nitrogen for three hours. Phosphorus oxychloride (POCl 3 ) was removed in vacuo and residual POCl 3 was removed as an azeotrope with toluene. The solid residue was slurried in eight liters of dichloromethane and the slurry slowly added to ice-cold H 2 O. The suspension was stirred and unreacted starting material (54.0 g.) was filtered off. The organic layer was separated, dried over sodium sulfate and filtered. The solution was concentrated and then 4 liters of hexane was slowly added. Upon cooling, a pale yellow product (346 g., 80.4%) was collected by filtration and recrystallized from toluene/ether, M.P. 153°-5° C.
Analysis, Percent Calcd. for C 10 H 8 Cl 2 N 2 O 2 : C, 46.35; H, 3.11; N, 10.81. Found: C, 46.14; H, 3.33; N, 10.60.
EXAMPLE 3
2-Chloro-4-amino-7,8-dimethoxyquinazoline (XIIa)
Ammonia was passed into a solution of 2,4-dichloro-7,8-dimethoxyquinazoline (287 g., 1.11 moles) in tetrahydrofuran (6 liters) for five hours at room temperature. After stirring an additional hour the suspension was concentrated in vacuo to 2 liters and filtered. The solid was suspended in 2 liters of water, filtered, washed with water and cold methanol. Recrystallization from dimethylformamide/water yielded 164 g. (62%) of pure product, M.P. 300°. (dec.).
Analysis, Percent Calcd. for C 10 H 10 ClN 3 O 2 : C, 50.11; H, 4.21; N, 17.53. Found: C, 50.07; H, 4.24; N, 17.58.
EXAMPLE 3A
When the appropriate starting material selected from those provided in Preparation I are employed in place of 3,4-dimethoxyanthranilic acid in the procedure of Example 1 and in each case the resulting product carried thorough the procedures of Examples 2 and 3, the following compounds are provided in a like manner.
______________________________________ ##STR42## Y.sup.2 Y.sup.3______________________________________ C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.3 O C.sub.2 H.sub.5 O n-C.sub.3 H.sub.7 O CH.sub.3 O C.sub.2 H.sub.5 O CH.sub.3 O n-C.sub.3 H.sub.7 O C.sub.2 H.sub.5 O______________________________________
EXAMPLE 4
2-[4-(2-Furoyl)piperazine-1-yl]-4-amino-7,8-dimethoxyquinazoline hydrochloride
A mixture of 2-chloro-4-amino-7,8-dimethoxyquinazoline (3.00 g., 12.5 mmoles) and 1-(2-furoyl)piperazine (2.71 g., 15.0 mmoles) was refluxed in 80 ml. isoamyl alcohol for two hours and then cooled in an ice-bath. The resulting white product was collected by filtration and recrystallized from methanol/ether to yield 4.53 g. (79%) of pure final product, M.P. 251° C. The water solubility was found to be 20 mg./ml.
Analysis, Percent Calcd. for C 19 H 21 N 5 O 4 .HCl: C, 54.35; H, 5.28; N, 16.68. Found: C, 54.14; H, 5.21; N, 16.42.
EXAMPLE 5
A. 6-Chloro-7,8-dimethoxyquinazoline-2,4-dione (Xb)
Acetic acid (10.5 g., 0.175 mole) was added to a vigorously stirred suspension of 5-chloro-3,4-dimethoxyanthranilic acid (28.9 g., 0.125 mole) in 600 ml. water. Then 506 ml. 5% potassium cyanate (0.312 mole) solution was gradually added and stirred 1 hour at 40° C. After cooling the reaction mixture to 20° C., 175 g. (4.37 moles) of sodium hydroxide pellets were added while maintaining the temperature below 40° C. The reaction mixture was heated to 90° C. for 45 minutes. Upon cooling in an ice bath, the sodium salt of the product precipitated, was filtered, resuspended in 125 ml. water, acidified with concentrated hydrochloric acid, cooled and filtered to yield 25.8 g. (80%) of colorless, pure product, M.P. 272°-3° C.
Analysis, Percent Calcd. for C 10 H 9 ClN 2 O 4 : C, 46.79; H, 3.53; N, 10.92. Found: C, 46.87; H, 3.60; N, 10.90.
B. 6-Chloro-7-methoxyquinazoline-2,4-dione (XVIII)
Similarly, 6-chloro-7-methoxyquinazoline-2,4-dione was prepared from 5-chloro-4-methoxyanthranilic acid in 83% yield, M.P. 356°-8° C.
Analysis, Percent Calcd. for C 9 H 7 ClN 2 O 3 : C, 47.70; H, 3.11; N, 12.36. Found: C, 47.72; H, 3.44; N, 12.27.
EXAMPLE 6
A. 2,4,6-Trichloro-7,8-dimethoxyquinazoline (XIb)
A mixture of 6-chloro-7,8-dimethoxyquinazoline-2,4-dione (25.5 g., 0.099 mole), phosphorous pentachloride (41.4 g., 0.199 mole) and 300 ml. phosphorous oxychloride was refluxed under nitrogen for three hours. Phosphorous oxychloride was removed in vacuo and residual POCl 3 was azeotroped with toluene. The reddish-orange solid was dissolved in 200 ml. dichloromethane and the solution was slowly added to ice-cold water. After stirring for 10 minutes the organic layer was separated, washed with water, and dried over sodium sulfate. The filtrate was concentrated and 150 ml. hexane was added slowly to precipitate the product as a pale yellow solid which was recrystallized from toluene/ether to afford 18.0 g. (62% yield), M.P., 154°-5° C.
Analysis, Percent Calcd. for C 10 H 7 Cl 3 N 2 O 2 : C, 40.91; H, 2.40; N, 9.55. Found: C, 41.05; H, 2.48; N, 9.61.
B. 2,4,6-Trichloro-7-methoxyquinazoline (XIX)
Refluxing 6-chloro-7-methoxyquinazoline-2,4-dione with PCl 5 in POCl 3 as described above afforded 2,4,6-trichloro-7-methoxyquinazoline in 74% yield, M.P., 150°-2° C.
Analysis, Percent Cald. for C 9 H 5 Cl 3 N 2 O: C, 41.02; H, 1.91; N, 10.63. Found: C, 40.90; H, 2.01; N, 10.54.
EXAMPLE 7
A. 2,6-Dichloro-4-amino-7,8-dimethoxyquinazoline (XIIb)
Ammonia was passed into a solution of 2,4,6-trichloro-7,8-dimethoxyquinazoline (31.4 g., 0.107 mole) in 650 ml. dry tetrahydrofuran for one hour at room temperature. After stirring for an additional hour, the suspension was concentrated in vacuo and filtered. The solid was resuspended in water, filtered, washed with water and methanol. Recrystallization from dimethylformamide/water yielded 23.7 g. (81%) of the desired product, M.P., 360° C.
Analysis, Percent Calcd. for C 10 H 9 Cl 2 N 3 O 2 : C, 43.82; H, 3.31; N, 15.33. Found: C, 43.95; H, 3.53; N, 15.35.
B. 2,6-Dichloro-4-amino-7-methoxyquinazoline (XX)
Reaction of 2,4,6-trichloro-7-methoxyquinazoline with ammonia as described above afforded 2,6-dichloro-4-amino-7-methoxyquinazoline as a white solid, M.P., 300° C. in 58% yield.
Analysis, Percent Calcd. for C 9 H 7 Cl 2 N 3 O: C, 44.28; H, 2.89; N, 17.22. Found: C, 44.12; H, 3.16; N, 17.19.
EXAMPLE 8
A. 2-[4-(2-Furoyl)piperazine-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazolinehydrochloride (XIIIb)
A mixture of 2,6-dichloro-4-amino-7,8-dimethoxyquinazoline (1.50 g., 5.47 mmole) and 1-(2-furoyl)piperazine (1.08 g., 5.99 mmole) was refluxed in 40 ml. isoamyl alcohol for 2 hours and then cooled overnight. The resulting solid was filtered and recrystallized from methanol/ether to yield 1.83 g. (74%) of pure final product, M.P., 208°-9° C.
Analysis, Percent Calcd. for C 19 H 20 ClN 5 O 4 .HCl 1/2.H 2 O: C, 49.25; H, 4.79; N, 15.17. Found: C, 49.03; H, 4.61; N, 15.35.
Water Solubility: 8 mg./ml.
B. 2-[4-(2-Furoyl)piperazine-1-yl]-4-amino-6-chloro-7-methoxyquinazoline hydrochloride
The title compound was prepared similarly by refluxing 2,6-dichloro-4-amino-7-methoxyquinazoline and 1-(2-furoyl)piperazine in isoamyl alcohol, M.P. 229°-31° C., 79% yield.
Analysis, Percent Calcd. for C 18 H 18 ClN 5 O 3 .HCl.H 2 O: C, 48.88; H, 4.79; N, 15.83. Found: C, 49.47; H, 4.70; N, 15.62.
Water Solubility: 5 mg./ml.
EXAMPLE 9
A. 2-Methyl-2-hydroxypropyl 4-[4-amino-6-chloro-7,8-dimethoxyquinazolin-2-yl]piperazine-1-carboxylate hydrochloride
A mixture of 2,6-dichloro-4-amino-7,8-dimethoxyquinazoline (1.50 g., 5.47 mmole) and 2-methyl-2-hydroxypropyl-4-piperazine-1-carboxylate (1.22 g., 6.03 mmole) was refluxed in 30 ml. methylisobutylketone for two days. The yellowish solid was filtered, resuspended in 40 ml. acetone and stirred for 15 minutes. The filtered solid was decolorized with charcoal and recrystallized twice from ethanol/ether to yield 1.47 g. (57%) of final product, M.P., 211°-3° C.
Analysis Percent Calcd. for C 19 H 26 ClN 5 O 5 .HCl; C, 47.90%; H, 5.50%; N, 14.70%. Found: C, 47.70%; H, 5.74%; N, 14.36%.
Water Solubility: 35 mg./ml.
B. 2-ethyl-2-hydroxypropyl 4-[4-amino-6-chloro-7-methoxyquinazolin-2-yl]piperazine-1-carboxylate hydrochloride [XXI, R 1 +R 2 =--COOCH 2 C(OH) (CH 3 ) 2 ]
The title compound was prepared similarly by refluxing 2,6-dichloro-4-amino-7-methoxy quinazoline and 2-methyl-2-hydroxypropyl-4-piperazine-1-carboxylate in methyl isobutyl ketone for 4 days, M.P. 243°-5° C., 69% yield.
Analysis Percent Calcd. for C 18 H 24 ClN 5 O 4 .HCl.H 2 O C, 46.55%; H, 5.86%; N, 14.08%.
Found: C, 46.89%; H, 5.67%; N, 15.22%.
Water Solubility: 6 mg./ml.
C. 2-[4-(1,4-Benzodioxan-2-carbonyl)piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline hydrochloride
The title compound was prepared by the procedure of Part A, above, by refluxing 2,6-dichloro-4-amino-7-methoxyquinazoline and N-(1,4-benzodioxan-2-carbonyl)piperazine in methylisobutylketone, M.P. 194°-196° C.
EXAMPLE 10
When the appropriate N-substituted piperazine is employed in the procedure of Example 4 in place of 1-(2-furoyl)piperazine, the analogous products tabulated below are obtained as the hydrochloride salts except as otherwise noted.
__________________________________________________________________________Example 10 (continued) ##STR43## Elemental Analysis Solubility Empirical Calcd.:W M.P. °C. mg./ml. Formula Found: % C % H % N__________________________________________________________________________COOR.sup.5 ;COOCH.sub.3 244-5 40 C.sub.16 H.sub.21 N.sub.5 O.sub.4.HCl 50.56 5.78 18.25 49.69 5.74 18.24COOCH.sub.2 CH.sub.3 238-40 50 C.sub.17 H.sub.23 N.sub.5 O.sub.4.HCl 50.74 6.13 17.41 .0.25 H.sub.2 O 50.83 6.03 17.25COO(CH.sub.2).sub.2 CH.sub.3 229-30 140 C.sub.18 H.sub.25 N.sub.5 O.sub.4.HCl 52.48 6.36 17.00 52.28 6.37 16.82COO(CH.sub. 2).sub.3 CH.sub.3 224-6 90 C.sub.19 H.sub.27 N.sub.5 O.sub.4.HCl 53.58 6.63 16.44 53.28 6.34 16.22COO(CH.sub.2).sub.4 CH.sub.3 114-6 40 C.sub.20 H.sub.29 N.sub.5 O.sub.4.HCl 54.60 6.87 15.92 54.73 6.98 15.92COOCH.sub.2 CH(CH.sub.3).sub.2 212-3.5 40 C.sub.19 H.sub.27 N.sub.5 O.sub.4.HCl 53.58 6.63 16.44 53.82 6.70 15.79COOR.sup.5 :COO(CH.sub.2).sub.2 CH(CH.sub.3).sub.2 192 25 C.sub.20 H.sub.29 N.sub.5 O.sub.4.HCl 54.60 6.87 15.92 54.99 7.18 15.91COOCH.sub.2 C(CH.sub.3).sub.2 165-70 -- C.sub.19 H.sub.27 N.sub.5 O.sub.4.HCl 48.66 6.66 14.93OH .0.5 H.sub.2 O 48.81 6.59 14.83COR.sup.4 : ##STR44## 237-8 150 C.sub.19 H.sub.25 N.sub.5 O.sub.4.HCl .0.5 H.sub.2 52.71 53.03 6.29 5.95 16.18 16.16 ##STR45## 237-8.5 11 -- -- -- -- ##STR46## -- -- -- -- -- -- ##STR47## 251-3 -- C.sub.15 H.sub.19 N.sub.5 O.sub.3.HCl .H.sub.2 48.45 48.30 5.96 5.65 18.83 18.72 ##STR48## 192-201 50 C.sub.21 H.sub.23 N.sub.5 O.sub.3.HCl .0.5 H.sub.2 57.46 56.99 5.74 5.66 15.96 15.87 ##STR49## -- -- C.sub.19 H.sub.26 N.sub.6 O.sub.3 -- -- -- ##STR50## 150 (dec) 15 C.sub.23 H.sub.25 N.sub.5 O.sub. 5.HCl .H.sub.2 54.59 54.27 5.58 5.39 13.84 13.85 ##STR51## -- -- -- -- -- -- ##STR52## 158-61 -- C.sub.20 H.sub.27 N.sub.5 O.sub.3 (free 62.32 62.10 7.06 7.27 18.17 18.19R.sup.3 :CH.sub.2 CH.sub.2 OH 205-8 95 C.sub.16 H.sub.23 N.sub.5 O.sub.3.HCl 48.71 6.54 18.94 50.01 6.55 18.85CH.sub.2 C.sub.6 H.sub.5 194-8 100 C.sub.21 H.sub.25 N.sub.5 O.sub.2.HCl 55.80 6.69 15.49 (dec) .2 H.sub.2 O 55.38 6.49 15.33C.sub.6 H.sub.5 185-7 25 C.sub.20 H.sub.23 N.sub.5 O.sub.2.HCl 59.77 6.02 17.43 59.10 6.09 17.233-CF.sub.3 C.sub.6 H.sub.4 218-9 8 C.sub.21 H.sub.22 N.sub.5 O.sub.2 F.sub.3.HCl 53.67 4.93 14.90 53.97 4.88 15.12CH.sub.2 CHCH.sub.2 195-6 50 C.sub.17 H.sub.23 N.sub.5 O.sub.2.HCl 54.46 6.72 18.68 .0.5 H.sub.2 O 53.73 6.46 18.44__________________________________________________________________________
EXAMPLE 11
2-[4-(2-Furoyl-homopiperazine-1-yl]-4-amino-7,8-dimethoxyquinazoline hydrochloride
A. N-(2-Furoyl)homopiperazine
Homopiperazine (70 g., 0.70 mole) in 160 ml. water was treated with 6 N hydrochloric acid to adjust to pH 5.5 Furoyl chloride (79.5 g., 0.60 mole) and 25% (w/w) aqueous sodium hydroxide solution were added simultaneously to maintain a pH of 4.5-5.5. Then additional sodium hydroxide was added to bring the mixture to pH 9.5. The solution was extracted with chloroform, dried over anhydrous potassium carbonate and distilled to afford 63 g. of product, B.P. 124°-130° C. at 10 mm.
B. 4-Amino-2-chloro-7,8-dimethoxyquinazoline (1.76 g., 7.3 mole), N-(2-furoyl)homopiperazine (1.50 g., 7.7 mole) and 40 ml. of isoamyl alcohol were combined and the mixture heated at reflux under a nitrogen atmosphere for 1.5 hours. After cooling to room temperature, the mixture was stirred for one hour, filtered and the precipitated product washed with ether and recrystallized from methanol/ether to afford 2.15 g. of the title compound, M.P. 182°-183° C.
Analysis, Percent Calcd. for C 20 H 23 N 5 O 4 .HCl.0.5 H 2 O: C, 54.23; H, 5.69; N, 15.81. Found: C, 53.84; H, 5.40; N, 15.49.
The solubility in water was found to be 30 mg./ml.
EXAMPLE 12
2-[4-(2-Tetrahydrofuroyl)homopiperazin-1-yl]-4-amino-7,8-dimethoxyquinazoline hydrochloride
A. N-(2-Tetrahydrofuroyl)homopiperazine
N-(2-Furoyl)homopiperazine (33.0 g.) in 200 ml. of ethanol was hydrogenated over 5% rhodium-on-carbon catalyst at three atmospheres pressure. The catalyst was removed by filtration and the product distilled to give the desired product, B.P. 135° at 1 mm.
B. 4-Amino-2-chloro-7,8-dimethoxyquinazoline (2.10 g., 8.75 mmole), N-(2-tetrahydrofuroyl)homopiperazine [1.9 g., 9.58 mmole) and 50 ml. of isoamyl alcohol were mixed and heated at reflux under nitrogen for 2.5 hours. The solvent was removed by evaporation in vacuo, the residue dissolved in water and filtered through a mixture of activated carbon and diatomaceous earth. The filtrate was adjusted to an alkaline pH by addition of sodium bicarbonate solution, extracted four times with 50 ml. portions of ethyl acetate and the extracts dried over sodium sulfate. The solvent was evaporated and the residue chromatographed on 30 g. of silica gel, eluting with chloroform/ethanol. The fractions containing the desired product (free base) were combined and evaporated to afford the free base as a foam, 1.0 g. The free base was dissolved in ether, saturated hydrogen chloride and filtered to obtain the title compound, M.P. 130° (dec.).
Analysis, Percent Calcd. for C 20 H 27 N 5 O 4 .HCl.0.50 H 2 O: C, 53.74; H, 6.54; N, 15.67. Found: C, 53.56; H, 6.68; N, 15.44.
Water Solubility: 120 mg./ml.
EXAMPLE 13
A. 2-(4-Benzylpiperidin-1-yl)-4-amino-7,8-dimethoxyquinazoline hydrochloride
4-Amino-2-chloro-7,8-dimethoxyquinazoline (2.40 g., 10 mmole), 4-benzylpiperidine (1.93 g., 11 mmole) and 50 ml. of isoamyl alcohol were heated at reflux under a nitrogen atmosphere for two hours and cooled to room temperature. Diethyl ether (50 ml.) was added and the mixture allowed to stand in the refrigerator for two days. The precipitated solid was collected by filtration and recrystallized from ethanol/diethyl ether to afford 2.50 g. (60%) of the title compound, M.P. 216°-217° C.
Analysis, Percent Calcd. for C 22 H 26 O 2 N 4 .HCl C, 63.68; H, 6.56; N, 13.50. Found: C, 63.78; H, 6.67; N, 13.89.
Water Solubility: 6 mg./ml.
EXAMPLE 14
Employing the appropriately substituted 2-chloro-(or 2-bromo) 4-amino quinazoline and amine of formula ##STR53## in the procedure of Example 13 the following products are obtained ##STR54## where a is 1 or m and m and n are 2, or 3.
______________________________________Y.sup.1 Y.sup.2 Y.sup.3 a n R.sup.7______________________________________H CH.sub.3 O CH.sub.3 O 1 2 CH.sub.3Cl CH.sub.3 O H 1 2 CH.sub.3 (CH.sub.2).sub.5Cl CH.sub.3 O CH.sub.3 O 1 2 (CH.sub.3).sub.2 CHCH.sub.2H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 1 2 C.sub.6 H.sub.5Cl C.sub.2 H.sub.5 O H 1 2 C.sub.6 H.sub.5 CH.sub.2Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 1 2 3-CH.sub.3 C.sub.6 H.sub.4H nC.sub.3 H.sub.7 O CH.sub.3 O 1 3 (CH.sub.3).sub.2 CHCl nC.sub.3 H.sub.7 O H 1 3 CH.sub.3 (CH.sub.2).sub.4Cl nC.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O 1 3 3-FC.sub.6 H.sub.4H CH.sub.3 O H 1 3 4-CH.sub.3 OC.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O CH.sub.3 O 2 2 4-HOC.sub.6 H.sub.4Cl CH.sub.3 O CH.sub.3 O 2 2 3-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4H CH.sub.3 O CH.sub.3 O 2 2 2-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O H 2 3 CH.sub.3 CH.sub.2Cl CH.sub.3 O CH.sub.3 O 2 3 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4H C.sub.2 H.sub.5 O H 2 3 CH.sub.3 (CH.sub.2).sub.3Cl CH.sub.3 O CH.sub.3 O 2 3 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O CH.sub.3 O 2 3 4-FC.sub.6 H.sub.4H CH.sub.3 O n-C.sub.3 H.sub.7 O 3 3 CH.sub.3Cl n-C.sub.3 H.sub.7 O H 3 3 C.sub.6 H.sub.5Cl CH.sub.3 O H 3 3 C.sub.6 H.sub.5 CH.sub.2H CH.sub.3 O CH.sub.3 O 3 3 4-CH.sub.3 C.sub.6 H.sub.4Cl CH.sub.3 O CH.sub.3 O 1 3 2-ClC.sub.6 H.sub.4 COCl CH.sub.3 O H 1 3 C.sub.6 H.sub.5 COH CH.sub.3 O CH.sub.3 O 1 2 4-BrC.sub.6 H.sub.4 COCl CH.sub.3 O H 1 2 4-HOC.sub.6 H.sub.4 COCl CH.sub.3 O CH.sub.3 O 2 2 4-CF.sub.3 C.sub.6 H.sub.4 COH CH.sub.3 O CH.sub.3 O 2 3 4-FC.sub.6 H.sub.4 COCl CH.sub.3 O H 3 3 3-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4 COCl CH.sub.3 O H 1 3 C.sub.6 H.sub.5 COH CH.sub.3 O CH.sub.3 O 1 2 HOCH.sub.2Cl CH.sub.3 O CH.sub.3 O 1 2 HOCH.sub.2 CH.sub.2Cl CH.sub.3 O H 1 2 (CH.sub.3).sub.2 C(OH)CH.sub.2H CH.sub.3 O CH.sub.3 O 1 3 (CH.sub.3).sub.2 CHCH(OH)CH.sub.2Cl CH.sub.3 O CH.sub.3 O 1 3 (CH.sub.3).sub.2 C(OH)CH.sub.2 CH.sub.2Cl CH.sub.3 O H 1 3 (CH.sub.3).sub.2 C(OH)H CH.sub.3 O CH.sub.3 O 2 2 CH.sub.2 OHCl CH.sub.3 O CH.sub.3 O 2 2 CH.sub.2 CH.sub.2 OHCl CH.sub.3 O H 2 2 CH.sub.3 CH(OH)H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 3 3 CH.sub.2 OHCl CH.sub.3 O CH.sub.3 O 3 3 (CH.sub.3).sub.2 C(OH)Cl CH.sub.3 H 3 3 (CH.sub.3 CH.sub.2).sub.2 C(OH)______________________________________
EXAMPLE 15
2-[4-(2-Tetrahydrofuroyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline
To 35 ml. of isoamyl alcohol were added 1.50 g. (5.47 mmole) of 4-amino-2,6-dichloro-7,8-dimethoxyquinazoline and 1.11 g. (6.02 mmole) of 1-(2-tetrahydrofuroyl)piperazine and the mixture was heated at reflux under a nitrogen atmosphere for 1.5 hours. The mixture was cooled, 20 ml. of ethyl ether was added and the resulting mixture stirred at room temperature overnight. It was then cooled in ice and the precipitated solid collected by filtration. The crude material was recrystallized once from a mixture of isopropanol, methanol and ethyl ether. The recrystallized material was dissolved in water made strongly alkaline with sodium hydroxide solution while stirring, the precipitated brownish solid collected by filtration, dried, decolorized with activated carbon and recrystallized from isopropanol/ethyl ether to obtain 0.38 g. of yellow solid, M.P. 192°-193° C.
Analysis, Percent Calcd. for C 19 H 24 O 4 N 5 Cl: C, 54.09; H, 5.73; N, 16.60. Found: C, 53.83; H, 5.73; N, 16.58.
Mass spectrum peaks (M + /e); 421 (molecular ion), 406, 392, 378, 350, 321, 293, 280 and 266.
EXAMPLE 16
Employing the procedures of Examples 8, 9 and 10 the following compounds are similarly prepared from the appropriate starting materials.
______________________________________ ##STR55##Y.sup.1 Y.sup.2 Y.sup.3 W______________________________________H CH.sub.3 O CH.sub.3 O HCl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.3H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.2 CH(CH.sub.3).sub.2Cl iso-C.sub.3 H.sub.7 O H CH.sub.2 (CH.sub.2).sub.4 CH.sub.3H CH.sub.3 O CH.sub.3 O CH.sub.2 CHCH.sub.2Cl CH.sub.3 O CH.sub.3 O CH.sub.2 C(CH.sub.3)CH.sub.2H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.2 CHCHCH.sub.3Cl C.sub.2 H.sub.5 O H CH.sub.2 C(CH.sub.3)CHCH.sub.3H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.2 (CH.sub.2).sub.2 CHCH.sub.2Cl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.2 CH.sub.2 OHH iso-C.sub.3 H.sub.7 O CH.sub.3 O CH.sub.2 CH.sub.2 OHCl CH.sub.3 O H CH.sub.2 CH(OH)CH.sub.3H CH.sub.3 O CH.sub.3 O CH.sub.2 C(OH)(CH.sub.3).sub.2Cl CH.sub.3 O CH.sub.3 O CH(CH.sub.3)CH(CH.sub.3)CH.sub.2 OHH C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.2 C(CH.sub.3).sub.2 CH.sub.2 OHCl C.sub.2 H.sub.5 O H C(CH.sub.3).sub.2 C(OH)CH.sub.3H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O cyclopropylCl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O cyclopentylH n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O cyclohexylCl CH.sub.3 O H cyclooctylH CH.sub.3 O CH.sub.3 O 4-ClC.sub.6 H.sub.4Cl CH.sub.3 O H 2-FC.sub.6 H.sub.4H CH.sub.3 O CH.sub.3 O 4-CH.sub.3 OC.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O H 3-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2H CH.sub.3 O CH.sub.3 O 4-HOC.sub.6 H.sub.4H CH.sub.3 O CH.sub.3 O 2-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4Cl CH.sub.3 O CH.sub.3 O 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4Cl C.sub.2 H.sub.5 O H 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4 CH.sub.2Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 4-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4 CH.sub.2Cl C.sub.2 H.sub.5 O H 4-BrC.sub.6 H.sub.4 CH.sub.2Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 2-CH.sub.3 C.sub.6 H.sub.4 CH.sub.2Cl C.sub.2 H.sub.5 O H 3-FC.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O H 2-fluoro-1-naphthylH CH.sub.3 O CH.sub.3 O 4-bromo-2-naphthylH CH.sub.3 O CH.sub.3 O 4-methyl-1-naphthylH CH.sub.3 O CH.sub.3 O 3-trifluoromethyl-1-naphthylCl CH.sub.3 O CH.sub.3 O 2-hydroxy-1-naphthylH CH.sub.3 O CH.sub.3 O 4-hydroxy-1-naphthylmethylCl CH.sub.3 O H 4-methoxy-2-naphthylmethylCl CH.sub.3 O CH.sub.3 O 3-fluoro-1-napthylmethylH CH.sub.3 O CH.sub.3 O 6-methylsulfonylamino-1- napthylmethylH CH.sub.3 O CH.sub.3 O 4-methylsulfonyl-1-naphthylH CH.sub.3 O CH.sub.3 O CH.sub.2 C CHCl CH.sub.3 O CH.sub.3 O CH.sub.2 C CCH.sub.3Cl CH.sub.3 O CH.sub.3 O CH.sub.2 C CCH.sub.2 CH.sub.3H CH.sub.3 O CH.sub.3 O CH.sub.2 (CH.sub.2).sub.2 C CHCl CH.sub.3 O H CHOCl CH.sub.3 O H COCH.sub.3H iso-C.sub.3 H.sub.7 O iso-C.sub.3 H.sub.7 O COCH(CH.sub.3).sub.2H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O COCH.sub.2 (CH.sub.2).sub.4 CH.sub.3Cl CH.sub.3 O CH.sub.3 O COCH.sub.2 (CH.sub.2).sub.2 CH(CH.sub.3).sub.2Cl CH.sub.3 O H COCH.sub.2 CHCH.sub.2H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O COCH.sub.2 C(CH.sub.3)CH.sub.2Cl CH.sub.3 O CH.sub.3 O COCH.sub.2 C(CH.sub.3)CHCH.sub.3Cl CH.sub.3 O H COCH.sub.2 C CHH CH.sub.3 O CH.sub.3 O COCH.sub.2 C CCH.sub.3H CH.sub.3 O CH.sub.3 O COC CCH.sub.2 CH.sub.2 CH.sub.3Cl CH.sub.3 O CH.sub.3 O cyclopropylcarbonylH CH.sub.3 O CH.sub.3 O cyclobutylcarbonylH C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O cycloheptylcarbonylH CH.sub.3 O CH.sub.3 O cyclooctylcarbonylH CH.sub.3 O CH.sub.3 O cyclopropylmethylcarbonylCl CH.sub.3 O H cyclooctylmethylcarbonylCl CH.sub.3 O H 3-thenoylH CH.sub.3 O CH.sub.3 O 5-chloro-2-thenoylH CH.sub.3 O CH.sub.3 O 4-methyl-3-thenoylCl CH.sub.3 O CH.sub.3 O 5-phenyl-2-thenoylH CH.sub.3 O CH.sub.3 O 5-ethyl-3-furoylH CH.sub.3 O CH.sub.3 O 5-phenyl-2-furoylH CH.sub.3 O CH.sub.3 O 2-pyridylcarbonylH CH.sub.3 O CH.sub.3 O 2-chloro-4-pyridylcarbonylCl CH.sub.3 O H 2-methyl-4-pyrimidinylcarbonylH CH.sub.3 O CH.sub.3 O 2-phenyl-4-pyrimidinylcarbonylH CH.sub.3 O CH.sub.3 O ##STR56##Cl CH.sub.3 O CH.sub.3 O ##STR57##Cl CH.sub.3 O H ##STR58##H CH.sub.3 O CH.sub.3 O ##STR59##H CH.sub.3 O CH.sub.3 O ##STR60##Cl CH.sub.3 O H ##STR61##Cl CH.sub.3 O CH.sub.3 O ##STR62##Cl CH.sub.3 O CH.sub.3 O ##STR63##H CH.sub.3 O CH.sub.3 O ##STR64##H CH.sub.3 O CH.sub.3 O ##STR65##Cl CH.sub.3 O H ##STR66##Cl CH.sub.3 O H 1-hydroxy-2-naphthoylH CH.sub.3 O CH.sub.3 O 4-chloro-1-naphthylmethyl- carbonylCl CH.sub.3 O H ##STR67##Cl CH.sub.3 O CH.sub.3 O ##STR68##H CH.sub.3 O CH.sub.3 O ##STR69##H CH.sub.3 O CH.sub.3 O ##STR70##Cl CH.sub.3 O H ##STR71##H CH.sub.3 O CH.sub.3 O ##STR72##Cl CH.sub.3 O CH.sub.3 O ##STR73##Cl CH.sub.3 O H ##STR74##H CH.sub.3 O CH.sub.3 O ##STR75##Cl CH.sub.3 O H ##STR76##H CH.sub.3 O CH.sub.3 O ##STR77##Cl CH.sub.3 O H CH.sub.3 OCOH CH.sub.3 O CH.sub.3 O CH.sub.3 (CH.sub.2).sub.5 CH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O cyclohexyl OCOH CH.sub.3 O CH.sub.3 O HOCH.sub.2 CH.sub.2 OCOCl CH.sub.3 O H (CH.sub.3).sub.2 C(OH)CH.sub.2 CH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O 4-BrC.sub.6 H.sub.4 CH.sub.2 OCOH CH.sub.3 O CH.sub.3 O 1-hydroxy-2-naphthylmethyl-OCOH CH.sub.3 O CH.sub.3 O CH.sub.2CHCH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O CH.sub.2C(CH.sub.3)CH.sub.2 OCOCl CH.sub.3 O H CH.sub.3 CHC(CH.sub.3)CH.sub.2 OCOCl C.sub.2 H.sub.5 O H cyclopropyl-OCOCl n-C.sub.3 H.sub.7 O H cyclohexyl-OCOH n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O cycloheptyl-OCOCl CH.sub.3 O CH.sub.3 O cyclooctyl-OCOCl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.3 CH(OH)CH.sub.2 OCOH C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 2-CH.sub.3 C.sub.6 H.sub.4 CH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O 3-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 OCOCl CH.sub.3 O CH.sub.3 O 4-CH.sub.3 OC.sub.6 H.sub.4 CH.sub.2 OCOCl CH.sub.3 O H 4-HOC.sub.6 H.sub.4 CH.sub.2 OCOCl CH.sub. 3 O H 3-CH.sub.3 SO.sub.2 C.sub.6 H.sub.4 CH.sub.2 OCOH CH.sub.3 O CH.sub.3 O 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4 CH.sub.2 OCOH CH.sub.3 O CH.sub.3 O 4-chloro-1-naphthylmethyl-OCOCl CH.sub.3 O H 1-fluoro-2-naphthylmethyl-OCOCl CH.sub.3 O CH.sub.3 O 3-hydroxy-2-naphthylmethyl-OCOCl CH.sub.3 O CH.sub.3 O 2-methyl-1-naphthylmethyl-OCOH CH.sub.3 O CH.sub.3 O 1-methoxy-2-naphthylmethyl-OCOCl CH.sub.3 O H 4-trifluoromethyl-1-naphthyl- methyl-OCOCl CH.sub.3 O H ##STR78##Cl CH.sub.3 O CH.sub.3 O ##STR79##H CH.sub.3 O CH.sub.3 O ##STR80##Cl CH.sub.3 O CH.sub.3 O ##STR81##H CH.sub.3 O CH.sub.3 O ##STR82##Cl CH.sub.3 O CH.sub.3 O ##STR83##Cl CH.sub.3 O H ##STR84##Cl CH.sub.3 O H ##STR85##H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O ##STR86##Cl CH.sub.3 O H ##STR87##Cl C.sub.2 H.sub.5 O H ##STR88##Cl CH.sub.3 O CH.sub.3 O ##STR89##H CH.sub.3 O CH.sub.3 O ##STR90##Cl CH.sub.3 O CH.sub.3 O ##STR91##Cl CH.sub.3 O H ##STR92##H CH.sub.3 O CH.sub.3 O ##STR93##Cl CH.sub.3 O CH.sub.3 O ##STR94##Cl CH.sub.3 O H ##STR95##H CH.sub.3 O CH.sub.3 O ##STR96##______________________________________
EXAMPLE 17
A. 3-Chloro-4-methoxy-6-isothiocyanatobenzonitrile
To a solution of 27.4 g. (0.15 mole) of 6-amino-3-chloro-4-methoxybenzonitrile in 150 ml. of 1,2-dichloro-ethane at 0°-5° C. is added with stirring a mixture of 23 g. (0.2 mole) thiophosgene, 100 ml. 1,2-dichloroethane, 20 g. (0.2 mole) calcium carbonate and 200 ml. of water. After the addition the mixture is stirred for one hour at 0°-5° C., warmed to 20° C. and stirred for 6 hours at this temperature and finally at 35° C. for an hour. The reaction mixture is filtered and the organic layer separated, washed with dilute hydrochloric acid, water and dried (MgSO 4 ). The solvent is removed by evaporation and the residue used without purification in the next step.
B. 3-Chloro-4-methoxy-6-(homomorpholin-4-yl)thiocarbamidobenzonitrile
To 11.3 g. (0.05 mole) of the above residue dissolved in 65 ml. of ethyl acetate is slowly added with stirring at 0° C., a solution of 5.1 g. (0.05 mole) of homomorpholine in an equal volume of the same solvent. The resulting mixture is cooled to -25° C. and allowed to stand overnight. The precipitate is collected by filtration, washed with cold ethyl acetate and dried to obtain the desired product.
C. N-(3-Methoxy-4-chloro-6-cyanophenyl)-(homomorpholin-4-yl)-methylthioformamidate
In 200 ml. of diglyme (diethylene glycol dimethylether) is dissolved 16.3 g. (0.05 mole) of 3-chloro-4-methoxy-6-(homomorpholin-4-yl)-thiocarbamidobenzonitrile and 14.2 g. (0.1 mole) of methyl iodide and the mixture heated at reflux (60° C.) for eight hours then cooled to room temperature. The resulting mixture is filtered, the solid product washed with ether and dried to obtain the hydroiodide salt of the title compound.
The hydroiodide salt is dissolved in 150 ml. of methanol and 90 ml. of 25% ammonium hydroxide is added with stirring. The resulting mixture is stirred for two hours at 0° C., filtered and washed with ether to obtain the title compound as the free base.
D. 2-(Homomorpholin-4-yl)-4-amino-6-chloro-7-methoxyquinazoline
To a solution of 3.4 g. (0.01 mole) of the free base obtained in Part C, above, in 75 ml. of formamide is added 1.3 g. of sodium amide and the resulting solution is cooled to 0° C. and saturated with ammonia gas. The cold solution is warmed slowly over 2-3 hours to 120° C., then maintained at this temperature for 4 hours. The reaction mixture is then cooled to room temperature, 100 ml. of ice-water added, the mixture extracted with chloroform, the extracts washed with water, dried and evaporated to dryness. The crude residual product is purified by crystallization.
EXAMPLE 18
Employing one of the procedures of Examples 4, 8, 9 and 17, the following compounds are prepared from the appropriate starting materials.
______________________________________ ##STR97##Y.sup.1 Y.sup.2 Y.sup.3 R.sup.1 R.sup.2______________________________________H CH.sub.3 O CH.sub.3 O H HH CH.sub.3 O CH.sub.3 O H CH.sub.3Cl CH.sub.3 O CH.sub.3 O H (CH.sub.3).sub.2 CHCl CH.sub.3 O H H (CH.sub.3).sub.2 CHCH(CH.sub.3)Cl C.sub.2 H.sub.5 O H CH.sub.3 CH.sub.3H CH.sub.3 O CH.sub.3 O CH.sub.3 (CH.sub.2).sub.3 CH.sub.2 CH.sub.3 CH.sub.2Cl CH.sub.3 O CH.sub.3 O CH.sub.3 (CH.sub.2).sub.3 CH.sub.2 CH.sub.3 (CH.sub.2).sub.3 CH.sub.2Cl CH.sub.3 O CH.sub.3 O H cyclopropylCl CH.sub.3 O H CH.sub.3 cyclopentylH CH.sub.3 O CH.sub.3 O H cyclooctylH CH.sub.3 O CH.sub.3 O cyclopropyl cyclopropylCl CH.sub.3 O CH.sub.3 O cyclohexyl cyclohexylCl CH.sub.3 O H cyclohexyl cyclooctylCl CH.sub.3 O H CH.sub.2CHCH.sub.2 CH.sub.2CHCH.sub.2H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O CH.sub.2CH(CH.sub.2).sub.3 CH.sub.2CH(CH.sub.2).sub.3Cl CH.sub.3 O H CH.sub.2C(CH.sub.3)CH.sub.2 CH.sub.2C(CH.sub.3)CH.sub.2Cl CH.sub.3 O CH.sub.3 O CH.sub.3 CH.sub.2CHCH.sub.2Cl CH.sub.3 O CH.sub.3 O H CH.sub.2CHCH.sub.2H CH.sub.3 O CH.sub.3 O H (CH.sub.3).sub.2 CCHCH.sub.2H CH.sub.3 O CH.sub.3 O H CHCCH.sub.2Cl CH.sub.3 O CH.sub.3 O H CHC(CH.sub.2).sub.3Cl CH.sub.3 O H CH.sub.3 CH.sub.2 CH.sub.2 CHCCH.sub.2Cl CH.sub.3 O CH.sub.3 O cyclopropyl CH.sub.3 C CCH.sub.2Cl CH.sub.3 O CH.sub.3 O cyclohexyl CHCCH.sub.2H CH.sub.3 O CH.sub.3 O CH.sub.2CHCH.sub.2 CHCCH.sub.2H CH.sub.3 O CH.sub.3 O CH.sub.3 (CH.sub.2).sub.4 CH.sub.2 CH.sub.2CHCH.sub.2Cl CH.sub.3 O CH.sub.3 O cyclooctyl CH.sub.3 CHCHCH.sub.2Cl CH.sub.3 O H CH.sub.3 (CH.sub.2).sub.3 CH.sub.2 (CH.sub.3).sub.2 CCHCH.sub.2Cl CH.sub.3 O H HOCH.sub.2 CH.sub.2 HOCH.sub.2 CH.sub.2H CH.sub.3 O CH.sub.3 O H HO(CH.sub.2).sub.5Cl CH.sub.3 O CH.sub.3 O H HOCH.sub.2 CH.sub.2Cl CH.sub.3 O H HO(CH.sub.2).sub.5 HO(CH.sub.2).sub.5Cl CH.sub.3 O H CH.sub.3 HOCH.sub.2 CH.sub.2 CH.sub.2H CH.sub.3 O CH.sub.3 O (CH.sub.3).sub.2 CHCH.sub.2 CH.sub.2 HOCH.sub.2 CH.sub.2Cl CH.sub.3 O CH.sub.3 O cyclohexyl CH.sub.3 CH(OH)CH.sub.2Cl CH.sub.3 O H CH.sub.2CHCH.sub.2 (CH.sub.3).sub.2 C(OH)CH.sub.2H CH.sub.3 O CH.sub.3 O CHCCH.sub.2 HO(CH.sub.2).sub.5H CH.sub.3 O CH.sub.3 O cyclopropyl HOCH.sub.2 CH.sub.2______________________________________
EXAMPLE 19
A. 2-(3-Thiazolidinyl)-4-amino-7,8-dimethoxyquinazoline Hydrochloride
A mixture of 4.8 g. (0.02 mole) of 4-amino-2-chloro-7,8-dimethoxyquinazoline and 4.5 g. (0.05 mole) of thiazolidine in 50 ml. of chlorobenzene is heated at reflux for 18 hours, cooled to room temperature and the precipitate collected by filtration to give the title compound which was purified by recrystallization.
B. 2-(3-Thiazolidinyl)-4-amino-7,8-dimethoxyquinazoline S-oxide
The product obtained in Part A, 1.0 g., is converted to the free base by partitioning between dilute aqueous sodium hydroxide and methylene chloride. The organic extracts are dried and concentrated in vacuo to 100 ml. To the methylene chloride solution of free base at 0° C. is added dropwise over 15 minutes a solution of 0.60 g. of m-chloroperbenzoic acid in 25 ml. of the same solvent. After stirring for 2 hours at 0° C. the reaction mixture is washed with dilute sodium bicarbonate and water. The organic extracts are dried (NaSO 4 ) and evaporated to dryness in vacuo to obtain the title S-oxide which purified by recrystallization, if desired.
The title compound is also obtained by the procedure of Part A, above, when thiazolidine-S-oxide is employed as starting material in place of thiazolidine.
C. 2-(3-Thiazolidinyl)-4-amino-7,8-dimethoxyquinazoline S,S-Dioxide
A mixture of 9.6 g. (0.04 mole) of 4-amino-2-chloro-7,8-dimethoxyquinazoline and 10.0 g. of thiazolidine S,S-dioxide in 200 ml. of chlorobenzene is heated at reflux for 24 hours, cooled to room temperature and the product collected by filtration. The crude title compound is purified, if desired, by recrystallization.
D.
Employing the above procedures or those of Examples 4, 8 or 17 the following compounds are similarly obtained from the appropriate starting materials.
______________________________________ ##STR98##Y.sup.1 Y.sup.2 Y.sup.3 NR.sup.1 R.sup.2______________________________________H CH.sub.3 O CH.sub.3 O ##STR99##Cl CH.sub.3 O H ##STR100##Cl CH.sub.3 O CH.sub.3 O ##STR101##H CH.sub.3 O CH.sub.3 O ##STR102##Cl CH.sub.3 O H ##STR103##Cl CH.sub.3 O CH.sub.3 O ##STR104##H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O ##STR105##Cl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O ##STR106##Cl CH.sub.3 O H ##STR107##H CH.sub.3 O CH.sub.3 O ##STR108##Cl CH.sub.3 CH.sub.3 O ##STR109##Cl CH.sub.3 O H ##STR110##______________________________________
EXAMPLE 20
A. 2-(3-Hydroxypyrrolidin-1-yl)-4-amino-6-chloro-7,8-dimethoxyquinazoline hydrochloride
A mixture of 4-amino-2,6-dichloro-7,8-dimethoxyquinazoline (5.48 g., 0.020 mole) and 3-pyrrolidinol (2.18 g., 0.025 mole) in 150 ml. of isoamyl alcohol is heated at reflux for five hours then cooled in ice. The precipitated product is collected by filtration and purified by recrystallization to obtain the title compound.
B. 2-[4-(2-Ethoxyethoxy)piperidin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinoxazoline hydrochloride
4-Amino-2,6-dichloro-7,8-dimethoxyquinazoline (4.9 g.), 4-(2-ethoxyethoxy)piperidine (3.2 g.) and triethylamine (10 ml.) in n-butanol (400 ml.) are heated at reflux overnight under an atmosphere of nitrogen. The mixture is then cooled, evaporated in vacuo, and the residue basified (aqueous Na 2 CO 3 ) and extracted 3 times with chloroform. The combined chloroform extracts are evaporated and the residue chromatographed on neutral alumina to give the crude product which is converted to the hydrochloride salt by treatment with hydrogen chloride in ethanol to afford the title compound.
C.
By the above procedures the following compounds are similarly provided from the appropriate starting materials in each case.
__________________________________________________________________________ ##STR111##Y.sup.1 Y.sup.2 Y.sup.3 NR.sup.1 R.sup.2__________________________________________________________________________H CH.sub.3 O CH.sub.3 O ##STR112##Cl CH.sub.3 O CH.sub.3 O ##STR113##Cl CH.sub.3 O CH.sub.3 O ##STR114##H CH.sub.3 O CH.sub.3 O ##STR115##H CH.sub.3 O CH.sub.3 O ##STR116##H CH.sub.3 O CH.sub.3 O ##STR117##Cl CH.sub.3 O H ##STR118##Cl CH.sub.3 O H ##STR119##Cl CH.sub.3 O H ##STR120##Cl CH.sub.3 O H ##STR121##Cl CH.sub.3 O H ##STR122##Cl CH.sub.3 O H ##STR123##Cl CH.sub.3 O H ##STR124##H CH.sub.3 O CH.sub.3 O ##STR125##H CH.sub.3 O CH.sub.3 O ##STR126##H CH.sub.3 O CH.sub.3 O ##STR127##Cl CH.sub.3 O CH.sub.3 O ##STR128##Cl CH.sub.3 O CH.sub.3 O ##STR129##Cl CH.sub.3 O CH.sub.3 O ##STR130##Cl CH.sub.3 O H ##STR131##Cl CH.sub.3 O H ##STR132##H CH.sub.3 O CH.sub.3 O ##STR133##Cl CH.sub.3 O H ##STR134##Cl CH.sub.3 O H ##STR135##__________________________________________________________________________
EXAMPLE 21
A. 2-(Octamethyleneimin-1-yl)-4-amino-7,8-dimethoxyquinazoline hydrochloride
To 500 ml. of isoamyl alcohol is added 23.9 g. (0.10 mole) 4-amino-2-chloro-7,8-dimethoxyquinazoline and 14.0 g. (0.11 mole) octamethyleneimine and the mixture is heated at reflux for 3.5 hours. After cooling, the precipitated solid is collected, washed with ether and dried to obtain the title compound.
B. By employing the above procedure with the appropriate starting materials in each case the following compounds are similarly provided.
______________________________________ ##STR136##Y.sup.1 Y.sup.2 Y.sup.3 2p + n______________________________________H CH.sub.3 O CH.sub.3 O 4Cl CH.sub.3 O CH.sub.3 O 5H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 6Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 7H n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O 8Cl iso-C.sub.3 H.sub.7 O H 9Cl CH.sub.3 O H 4Cl CH.sub.3 O H 5Cl CH.sub.3 O CH.sub.3 O 4H CH.sub.3 O CH.sub.3 O 5______________________________________
EXAMPLE 22
2-(3-Methylpiperidin-1-yl)-4-amino-7,8-dimethoxyquinazoline
Equimolar amounts (0.10 mole) of 7,8-dimethoxy-2,4-(1H,3H)-quinazolinedione and phosphorous oxychloride are stirred at room temperature overnight and the volatiles evaporated in vacuo to afford a residue of 2-chloro-7,8-dimethoxy-4-(3H)-quinazolineone which is purified by washing with aqueous sodium bicarbonate, extraction with chloroform and evaporation of solvent. To the residue is added a solution of 0.10 mole of 3-methylpiperidine in 300 ml. of isoamyl alcohol and the mixture heated at reflux for three hours, the solvent is then evaporated in vacuo to afford 2-(3-methylpiperidin-1-yl)-7,8-dimethoxy-4(3H)-quinazolineone hydrochloride. To this is added 150 ml. of phosphorous oxychloride and the resulting mixture is heated at reflux for two hours. The liquids are evaporated to give a residue of 2-(3-methylpiperidin-1-yl)-4-chloro-7,8-dimethoxyquinazoline hydrochloride. The product is dissolved in dilute aqueous sodium bicarbonate, extracted with chloroform, dried (Na 2 SO 4 ) and the solvent evaporated.
The above product is dissolved in 350 ml. of tetrahydrofuran and a solution of anhydrous ammonia (5.3 g.) in the same solvent is added. The mixture is stirred at room temperature for 24 hours, the precipitate collected by filtration and purified by recrystallization to obtain the title compound.
EXAMPLE 23
2-(3-n-Hexylpyrrolidin-1-yl)-4-amino-6-chloro-7,8-dimethoxyquinazoline
To 12 grams of 6-chloro-7,8-dimethoxy-2,4-(1H,3H)-quinazolinedione in 200 ml. of pyridine is added 30 g. of phosphorous pentasulfide and the mixture is refluxed with continuous stirring for five hours. The solvent is evaporated in vacuo and the residue decomposed with hot water. The solid material is filtered to obtain 6-chloro-7,8-dimethoxy-2,4-(1H,3H)-quinazolinedithione.
To 0.1 mole of 6-chloro-7,8-dimethoxy-2,4-(1H,3H)-quinazolinedithione in 220 ml. 1 N potassium hydroxide solution and 100 ml. methanol, is added slowly with stirring, 0.22 mole of methyl iodide. The mixture is heated on a steam bath for 2 hours, cooled, and the resulting precipitate is filtered from the mixture. The product is 6-chloro-2,4-dimethylmercapto-7,8-dimethoxyquinazoline.
To 0.1 mole of 6-chloro-2,4-dimethylmercapto-7,8-dimethoxyquinazoline in 200 ml. of tetrahydrofuran is added a solution of 0.1 mole of anhydrous ammonia in tetrahydrofuran. The mixture is stirred at room temperature for 18 hours and the precipitate which forms is collected and recrystallized from dimethylformamide/water to yield 2-methylmercapto-4-amino-6-chloro-7,8-dimethoxyquinazoline.
A mixture of 0.1 mole of 2-methylmercapto-4-amino-6-chloro-7,8-dimethoxyquinazoline and 0.12 mole of 3-n-hexylpyrrolidine in isoamyl alcohol is heated at reflux for 16 hours, cooled, washed with water and the organic phase is concentrated in vacuo. Hexane is slowly added to the residue and the solid title compound is collected and purified, if desired by silica gel column chromatography.
EXAMPLE 24
2-[4-(2,3-Dihydro-4H-benzopyran-2-carbonyl)-piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline hydrochloride
To 0.10 mole of 2-(piperazin-1-yl)-4-amino-6-chloro-7-methoxyquinazoline in 300 ml. of methanol is added with vigorous stirring, 0.10 mole of 2,3-dihydro-4H-benzopyran-2-carboxylic acid chloride. After the addition is complete, the mixture is stirred for three hours at room temperature and the precipitated title compound is collected by filtration.
EXAMPLE 25
2-Diethylamino-4-amino-6-chloro-7-methoxyquinazoline
To 0.1 mole of 2,5-dichloro-4-methoxybenzonitrile in dimethylformamide (300 ml.) is added 0.5 mole of N,N-diethylguanidine and the mixture is heated at 150° C. for 12 hours. The solution is concentrated in vacuo to a small volume and poured into ice-water. The precipitated solid is collected by filtration and the crude product purified by silica gel column chromatography.
When 2-amino-5-chloro-4-methoxybenzontrile or 2-amidino-5-chloro-4-methoxyaniline is employed in the above reaction in place of 2,5-dichloro-4-methoxybenzonitrile the same compound is obtained.
EXAMPLE 26
2-(N-methyl-N-cyclohexylamino)-4-amino-6-chloro-7,8-dimethoxyquinazoline
A. To 5 liters of ethanol containing 0.2 mole of sodium ethoxide is added slowly with stirring 0.1 mole each of phenol and 2,4,6-trichloro-7,8-dimethoxyquinazoline. The mixture is heated to boiling then allowed to stand at room temperature overnight, poured into ice-water, stirred 15 minutes and the precipitate collected by filtration. The cake is washed with water, then cold ethanol, dried and recrystallized from ethanol/hexane to obtain 2,6-dichloro-7,8-dimethoxy-4-ethoxyquinazoline.
B. A mixture of 0.1 mole of the above product and 0.11 mole of N-methylcyclohexylamine in 350 ml. of ethanol is heated at reflux for three hours, cooled and poured into dilute aqueous sodium carbonate solution. The precipitated product is extracted with chloroform and the extracts evaporated to dryness to obtain 2-(N-methyl-N-cyclohexylamino)-4-ethoxy-7,8-dimethoxyquinazoline suitable for use in the next step.
C. To 0.1 mole of the product of Part B in 300 ml. of tetrahydrofuran, anhydrous ammonia is passed through until the mixture has absorbed 0.11 mole. The mixture is then stirred for 24 hours at room temperature, then heated at reflux for two hours and cooled in ice. The precipitated solid is collected by filtration to afford the title compound which may be purified, if desired, by recrystallization or by chromatography.
D. When 2,6-dichloro-7,8-dimethoxy-4-methyl-thioquinazoline (prepared from the corresponding 2,4,6-trichloro- compound and methylmercaptan in the presence of sodium ethoxide by the procedure of Curd et al., J. Chem. Soc., 775-783 (1947) for 2-chloro-4-methylthioquinazoline) is used in place of 2,6-dichloro-7,8-dimethoxy-4-ethoxyquinazoline in Part B, above, and the resulting product carried through the above procedures the title compound is similarly obtained.
EXAMPLE 27
2-(Morpholin-4-yl)-4-amino-7,8-dimethoxyquinazoline hydrochloride
To 500 ml. of methylethylketone is added 0.1 mole of 4-amino-2-chloro-7,8-dimethoxyquinazoline and 0.12 mole of morpholine and the mixture is refluxed overnight. After cooling in ice-water the solid precipitated is collected by filtration, washed with ether and air dried to obtain the title compound.
When the appropriate starting materials are employed in each case in the above procedure or any of the procedures of Examples 17, or 22-26, the following compounds are likewise obtained.
______________________________________ ##STR137##Y.sup.1 Y.sup.2 Y.sup.3 m n______________________________________H CH.sub.3 O CH.sub.3 O 2 3Cl C.sub.2 H.sub.5 O CH.sub.3 O 2 2Cl n-C.sub.3 H.sub.7 O H 3 3Cl CH.sub.3 O H 2 2Cl CH.sub.3 O H 2 3Cl CH.sub.3 O CH.sub.3 O 2 3H CH.sub.3 O CH.sub.3 O 3 3Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 3 3______________________________________
EXAMPLE 28
A. ##STR138##
To a stirred solution of 1.78 g. (0.01 mole) 3,4-dimethoxy-2-aminobenzonitrile in 30 ml. of N,N-dimethylformamide is added 2.88 g. (0.01 mole) ethyl 4-(2-furoyl)piperazin-1-ylformimidate hydrochloride followed by 855 mg. (0.02 mole) of a 56.1% dispersion of sodium hydride in mineral oil. The reaction mixture is stirred at ambient temperature for 30 minutes, and then it is heated to ca. 100° C. and maintained at that temperature for 12 hours. The reaction mixture is cooled to ambient temperature, diluted with an excess of water, and then extracted with chloroform. The chloroform extract is washed several times with water, dried using anhydrous magnesium sulfate, and then evaporated to dryness in vacuo. This affords crude 7,8-dimethoxy-4-amino-2-[4-(2-furoyl)piperazin-1-yl]quinazoline, which is purified further by recrystallization from aqueous ethanol.
B. The above procedure is repeated, except that the ethyl 4-(2-furoyl)piperazin-1-ylformimidate hydrochloride used therein is replaced by an equimolar amount of:
ethyl 4-allylpiperazin-1-ylformimidate methanesulfonate,
methyl 4-benzoylpiperazin-1-ylformimidate hydrochloride,
isopropyl 4-(3-furoyl)piperazin-1-ylformimidate hydrochloride,
methyl 4-(allyloxycarbonyl)piperazin-1-ylthioformimidate hydroiodide,
ethyl 4-(2-methylprop-2-enyloxycarbonyl)piperazin-1-ylthioformimidate hydrobromide and
ethyl- 4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-ylthioformimidate hydrobromide, respectively.
This affords:
7,8-dimethoxy-4-amino-2-(4-allylpiperazin-1-yl)quinazoline,
7,8-dimethoxy-4-amino-2-(4-benzoylpiperazin-1-yl)quinazoline,
7,8-dimethoxy-4-amino-2-[4-(3-furoyl)piperazin-1-yl]quinazoline,
7,8-dimethoxy-4-amino-2-[4-(allyloxycarbonyl)piperazine-1-yl]quinazoline,
7,8-dimethoxy-4-amino-2-[4-(2-methylprop-2-enyloxycarbonyl)piperazin-1-yl]quinazoline and
7,8-dimethoxy-4-amino-2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]quinazoline, respectively.
C. The procedure of Part A is repeated, except that the 3,4-dimethoxy-2-aminobenzonitrile used therein is replaced by an equimolar amount of:
5-chloro-3,4-dimethoxy-2-aminobenzonitrile,
5-chloro-3,4-diethoxy-2-aminobenzonitrile,
5-chloro-4-methoxy-2-aminobenzonitrile, or
5-chloro-4-isopropoxy-2-aminobenzonitrile,
to provide the following compounds, respectively,
______________________________________ ##STR139## Y.sup.2 Y.sup.3______________________________________ CH.sub.3 O CH.sub.3 O C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O CH.sub.3 O H (CH.sub.3).sub.2 CHO H______________________________________
EXAMPLE 29
5-Chloro-4-methoxy-2-aminobenzamidine hydrochloride prepared by the procedure of U.S. Pat. No. 3,935,213 for analogous compounds (0.01 mole) and an equimolar amount of 1-cyano-4-ethoxycarbonylpiperazine also provided in the same reference, are dissolved in 50 ml. of anhydrous ethanol and stirred overnight at ambient temperature. A 5 ml. aliquot of triethylamine is added and the mixture is heated at reflux for 12 hours. The solvent is evaporated to provide 4-amino-6-chloro-7-methoxy-2-[4-ethoxycarbonylpiperazin-1-yl]quinazoline as the hydrochloride salt.
EXAMPLE 30
A stirred solution of 24 ml. of concentrated sulfuric acid dissolved in an equal volume of water was cooled to 10°-12° C. and 0.015 mole of methallyl 4-(4-amino-6-chloro-7,8-dimethoxyquinazolin-2-yl)piperazine-1-carboxylate is added in small portions with stirring. The addition is carried out at a rate sufficient to keep the reaction temperature below 20° C. The resulting mixture is stirred for 15 minutes at 15°-20° C., then for two hours at 10°-15° C. The reaction mixture is diluted with 150 ml. of ice-water and adjusted to pH 10 with sodium hydroxide while maintaining the temperature below 12° C. After extraction with chloroform, the combined extracts are washed with water and dried over anhydrous sodium sulfate. The solvent is evaporated in vacuo and the residue recrystallized to afford 2-methyl-2-hydroxypropyl 4-(4-amino-6-chloro-7,8-dimethoxyquinazolin-2-yl)piperazine-1-carboxylate.
EXAMPLE 31
2-[4-(3-hydroxypropyl)homopiperazin-1-yl]-4-amino-7,8-dimethoxyquinazoline hydrochloride
A. 2-Chloro-4-amino-7,8-dimethoxyquinazoline, 17 g. and N-formylhomopiperazine, 18.2 g. are added to 170 ml. n-butanol and the mixture is refluxed for three hours, cooled and the precipitated solid collected by filtration. The precipitate is washed with a small amount of ethanol and air-dried. A mixture of 13 g. of this solid and 80 ml. of 9% (by weight) hydrochloric acid are heated at reflux for 60 minutes, then allowed to cool and the precipitate of 2-homopiperazino-4-amino-7,8-dimethoxyquinazoline is collected and purified, if desired, by recrystallization.
B. A mixture of 4 g. of triethylamine, 3.0 g. of 2-homopiperazino-4-amino-7,8-dimethoxyquinazoline, 4.5 g. of 3-bromo-1-propanol and 50 ml. of diethyleneglycol dimethylether is heated at 100°-120° C. with stirring for 16 hours. The reaction mixture is concentrated in vacuo and the residue made alkaline by addition of sodium hydroxide solution. The mixture is extracted with chloroform, the extracts washed with water, dried with potassium carbonate and filtered. The filtrate is concentrated, the residue taken up in isopropanol and a solution of hydrogen chloride in isopropanol added until precipitation is complete. The title compound is collected by filtration and dried.
C. When an equivalent amount of 1,3-propandiol monotosylate or 1,3-propandiol monomethylsulfonate are employed in place of 3-bromo-1-propanol in Part B, above, the results are substantially the same.
EXAMPLE 32
Employing the appropriate starting materials in each case the following compounds are prepared by the procedures of Examples 31 according to the equation ##STR140##
Where a is 1 or m; m and n are 2 or 3 and Q is a leaving group such as Br, Cl, p-toluenesulfonyloxy or methanesulfonyloxy.
______________________________________Y.sup.1 Y.sup.2 Y.sup.3 a n R.sup.3______________________________________Cl CH.sub.3 O H 1 2 CH.sub.3Cl CH.sub.3 O CH.sub.3 O 1 3 CH.sub.3 (CH.sub.2).sub.3H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O 2 2 (CH.sub.3).sub.2 CH(CH.sub.2).sub.3Cl C.sub.2 H.sub.5 O H 2 2 CH.sub.3 (CH.sub.2).sub.5Cl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O 2 2 CH.sub.2CHCH.sub.2H i-C.sub.3 H.sub.7 O i-C.sub.3 H.sub.7 O 3 2 CH.sub.3 CHCHCH.sub.2Cl CH.sub.3 O H 3 2 (CH.sub.3).sub.2 CCHCH.sub.2Cl CH.sub.3 O CH.sub.3 O 3 3 HC CCH.sub.2H CH.sub.3 O CH.sub.3 O 3 3 CH.sub.3 C CCH.sub.2Cl CH.sub.3 O CH.sub.3 O 1 2 HOCH.sub.2 CH.sub.2Cl CH.sub.3 O H 2 2 (CH.sub. 3).sub.2 C(OH)CH.sub.2H CH.sub.3 O CH.sub.3 O 1 2 (CH.sub.3).sub.2 C(OH)CH.sub.2 CH.sub.2Cl CH.sub.3 O H 2 2 cyclopropylCl CH.sub.3 O CH.sub.3 O 2 3 cyclopentylH CH.sub.3 O CH.sub.3 O 3 3 cyclohexylCl CH.sub.3 O H 2 2 cycloheptylCl CH.sub.3 O CH.sub.3 O 2 2 cyclooctylH CH.sub.3 O CH.sub.3 O 2 3 1-naphthylH CH.sub.3 O CH.sub.3 O 2 2 2-naphthylmethylH CH.sub.3 O CH.sub.3 O 2 2 4-HOC.sub.6 H.sub.5H CH.sub.3 O CH.sub.3 O 2 2 4-BrC.sub.6 H.sub.4 CH.sub.2H CH.sub.3 O CH.sub.3 O 1 2 3-CH.sub.3 C.sub.6 H.sub.4 CH.sub.2Cl CH.sub.3 O CH.sub.3 O 1 3 ##STR141##H CH.sub.3 O CH.sub.3 O 2 3 ##STR142##H CH.sub.3 O CH.sub.3 O 2 2 ##STR143##H CH.sub.3 O CH.sub.3 O 1 2 ##STR144##______________________________________
EXAMPLE 33
A. 2,3-Dimethoxyaniline obtained by the method of Gibson et al., J. Chem. Soc., 111, 79 (1917), is converted to 2,3-dimethoxy isothiocyanate according to the procedure of Dyson et al., J. Chem. Soc., 436 (1927) for analogous compounds.
A solution of 2,3-dimethoxy isothiocyanate (32.1 g., 0.164 mole) in 100 ml. of absolute ethanol is added to a stirred solution of 1-(2-furoyl)piperazine (29.6 g., 0.164 mole) prepared by the method of Desai et al., Org. Prep. Proced. Int., 8, 85 (1976) in 350 ml. of absolute ethanol and the mixture heated at reflux for 2.5 hours. The crude 4-(2-furoyl)piperazine-1-(N-2,3-dimethoxyphenyl)carbothioamide is isolated by evaporation of solvent in vacuo and purified by recrystallization.
B. To a suspension of 22.0 g. (0.0586 mole) of the product obtained in Part A, above, in 400 ml. of methanol is added methyl iodide 8.32 g. (0.0586 mole). The mixture is stirred at reflux for 2.5 hours, cooled to 20° C., 18.7 g. of cyanamide (0.445 mole) is added and the resulting mixture is heated at reflux for an additional 16 hours. The solvent is evaporated in vacuo and the residue made strongly basic with 4.0 N sodium hydroxide. The alkaline mixture is extracted with chloroform, the extracts washed first with water then with saturated brine and dried over anhydrous magnesium sulfate. The dried extract is concentrated to dryness under reduced pressure and the residue crystallized to afford 4-(2-furoyl)piperazine-1-[N-cyano-N'-(2,3-dimethoxyphenyl)]carboxamidine.
C. Following the procedure of Part A, above, but employing an equimolar amount of 2,3-dimethoxyphenyl isocyanate in place of 2,3-dimethoxyphenyl isothiocyanate, there is obtained N-(2,3-dimethoxyphenyl)-4-(2-furoyl)-1-piperazinecarboxamide. Reaction of this carboxamide with methyl fluorosulfonate and then with cyanamide according to the procedure of Part B, above, provides the same product obtained in Part B.
D. By employing other amines of formula R 1 R 2 NH, where R 1 and R 2 are as shown in Examples 18 and 19 or taken together R 1 and R 2 are ##STR145## as in Examples 10 and 16 or ##STR146## as in Example 14, in the procedures of Parts A and B or Part C, above, provides compounds of the following formula in like manner. ##STR147## Y 1 , Y 2 , Y 3 have the values shown in Examples 10, 14, 16, 18 and 19.
EXAMPLE 34
4-Amino-7,8-dimethoxy-2-[4-(2-furoyl)piperazin-1-yl]quinazoline hydrochloride
A. To 10 ml. of phosphorus oxychloride is added with stirring 0.31 g. of phosphorus pentachloride (1.48 mmoles) followed by 0.54 g. (1.48 mmoles) of 4-(2-furoyl)piperazine-1[N-cyano-N'-(2,3-dimethoxyphenyl)]carboxamidine of Example 33, Part B. The reaction mixture is heated at 95°-98° C. for 2.5 hours, cooled to 30° C. and excess phosphorus oxychloride is evaporated in vacuo and the residue is triturated with ice water. The aqueous phase is filtered and the filtrate concentrated in vacuo to provide the crude product which is purified by crystallization or column chromatography.
B. When the phosphorus pentachloride used above is replaced by an equimolar amount of hydrogen chloride gas, phosphorus pentabromide, trifluoroacetic acid, ZnCl 2 , FeCl 3 , AlCl 3 or AlBr 3 and the reaction carried out at 70°-100° C. for one to three hours the results are substantially the same as in Part A.
EXAMPLE 35
Tablets
A tablet base is prepared by blending the following ingredients in the proportion by weight indicated:
Sucrose, U.S.P.--80.3
Tapioca starch--13.2
Magnesium stearate--6.5
Into this base is blended sufficient 2-[4-(2-furoyl)-1-piperazinyl]-4-amino-6-chloro-7-methoxyquinazoline hydrochloride to provide tablets containing 0.5, 1.0, 10, 100 and 250 mg. of active ingredient.
EXAMPLE 36
Capsules
A blend is prepared containing the following ingredients:
Calcium carbonate, U.S.P.--17.6
Dicalcium phosphate--18.8
Magnesium trisilicate, U.S.P.--5.2
Lactose, U.S.P.--5.2
Potato starch--5.2
Magnesium stearate A--0.8
Magnesium stearate B--0.35
To this blend is added sufficient 2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl[piperazin-1-yl]-4-amino-6-chloro-7-methoxyquinazoline to provide formulations containing 0.5, 1.0, 5, 10, 100, 250 and 500 mg. of active ingredient, and the formulations are filled into hard gelatin capsules of a suitable size.
EXAMPLE 37
Injectable Preparation
2-[4-(2-furoyl-1-piperazinyl]-4-amino-6,7-dimethoxyquinazoline hydrochloride is intimately mixed and ground with 2500 g. of sodium ascorbate. The ground dry mixture is filled into vials, sterilized with ethylene oxide and the vials sterile stoppered. For intravenous administration sufficient water is added to the vials to form a solution containing 10 mg. of active ingredient per milliliter.
EXAMPLE 38
Solution
A solution of 2-[4-(2-hydroxy-2-methylprop-1-yloxycarbonyl)piperazin-1-yl]-4-amino-6-chloro-7,8-dimethoxyquinazoline or a pharmaceutically acceptable salt thereof is prepared with the following composition:
Effective ingredient--30.22 g.
Magnesium chloride hexahydrate--12.36 g.
Monoethanolamine--8.85 ml.
Propylene glycol--376 g.
Water--94 ml.
The solution has a concentration of 50 mg./ml. and is suitable for parenteral and especially for intramuscular administration.
PREPARATION A
4-Acetoxy-3-methoxybenzaldehyde (IV)
Triethylamine (2.8 liters, 20.1 moles) was added dropwise to a solution of vanillin (2.00 kg., 13.15 moles) and acetic anhydride (2.6 liters, 27.5 moles) in methylene chloride (11.3 liters) maintaining temperature below 25° C. After adding 4-dimethylaminopyridine (20 g.) the solution was stirred at room temperature for 30 minutes. The reaction mixture was washed twice with water, followed by 20% (w/w) hydrochloric acid and brine. The organic layer was dried over sodium sulfate and concentrated in vacuo to 8 liters. Hexane (15 liters) was added slowly while removing remaining methylene chloride. After cooling, 2.45 kg. (96% yield) product was filtered off. Recrystallization of a small sample from anhydrous ether gave the acetate as fine yellow needles, M.P. 76°-78° C.
PREPARATION B
4-Acetoxy-3-methoxy-2-nitrobenzaldehyde (V)
Over a period of 1.5 hours 4-acetoxy-3-methoxybenzaldehyde (1120 g., 5.77 moles) was added in small portions to 4 liters of red fuming nitric acid cooled to 0° C. After allowing to stir for one hour below 5° C., the reaction mixture was added to large amount of ice-water and stirred an additional hour. The resulting yellow product (1130 g., 82% yield) was filtered and washed three times with water, and was sufficiently pure for use directly in the next step. Recrystallization from ether/cyclohexane furnished the pure nitroaldehyde, M.P. 84°-86° C.
PREPARATION C
4-Hydroxy-3-methoxy-2-nitrobenzaldehyde (VI)
4-Acetoxy-3-methoxy-2-nitrobenzaldehyde (1120 g., 4.72 moles) was added portionwise to a freshly prepared 33% (w/w) NaOH solution (4.5 liters). The resulting slurry was heated on steam bath at 75° C. for 10 minutes after which it was diluted with 5 liters of water. The reaction mixture was acidified with 6.4 liters of 6 N hydrochloric acid while cooling, and the resulting product (794 g., 85% yield) was filtered and washed with water. Recrystallization from ether/cyclohexane gave the desired product as light yellow solid, M.P. 136°-137° C.
PREPARATION D
i. 3,4-Dimethoxy-2-nitrobenzaldehyde (VII)
Anhydrous sodium carbonate (957 g., 9.03 moles), toluene (5 liters), 4-hydroxy-3-methoxy-2-nitrobenzaldehyde (1424 g., 7.22 moles) and dimethyl sulfate (810 ml., 8.67 moles) were refluxed for 4 hours. Toluene was removed in vacuo and the residual solid dissolved in 5 liters of ethyl acetate and 3 liters of water. The organic layer was separated, washed with 2 liters of 1 N NaOH and 6 liters of brine, decolorized with charcoal, dried over magnesium sulfate and filtered. Hexane (7.6 liters) was added slowly. After cooling in an ice bath, 1527 g. product was obtained by filtration. The crude material was recrystallized from ethanol to yield 1187 g. (78%) of the title compound as a pale yellow solid, 60°-62° C.
ii. By employing diethyl sulfate in place of dimethyl sulfate in the above procedure, 4-ethoxy-3-methoxy-2-nitrobenzaldehyde is similarly obtained.
iii. When n-propyl bromide is employed as the alkylating agent the corresponding 4-n-propyloxy compound is provided.
PREPARATION E
3,4-Dimethoxy-2-nitro-benzoic acid (VIII)
A solution of 823 g. potassium permanganate in about 8.5 liters of H 2 O was gradually added to a refluxing solution of 3,4-dimethoxy-2-nitrobenzaldehyde (550 g., 2.60 moles) in 5.6 liters of acetone. The reaction mixture was refluxed for four more hours, then filtered through diatomaceous earth while hot and the filter cake washed with hot water. The acetone was removed in vacuo and a small amount of unreacted solid was filtered off. The aqueous solution was acidified with 2 N hydrochloric acid (1.8 liters) to yield 505 g. (85%) of the essentially pure title compound. Recrystallization from water afforded colorless crystals, M.P. 200°-202° C.
PREPARATION F
3,4-Dimethoxyanthranilic acid (IXa, R=CH 3 )
A solution of 3,4-dimethoxy-2-nitro benzoic acid (1011 g., 4.45 moles) in 14 liters of 1.3 N ammonium hydroxide was reduced at 60 psi in presence of 60 grams of palladium on barium carbonate. Hydrogen uptake ceased after four hours. The reaction mixture was filtered through diatomaceous earth and acidified with glacial acetic acid (1.2 liters) to yield 685 grams (78%) of the anthranilic acid, M.P. 183°-184° C.
PREPARATION G
4-Methoxy anthranilic acid (XXII)
i. 4-Cyano-3-nitroanisole (XIX)
A saturated solution of sodium nitrite (33.5 g., 0.485 mole) was added dropwise to a cooled solution of 4-methoxy-2-nitroaniline (68.0 g., 0.404 mole) in 300 ml. water and 94 ml. concentrated hydrochloric acid, while maintaining the temperature at 0° C. and the pH at 6 by addition of sodium carbonate.
The cold solution of diazonium salt was added carefully through a jacketed dropping funnel to a hot solution of cuprous cyanide (36.2 g., 0.404 mole) and potassium cyanide (42.1 g., 0.646 mole) in 500 ml. water, with vigorous stirring and intermittent heating on a steambath. The stirred yellow suspension was heated an additional fifteen minutes. The solid was filtered, dried and dissolved in ethyl acetate, discarding the undissolved inorganic salts. After decolorization with charcoal, concentration of the ethyl acetate solution yielded 55.1 g. (71%) of bright yellow-orange crystals, M.P. 135°-7° C.
Analysis, Percent Calcd. for C 8 H 6 N 2 O 3 : C, 53.93; H, 3.39; N, 15.73. Found: C, 53.92; H, 3.47; N, 15.85.
ii. 4-Methoxy-2-nitrobenzoic acid (XXI)
4-Cyano-3-nitroanisole (52.3 g., 0.294 mole) was slowly added to a cooled solution of 53 ml. each of acetic acid, water and sulfuric acid. The solution was refluxed for 5 hours, and then diluted with 160 ml. water. After cooling, the resulting solid was filtered and dissolved in 10% sodium hydroxide solution. After decolorization with charcoal the solution was acidified with 6 N HCl, cooled and the yellow product (51.0 g., 88% yield) was filtered. An analytical sample was recrystallized from methanol/water, M.P. 196°-7° C.
Analysis, Percent Calcd. for C 8 H 7 NO 5 : C, 48.74; H, 3.58; N, 7.11. Found: C, 48.37; H, 3.57; N, 7.03.
iii. 4-Methoxy anthranilic acid (XXII)
A solution of 4-methoxy-2-nitrobenzoic acid (19.3 g., 97.9 mmole) in 200 ml. 1 N NH 4 OH was reduced overnight in presence of 5% Pd/BaCO 3 . The reaction mixture was filtered and acidified with acetic acid to yield 15.8 g. (96%) of the anthranilic acid, M.P. 186°-188° C.
iv.
Employing 4-ethoxy-2-nitroaniline or the corresponding 4-n-propoxy- or 4-isopropoxy- compounds as starting material in the above procedures the following products are similarly obtained. ##STR148## where Y 2 is ethoxy, n-propoxy or isopropoxy.
PREPARATION H
i. Methyl-3,4-dimethoxyanthranilate
Hydrogen chloride was passed into a solution of 3,4-dimethoxyanthranilic acid (100 g., 0.51 mole) in 1.5 liters methanol for 40 minutes. The reaction mixture was refluxed for 4 days while introducing hydrogen chloride gas intermittently. The solvent was removed in vacuo, and the residual white solid was dissolved in 500 ml. water, cooled and basified to pH 10 with sodium hydroxide solution. After cooling for an additional hour, the cream color product (87.0 g., 82% yield) was filtered. Recrystallization from methanol furnished pure product, M.P. 66°-67° C.
Analysis, Percent Calcd. for C 10 H 13 NO 4 : C, 56.86; H, 6.20; N, 6.63. Found: C, 56.56; H, 6.15; N, 6.66.
ii. Methyl-4-methoxyanthranilate
Esterification of 4-methoxy anthranilic acid as described above afforded methyl-4-methoxyanthranilate, M.P. 77°-79° C., in 77% yield.
PREPARATION I
i. 5-Chloro-3,4-dimethoxyanthranilic acid (IXb, R=CH 3 )
Sulfuryl chloride (19.3 ml., 0.24 mole) was added dropwise to a cooled solution of methyl 3,4-dimethoxyanthranilate (42.2 g., 0.20 mole) in 400 ml. chloroform at 0° C. (The sulfur dioxide produced was passed through a water trap). After stirring 30 minutes at ambient temperature the solution was refluxed for 2 hours. The black solution was treated with charcoal and the solvent was evaporated. The 1 H-NMR spectrum indicated that the black, oily residue was largely the desired intermediate ester. The crude methyl ester was saponified with 400 ml. 5% (w/v) sodium hydroxide on a steam bath for one hour. After cooling, the basic suspension was acidified with acetic acid to precipitate a brown solid which was filtered and recrystallized from carbon tetrachloride to afford light-brown crystalline product (29.0 g., 63.1% yield), M.P. 140°-2° C. [Reported M.P. 142°-3° C., J. Chem. Soc., 4310-4, 1964].
Analysis, Percent Calcd. for C 9 H 10 ClNO 4 : C, 46.66; H, 4.35; N, 6.05. Found: C, 46.45; H, 4.45; N, 5.90.
ii. 5-chloro-4-methoxyanthranilic acid (IXc, R=CH 3 )
Treatment of methyl-4-methoxyanthranilate with sulfuryl chloride as described above afforded methyl-4-methoxy-5-chloroanthranilate, M.P., 197°-200° C. in 90% yield.
Saponification of methyl-4-methoxy-5-chloro anthranilate yielded 5-chloro-4-methoxyanthranilic acid in 64% yield, M.P., 210°-3° C.
Analysis, Percent Calcd for C 8 H 8 ClNO 3 : C, 47.66; H, 4.00; N, 6.95. Found: C, 48.00; H, 4.11; N, 6.94.
When methyl 4-ethoxyanthranilate or methyl 4-n-propyloxyanthranilate are carried through the above procedure 5-chloro-4-ethoxyanthranilic acid and 5-chloro-4-n-propyloxyanthranilic acid are obtained in like manner.
PREPARATION J
When ethyl vanillin (3-ethoxy-4-hydroxybenzaldehyde) or propyl vanillin, (4-hydroxy-3n-propyloxybenzaldehyde) are employed as starting material in the procedure of Preparation A in place of vanillin and the resulting products carried in turn, through the procedures of Preparation B-F and optionally chlorination by the procedures of Preparations H and I, the corresponding compounds of the following formula are similarly obtained.
______________________________________ ##STR149##Y.sup.1 Y.sup.2 Y.sup.3 Y.sup.1 Y.sup.2 Y.sup.3______________________________________H C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O Cl C.sub.2 H.sub.5 O C.sub.2 H.sub.5 OH n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 O Cl n-C.sub.3 H.sub.7 O n-C.sub.3 H.sub.7 OH CH.sub.3 O C.sub.2 H.sub.5 O Cl CH.sub.3 O C.sub.2 H.sub.5 OH n-C.sub.3 H.sub.7 O CH.sub.3 O Cl C.sub.2 H.sub.5 O CH.sub.3 OH C.sub.2 H.sub.5 O CH.sub.3 O Cl n-C.sub.3 H.sub.7 O CH.sub.3 OH n-C.sub.3 H.sub.7 O C.sub.2 H.sub.5 O Cl n-C.sub.3 H.sub.7 O C.sub.2 H.sub.5 O______________________________________
PREPARATION K
3-(m-Trifluoromethylphenyl)piperidine
i. N-Benzyl-3-hydroxy-3-(m-trifluoromethylphenyl)piperidine
Under anhydrous conditions, to a mixture of 11 g. of magnesium in 15 ml. of ethyl ether an iodine crystal is added followed by the addition of a solution of 100 g. of m-bromotrifluoromethylbenzene in 300 ml. of ether over a two hour period. The resulting mixture is stirred for two hours at ambient temperature then cooled to 5° C. A solution of 70 g. of N-benzyl-3-piperidone in 300 ml. of ether is added at this temperature over one hour. After stirring for 15 minutes at 5° C. and one hour at 20°-25° C., the reaction mixture was poured onto 800 ml. of ice-water with stirring. The mixture is filtered, the organic layer extracted with 4×100 ml. of 1 N hydrochloric acid and once with brine. The aqueous phase is made alkaline by addition of triethylamine in the cold and the resulting mixture extracted with ethyl acetate. The combined extracts are washed with brine, dried (MgSO 4 ) and evaporated to dryness. The crude product is purified by silica gel chromatography, eluting with cyclohexane/chloroform/triethylamine (85:10:5 by volume) to obtain the desired product as an orange colored solid.
ii. N-Benzyl-3-acetoxy-3-(m-trifluoromethylphenyl)piperidine hydrochloride
A mixture of 37 g. of N-benzyl-3-hydroxy-3-(m-trifluoromethylphenyl)piperidine, 220 ml. of acetic anhydride and 0.3 ml. of concentrated sulfuric acid is heated to 110° C. for one hour. After cooling it is poured onto ice-water, the resulting mixture agitated for 15 minutes and made alkaline by addition of sodium hydroxide solution. The mixture is extracted with ethyl acetate, the extracts washed with brine, dried (MgSO 4 ) and evaporated to dryness to obtain 39 g. of the free base. This is dissolved in 600 ml. of ethyl acetate, cooled in ice, and 100 ml. of ethanol saturated with hydrogen chloride is added. The solvent is removed by evaporation in vacuo and the residue triturated with 200 ml. of ethyl acetate then 200 ml. of ethyl ether is added and the mixture allowed to stand overnight. The crystalline title compounds is collected by filtration, washed with ether and dried to obtain 36 g., M.P. 206°-207° C.
iii
The product obtained in Part ii is dissolved in 700 ml. of ethanol. Palladium-on-carbon catalyst (40 g.) is added and the mixture hydrogenated at room temperature. When hydrogen uptake ceases the catalyst is removed by filtration and solvent evaporated in vacuo. The resulting solid is washed with ether and dried to obtain 21 g. of 3-(m-trifluoromethylphenyl)piperidine hydrochloride as colorless crystals, M.P. 200° C.
iv
Employing the appropriate cyclic aminoketone, selected from N-benzyl-3-pyrrolidone, N-benzyl-3-piperidine, N-benzyl-4-piperidone, N-benzyl-4-oxoazacycloheptane and N-benzyl-4-oxo-azacyclooctane, and the appropriate R 7 Hal (where Hal is Cl, Br or I) in the above procedure the following compounds are obtained in similar manner.
______________________________________ ##STR150##a n R.sup.7______________________________________1 2 CH.sub.31 2 CH.sub.3 (CH.sub.2).sub.51 2 (CH.sub.3).sub.2 CHCH.sub.21 2 C.sub.6 H.sub.51 2 C.sub.6 H.sub.4 CH.sub.21 2 4-ClC.sub.6 H.sub.4 CH.sub.21 2 3-CH.sub.3 C.sub.6 H.sub.41 3 (CH.sub.3).sub.2 CH1 3 CH.sub.3 (CH.sub.2).sub.41 3 3-FC.sub.6 H.sub.41 3 4-CH.sub.3 OC.sub.6 H.sub.4 CH.sub.22 2 4-HOC.sub.6 H.sub.42 2 3-CH.sub.3 SO.sub.2 C.sub.6 H.sub.42 2 2-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.4 CH.sub.22 3 CH.sub.3 CH.sub.22 3 4-CH.sub.3 SO.sub.2 NHC.sub.6 H.sub.42 3 CH.sub.3 (CH.sub.2).sub.32 3 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.22 3 4-FC.sub.6 H.sub.43 3 CH.sub.33 3 C.sub.6 H.sub.53 3 C.sub.6 H.sub.5 CH.sub.23 3 4-CH.sub.3 C.sub.6 H.sub.43 3 3-CH.sub.3 OC.sub.6 H.sub.4______________________________________
PREPARATION L
i. 3-Benzoylpiperidine hydrochloride
The method is that of U.S. Pat. No. 3,576,810. To 500 ml. of thionyl chloride was added 85.6 g. (0.5 mole) of 1-acetylnipecotic acid. The stirred mixture was heated at ca. 60° C. for two hours and then the solvent was evaporated at reduced pressure. The crude acid chloride was taken up in 200 ml. of dry benzene and the resulting solution added slowly to a mixture of 133 g. (1.0 mole) of aluminum chloride in 400 ml. of dry benzene. After the addition was complete the mixture was refluxed one hour and then poured onto cracked ice. The organic layer was separated and the aqueous layer was extracted with benzene. The combined extracts were dried over magnesium sulfate and the solvent was evaporated at reduced pressure. The residual oil which did not crystallize on cooling was distilled at reduced pressure and the fraction boiling at 160°-170° C./0.05 mm. collected. The crude product weighed 50 g. A mixture of 50 g. of the crude 1 -acetyl-3-benzoylpyrrolidine and 200 ml. of 6 N hydrochloric acid was refluxed 12 hours, cooled and extracted with benzene. The combined extracts were washed with water, dried over magnesium sulfate and the solvent evaporated at reduced pressure. The residual oil weighed 15.1 g. (16% yield). A portion (2.5 g.) of the free base was dissolved in 50 ml. of isopropanol and treated with ethereal hydrogen chloride. The white crystalline salt which formed weighed 2.4 g. and melted at 193°-195° C.
ii
Employing the appropriate N-acetylamino acid in place of N-acetylnipecotic acid and benzene or the appropriately substituted benzene in each case, the following compounds are obtained by the above procedure. When R 8 is OH the starting material is the corresponding acetate and the final product is obtained after hydrolysis, if desired.
______________________________________ ##STR151##a n R.sup.8 a n R.sup.8______________________________________1 2 H 2 2 4-CF.sub.31 2 4-Br 2 2 2-CH.sub.3 O1 2 4-OH 2 3 4-F1 3 H 2 3 3-CH.sub.3 SO.sub.21 3 2-Cl 3 3 4-OH1 3 4-Cl 3 3 4-F______________________________________
PREPARATION M
N-(1,4-Benzodioxan-2-carbonyl)piperazine
1,4-Benzodioxan-2-carboxylic acid, prepared by oxidation of 2-hydroxymethyl-1,4-benzodioxan with potassium permanganate in aqueous potassium hydroxide at 5°-15° C., was converted to the acid chloride by reaction with thionyl chloride in the standard manner.
A suspension of piperazine (11.88 g.) and sodium acetate (20.30 g.) in a mixture of water (70 ml.) and acetone (95 ml.) was stirred at 10°-15° C., then concentrated hydrochloric acid was added (about 35 ml.) until the pH of the solution reached 1.5. 1,4-Benzodioxan-2-carbonyl chloride (31.0 g.) and sodium hydroxide (5 N, about 45 ml.) were then added portionwise while maintaining the temperature at 10°-15° C., the sodium hydroxide maintaining the pH at 1.7-2.2. After the addition was complete, the pH was adjusted to 2.0 by the addition of sodium hydroxide, the suspension was stirred for a further 30 minutes. Water was then added until a homogeneous solution resulted, the acetone removed in vacuo, and the aqueous phase was basified to pH 8-9 with sodium hydroxide (5 N), re-extracted with chloroform (3×200 ml.) and the extracts washed with water, dried (MgSO 4 ) and evaporated in vacuo. The oily residue was dissolved in ethyl acetate, treated with ethereal hydrogen chloride, evaporated in vacuo and the solid residue triturated with ether, followed by recrystallization from methanol to give N-(1,4-benzodioxan-2-carbonyl)piperazine hydrochloride (4.85 g.), M.P. 265°-267° C.
PREPARATION N
N-Acetyl-4-allyloxypiperidine
A solution of N-acetyl-4-hydroxypiperidine (100 g.) in dimethylformamide (250 ml.) was added dropwise to sodium hydride (38 g., 50% mineral oil dispersion) under an atmosphere of nitrogen. The mixture was stirred for 2 hours then allyl bromide (93 g.) was added slowly whilst maintaining the reaction temperature at 25° C. by external cooling. The mixture was then stirred at room temperature overnight, diluted with isopropanol (20 ml.) and ether (500 ml.), filtered, and evaporated in vacuo. Distillation of the residue gave N-acetyl-4-allyloxypiperidine (108.8 g.), B.P. 128° C./2 mm., identified spectroscopically.
PREPARATION O
4-(2-Methoxy-n-propoxy)piperidine
A solution of N-acetyl-4-allyloxypiperidine (6.4 g.) in dry methanol (10 ml.) is added dropwise to a stirred suspension of mercuric acetate (11.5 g.) in methanol (50 ml.) at room temperature. After 20 minutes the mercuric acetate is dissolved and the mixture is stirred for a further 40 minutes, cooled in ice-water, and sodium hydroxide (20 ml., 5 N) is then added. A yellow precipitate formed during the addition. A solution of sodium borohydride (1.3 g.) in sodium hydroxide (20 ml., 5 N) is then added, the mixture stirred for 10 minutes, and acetic acid added to bring the pH to 6. The mixture is filtered from precipitated mercury, the ethanol evaporated in vacuo, and the resulting aqueous phase extracted with chloroform.
The organic extracts are dried (Na 2 SO 4 ), evaporated in vacuo, and the resulting crude residue taken up in methanol (50 ml.) and heated under reflux overnight with sodium hydroxide (20 ml., 5 N) and water (20 ml.). Most of the alcohol is then removed in vacuo, the aqueous layer extracted with ether, the extracts dried (Na 2 SO 4 ) and evaporated to leave a residue. The residue is treated with hydrochloric acid (20 ml., 2 N) and heated on a steam bath for 10 hours. The mixture is then washed with ether, the aqueous phase basified (Na 2 CO 3 ), extracted with ether and the organic extract dried (Na 2 SO 4 ) and evaporated to leave a residue. Distillation of the residue at reduced pressure affords the title compound.
PREPARATION P
4-(2-Hydroxy-n-propoxy)piperidine
N-Acetyl-4-allyloxypiperidine (18 g.) in tetrahydrofuran (30 ml.) was added dropwise to a stirred yellow suspension of mercuric acetate (34 g.) in a mixture of water (120 ml.) and tetrahydrofuran (120 ml.). The suspension dissolved during the addition and the resulting clear solution was stirred at room temperature for 20 minutes, then sodium hydroxide (70 ml., 5 N) was added, accompanied by ice/water cooling. The intermediate thus obtained was then reduced by the addition of sodium borohydride (2 g.) in sodium hydroxide (40 ml., 5 N), the excess hydride being destroyed after 10 minutes with glacial acetic acid. The liquid phase was then decanted off, saturated with sodium choride, the organic phase separated, and the remaining aqueous layer extracted four times with chloroform. The combined organic phases were dried (Na 2 SO 4 ), and evaporated in vacuo to leave a colorless oil (23 g.).
This oil was stirred with 5 N sodium hydroxide at room temperature for 16 hours, then at 100° C. for 2 hours. The solution was then extracted with chloroform (four times), the combined extracts dried (Na 2 SO 4 ), and evaporated in vacuo to leave a crude crystalline product (16.1 g.). This was taken up in methylene chloride, filtered, evaporated, and the residue triturated with petroleum ether (B.P. 40°/60° C.) to yield 4-(2-hydroxy-n-propoxy)piperidine (11.0 g.), M.P. 55°-57° C. The oxalate salt thereof was prepared by combining ethereal solutions of the two reactants and recrystallized from isopropanol, M.P. 104°-105° C.
PREPARATION Q
4-(3-Methoxypropoxy)piperidine
A solution of N-acetyl-4-hydroxypiperidine (30.5 g.) in dimethylformamide (200 ml.) is added dropwise to a stirred suspension of sodium hydride (11.26 g., 50% dispersion in mineral oil) in dimethylformamide (300 ml.) under an atmosphere of nitrogen. The reaction temperature is kept below 30° C. by external cooling and, after the addition is complete, stirring is continued for a further 11/4 hours. A solution of 1-bromo-3-methoxypropane (35.2 g.) in dimethylformamide (100 ml.) is then added dropwise with external cooling, and the resulting clear solution is stirred at room temperature overnight. The reaction mixture is then evaporated in vacuo, the residue partitioned between water and chloroform, the organic extracts dried (Na 2 SO 4 ) and evaporated to leave a crude residue. The above aqueous phase is saturated with sodium chloride, further extracted with chloroform, and the organic phase is dried (Na 2 SO 4 ), and evaporated to leave a further residue. This residue is combined with the original residue and heated on a steam bath overnight with hydrochloric acid (243 ml., 2 N). The reaction mixture is extracted with chloroform to remove the residual mineral oil, the aqueous phase concentrated, basified with sodium hydroxide (pH 12), then reextracted with chloroform. The organic extracts are washed with brine, dried (Na 2 SO 4 ) and evaporated to afford the desired product.
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2,4-Diaminoquinazolines of the formula ##STR1## wherein Y 1 is hydrogen or chloro, Y 2 is OR, Y 3 is hydrogen or OR such that when Y 1 is hydrogen, Y 3 is OR and when Y 1 is chloro, Y 3 is hydrogen or OR, and the pharmaceutically acceptable salts thereof; R represents an alkyl group having from one to three carbon atoms;
taken separately, R 1 and R 2 are each hydrogen, alkyl having from one to five carbon atoms, cycloalkyl having from three to eight carbon atoms, alkenyl or alkynyl each having from three to five carbon atoms or hydroxy substituted alkyl having from two to five carbon atoms, when taken together with the nitrogen atom to which they are attached R 1 and R 2 form a substituted or unsubstituted heterocyclic group optionally containing an atom of oxygen, sulfur or a second atom of nitrogen as a ring member; their use as antihypertensive agents, pharmaceutical compositions containing them and intermediates for their production.
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FIELD OF THE INVENTION
The invention relates to a coupling apparatus and, more particularly, the invention concerns a magnetically induced coupling and drive apparatus that utilizes a magnetically induced coupled wear and abrasion resistant roller assemblage useful for conveying photosensitive web of indeterminate length in chemically corrosive environments.
BACKGROUND OF THE INVENTION
In the production of media webs, particularly photosensitive film web, devices that employ mechanically coupled rotatable elements are widely used to convey the web of indeterminate length between a variety of processing stations. More particularly, such apparatus will normally guide and move the web through a processing sequence involving developer, fixer, washing, and drying bath stations which tend to expose the conveyance rotatable elements of the apparatus to corrosive materials. With mechanically coupled driven rotatable elements of the type presently used in web conveyance equipment, sensitive mechanical gears that synchronize the rotation of the rotatable elements and some sort of drive means, typically a motor, coupled to the rotatable elements for producing the desired rotation may be interrupted if exposed to harmful and deleterious materials.
Hence, it is well known that one major shortcoming of conventional mechanically coupled rotatable elements is that the excessive exposure of the mechanical elements to various corrosive materials will invariably result in degraded mechanical performance. As a consequence, the equipment, and therefore production, must be frequently interrupted for maintenance and parts replacement.
Moreover, during the processing of photosensitive web, experience indicates that the web will invariably tend to show signs of objectionable wear and abrasion as the performance of conventional mechanically coupled conveyance rotatable elements degrade during extensive and continuous exposure to corrosive materials. Hence, degraded rotatable elements and associated web conveyance elements tend to have an adverse effect on the quality of the costly photosensitive web product.
Another well recognized problem associated with conventional web conveyance equipment is that such equipment does not easily accommodate photosensitive film webs having a variety of thickness. In order to accommodate the processing of such film webs (each having a different thickness) enormous downtime and production cost sacrifices are realized so that required adjustments to a transfer nip separating the mechanically coupled rotatable elements can be made. Thus, photosensitive film web processing equipment that utilizes conventional mechanically coupled rotatable elements as a means of conveying the film web through various processing stations require costly and time consuming maintenance and adjustment.
Therefore, a need persists for a magnetically induced coupling and drive apparatus suitable for conveying photosensitive web materials in corrosive environments without the concerns that the equipment will require excessive and costly maintenance as well as will impart harmful defects to the film web. Moreover, there exists a need for such apparatus and method that easily accommodates adjustments for processing webs of different thickness.
SUMMARY OF THE INVENTION
It is, therefore, one object of the invention to provide a magnetically induced coupling and drive apparatus that is particularly suitable for conveying a media web in a corrosive environment without undergoing frequent maintenance and adjustments.
Another object of the invention is to provide a coupling and drive apparatus that employs magnetically driven and coupled rotatable elements capable of conveying a web of media in a corrosive environment.
It is another object of the invention to provide magnetically coupled rotatable elements that are wear and abrasion resistant.
It is a feature of the invention that a magnetically induced coupling and drive apparatus useful for conveying a media web incorporates a pair of conveyance rotatable elements each of which includes a corrosion resistant layer and a wear and abrasion resistant layer surrounding a magnetic core, the magnetic core providing means for magnetically coupling the pair of rotatable elements.
To solve one or more of the problems above, there is provided, in one aspect of the invention, a magnetic drive apparatus comprising magnetically coupled first and second rotatable elements. First rotatable element has a first magnetic core and a first media bearing surface at least partially surrounding the first magnetic core. The first media bearing surface comprises a mixture of a polymeric matrix and a hard, inorganic particulate material. Similarly, second rotatable element has a second magnetic core and a second media bearing surface at least partially surrounding the second magnetic core. The said second media bearing surface comprises a mixture of a polymeric matrix and a hard, inorganic particulate material.
Additionally, there is a frame for supporting the first rotatable element in a magnetic coupled relation with the second rotatable element. The first and second elements are supported in the frame and have a substantially uniform nip width therebetween for conveying a contacting web therethrough.
Moreover, means is provided for rotating one of the first and second rotatable elements. In our invention, a ferromagnetic stator member is integrally associated with one of the first and second rotatable elements. The stator member has a plurality of spatially separated pole teeth, each pole teeth having an operably connected coil arranged for producing rotation of one of the first and second rotatable elements. A source of energy is provided to energize the coils. Thus when the coils are energized, rotation of either one of the first and second rotatable elements causes rotation of the corresponding magnetic core in the rotated first or second rotatable element. Because the rollers are magnetically coupled via the respective magnetic cores, the other roller will simultaneously and synchronously rotate.
It is, therefore, an advantageous effect of the present invention that the magnetic induced coupling and drive apparatus is useful for conveying a web, such as photosensitive film web, in a corrosive environment without degradation of the conveyance elements. A further advantage of the present invention is that the conveyance elements can be easily adjusted to accommodate webs of different thicknesses. An additional advantage of the present invention is that a preselected one of the magnetically coupled elements has the dual function of being an integral part of the drive mechanism thereby reducing the number of parts and thus cost of the apparatus and associated system. A further advantage of the invention is that the media bearing surface is sufficiently compliant to accommodate media of varying thickness. Further, the conveyance apparatus of the invention offers the advantage of providing sufficient friction to enable the movement of abrasive media between independent processing stations.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other objects, features and advantages of the invention and the manner of attaining them will become more apparent and the invention itself will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a web being transported by the web transport apparatus of the invention;
FIG. 2 is a perspective view of the web transport apparatus of the present invention;
FIG. 3 is a sectional view of the transport rollers taken along line III--III of FIG. 2;
FIG. 4 is a sectional view of a motor drive mechanism taken along line IV--IV of FIG. 2;
FIG. 5 is a sectional view taken along line V--V of FIG. 2 showing a wear and abrasion resistant coating on the outer surface of a roller;
FIG. 6 is a sectional view taken along line VI--VI of FIG. 3 showing wear and abrasion resistant particles embedded in a transport roller;
FIG. 7 is a perspective view of a transport roller and end shaft member;
FIG. 8 is a perspective view of the frame; and
FIG. 9 is an exploded perspective view of the frame assembly with sleeve bearings and threaded insert.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1, 2, and 3 perspective and sectional views are shown of a web transport apparatus 40 of the invention. The web transport apparatus 40 for conveying an abrasive web 98, includes closely spaced first and second rotatable elements 132, 134. It is within the contemplation of the invention that any one of the first and second rotatable elements 132, 134 has a media bearing surface coated with an inorganic particulate in a polymeric matrix. For clarity, the media bearing surface (designated 180 in FIG. 5 or 190 in FIG. 6) is defined as the outermost surface of the rotatable element on which the web 98 rides as it is being conveyed through the transport nip or close spacing 46 between the rotatable elements 132, 134. Skilled artisans will appreciate that while both rotatable elements 132, 134 have media bearing surfaces 180, 190, the media bearing surfaces 180, 190 need not include the entire surface area of the rotatable element, but only the active portion of the outermost surface minimally required to promote continuous movement of the abrasive web 98 through the nip 46. It is further within the contemplation of the invention that a plurality of cooperating conveyance rotatable elements (not shown) may have coated media bearing surfaces of the type described herein. Alternatively, the media bearing surfaces 180, 190 may include a thin inorganic coating, as described below. Thus, a media bearing surface 180, 190 having a polymeric/inorganic particulate composite coating (or alternatively, a thin inorganic coating) was selected because it provides sufficient compliancy to accommodate abrasive media of varying thickness. Importantly, as indicated, media bearing surfaces 180, 190 also provide sufficient friction to enable continuous movement of the abrasive web 98 as it is conveyed between the nip 46 of first and second rotatable elements 132, 134. Skilled artisans will appreciate that while any one of rotatable elements 132, 134 (shown in FIG. 2) may have media bearing surfaces 180, 190 comprising polymeric/inorganic particulate coating or a thin inorganic coating, it is within the contemplation of the invention that both rotatable elements 132, 134 (shown in FIGS. 2 and 3), or a portion of any of the media bearing coated surfaces 180, 190 (shown in FIGS. 5 and 6, respectively) may comprise any one or both of our preferred wear and abrasion resistant coatings.
Referring specifically to FIG. 2, the web transport apparatus 40 broadly defined, includes a first rotatable element or roller 132 magnetically coupled to a second rotatable element or roller 134. Magnetic drive means 60 (described below) which induces the magnetic coupling of the first and second rotatable elements 132, 134 is uniquely integrally associated with one of the first and second rotatable elements 132, 134 in a manner described more fully below. In a preferred embodiment, magnetic drive means 60 is operably associated with first rotatable element 132. Alternatively, magnetic drive means 60 may be integrally associated with second rotatable element 134 with similar results. Frame members 100A, 100B support the first and second rotatable elements 132, 134 in a magnetically coupled relation, described below.
Referring again to FIG. 2, magnetic drive means 60, more particularly, is fixedly attached to a rigid support member 72. In this way, magnetic drive means 60 is held stationary against any movement relative to the second rotatable element 134. Practically any suitable means of attaching magnetic drive means 60 to support member 72 may be used, e.g., bolting. A motor driver 70 (see for instance various motor drivers described in "Permanent Magnets and Brushless DC Motors," by T. Kenjo and S. Nagamori, Oxford University Press, 1984) is operably connected to magnetic drive means 60 via a plurality of conductors 68A, 68B, 68C, and 68D. Conductors 68A, 68B, 68C, and 68 D provide electrical connection between the motor driver 70 and magnetic drive means 60. Therefore, when current is provided from the motor driver 70 it flows through conductors 68A, 68B, 68C, and 68D into ferromagnetic stator member 62 (shown in FIG. 4) of magnetic drive means 60 that drives one of the rotatable elements 132, 134.
As shown in FIG. 2, first and second rotatable elements, 132, 134 are mounted for rotational support in opposing frame members 100A and 100B. By precisely positioning rotatable elements 132, 134 in frame members 100A, 100B, a substantially uniform nip 46 (shown in FIG. 3) or spacing is formed between the mounted first and second rotatable elements 132, 134 through which a contacting web 98 can be conveyed (FIG. 1).
Turning to FIG. 3, first and second rotatable elements 132, 134 are shown in a sectional view taken along line III--III of FIG. 2. As depicted, first and second rotatable elements 132, 134 are spaced slightly apart in frame member 100A forming nip 46 between them so as to accommodate a web of predetermined thickness.
Referring to FIGS. 3 and 5, it is important to our invention that first and second rotatable elements 132, 134 are similarly constructed. In our preferred embodiment of the invention, first and second rotatable elements 132, 134 have first and second magnetic cores 136, 138, respectively. First and second magnetic cores 136, 138 are preferably made from a non rare-earth permanent magnet material such as aluminum-nickel-cobalt, barium-ferrite, copper-nickel-iron alloy, or iron-cobalt-molybdenum alloy. Most preferred of the non rare-earth materials is aluminum-nickel-cobalt.
Alternatively, first and second magnetic cores 136, 138 may also be made of a rare-earth material such as neodymium-iron-boron, samarium-cobalt, or a mixture thereof. In this instance, the most preferred material is neodymium-iron-boron manufactured by Magnaquench, Inc., of Indiana.
Referring to FIG. 3, it is also important to our invention that first and second magnetic cores 136, 138 are polarized with a plurality of radially disposed surface poles of alternating polarity around their circumferences. This arrangement of surface poles is required so that a select one of the magnetic cores 136, 138 will function as a motor rotor when the selected magnetic core 136, 138 is in operable relations with magnetic drive 60. Further, the arrangement of surface poles is required so that magnetic core 136 interacts with magnetic core 138 thereby providing a magnetic coupling between the magnetic cores 136, 138.
Referring now to FIG. 4, magnetic drive means 60 is illustrated in a sectional view taken along line IV--IV in FIG. 3. Magnetic drive means 60 comprises a ferromagnetic stator member 62 with stator pole teeth 64A, 64B, 64C, and 64D and coils 66A, 66B, 66C, and 66D. The ferromagnetic stator member 62 is fixedly attached to support member 72 (FIG. 2) which holds it stationary. The coils 66A, 66B, 66C, and 66D are wrapped around the stator pole teeth 64A, 64B, 64C, and 64D, respectively. Motor driver 70 supplies power to the coils 66A, 66B, 66C, and 66D through conductors 68A, 68B, 68C, and 68D, respectively, as shown in FIGS. 1 and 2.
As depicted in FIG. 4, first roller 132 passes through a central opening 74 in the ferromagnetic stator member 62. The first magnetic core 136 of first roller 132 functions as the motor rotor, as shown. To cause rotation of the first roller 132, motor driver 70 supplies current through the conductors 68A, 68B, 68C, and 68D to the coils 66A, 66B, 66C, and 66D, respectively, in a synchronous fashion thereby creating a magnetic field in the ferromagnetic stator member 62. This magnetic field, in turn, produces a corresponding magnetic field between the neighboring ferromagnetic stator teeth 64A, 64B, 64C, and 64D in a synchronous fashion. Interactions between these magnetic fields produces rotation of the first magnetic core 136 of first rotatable element 132 in a manner that is well known in the art. (See for example "Permanent Magnets and Brushless DC Motors," by T. Kenjo and S. Nagamori, Oxford University Press, 1984.) It should be clear to those skilled in the art that an important advantage of this integral relationship between stator member 62 and first roller 132 (shown clearly in FIG. 4) is that apparatus 40, and any associated equipment employing the apparatus 40, requires significantly fewer elements and, therefore, is considerably easier to assemble and more cost effective to manufacture.
Turning now to FIG. 5, a sectional view is shown of transport rotatable element 132 taken along line V--V of FIG. 2 (transport roller 134 is of similar construction). Transport roller 132 has an abrasive media bearing surface 180. Coating 184 is deposited on polymeric substrate 172, which is supported on the magnetic core 136. In the preferred embodiment, media bearing surface 180 comprises a composite coating. While there are a range of composite coatings within the contemplation of the invention, a composite coating containing polyurethane binder mixed with hard inorganic particulates is most preferred, as described below. Other embodiments may include polymeric binders, such as polyvinyl alcohol, polyalkylene glycols, polyacrylates, and polymethacrylates.
Referring again to FIG. 5, the relatively harder shell or coating 184 of the media bearing surface 180, applied on a polymeric substrate 172, comprises primarily inorganic particles selected from the group comprising metal oxides, metal carbides, metal nitrides, and metal borides. More particularly, such metal composites include silica, titania, zirconia, alumina, silicon carbide, silicon nitride, titanium nitride, titanium diboride, zirconium boride, and a mixture thereof.
With further reference to FIG. 5, polymeric substrate 172 is preferably made of polyurethane. Polymeric substrate 172 may also be made from other materials with similar results including synthetic rubber, polyurethane, or a mixture thereof.
Preferably, coating or shell 184, includes one or more polymeric binder materials to adhere or coalesce the inorganic particles in the coating solid form. These polymeric binders are not cross-linkable, but provide a physical bonding among the inorganic particles as well as adhesion to the polymeric substrate 172. Such binder materials include, but are not limited to, polyvinyl alcohol, polyalkylene glycols, polyacrylates, polymethacrylates, and polyurethane. The thickness of the coating or shell 184 is preferably between about 0.25 inch and about 0.001 inch, preferred being 0.01 inches. Further, the Rockwell hardness of coating 184 at 75° F. is preferably in the range between Shore hardness D40 and D75.
For best results, inorganic particle concentration of the shell or coating 184 is preferably in the range of 50 to 95% by weight, most preferably in the range of between 70 to 85% by weight.
Referring now to FIG. 6, an alternative embodiment, transport roller assemblage 132 (FIG. 3) of web transport apparatus 40 may include at least one of the first and second rotatable elements 132, 134 having a media bearing surface comprising a harder (compared to the coating described above) and semi-compliant thin coating 182 applied over a semi-compliant polymeric/inorganic particulate composite substrate 172. The relatively harder shell 182 is selected from the group comprising metal oxides, metal carbides, metal nitrides, and metal borides. More particularly, such metal composites include such materials as silica, titania, zirconia, alumina, silicon carbide, silicon nitride, titanium nitride, titanium diboride, zirconium boride, and a mixture thereof. The thin coating 182 may be applied by physical vapor deposition or thermal spray coating. Alternatively, the thin coating 182 may be accomplished by dip coating or spin coating of inorganic sol-gel particles. The sol-gel coating is performed by selecting one or more colloids of titania, zirconia, alumina, silica, or a transition metal oxide. Such colloids are obtained from hydroxytitanates, hydroxyzirconates, hydroxyaluminates, or hydroxysilicates. Stable dispersions of such materials can be purchased from various commercial sources including DuPont Company. The colloidal dispersion comprising about 5 weight % solids are used and applied onto the substrate by either spin coating or dip coating. The coating is then allowed to dry at about 100° C. for about 1 to 2 hours. Preferably, the thickness of the coating or shell 182 is between about 0.001 inch and about 0.0001 inches. Further, it is preferred that the hardness of the shell 182 be in the range of about Rockwell C30 to about Rockwell C60.
Referring again to FIG. 6, media bearing surface 190 comprises a polymeric/inorganic particulate composite substrate 182 which is formed by mixing inorganic particulate materials, preferably ceramic particles such as alumina, zirconia, silicon carbide, silicon nitride, and the like, with an organic polymeric slurry comprising rubber, silicone, or polyurethane. The mixture is then cast on the magnetic core 136. The mixture contains preferably at least about 5 weight % inorganic particles and must not exceed about 50 weight % so that the hardness of the composite (polymer+inorganic particles) roller does not exceed Shore hardness A 70, and preferably lies within about 60 and about 70.
Referring again to FIGS. 2 and 4, first and second rotatable elements, 132, 134 each have end support members 50, 52 and 54, 56, respectively, which are shrunk fit onto end portions of the first and second rotatable elements 132, 134, as described below. The shaft portions 51, 53 and 55, 57 of end support members 50, 52 and 54, 56, respectively, pass through respective sleeve bearings in frame members 100A and 100B. Thus, first and second rotatable elements 132, 134 are free to rotate about their respective longitudinal axis. When magnetic drive means 60 is energized by the motor driver 70, as described above, it causes rotation of the second roller 32 which, in turn, causes synchronized rotation of the first roller 132 due to their mutual magnetic coupling (see rotation arrows 90, 92). The end support members 50, 52 and 54, 56 are made from AISI 316 stainless steel, wherein the end shaft portions 51, 53 and 55, 57 are electroplated with Teflon™ impregnated nickel so as to reduce the coefficient of friction.
Referring to FIG. 7, a perspective view of the first roller 132 and end support member 50 is depicted. End support member 50 has a cavity 58 for receiving the tapered end 44 of the first roller 132. The end support member 50 is fixedly attached to the end of the first roller 132 by shrink fitting or alternatively by press fitting. The other end support members 52, 54, 56, which are identical to end support member 50, are fixedly attached in a similar fashion to a respective end of the first and second rotatable elements 132, 134, as shown in FIG. 2.
Depicted in FIG. 8, a perspective view of frame member 100A is illustrated. Frame member 100A comprises a bearing bracket component 110 with a through-hole 112, insert receiving hole 114 and wall 116. Further, frame member 100A has a bearing bracket component 120 with a through-hole 122 and walls 124, 126 with insert receiving holes 128, 130, respectively.
Turning now to FIG. 9, an exploded view of a partially assembled frame member 100A is depicted. As illustrated, bearing bracket component 110 abuts bearing bracket component 120 such that wall 116 of bearing bracket component 110 is between walls 124, 126 of bearing bracket component 120 with insert receiving hole 114 aligned with insert receiving holes 128, 130 forming insert receiving hole 140. Distance (d) between centerlines passing through through-hole 112 of bearing bracket component 110 and through-hole 122 of bearing bracket component 120 is determined by the width of insert 150 which is inserted into the insert hole 140. Thus, insert members of different widths can be used to vary the distance (d) between through-holes 112, 122. The insert member 150 with threaded portions 160A, 160B, 160C, 160D is fixedly attached to assembled frame member 100A. Specifically, insert member 150 is inserted into receiving hole 140 and fixedly attached to frame member 100A by screwing bolts 170A, 170B, 170C, 170D onto threaded portions 160A, 160B, 160C, 160D, respectively. Bearing sleeves 200 and 210 are shrunk fit into through-holes 112, 122, respectively.
The invention has been described with reference to a preferred embodiment; However, it will be appreciated that variations and modifications can be effected by a person of ordinary skill in the art without departing from the scope of the invention.
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A magnetically driven apparatus useful, for instance, for conveying webs, utilizes magnetically coupled first and second rotatable elements and means for rotating one of the rotatable elements which causes the simultaneous synchronous rotation of the other rotatable element. Both first and second rotatable elements include a magnetic core, and a media bearing surface comprising a mixture of a polymeric matrix and a hard, inorganic particulate material wear and abrasion resistant layer surrounding the magnetic core. The means for rotating one of the rotatable elements includes a ferromagnetic stator member integrally associated with one of said first and second rotatable elements. The ferromagnetic stator member has a plurality of spatially separated pole teeth, wherein each of the pole teeth has an operably connected coil arranged for producing rotation of one of said first and second rotatable elements once the coil is energized.
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BACKGROUND OF THE INVENTION
The present invention relates to an electromagnetic type fluid flow control valve in which a fluid to be controlled is heated by a variation of magnetic field strength.
Each of Publications of Japanese Patent 49-45249 and Japanese Patent 49-45250 discloses a prior-art fuel injector which includes an induction heating apparatus to supply a heated fuel to an internal combustion engine of automobile. In the prior-art fuel injector, an electromagnetic heater coil is mounted on a forward end of the fuel injector and a high-frequency alternating current is supplied to the electromagnetic heater coil to heat the fuel injected from the fuel injector so that a vaporization of the fuel is accelerated for an easy engine start in a cold condition, a decrease in fuel consumption and a decrease in harmful substance in exhaust gas. The prior-art fuel injector includes the electromagnetic heater coil for heating the fuel injector and the injected fuel, and the prior-art fuel injector further includes an electromagnetic solenoid coil for driving a valve needle by which a fuel flow is controlled. That is, the prior-art fuel injector includes a plurality of electromagnetic coils.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a fluid flow control valve in which a fluid to be controlled is heated by a variation of magnetic field strength through a simple structure.
According to the present invention, a fluid flow control valve comprises a fuel heating means for supplying a heat energy to a fluid, a valve means for controlling a flow rate of the fluid, an electromagnetic coil for generating a magnetic field at the fuel heating means and the valve means so that the fuel heating means is heated to supply the heat energy to the fluid and the valve means is operated to control the flow rate of the fluid, and
a power source for applying a voltage to the electromagnetic coil to generate the magnetic field by a current caused by the applied voltage, the power source supplying the current whose value fluctuates to the electromagnetic coil when the fuel heating means supplies the heat energy to the fluid.
Since the electromagnetic coil generates the magnetic field so that the fuel heating means is heated to supply the heat energy to the fluid and the valve means is operated to control the flow rate of the fluid, the power source applies the voltage to the electromagnetic coil to generate the magnetic field, and the power source supplies the current whose value fluctuates to the electromagnetic coil when the fuel heating means supplies the heat energy to the fluid, both of the supply of the heat energy to the fluid and the flow rate of the fluid can be controlled by one electromagnetic coil.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view showing an embodiment of the present invention.
FIG. 2 is a diagram showing a relation between a voltage applied to an electromagnetic coil of the present invention and a time, that is, a voltage variation relative to time.
FIG. 3 is a diagram showing another relation between a voltage applied to an electromagnetic coil of the present invention and a time, that is, another voltage variation relative to time.
FIG. 4 is a cross-sectional view showing a modification of a fuel path tube.
FIG. 5 is a cross-sectional view showing another embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 1, a fluid flow control valve according to the present invention, has a valve housing 1 made of a magnetically permeable material, a bobbin 2 made of a non-magnetically-permeable material and received by the valve housing 1, an electromagnetic coil 5 wound on the bobbin 2, and an iron core 3 which is movable in the valve housing 1 and is joined with a needle 4. A nozzle body 7 is mounted on a forward end of the valve housing 1 with a spacer 7a therebetween. The needle 4 extends through the spacer 7a and is supported by an inner circumferential surface of the nozzle body 7. A forward end of the needle 4 can close an injection opening formed at a forward end of the nozzle body 7. A combination of the needle 4 and the iron core 3 is urged toward the nozzle body 7 by a return spring 6. The electromagnetic coil 5 is electrically connected to a terminal 8 so that the electromagnetic coil 5 is electrically connected to a driver circuit 9 for the fluid flow control valve through a lead line 10. The driver circuit 9 includes an injection rate control circuit 9a and a fluctuating current supply circuit 9b. The injection rate control circuit 9a calculates a timing of fluid injection on the basis of values measured by, for example, an engine rotational speed sensor, an intake air sensor and so forth so that the current is supplied to the electromagnetic coil 5 at the calculated timing and during a time period determined according to an amount of fluid to be injected. The fluctuating current supply circuit 9b supplies a current whose value fluctuates to the electromagnetic coil 5 when the injection rate control circuit 9a does not supply the current to the electromagnetic coil 5. The terminal 8 is held on a housing 11 made of an electrically insulant material. A fluid path tube 12 is made of a magnetically permeable material, for example, iron and is fixed to the valve housing 1 in the bobbin 2. Reference numerals 14, 16, 17 and 18 indicate O-rings for sealing, and a cap 19 protects the nozzle body 7. A pressurized fluid is supplied into the fluid flow control valve through a pipe 13 and a filter 15.
When a magnetic force for moving the combination of the needle 4 and the iron core 3 by a magnetic field generated by the electromagnetic coil 5 is more than a total amount of a frictional force generated between the combination of the needle 4 and iron core 3 and surfaces contacting with the combination, a return force of the return spring 6 and so forth, the combination of the needle 4 and the iron core 3 is moved by the generated magnetic field to control the fluid flow according to a strength degree of the generated magnetic field so that the fluid flow control valve is operated. When the magnetic force is less than the total amount, the combination of the needle 4 and the iron core 3 is not moved by the generated magnetic field so that the fluid flow control valve cannot be operated to control the fluid flow according to the strength degree of the generated magnetic field.
As shown in FIG. 2, when the fluid is injected from the fluid flow control valve without heating the injected fluid, a voltage whose value substantially does not fluctuate or is substantially constant is supplied to the electromagnetic coil 5 so that the current flowing in the electromagnetic coil 5 generates the magnetic field whose value substantially does not fluctuate or is substantially constant. Therefore, the combination of the needle 4 and the iron core 3 is drawn toward the fluid path tube 12 to form a clearance between the needle 4 and the nozzle body 7 so that the pressurized fluid without being heated flows out from the clearance to the outside of the fluid flow control valve.
A response delay Td between a start of supplying voltage to the electromagnetic coil 5 and a start of drawing the needle 4 toward the fluid path tube 12 is caused by an electromagnetic response delay determined by an inductance of the electromagnetic coil 5, the return force of the return spring 6, the frictional force and an inertia of the combination of the needle 4 and the iron core 3.
When the fluid is not injected from the fluid flow control valve and the injected fluid is heated by the generated magnetic field, a voltage whose value fluctuates or is not constant and whose effective value is not sufficient for making the magnetic force for moving the combination of the needle 4 and the iron core 3 more than the total amount of the frictional force generated between the combination of the needle 4 and iron core 3 and the surfaces contacting with the combination, the return force of the return spring 6 and so forth is supplied to the electromagnetic coil 5 so that the current flowing in the electromagnetic coil 5 generates the magnetic field whose value fluctuates to heat the fluid and the combination of the needle 4 and the iron core 3 is not drawn toward the fluid path tube 12 by the generated magnetic field to prevent the fluid injection. In order for the effective value of the voltage applied to the electromagnetic coil 5 to be made insufficient for making the magnetic force for moving the combination of the needle 4 and the iron core 3 more than the total amount of the frictional force generated between the combination of the needle 4 and iron core 3 and the surfaces contacting with the combination, the return force of the return spring 6 and so forth to prevent a movement of the combination of the needle 4 and the iron core 3, it is advisable that the effective value of the voltage is kept substantially zero and/or a half of cycle of supplying alternating voltage to the electromagnetic coil 5 is less than Td and/or the absolute value of the voltage is kept small. That is, the voltage value applied to the electromagnetic coil 5 is decreased before the combination of the needle 4 and iron core 3 starts to be drawn toward the fluid path tube 12 or is kept insufficient for drawing the combination of the needle 4 and iron core 3 toward the fluid path tube 12.
When the fluctuating voltage is applied to the electromagnetic coil 5, the fluctuating current flows in the electromagnetic coil 5 so that a magnetic field whose strength fluctuates is generated in the fluid path tube 12. Since a material of the fluid path tube 12 has a large iron loss or hysteresis loss and/or a small electrical resistance for a large eddy current loss, the fluid path tube 12 is effectively heated by the fluctuating magnetic field. A heat energy generated in the fluid path tube 12 is transmitted to the fluid flowing in the fluid path tube 12 so that the heated fluid flows out from the fluid flow control valve when the needle 4 is drawn. In order to increase a strength of the generated magnetic field in the fluid path tube 12, the valve housing 1 surrounding the fluid path tube 12 to connect magnetically an end of the fluid path tube 12 to another end of thereof is made of a high-magnetic-permeability and low-hysteresis-loss material, for example, ferrite.
As shown in FIG. 3, when the fluid is injected from the fluid flow control valve and the fluid is heated by the magnetic field, a voltage whose valve fluctuates or is not constant and whose effective value is sufficient for making the generated magnetic force for moving the combination of the needle 4 and the iron core 3 more than the total amount of the frictional force generated between the combination of the needle 4 and iron core 3 and the surfaces contacting with the combination, the return force of the return spring 6 and so forth is supplied to the electromagnetic coil 5 so that the current flowing in the electromagnetic coil 5 generates the magnetic field whose value fluctuates to heat the fluid and the combination of the needle 4 and the iron core 3 is drawn toward the fluid path tube 12 by the generated magnetic field to form the fluid injection. The voltage whose value fluctuates and whose effective value is sufficient for making the generated magnetic force for moving the combination of the needle 4 and the iron core 3 more than the total amount may be composed of a fluctuating voltage component and a constant voltage component.
The fluid path tube 12 may be replaced by a fluid path tube 32 whose inner surface forming the fluid path has a plurality of curvatures as shown in FIG. 4, so that an area of the inner surface contacting with the fluid is increased and the heat energy generated in the fluid path tube 32 is effectively transmitted to the fluid.
As shown in FIG. 5, the fluid flow control valve according to the present invention may be mounted on a supplemental air path of an internal combustion engine system to control a supplemental air flow mixed with a fuel. A valve housing 101 made of a magnetically permeable material receives a bobbin 102 made of a non-magnetically-permeable material. An electromagnetic coil 105 is wound on the bobbin 102. An iron core 103 is movable in the valve housing 101 and is jointed with a needle 104. A nozzle body 107 is mounted on the valve housing 101 with a spacer 107a therebetween. The needle 104 extends through the spacer 107a and is supported on an inner circumferential surface of the needle body 107. A forward end of the needle 104 can close and open an air outlet formed at a forward end of the nozzle body 107. A combination of the needle 104 and the iron core 103 is urged toward the nozzle body 107 by a return spring 106. The electromagnetic coil 105 is electrically connected to a terminal 108 so that the electromagnetic coil 105 is controlled by an air flow control valve driver circuit 109 through a lead line 110. The driver circuit 109 includes an air flow control circuit 109a and a fluctuating current heater circuit 109b.
The air flow control circuit 109a supplies a driving current to the air flow control valve to inject the fuel when an air is needed to be supplied to accelerate atomization of the injected fuel. The fluctuating current heater circuit 109b supplies a fluctuating current to the electromagnetic coil 105 when the driving current is not supplied.
The terminal 108 is held in a housing 111 made of an electrically insulating material. An air path tube 112 is made of iron with a magnetical permeability, a high hysteresis or iron loss characteristic and a low electrical resistance. The air path tube 112 is received by the bobbin 102 to be fixed to the housing 101. Reference numerals 115, 117 and 118 indicates O-rings for sealing, and a cap 119 protects the nozzle body 107. A throttle valve 52 is mounted on a combustion engine intake manifold 51, and a fuel injector 53 is arranged at a downstream side of the throttle valve 52 in an air flow direction to inject the fuel into the intake manifold 51. The fuel in a fuel tank 54 is pressurized by a fuel pump 55 and a pressure of the fuel is kept at a predetermined degree by a fuel pressure regulator 56 to be supplied to the fuel injector 53. The fuel injector 53 is controlled by a control circuit 57 so that the fuel is injected with a predetermined timing and by an amount determined according to a condition of the internal combustion engine. The air from an air inlet 58 arranged at an upstream side of the throttle valve 52 in the air flow direction is pressurized by an air compressor 59, and subsequently a pressure thereof is adjusted at a predetermined degree by an air pressure regulator 60 so that the pressure controlled air is supplied to the air path tube 112. The air from the air flow control valve is supplied to a supplemental air inlet 61 formed in the intake manifold 51. The supplemental air inlet 61 communicates fluidally with a downstream side of a fuel injection opening of the fuel injector 53 so that a supplemental air is injected into the intake manifold 51 together with the fuel. The pressurized and injected supplemental air collides with the fuel injected from the fuel injector 53 to accelerate a generation of fine fuel mist and the atomization of the injected fuel, so that a desirable mixture of the fuel and air is supplied to the internal combustion engine for a desirable combustion condition thereof.
The fluctuating current is supplied from the fluctuating current heater circuit 109b to the air flow control valve to be heated. Therefore, water in the supplemental air is prevented from freezing in the air flow control valve and an operation stop of the air flow control valve does not occur. Alternatively, ice in the air flow control valve can be melted by heat energy generated by the fluctuating current in the air path tube 112, even if the ice is made during an engine stoppage. As described above, the present invention may be applied to a top-feed type fuel injector, alternatively, the present invention may be also applied to a bottom-feed type fuel injector. The fluctuating current may be supplied only in a predetermined time period, for example, when the engine is started in a cold circumferential condition, so that an unnecessary degree of vaporization of the fuel by an undesirable degree of temperature increase of the fuel is prevented, and a decrease of the fluctuating current by an undesirable degree of temperature increase of the electromagnetic coil is prevented.
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A fluid flow control valve comprises a fluid heating device for supplying a heat energy to a fluid, a valve device for controlling a flow rate of the fluid, an electromagnetic coil for generating a magnetic field at the fluid heating device and the valve device so that the fluid heating device is heated to supply the heat energy to the fluid and the valve device is operated to control the flow rate of the fluid, and a power source for applying a voltage to the electromagnetic coil to generate the magnetic field, the power source supplying a current whose value fluctuates to the electromagnetic coil when the fluid heating device supplies the heat energy to the fluid.
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FIELD OF THE INVENTION
This invention relates to gas spectrometers for measuring the concentration of predefined components of a gas sample, and is particularly apt for use in respiratory gas spectrometers for measuring the concentration of oxygen, CO 2 and/or one or more anesthetic agents in a respiratory gas stream sample.
BACKGROUND OF THE INVENTION
Gas spectrometers are utilized in a wide variety of industrial and medical applications to monitor the presence and concentration of one or more predefined components in a gas sample. Typically, light of a known spectral content is directed through a gas sample and the intensity of the transmitted light at a number of different center-wavelengths is detected. By utilizing known light absorption characteristics of the predefined gas components at the center-wavelengths, the detected light intensities provide a basis to determine, via statistical processing, the concentrations of the predefined components. As will be appreciated, it is important that the initial calibration conditions of the spectrometer be maintained in order to accurately relate the measured light intensities to gas component concentrations.
This is particularly true in respiratory gas spectrometers for measuring the concentration of carbon dioxide and/or oxygen, and one or more anesthetic agents such as nitrous oxide, halothane, enflurane, isoflurane, sevoflurane and desflurane in a respiratory gas stream. In such applications, a separate sample stream is typically drawn from the patient respiratory gas assembly and directed into a sample chamber that is positioned on the optical path between the light source and detector.
It is particularly important in respiratory gas spectrometry that any significant absorbers of light at the center-wavelengths of interest that are on the optical pathway between the light source and detector be accounted for in calibration, and that the related calibration conditions be maintained during use. In this regard, the optical pathway(s) utilized in many respiratory gas spectrometers lie substantially within a sealed sample gas chamber. Further, given the responsivity needs of respiratory gas spectrometers, it is also important that the transmitted light reaching the detector be of an intensity that yields an acceptable signal to noise ratio.
SUMMARY OF THE INVENTION
In view of the foregoing, a primary objective of the present invention is to provide a gas spectrometer having a high degree of maintainable accuracy, and more particularly, which is capable of maintaining its initial calibration condition to reliably achieve the desired accuracy.
A related objective is to provide a highly accurate and responsive respiratory gas spectrometer that maintains and is readily serviceable to maintain its calibration conditions.
To achieve such objectives and realize other associated advantages, the gas spectrometer of the present invention recognizes the importance of maintaining calibration conditions in portions of the optical pathway(s) between a light source and detector that are within a contained area, yet outside of the sample gas region (i.e. between the light source and the sample gas region and/or between the sample gas region and the detector). More specifically, the present invention recognizes and addresses the need to maintain calibration conditions in the noted optical pathway portions, particularly in relation to one or more gaseous component(s) that correspond with one or more of the predefined gas component(s) to be measured in the sample gas stream or that "interfere" with such predefined gas component(s) (i.e. by absorbing radiation at the centerwavelength(s) of interest for such predetermined components).
In a respiratory gas spectrometer application, the present invention includes a housing assembly defining one or more enclosed, internal containment area(s), and an infrared radiation source and optical assembly positioned within the housing assembly to provide infrared radiation on one or more optical pathways. A sample gas chamber is positioned on at least one optical pathway within the housing assembly for containing and cycling a respiratory gas sample therethrough. A detector assembly is positioned within the housing assembly to receive the unabsorbed infrared radiation transmitted through the sample gas chamber. Finally, a gas removal assembly is interconnected to and is at least partially positionable within a corresponding internal containment area of the housing assembly for contacting and removing one or more predefined and undesired gas component types. The gas removal assembly may include a holder and at least one gas component removal material(s) retained by the holder. More particularly, the holder may include one or more openings through which an undesired gas component may diffuse and be absorbed by the removal material(s). The holder is selectively retractable relative to the housing assembly to facilitate periodic servicing/replacement of the gas component removal material(s) during field use of the spectrometer, thereby enhancing maintenance of the desired calibration conditions within the corresponding internal containment area of the housing assembly. Importantly, such maintenance can be readily achieved without disassembly of the housing assembly, thereby facilitating use and avoiding calibration complications that could arise upon disassembly/reassembly.
The gas removal material(s), or absorbent, utilized in the removal assembly may be advantageously selected to remove one or more gas component type(s) that correspond or interfere with one or more of the predefined gas components to be measured in the gas sample. In this regard it has been recognized that, in respiratory gas spectrometry, even relatively low carbon dioxide concentrations in the optical pathway lying outside of the respiratory gas sample chamber can potentially compromise the desired accuracy of CO 2 measurement of the device. This is particularly true where, for example, a significant portion of the overall length of the optical pathway lies outside of the gas sample chamber (e.g., more than at least about 90%). In order to maintain carbon dioxide levels at or below an initial calibrated level, a carbon dioxide absorbent, such as a granular soda lime material, may be utilized to absorb any CO 2 that is introduced into the corresponding internal containment area during use. In this regard, it is believed that adhesives, lubricants and other materials utilized in gas spectrometers may become sources of CO 2 during use.
It has also been recognized that, in certain situations, water vapor may accumulate in the optical path outside of the sample gas chamber, and that such water vapor may adversely impact the accuracy of the device, e.g., due to condensation on optical components within the gas spectrometer and resultant degradation of the signal to noise ratio at the detector assembly. To remove such undesired water vapor from the ambient atmosphere in the spectrometer, the present invention may also employ a water vapor desiccant, such as a ceramic-based molecular sieve or, silica gel. Further, the gas removal material may include an absorbent such as charcoal chips to remove other potential contaminants from within the corresponding internal containment area. As indicated, the gas removal assembly is selectively retractable, and may be removable from the respiratory gas spectrometer housing in order to facilitate servicing. In one embodiment, the holder of the gas removal assembly includes a hollow, elongated body and an enlarged head. A portion of the body may be threaded for selective engagement/disengagement with a correspondingly threaded access opening in the housing assembly. An o-ring (e.g., of butyl rubber construction) or other appropriate sealing member may be interposed between the enlarged head and outer surface of the housing assembly. To facilitate periodic maintenance, an indicator may be included in the gas removal assembly or in a user interface (e.g. an electronic display or alarm) for alerting a user to replace the gas removal material on a predetermined basis. For example, a window may be disposed in the enlarged head of the holder to permit visual, external observation of granular soda lime material contained therein, such material changing from a white color to purple color upon becoming saturated by CO 2 . Where water vapor sensing is desired an RH-sensitive paper test strip may be similarly disposed in the holder for external, visual inspection by a user. When a user interface is utilized as an indicator, servicing alert may entail periodic comparison (e.g., utilizing an on-board processor) between a detected/stored radiation intensity value(s) (e.g., at one or more predetermined center-wavelengths) established during calibration, and a subsequently detected radiation intensity value(s) (e.g., at the same center-wavelength(s)) after the unit is put into use. In this regard, the center-wavelength(s) should be within the wavelength range in which the gas component type(s) to be removed from the corresponding internal containment area displays absorbency characteristics. For example, where CO 2 removal and calibration condition maintenance is desired, the stored value(s) established during calibration and the detected value(s) obtained after the unit has been put into use may be at a center-wavelength(s) within the 4-5 micron range. As will be appreciated, the present invention provides an improved method for maintaining calibration conditions within a gas spectrometer, including in particular respiratory gas spectrometers used for determining the concentration of one or more predetermined components of a respiratory gas sample. More particularly, in the inventive method, a respiratory gas spectrometer may be assembled to define one or more containment area(s) and one or more optical pathways therewithin, and thereafter initially calibrated at desired calibration conditions (e.g., at the production facility to ensure accurate correlation between detected radiation intensity measurements and gas concentration determination(s)). Importantly, in conjunction with such assembly and calibration, an absorbent is exposed within one or more containment area(s) of the assembled gas spectrometer, wherein the absorbent is selected to remove one or more types of undesired gas component(s) that could be introduced during field use of the device (e.g., from adhesives or lubricants used in the device, out-gassing of sealing components used in the device, and/or leakage through components). By virtue of such exposure, the absorbent is capable of absorbing the undesired gas component type(s) from within the one or more internal containment area(s) on a continuous, ongoing basis so that the initial, desired calibration conditions within the spectrometer can be dynamically maintained, thereby enhancing continued accuracy of the device.
As noted above, the absorbent may comprise an appropriate material for removal of CO 2 (e.g., soda lime). Additionally, the absorbent may comprise a desiccant (e.g., a ceramic-based molecular sieve or silica gel) for removal of water vapor from within the internal containment area. Further, the absorbent may include an additional contaminant scrubber, such as activated charcoal chips for removal of undesired gas component(s) that may leak into or be generated within the internal containment area.
The inventive method further provides for the servicing and replacement of the absorbent from within an internal containment area, free from disassembly of the respiratory gas spectrometer. In this regard, the described arrangement also facilitates replacement of the absorbent without necessitating re-calibration of the spectrometer. More particularly, a holder for retaining an absorbent may be selectively withdrawn from a corresponding internal containment area via an access aperture in the housing assembly, serviced so as to replace depleted absorbent with fresh absorbent, and sealably reinserted into the internal containment area. Alternatively, a holder containing used absorbent may be selectively withdrawn and disposed of, and a new holder with fresh absorbent sealably inserted through the access aperture.
Relatedly, the inventive method may also provide for indicating to a user that the absorbent should be replaced. By way of example, such indication could be provided via a window in the absorbent holder (e.g. allowing external visual inspection of the color of an absorbent and/or RH-sensitive paper) or via an appropriate user interface (e.g., via a visual display and/or audible alarm indication). As noted hereinabove, the indication may entail an automatic or user initiated comparison between a stored value(s) (e.g., corresponding with a measured intensity value upon calibration at a selected, center-wavelength), and a corresponding measured value(s) during use (i.e. measured at the same selected, center- wavelength). Should such comparison result in a difference that exceeds a predetermined tolerance value, a user alert will be automatically generated.
As noted, for purposes of absorbent replacement, the inventive method may advantageously include the selective retraction and removal of a holder from within a corresponding internal containment area via an opening in the respiratory gas spectrometer. The holder may be advantageously sized for hand-held manipulation and ready reinsertion back into the opening upon replacement of the absorbent. In this regard, the holder is provided for ready, sealable engagement with gas spectrometer.
The holder is provided with at least one opening in that portion which is insertable into the internal containment area, wherein the undesired gas component type to be removed will diffuse through the opening from the ambient internal containment area for absorbance during use. The insertable holder portion may be readily defined by hollow, cylindrical configuration having an open end for receiving the absorbent and a screen for containment of the absorbent. A hollow insertable holder portion may also be employed that comprises a plurality of openings in the sidewalls thereof, such openings being sized so as to contain granular absorbent material therewithin, yet permit ready diffusion of the undesired gas component type(s) to be removed therethrough.
Numerous variations and advantages of the invention will be apparent to those skilled in the art. By way of example, a separate, retractable absorbent holder and access aperture in the housing assembly could be provided in one-to-one relation to each of a plurality of internal containment areas within the housing assembly. Alternatively, in such an arrangement, the absorbent provided to one of the containment areas (e.g., a smaller secondary area) may be contained in a porous bag or the like which is serviceable upon disassembly/reassembly.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top cross-sectional view of a housing assembly, shown in schematic combination with other components of a respiratory gas spectrometer embodiment of the present invention.
FIGS. 2a and 2b illustrate a perspective, exploded assembly view of a gas component removal assembly and a side view of the gas component removal assembly, respectively.
FIGS. 3a and 3b illustrate elevated front perspective and elevated rear perspective views, respectively, of the housing assembly of the embodiment of FIG. 1.
DETAILED DESCRIPTION
FIG. 1 illustrates a respiratory gas spectrometer embodiment 10, including a top cross-sectional, partially cut-away view of a housing assembly 20 shown in schematic combination with a processor 30 and user interface 40. The housing assembly 20 defines a primary enclosed, internal containment area 22a and a secondary, enclosed, internal containment area 22b. An infrared radiation assembly 50, optical assembly 60 and gas component removal assembly 100 are all at least partially disposed within the primary containment area 22a. A detector assembly 80 and gas sampling assembly 70 are each at least partially disposed in the secondary containment area 22b. The noted components cooperate to provide for accurate monitoring of the concentration of selected components within a respiratory gas stream cycled through gas sampling assembly 70. In this regard, the present invention may be readily utilized in a respiratory gas spectrometer as disclosed in U.S. patent application Ser. No. 08/403,161, now U.S. Pat. No. 5,731,581 hereby incorporated by reference in its entirety.
The infrared radiation assembly 50 includes an elongated, upstanding infrared source element 52 and a cylindrical, concentrically disposed light chopper 54. Chopper 54 includes a window 56 and is rotatable about source element 52 for alternatively transmitting radiation on first and second optical paths 12a and 12b, at least partially defined by optical assembly 60.
The optical assembly 60 includes first and second spherical mirrors 62a and 62b, for collecting and directing radiation from source element 52 on first and second optical paths 12a and 12b, respectively. The resultant, converging optical beams on paths 12a and 12b are separately redirected via first and second flat mirrors 64a and 64b, respectively.
As illustrated, the housing assembly 20 includes an internal wall 21 defining the separate containment areas 22a and 22b. Internal wall 21 is provided with an opening therethrough so as to receive gas sampling assembly 70 and transparent window member 23, as shown by a partially cut-away portion of wall 21 in FIG. 1. Both window member 23 and gas sampling assembly 70 are positioned on optical paths 12a, 12b. The gas sampling assembly 70 includes a gas sample chamber 72 and reference gas chamber 74 disposed relative to optical assembly 60 such that the first converging beam on path 12a passes through opposing, transparent windows of gas sample chamber 72, and the second converging beam on path 12b passes through opposing, transparent windows of the reference gas chamber 74. The gas sample assembly 70 is interconnected to gas flow lines (not shown) for continuously cycling a sample stream of respiratory gas from a patient through the gas sample chamber 72.
The detector assembly 80, includes an upstanding linear variable filter (not shown), an adjacent CO 2 band pass filter 82 positioned thereabove, and an upstanding linear array of pyro-electric detector elements 84 positioned behind the linear variable filter and band pass filter 82. The detector assembly 80 is positioned so that non-absorbed radiation transmitted through gas sample chamber 72 and reference gas chamber 74 on paths 12a and 12b, respectively, is filtered by the linear variable filter and the band pass filter 82, and detected by linear detector array 84. As will be appreciated, the detected radiation will not include radiation that is absorbed by gas component(s) present along paths 12a and 12b, including in particular gas component(s) contained within chamber 72. In operation, the linear variable filter will simultaneously filter transmitted radiation in a spatially distributed manner across a wavelength range, including the 7-10 micron range. The 7-10 micron range covers sub-ranges across which many anesthetic gas agents will display unique radiation absorbance characteristics. The CO 2 band pass filter 82 will pass unabsorbed radiation in the 4-5 micron range, which range encompasses that within which CO 2 displays unique radiation absorbance characteristics. By utilizing detector array 84 to simultaneously obtain intensity measurement values at predetermined center-wavelengths across the 7-10 and 4-5 micron wavelength range, the resultant data can be provided to processor 30 for multi-variate statistical processing, and determination of the concentration of one or more anesthetic gas agents and CO 2 for visual or audible output/alarm by user interface 40. The described arrangement is highly robust in terms of accuracy and responsivity. As can be appreciated, the continued accuracy of the gas spectrometer 10 during field use depends in part upon maintenance of predetermined calibration conditions within housing assembly 20.
In this regard, gas component removal assembly 100 is disposed partially within the primary internal containment area 22a for removing one or more types of undesired gas components, e.g., CO 2 , from the internal containment area 22a during field use of the respiratory gas spectrometer 10. Additionally, an optional gas removal member 25 may be provided in secondary containment area 22b for removing one or more types of undesired gas components from containment area 22b. By way of example, gas removal member 25 may be a porous bag of fiber construction filled with a CO 2 gas removal material (e.g. granular soda lime).
As illustrated, gas removal assembly 100 is provided for selective, sealable engagement/disengagement with housing assembly 20. This arrangement advantageously facilitates selective servicing of the gas component removal assembly 100 during field operation, free from disassembly of housing assembly 20. More particularly, and as illustrated in FIGS. 2a and 2b, gas component removal assembly 100 may comprise an open-ended, metal holder 110 having a barrel 112 and enlarged, close-ended head 114. Enlarged head 114 may be of a hexagonal configuration adapted for engagement with a wrench tool. In this regard, barrel 112 includes an outer threaded portion 116 for engagement/disengagement with a threaded opening 27 of housing assembly 20.
The gas removal assembly 100 further includes an o-ring 130, positionable over a seat portion 124 of barrel 112, for sealing the interface between the enlarged head 114 and the outside surface of housing assembly 20 during use. By way of example, o-ring 130 may comprise butyl rubber, which has been found to be of particular advantage due to its low CO 2 and water vapor permeability properties. Alternatively, a fluorocarbon material such as viton may be employed in o-ring 130. Gas removal assembly 100 also includes a gas removal absorbent material 140 contained within internal space 118 of holder 110. In this regard, the absorbent material 140 is preferably in a loose, granular or other like form to increase the exposed surface area for absorption. The absorbent material 140 may include a granular soda lime material, which has been recognized as particularly effective for the removal of CO 2 from the containment space 22a upon passive contact. In this regard, by providing a transparent window 122 in head 114 of holder 110, saturation of a granular soda lime absorbent material can be visually indicated external to housing assembly 20 since such absorbent can be provided to change color upon use (e.g. from white to purple upon becoming saturated with CO 2 ).
In situations where it is desirous to remove water vapor, the gas removal absorbent 140 may comprise a desiccant such as a ceramic-based molecular sieve or silica gel. In such cases, an RH-sensitive paper may be disposed in holder 110 for visual observation via window 122 to indicate when the desiccant is saturated and in need of replacement (i.e. when RH-sensitive vapor changes color). To remove organics, it may also be desirable to employ an absorbent such as activated carbon (e.g., charcoal chips).
To retain the loose gas component removal absorbent 140 within the open end of the barrel portion 112 of holder 110 during use, yet permit passive gas contact with the gas component removal material 140, a porous screen 150 and threaded retainer ring 160 are positioned within the internally threaded region 120 of holder 110. As illustrated, screen 150 is restricted between retainer ring 160 and an internal ledge 126 provided within the barrel 112 of holder 110. In another arrangement, barrel 112 could be integrally provided with small holes along and about its length or could otherwise be constructed from a porous material to enhance diff-usion of the undesired gas component(s) therethrough.
Referring again now to FIG. 1, it can be seen that the barrel 112 of holder 110 of removal assembly 100 is sized and positioned relative to the other components of the respiratory gas spectrometer 10 so that it does not cross or otherwise impede any portion of the first optical path 12a or second optical path 12b. Further, holder 110 is positioned so that any CO 2 or other undesired component(s) that may be introduced into internal containment area 22a during field operation may readily pass directly into the open end of barrel 112 and contact the gas removal material 140 contained therewithin.
FIGS. 3a and 3b provide additional views of the above-noted components within housing assembly 20. As illustrated, the gas removal assembly 100 is positioned outside of the optical pathways. FIGS. 3a and 3b also show that housing assembly 20 may be principally defined by a top member 24 and bottom member 26, which may be sealably assembled together. In this regard, a sealing member (e.g. a resilient, continuous gasket) 28 may be provided at the interface between the top member 24 and bottom member 26 of housing assembly 20, and the two members may be securely interconnected via screws and threaded holes about their periphery. Upon assembly of the respiratory gas spectrometer embodiment 10, including interconnection of the top and bottom members 24 and 26 of housing assembly 20, the internal containment areas 22a, 22b are defined therewithin. As illustrated in FIG. 1, over 90% of the length of optical paths 12a, 12b from source 52 to detector assembly 80 lies outside chambers 72, 74. Further, the majority of such optical paths 12a and 12b lie within the primary containment area 22a serviced by gas removal assembly 100. In conjunction with the assembly of the spectrometer 10, the gas removal assembly 100 may be inserted into threaded opening 27 within the bottom member 26 and rotated relative thereto for threading engagement between threaded portion 116 on the barrel 112 of the holder 110 and the threaded opening 27. In this regard, it is noted that the threaded portion 116 on the barrel 112 of holder 110 is spaced from the enlarged head 114 such that the oring 130 is received by intermediate portion 124. As such, threaded rotation of holder 110 relative to the threaded opening 27 will be properly restricted when the end of threaded portion 116 is reached so as to allow appropriate compression of o-ring 130 against the outer wall of housing assembly 20 to achieve sealing, yet not over-stress the o-ring 130 due to over-rotation of holder 110 causing over- compression of o-ring 130.
Upon assembly of the respiratory gas spectrometer 10, initial calibration can be completed at the production facility (at desired calibration conditions, within containment spaces 22a and 22b). By way of example, such calibration may typically include obtaining radiation measurements at numerous center-wavelengths and processing the measurement values via processor 30 to ensure that accurate determinations of predefined respiratory gas component(s) will be obtained when the spectrometer 10 is introduced into field use.
After final calibration, the respiratory gas spectrometer 10 is ready for field use, wherein the gas removal material 140 is continuously exposed within the internal containment area 22a. By virtue of such exposure the undesired gas components which are to be removed from containment area 22a are free to diffuse through screen 150 for absorption by the absorbent material 140. Such diffusion will continue on an ongoing basis as undesired gaseous components are introduced into the internal containment space during use. As will be appreciated, barrel 112 may be constructed from a porous material or may otherwise comprise small holes about and along the length thereof to facilitate CO 2 diffusion therethrough.
The processor 30 may be adapted to automatically provide a signal to the user interface 40 so as to indicate to a user when the gas removal material 140 should be replaced or tested for replacement. Such indication may be provided in the way of a visual display and/or audible alarm. The triggering of such a signal may be based on periodic comparison between calibration and in-use measurement values obtained at one or more center-wavelengths.
To service the respiratory gas spectrometer 10, a user simply rotates the gas removal assembly 100 (e.g., with the use of a wrench tool), and withdraws the gas removal assembly 100 from housing assembly 20. A gas removal assembly 100 with "fresh" gas removal material 140 contained therein may then be screwed into housing assembly 20. Alternatively, the "old" gas removal assembly 100 may be serviced for reuse. Specifically, retainer ring 160 may be unscrewed from the barrel 112 of the holder 110, the screen 150 removed, and the gas removal material 140 disposed of. The fresher replacement gas removal material 140 may then be introduced and the gas removal assembly 100 reassembled. Gas removal assembly 100 may then be easily positioned back through threaded opening 27 of the housing assembly 20. As will be appreciated, the described arrangement thus avoids disassembly of the housing assembly 20 for servicing purposes, and does not necessitate re-calibration of the device.
Numerous additional embodiments and variations of the invention will be apparent to those skilled in the art and are intended to be within the scope of the present invention, as defined by the following claims.
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A gas spectrometer is provided having an enhanced capability for maintaining initial calibration conditions therewithin. The gas spectrometer is particularly apt for respiratory gas analysis applications and includes a housing assembly that defines an internal containment area(s), within which a radiation source, optical assembly, sample gas assembly and radiation detection assembly are positioned. A gas removal assembly is provided for removing one or more undesired gas component types from within the internal containment area during field use. The gas removal assembly is selectively retractable from the housing assembly to permit periodic servicing (e.g., replacement of CO 2 absorbent) without requiring disassembly or recalibration of the spectrometer.
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[0001] The invention pertains to machines for brewing and dispensing espresso drinks. In particular, the invention is an apparatus and associated method for controlling, automating, and duplicating the brewing conditions for multiple doses of espresso.
[0002] Machines for preparing espresso drinks in a commercial retail environment are well known. In general, these espresso machines include a heating source for generating steam and hot water in a reservoir, a basket for holding ground espresso, and a dispensing spout. There are several increasingly sophisticated means of controlling the flow of the steam and hot water through the espresso, out the spout, and into the cup. Perhaps the simplest means is a manually-controlled valve which is opened to permit a pressurized flow of hot water through the grounds and out the spout into a cup below. More modern machines, such as the Hydra TM espresso machine manufactured by Synesso Incorporated of Seattle Washington, incorporate computer control of the valve. The operator of such machines either presses a button or operates a toggle switch, sensed by the computer to control the valve. Some espresso machines fully automate the brewing sequence, such that a single operation of the button provides a precise dose of water through the grounds, with attendant precise control of the water temperature and driving pressure. Commercial machines may include several dispensing heads.
[0003] A commercial establishment for preparing and selling espresso drinks faces several inter-related problems, each of which is influenced by the particular espresso machine that the establishment has chosen to adopt. The first problem is one of simplicity of use. Because it is often a primary source of business revenue, the espresso machine must be capable of dispensing drinks at a high rate. The procedures for setting up the machine for each dose must be as short and simple as possible. Many existing espresso machines are automated for this reason. An attendant advantage to this automation is that that brewing sequence for each successive dose of espresso is highly consistent.
[0004] Automation presents a competing problem, however. The operating mechanism in existing automated espresso machines is largely limited to an on/off switch or button. The competing problem to simplifying the operation for employees also serves to limit the ability of them to vary the espresso making process to account for changes in the coffee. The taste of the final espresso product can vary significantly with the type of coffee, the grind, and the age of the coffee, for example. Current machines have very limited capability for the experienced user to adjust the brew on the fly to account for these changes.
[0005] The inventors have recognized these problems in the prior art, and have arrived at a novel and ingenious solution. An improved espresso machine is described here which incorporates a control scheme for detecting the operating input from the user during the brewing process. The espresso machine senses the operating inputs from the user and saves those inputs to a computer memory as an adjusted set of brewing parameters. The adjusted brewing parameters may then be employed during subsequent use of the machine. Thus, an experienced user can vary the brewing process on the fly, and without the need for time-consuming programming or process set-up. The invention simultaneously provides for a better coffee brew and increased product throughput.
[0006] In accordance with the principles of the present invention, an improved espresso brewing apparatus is described which combines an espresso dosing unit, pump, and a group control head disposed adjacent the dosing unit with a controller and computer temporary brew memory. An actuation of the group control head handle actuates at least one of the controller, the pump and a control valve in the dosing unit to provide a controlled dose of hot water through a filter. The controller also saves parameters related to two or more signal inputs from the group control head into the temporary brew memory. The controller is also operable to retrieve the parameters for use during a programmed brew sequence used in a subsequent operation of the espresso machine.
[0007] Also in accordance with the principles of the present invention, an improved method for providing a controlled dose of hot water the improved espresso machine is described. The method comprises the steps of sensing a momentary actuation of the group control head handle to an angular brew position. Steps of opening a control valve to begin the dose and initiating a saving of subsequent actuating step into the temporary brew memory responsively follow. The method also comprises a step of sensing a subsequent actuation of the handle which starts a pump and saves the parameter to the temporary memory. The method also comprises a step of sensing a third actuation of the handle which stops the pump to end the dose and saves this parameter to the temporary memory. The saved parameters become a set of brew parameters in the memory. If the first momentary actuation is not followed by any further actuations, then the parameters stored in the temporary memory become identical to the set of parameters already used by the programmed brew sequence.
[0008] As used herein for purposes of the present disclosure, the term “processor” or “controller” is used generally to describe various apparatus relating to the operation of the inventive apparatus, system, or method. A processor can be implemented in numerous ways (e.g. such as with dedicated hardware) to perform various functions discussed herein. A processor is also one example of a controller which employs one or more microprocessors that may be programmed using software (e.g. microcode) to perform various functions discussed herein. A controller may be implemented with or without employing a processor, and may also be implemented as a combination of dedicated hardware to perform some functions and a processor (e.g., one or more programmed microprocessors and associated circuitry) to perform other functions. Examples of controller components that may be employed in various embodiments of the present disclosure include, but are not limited to, conventional microprocessors, application specific integrated circuits (ASICs), and field-programmable gate arrays (FPGAs).
[0009] It is understood that the term “memory” refers to computer storage memory of types generally known in the art. Memory may be volatile or non-volatile computer memory such as RAM, PROM, EPROM, and EEPROM, floppy disks, compact disks, optical disks, magnetic tape, etc. In some implementations the computer memory media may be encoded with one or more programs that, when executed on the one or more processors and controllers, perform at least some of the functions discussed herein. Various storage media may be fixed within a processor or controller or may be transportable, such that the one or more programs stored thereon can be loaded into a processor or controller so as to implement various aspects of the present invention. The terms “program” or “computer program” are used herein in a generic sense to refer to any type of computer code (e.g. software or microcode) that can be employed to program one or more processors or controllers.
[0010] In various implementations, there terms “outputs”, “inputs”, “signals”, and the like may be understood to be electrical or optical energy impulses which represent a particular detection or processing result.
IN THE DRAWINGS
[0011] FIG. 1 illustrates an embodiment of an espresso machine according to the present invention.
[0012] FIG. 2 illustrates the plumbing system of the FIG. 1 espresso machine.
[0013] FIG. 3 illustrates an exploded diagram of one embodiment of the inventive group control head.
[0014] FIGS. 4( a ), 4( b ) and 4( c ) illustrate the operation of the FIG. 3 group control head.
[0015] FIG. 5 is a system block diagram of one embodiment of the electrical sensing and control circuit.
[0016] FIG. 6( a ) and FIG. 6( b ) illustrate two embodiments of a visual display for the espresso machine of the present invention.
[0017] FIG. 7 illustrates a brewing sequence for the espresso machine.
[0018] FIG. 8 illustrates an embodiment of an inventive method for operating the espresso machine of the present invention.
[0019] FIG. 9 illustrates a flow chart method for saving and retrieving a set of brew parameters in the espresso machine.
[0020] FIG. 10 is a state machine diagram for a simplified method of saving a set of brew parameters to the espresso machine.
[0021] FIGS. 11( a ), 11( b ), 11( c ), and 11( d ) illustrate a set of state machine diagrams for a various operating modes of the espresso machine.
[0022] FIG. 12 illustrates a visual display for saving a set of brew parameters from one dosing unit to other dosing units in the espresso machine.
[0023] FIG. 13 illustrates a more detailed view of an external programming controller for the espresso machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Espresso Machine Including Improved Non-contact Group Control Head
[0025] Now turning to the illustrations, FIG. 1 shows an espresso machine_of the present invention. Espresso machine 100 includes an espresso dosing unit 102 having at least one group control head 110 which controls the operation of the machine to provide an espresso dose. Espresso machine 100 includes an internal source of water and steam pressure. Each dose of espresso is dispensed from a brew tank 150 at the outlet of the water source. Brew tank 150 is sized to contain hot water under pressure with enough volume, for example about 1.9 liters, for one or more doses of espresso. Typically, brew tank 150 includes a heating element to maintain the water temperature at an optimal temperature for brewing.
[0026] At the outlet of brew tank 150 is a filter 160 for holding ground coffee. Filter 160 is sized to hold enough tamped-in grounds for one dose of espresso. Filter 160 is of course removable so that coffee grounds can be replaced after each use. At the outlet of filter 160 is an outlet spout 170 for guiding the dispensed dose of espresso into a cup, not shown, held or placed below the spout. For the purposes of this description, an espresso dosing unit 102 is generally understood to include at minimum the brew tank 150 , filter 160 and outlet spout 170 .
[0027] Many commercial espresso machines include a visual display 180 disposed on the group control head 110 , or on the machine 100 adjacent the dosing unit or group control head. Visual display 180 can display basic shot parameters such as time to completion, dose size, and the like. Because of the need for quick and efficient dosing of espresso shots in commercial settings, it is important that the information provided on visual display 180 is kept as simple, clear and as uncluttered with unneeded data as possible.
[0028] It may be noted that the type of grounds placed in the filter 160 may vary. The harvested source and variety of coffee, the texture of the grind, and the age of the coffee grounds affect the taste of the final product in several ways. The coffee variation may affect the tamp of the grounds in the filter 160 and the resulting pressure differential between the brew tank and the spout. The coffee variation also affects the interaction between the grounds and the hot water flowing through them. Each of these factors changes the taste of the dosed espresso. An experienced user desiring to optimize taste needs the ability to vary properties of the brew to account for these variations.
[0029] The espresso machine of FIG. 1 also illustrates additional dosing units which include additional group control heads such as second group control head 110 ′ and third group control head 110 ″. The additional dosing units allow for increased throughput of espresso drinks. Each of the additional dosing units may also include dedicated visual displays such as shown in FIG. 1 at second visual display 180 ′ and third visual display 180 ″. The number of dosing units is not important to the invention.
[0030] Any of the optional dosing units may be pre-programmed using an optional external programming controller 190 . Default brew parameters such dispensing temperature, dose size, and applied pressure profile may be entered via programming controller 190 . With reference to FIG. 13 , programming controller 190 includes a programmer display 192 , which may display text related to a current state of the selected dosing unit or may display text related to a programmed brewing sequence parameter. User selection of the text to be viewed on the controller 190 may be selected via one or more programmer selection buttons 194 disposed next to the corresponding text line, or may be selected via a set of up-and-down programmer scrolling arrows 196 . Adjustment of parameters may be entered via the scrolling arrows 196 . Other user interfaces such as keyboards, touch pad screens, and the like may be used as well for these functions.
[0031] It should be noted that efficient use of controller 190 may entail a more advanced operating skill, and may distract from the ongoing dosing unit operation. Thus, use of programming controller 190 may be generally more desirable during business idle time or downtime.
[0032] Now referring to FIG. 2 , a plumbing arrangement 200 that may be incorporated within the FIG. 1 espresso machine is shown. A single steam tank 202 is generally located within the main housing of the espresso machine, heated to provide a constant temperature and pressure steam source that is commonly used for foaming milk and the like. An external water source 210 , such as from building plumbing, and associated valve arrangement provides fill water for the steam tank 202 . The water source 210 is also used by a pump 204 as a source of water to brew tank 250 and optional brew tanks 250 ′ and 250 ″. Pump 204 may also operate under computer control to control or vary the pressure in brew tank 250 and consequently the pressure profile across the coffee grounds in the filter 260 as the shot is flowing. An optional bypass control valve 208 and associated plumbing from the pump 204 discharge, i.e. between brew tank 250 and pump, back to the pump 204 suction is also shown. Computer control may operate the optional bypass control valve 208 during the pump operation to establish a time-pressure profile across the filter by diverting the high pressure pump water away from the operating brew group.
[0033] As can be seen in FIG. 2 , flow of pressurized water from pump 204 to brew tank 250 may pass through the steam tank 202 . This feature permits feed water to be pre-heated before entering the brew tank 250 , which makes temperature control at the brew group more precise.
[0034] Brew tank 250 holds pressurized hot water that is ready for dispensing through the filter 260 . Brew tank 250 typically includes a heating element for continued precise temperature control, as well as a temperature sensor and an optional pressure sensor. Brew tank 250 or the dedicated plumbing leading to it may also include a flowmeter.
[0035] Control valve 206 starts and stops the pressurized hot water flow from brew tank 250 through filter 260 through the outlet spout 170 . In a preferred embodiment, control valve 206 is operated under control of an automated controller, which in turn operates responsive to an actuation signal input from the group control head. Control valve 206 under such control thus provides a controlled volume output of the shot.
[0036] If control valve 206 is opened without the pump 204 operating, a reduced flow through the brew tank still occurs. This state is useful at the beginning of a brew to pre-infuse dry coffee grounds with hot water before pumped flow begins. This state may also be useful at the end of the brew to avoid excessive “blonding” of the flow as the grounds are expended. The time between the stopping of the pump and final closing of the control valve establishes a low pressure finish. The value of the low pressure finish may be a percentage of the pumped flow volume to the total flow volume of the brew shot.
[0037] FIG. 3 illustrates an exploded diagram of a preferred embodiment of a group control head 300 assembly according to the present invention. The assembly is mounted to the espresso machine 100 via a base 302 . Base 302 may be generally cylindrically shaped with a center axis disposed in the vertical plane. Base 302 may optionally be part of brew tank 250 , and may include a shroud surrounding the lower vertical portion.
[0038] A top plate 324 is disposed on base 302 . Top plate 324 comprises a pivot pin 325 centered on the center axis. Pivot pin 325 is arranged to provide a rotational axis for an actuator 340 . In addition, a centering post 350 is disposed at a radial idle position on the top plate 324 , the post arranged orthogonally from the vertical center axis. Preferably, centering post 350 is disposed near an edge of top plate 324 . Centering post 350 is preferably constructed of a ferrous material that is magnetically attractive to a magnet.
[0039] Actuator 340 is disposed on top plate 325 at pivot pin 325 . Actuator 340 includes a mounting arm, at the end of which a magnet 342 is disposed. The arrangement of actuator 340 on top plate 325 is such that magnet 342 rests adjacent to but not touching center post 350 . Actuator 340 is also free to rotate about pivot pin 325 but is held in an idle position 400 , FIG. 4 , by the magnetic force between magnet and post. This biasing force opposes any rotational force which rotates the actuator 340 , and causes the actuator to return to the radial idle position when the rotational force is removed. This holding feature thus serves as an automatic centering feature.
[0040] Affixed to top plate 324 is at least one proximity sensor 375 which is operable to sense a position of the magnet 342 with respect to the sensor. Proximity sensor 375 is disposed at a fixed angle away from the radial idle position. When an actuating force rotates the actuator magnet 342 away from the idle position, magnet 342 is positioned near sensor 375 . An optional second proximity sensor 376 may be disposed at a second fixed angle from the radial idle position. The second fixed angle may be the opposite angle from the radial idle position. Similarly, when an actuating force rotates the actuator magnet 342 in the opposite direction away from the idle position, magnet 342 is positioned near and is detected by sensor 376 .
[0041] Proximity sensors 375 , 376 are preferably arranged on a proximity sensor board 374 which is held in fixed position above top plate 324 and actuator magnet 342 . Magnet 342 is thus free to rotate under the proximity sensor board. In addition, a preferred arrangement is of a single magnet 342 which serves as both an automatic centering magnet and a positioning source to be detected. The arrangement is simpler and requires fewer parts. Of course, the particular arrangement of magnet to sensor(s) may be modified within the scope of the invention.
[0042] A preferred type of proximity sensor 375 , 376 is a linear type Hall Effect sensor. Such a sensor is commonly understood to provide an analogue output which corresponds to the relative position of a magnet. One advantage of a Hall Effect sensor is that it is non-contact and so has no parts to wear out. The Hall Effect sensor requires minimal periodic adjustment or calibration, and optionally could be used with a comparator to provide a more precise positioning over a large number of cycles.
[0043] Importantly, the Hall Effect sensor provides an analogue output that contains more than a simple binary actuation signal or pattern of binary signals. The sensor can provide a signal input to a device controller which is representative of the magnitude of the magnet movement, the velocity of relative movement, and the duration of a held magnet rotation. Thus, the Hall Effect sensor provides the user with a more precise and useful control of the group head.
[0044] The user interface portion of the FIG. 3 group control head is a rotational handle 314 , which is fixed by screws or other means to actuator 340 . The handle 314 may comprise a protective shell which fits over the top plate 324 , actuator 340 and the arrangement of sensors 375 , 376 . A paddle 316 is preferably disposed on handle 314 extending away from the protective shell and in such a manner as to provide easy rotational actuation of the group control head.
[0045] In operation, the user experiences a resistive force not unlike a spring force when she rotates the paddle. When the paddle is released, the entire group head control assembly returns to the idle position due to the attraction of magnet and post.
[0046] FIGS. 4( a ), 4( b ) and 4( c ) illustrate the operation of the FIG. 3 group control head 300 , wherein magnet 342 may be positioned over an arc in proximity to, but not in contact with, at least one proximity sensor. At rest, the group control head is automatically centered and held in the idle position 400 as shown in FIG. 4( a ) . The magnetic attraction between magnet 342 and post 350 provides the holding force. The output of proximity sensor 375 and/or optional sensor 376 indicates that the magnet 342 is in the idle position 400 .
[0047] FIG. 4( b ) shows the group control head 300 in a brew position 410 . Here, the user has rotated paddle 316 in the clockwise, or left, direction such that proximity sensor 375 senses the proximity of magnet 342 . The user also experiences a counterclockwise resistive force not unlike a spring force when she rotates the paddle 316 , due to the ongoing attraction between displaced magnet 342 and post 350 . The attraction repositions the actuator 342 to the idle position 400 when the paddle 316 is released. The effect of the paddle rotation of FIG. 4( b ) is to send an input signal corresponding to the sensed magnet position to a controller. The controller in turn may begin a programmed sequence of outputs to the espresso machine to dispense a shot of coffee.
[0048] FIG. 4( c ) illustrates an optional control position 420 of the group control head 300 corresponding to a counterclockwise, or right, rotation of paddle 316 . Second proximity sensor 376 senses the proximity of magnet 342 . The user also experiences a clockwise counter-force not unlike a spring force when she rotates the paddle 316 , due to the ongoing attraction between displaced magnet 342 and post 350 . The attraction repositions the actuator 342 to the idle position 400 when the paddle 316 is released. The effect of the paddle rotation of FIG. 4( c ) is to send a second input signal corresponding to the sensed magnet position to a controller. The controller in turn may perform an auxiliary action, such as ending an ongoing shot.
[0049] The user of course experiences the above described group control head 300 as having one actuator which has a clockwise, or left, paddle position and a counter-clockwise, or right, paddle position. As will be further described, actuations of short duration and longer duration may provide different responses in the machine control. A short duration actuation may be referred to as a “bump”, while longer duration actuations may be referred to as a “hold” or a “long hold.” A bump may be, for example, a paddle rotation and release lasting less than 250 milliseconds. An example hold may be from greater than 250 milliseconds up to greater than about 2.5 seconds.
[0050] FIG. 5 illustrates a system block diagram of one embodiment of the electrical sensing and control circuit for an espresso machine electrical system 500 . The electrical system 500 can be arranged on a single central printed circuit board or may be distributed among several sub-units. For example, FIG. 5 shows one hardware controller 510 , but system 500 could equivalently include a separate controller 510 disposed on each group control head in the apparatus. Either the single visual display 520 as shown or a display 520 dedicated to each separate group control head may be used to convey status information. A power supply 540 provides electrical power to the system 500 .
[0051] The heart of system 500 is controller 510 , which can be any of a known CPU or other computer processing unit such as an application specific integrated circuit (ASIC), field programmable gate array (FPGA), or reduced instruction set computing (RISC) type. Controller 510 operates to control the espresso brewing process in response to various inputs. Controller 510 may also operate in accordance with a computer program stored in a computer memory 530 . Controller 510 and the computer program then provide a repeatable and coordinated sequence of outputs that generate a controlled dose of espresso. Controller 510 may also be arranged in a programming mode to accept programming instructions from external programming controller 190 and to store those instructions in memory 530 for later use. Similarly, controller 510 may provide a program control data set point or parameter from a user interface to memory 530 . Controller 510 may also provide output to a visual display 520 that is located near the respective group control head such that important operating status information can be seen at a glance.
[0052] Also shown in FIG. 5 is that memory 530 is preferably apportioned into several parts. A first part is the computer temporary brew memory 532 , which as will be described saves parameters related to the current brewing process. The temporary brew memory essentially contains a set of brewing parameters established at the last brew. For example, if the user shortens a pre-infusion period by actuating the group control head handle, that new pre-infusion duration is captured in the temporary brew memory. Each dosing unit has its own temporary brew memory.
[0053] Another part of memory 530 comprises a computer storage memory 534 for storing previously saved complete sets of brewing parameters. The portions may be arranged in pages, with a left portion and a right portion for each page. In one embodiment, each dosing unit is provided with from one to three pages. More preferably, computer storage memory 534 comprises at least two storage locations, without any paging arrangement. Shown in FIG. 5 is an exemplary embodiment of storage memory 534 having six storage locations 541 through 546 . Each portion or storage location is sized to contain one set of brewing parameters. Each dosing unit has its own computer storage memory 534 .
[0054] Outputs from each group head are provided as inputs to controller 510 . Examples of inputs are a group head water flow meter 502 and a brew tank temperature sensor 504 . Controller 510 may use these inputs to start or stop the brew program or to otherwise control various heating and pumping components. Controller 510 preferably operates under the further control of an internal clock or timer to shift between various phases of the brew process.
[0055] Controller 510 also accepts signal inputs from each respective group control head 300 via proximity sensor outputs 375 , 376 . The accepted signal inputs control the program sequence that provides the espresso dose. An example is a received input from non-contact proximity sensor 375 that corresponds to a single actuation of the group control head handle. Controller 510 then issues a coordinated program sequence of output instructions to provide the dose. The outputs can be one or more of a pump control output 522 , a control valve control output 524 , and a bypass valve output 526 .
[0056] A second input control example is a received signal input from the second non-contact proximity sensor 376 that corresponds to a different single actuation of the group control head handle. Controller 510 responsively issues an output to one or more of a pump control output 522 , a control valve control output 524 , and a bypass valve output 526 to, for example, immediately end the controlled dose.
[0057] FIG. 6( a ) and FIG. 6( b ) illustrate two embodiments of the information provided on the optional visual display 180 for the espresso machine of the present invention. The displayed information provides the user with the current status of the machine and group control head guidance instructions with simple indications.
[0058] FIG. 6( a ) shows an operational display 600 provided during normal operation or during a programmed brewing sequence. The most prominent feature of this display is a shot timer 602 . Shot timer 602 will typically display the total duration of the shot, e.g. 32 seconds, during idle times between brews. During the brew sequence, shot timer 602 preferably displays the elapsed time from the start of the shot, although similar indications of shot progression such as count-down time or time from the start of a particular sequence phase are included within the scope of this invention.
[0059] Mode icon 604 shows the espresso machine mode of operation, which may include a manual mode, a manual program or a volumetric program mode. Here shown on icon 604 is the volumetric program mode icon VP. An espresso machine operating in volumetric program mode is typically controlled on a flow basis as sensed by the flow meter. An espresso machine operating in manual program mode MP is typically controlled by the sequence timer with some control by the user. Manual mode M is typically a mode of operation under full control by the user.
[0060] Phase icon 606 indicates a relative duration of each phase of the brewing sequence. The phases will be described in more detail with reference to FIG. 7 . The embodiment shown uses simple bar graphs to display the relative length of each of three phases.
[0061] Memory storage location icon 608 shows the memory portion of computer storage memory 534 that is currently selected for use. Here, icon 608 is a dot which points to a first memory storage location. Additional storage location icons, if available, may be arrayed below icon 608 or along the right border of display 600 . If the storage memory location is ready to receive data, a save icon 610 is shown.
[0062] FIG. 6( b ) shows a save mode display 620 that is shown during the transfer of brew parameters between the temporary memory and/or storage memory locations. When in save mode, and when the storage memory location is ready to receive data, one display embodiment incorporates a save left icon 622 and a storage memory cycling icon 624 guides the user to save the current data via a left bump and to select the storage memory for saving by cycling through the locations with one or more right bumps of the group control head respectively. In this case, the “M” mode icon 604 indicates that the saving is being performed from a manual mode of operation.
[0063] FIG. 7 illustrates a brewing sequence 700 for the espresso machine. From an idle state, the sequence is started at start step 702 by the user operating the group control head paddle or by pushing a button. The controller 510 initiates the programmed sequence at step 716 using the currently-selected set of brew parameters and also begins to save brewing data into the temporary memory 532 .
[0064] The brewing phases then begin at a pre-infusion brew phase 717 . During this phase, controller 510 opens the dosing unit control valve 524 , 206 to pre-infuse the dry coffee grounds with unpressurized water from the brew tank 250 . This phase typically begins in response to the same first input signal received from the user at the start step 702 .
[0065] At the end of the pre-infusion phase, an optional pressure ramp up phase 720 begins. The transition from pre-infusion to pressure ramp up may be in response to a programmed sequence time or to a user input from the group control head paddle. Pressure ramp up phase 720 starts the pump 204 and optionally opens the bypass control valve 208 to gradually pressurize the brew tank 250 to drive water through the grounds.
[0066] In response to a programmed sequence time or to a user input from the group control head paddle, a full pressure brew phase 720 begins. During this phase, the bypass control valve is closed and the pump is running to provide maximum shot flow through the grounds.
[0067] Depending on the particular grounds in use, an undesirable “blonding” of the flow may occur as the grounds are used up during the full pressure brew phase 720 . To avoid the effects of blonding, the sequence may then transition to an optional pressure ramp down phase 724 . Like ramp up phase 720 , the pump is running and the bypass control valve is opened to gradually reduce pressure on the grounds. The beginning of this phase may occur in response to a programmed sequence time or to a user input from the group control head paddle.
[0068] A stop shot phase 726 ends the brewing sequence. This phase typically functions to ensure that the precise shot volume is dispensed. Here, the pump is not running but the control valve is still open. The transition into the stop shot phase 726 may be in response to a programmed sequence time or to a user input from the group control head paddle. Similarly, the stop shot phase is ended by closing control valve 524 , 206 when the full dose has been dispensed as sensed by elapsed time, flow meter volume, or by user input. The machine then re-enters an idle mode at end step 727 .
[0069] Shown next to each phase of the sequence is an exemplary operational display 600 on visual display 180 . Shown is the total time of the sequence at the beginning and end as well as the elapsed time during the sequence. Also shown is the Manual Programming MP operating mode and the stored parameter set that is in use. Optionally, display 180 may show a volume dispensed instead of an elapsed time during the brewing phases.
[0070] The above described sequence is driven by a set of parameters or settings which control each phase. For example, the set of parameters may include a pre-infusion time, a low pressure ramp up time, a full pump dispense time, a ramp down time, and a total dose water volume dispensed. Generally, a set can be defined with four parameters. End step 726 , for example, can be defined with the low pressure finish percent, which may be a percent of overall shot time or overall shot volume.
[0071] Method and Apparatus for Optimizing a Set of Brew Parameters
[0072] FIG. 8 illustrates a flow chart for an inventive method of operating the espresso machine of the present invention, and in particular a method 800 for optimizing and storing the conditions for a controlled dose of hot water dispensed from the machine. The method then saves the optimized set of brew parameters for a subsequent use of the espresso machine. Method 800 begins at start step 802 . The method then proceeds to a step 804 of providing the espresso machine apparatus as previously described, including the dosing unit, the group control head 110 , 300 , the pump 204 , the temporary brew memory, and the controller. Providing step 804 may also include the steps of activating the apparatus, initiating the program stored in memory, preheating and pre-pressurizing the system, and/or preparing and installing the grounds filter. After completion of providing step 804 , the espresso machine is ready to dispense espresso, and begins to monitor at the group control head proximity sensor 375 , 376 inputs.
[0073] Step 806 is for monitoring and sensing a momentary actuation or bump of the group control head handle to a particular angular brew position. Step 806 pauses at monitoring sub-step 807 until controller 510 senses an actuation. When an actuation is sensed, another sub-step, mode decision step 808 determines the type of actuation and continues the method accordingly. For example, a sensed bump actuation may send the method into the brew mode 812 , and a long duration actuation may send the method into a programming or saving mode of operation 912 . The saving mode of operation, and its return to the monitoring step 806 will be described in more detail.
[0074] An actuation direction decision step 810 immediately follows step 808 . The direction of actuation, clockwise/left (CW) or counter-clockwise/right (CCW), may cause the method 800 to respond differently depending on whether a shot is brewing at the time of actuation or not, i.e. in an idle state. If no shot is brewing at actuation, as sensed by the controller at shot brewing decision steps 814 and 820 , the direction may determine which of two sets of parameters is used for the subsequent shot, i.e. the set stored in the current computer temporary brew memory or a different set stored in the computer storage memory respective to the CW left or CCW right bump. In a preferred embodiment, a sensed CCW right bump with no shot brewing causes the controller to retrieve the set of brew parameters stored at the next sequential memory storage location 541 - 546 for that group head at cycling step 821 . That set is placed into the temporary brew memory at step 824 . If the CCW right bump is repeated, the brew parameters at the next sequential memory storage location 541 - 546 is retrieved into temporary memory at 821 , and so on. Thus, the operator experiences a cycling of stored recipes on that group head.
[0075] If a CW left bump is sensed while in the idle state, method 800 proceeds to begin the programmed sequence at step 816 according to the selected set of parameters stored from step 824 in the temporary computer brew memory. The programmed brew sequence then begins as described in FIG. 7 with the pre-infusion step 717 of opening the control valve to begin the controlled dose of hot water. Step 816 also initiates a saving into the computer temporary memory of subsequent actuation steps. Then the method 800 returns to the sensing/monitoring step 806 to await the next sensed actuation of the group control head paddle.
[0076] If no further actuations occur, the programmed sequence of FIG. 7 automatically completes itself and delivers a controlled dose in accordance with the selected set of parameters. The set of parameters saved to the temporary brew memory would in this case be identical to the selected set.
[0077] If the selected set of parameters is set to a null manual MAN setting or the mode of operation is in the Manual mode, the method 800 may continue in a completely manual sequence. The sequence still follows the FIG. 7 sequence, but the transition between each phase occurs at an actuation sensing and never at an elapsed time. In an example manual mode operation, the first momentary action of the group control head handle begins the pre-infusion step whereby the control valve is opened and the parameter saving is initiated. The controller would respond to subsequent CW momentary actuations of the handle by repeatedly proceeding along the cycle of step 808 , step 810 , step 814 , a proceed to next shot phase 818 , and a return to step 806 . Thus, the full pressure phase, and/or the optional pressure ramp up or ramp down phase is controlled by the repeated sensed CW actuations at next shot phase 818 . These phases involve starting and running the pump to provide the controlled dose of hot water through the dosing unit. At each phase transition, a parameter related to the duration of each phase is saved into the computer temporary memory at saving step 824 .
[0078] In one embodiment of the completely manual mode, the third actuation of the proceed to next shot phase 818 stops the pump to end the controlled dose of hot water. Optionally, a fourth actuation of the next shot phase 818 closes the control valve at the proper shot dose volume corresponding to end sequence step 726 . The duration of each of these phases is saved into the temporary memory at saving step 824 . The overall saving of these steps thus creates a complete set of brew parameters in memory. The saved set of brew parameters may be used in subsequent programmed brew sequences.
[0079] As can be seen in FIG. 8 , a CCW bump of the group control head handle sensed at step 810 while the shot is brewing as sensed at step 820 always causes the method to immediately proceed to stop shot step 822 . This step 822 stops the pump and closes the control valve to end any further flow through the dosing unit. A user may also perform this actuation if, for example, when the desired brew volume has already been reached but the flow is continuing under the ongoing programmed sequence.
[0080] FIG. 8 also illustrates how the method 800 may be used to dynamically adjust, while operating in the automatic programmed brew sequence mode, a set of parameters that have already been saved in memory. In this situation, the espresso machine is prepared to dispense the next dose using a previously saved set of parameters. When the momentary actuation is repeated and sensed at step 806 , the control valve is re-opened and the controller newly initiates the saving of parameters into the temporary memory. The new programmed brew sequence begins again. If no further actuations are sensed during the brew, then the programmed brew sequence automatically controls the control valve and pump to replicate the previous controlled dose of hot water.
[0081] But if the user desires to adjust, i.e. shorten, one or more of the sequence phases, then she merely again bumps the paddle CW to truncate that phase and immediately start the next phase at step 818 . This action may, for example be a repeat of the third momentary actuation step, which stops the pump and therefore stops the replication. The phase duration as defined by the actuation is saved into the temporary memory as part of a new, i.e. second, set of brew parameters. In one embodiment the saving at step 824 further comprises the step of overwriting the previous set of brew parameters with the second set of parameters in the temporary memory. This second set can then be used for subsequent brews. In a preferred embodiment, adjustment of every brew phase is enabled for Manual mode of operation, and a limited adjustment of only the low pressure finish phase, step 724 of FIG. 7 , is enabled during Manual Program mode of operation.
[0082] A summary of the FIG. 8 operation is illustrated in state table 801 . There shown is the response in the espresso machine corresponding to each particular operation of the group head control handle during the normal, or brew mode of operation.
[0083] The espresso machine apparatus that is previously described may be modified to use the method 800 for storing and adjusting the dosing conditions. In addition, the machine may optionally comprise visual display 180 , which displays the phase of the sequence as the sequence proceeds. After the sequence is complete, the visual display 180 may display an indication that the phases have been saved as a new set of parameters.
Example
[0084] The barista prepares the espresso dosing unit and refreshes the grounds in the filter. She decides to manually brew a shot. The barista bumps the group control head paddle to the left to begin pre-infusion and watches for the first drips to pass the filter basket. Once the basket is saturated, she bumps the paddle left again to add pump pressure. The shot speed begins to increase and the color of the flow begins to lighten toward the end of the shot. She bumps the paddle left again to return to line pressure, then bumps it right to end the shot.
[0085] Example parameters saved into temporary memory for this manual shot are 6.2 seconds pre-infusion and 60 milliliters water volume with a 97% low pressure finish. This set of parameters is now available to save for future replication.
[0086] Of course, if the sequence is not progressing satisfactorily, a bump of the paddle to the right while the shot is in progress immediately ends the shot.
[0087] Method and Apparatus for Saving an Optimized Set of Brew Parameters
[0088] FIG. 9 continues the FIG. 8 method flow, further describing a method 900 for storing brewing parameters in an espresso machine. The method starts when the first sensed actuation of the group control head handle at step 806 enters the machine into a program and save mode of operation 912 . This path is shown by the indicator AP. An example first actuation is a long hold, e.g. greater than 250 milliseconds, to enter this mode.
[0089] Responsive to entering the program and save mode of operation 912 , the current set of brew or shot parameters is obtained from the computer temporary brew memory at step 902 . The visual display 180 corresponding to the dosing unit may begin to flash the save icon 610 at this time to indicate the saving/programming mode of operation. One object of this invention is that this current set of shot parameters can then be assigned to as many computer storage memory locations on as many different group control heads in the system as desired. In addition, the visual display 180 may also begin to indicate the current set of brew parameters. Of course, if the operator desires to store a set of brew parameters that is not currently in the computer temporary brew memory, she may transfer the desired set of parameters from a computer storage location to the temporary brew memory prior to the obtaining step above. Preferably, this is done by selecting the computer storage location with the desired parameters with one or more right bumps from idle, step 821 , and then running that shot with a left bump, step 816 shown in FIG. 8 .
[0090] Also responsive to entering the program and save mode of operation 912 at the first sensed actuation, the controller selects a default or initial computer storage memory location at initial storage memory step 903 . This default computer storage location may be pre- selected to appear each time the save mode is entered, or may simply be the last storage memory location used. If the espresso machine has multiple dosing units, the controller may select a default memory location at each group control head. Preferably, the visual display(s) 180 displays the active computer storage memory location at this step. The group control head of the first sensed actuation may optionally display brew parameters from the set in the temporary brew memory or the computer storage memory at the obtaining step.
[0091] Method for Storing Brewing Parameters, Single Dosing Unit
[0092] After entering the save mode of operation 912 , the method proceeds to the step of saving the set of parameters from the last shot brewed, i.e. the parameters in the computer temporary brew memory, into a computer storage memory location. In one simple embodiment, the operator merely bumps the group control head handle to the left, sensed as a second actuation by the controller. The method flow shows the bump sensed as a left actuation at direction step 906 and as a bump at duration step 910 . The left bump causes the controller to save the set of brew parameters into the default or initial storage memory from step 903 .
[0093] The operator may wish to save the set of brew parameters into a different computer storage memory location than the default location. The operator selects a different location by scrolling through the available locations with one or more right bumps of the group control head handle. The controller senses the input at direction step 906 and duration step 911 to scroll to the next available storage memory at step 914 . Step 914 preferably includes the display of the computer storage memory location on visual display 180 , as exemplified in FIG. 6( b ) . A subsequent left bump, steps 906 , 910 saves the set of parameters to the selected location at step 908 . It is preferable that the bumps for scrolling and saving are in opposite directions of the handle, but the particular directions described above may be swapped within the scope of the invention.
[0094] The operator exits the save mode of operation at step 940 and returns to the brew mode of operation. The controller may exit the save mode in several ways, e.g. by a time-out or immediately upon the saving step. Preferably, an affirmative actuation triggers the exit, such as a group head control handle “right hold” actuation, as shown by the path of direction step 906 and as a hold at duration step 911 .
[0095] An additional function may be provided while in the save mode of operation. The controller may cycle to another of a group mode at cycle mode step 909 , e.g. Manual Mode or Manual Program Mode or Volumetric Program Mode, responsive to a sensed left hold from the group control head handle via direction step 906 and duration step 910 . When a set of parameters is subsequently saved, the set will correspond to that particular group mode.
[0096] A summary of the FIG. 9 operation is illustrated in state table 901 . There shown is the response in the espresso machine corresponding to each particular operation of the group head control handle during the program and save mode of operation.
[0097] Transferring a Set of Brew Parameters between Espresso Dosing Units
[0098] If the espresso machine is a multi-head device having a plurality of previously described espresso dosing units, the machine may be arranged to transfer a desired set of brewing parameters from one of the dosing units to another. In this embodiment, a controller 510 is in communication with all of the group control heads, temporary memories, and storage memories. A visual display is optionally associated with each dosing unit.
[0099] The system is arranged such that when a program and save mode of operation is entered at any of the dosing units, for example by the method flow chart of FIG. 9 , controller 510 activates all of the dosing units for saving.
[0100] FIG. 12 illustrates one embodiment of the group display 1200 . After entering the save mode 900 and obtaining the desired set of brew parameters with one of the group control heads, all of the visual displays 180 , 180 ′, 180 ″ will display a save screen 620 , 620 ′, 620 ″ and a flashing save icon 610 . Any of the other group control heads can be scrolled as described above to select that dosing unit's desired storage location for saving. Then each group control head can separately save the desired set of brew parameters to the selected memory and exit the save mode as described above. Exiting from the save mode alternatively may be accomplished all at once by exiting the save mode, step 940 , at the source group control head.
[0101] After either of the above described transferring steps, a programmed brew sequence may be initiated at any of the dosing units according to the transferred set of brew parameters. When a subsequent group control handle bump for another of the dosing units is sensed at its step 806 , then a new programmed brew sequence is initiated according to the transferred set of parameters. The espresso machine then automatically conducts the programmed sequence at step 812 to dispense the new dose of espresso. Thus the conditions for the desired dose are replicated across the dosing units.
[0102] FIG. 10 illustrates example visual display graphics and state machine diagram 1000 that accompany the program and save mode of operation. Prior to entering the save mode, the espresso machine is in the brew mode of operation 1001 , and typically runs a shot to automatically save the last shot into the computer temporary brew memory at step 1002 . The operator then performs a right hold, e.g. for 2.5 seconds, at enter save mode step 1004 , whereupon the visual display 180 begins to flash the save icon. The operator then optionally bumps right one or more times at step 1006 to change the desired computer storage memory location for saving. When the desired location is selected, the operator bumps left at save step 1008 to save the shot parameters to the location. The operator then exits the save mode at step 1010 with a right hold, e.g. for 2.5 seconds.
[0103] After the save mode of operation ends at exit step 940 , the espresso machine is then ready to enter the brew mode again with the newly saved and selected set of brew parameters. If a different set of brew parameters is desired, the operator simply bumps right one or more times to cycle through the recipes, and stops when the desired recipe is reached. When a subsequent group control handle bump is sensed at step 806 , then the new programmed brew sequence is initiated according to this new second set of parameters. The espresso machine then automatically conducts the programmed sequence at step 812 to dispense the new dose of espresso.
[0104] FIGS. 11( a ) through 11( d ) illustrate an additional series of state machine diagrams for the operation of the espresso machine. FIG. 11( a ) illustrates program mode adjustment state machine 1102 . When the controller senses a left hold, e.g. 2.5 seconds, on a group control head handle, the controller enters the cycle program mode. Subsequent left holds cause the controller to cycle its program mode through the available programs, here shown the modes Manual 1104 , Manual Program 1106 , Volumetric Program 1108 , and cycle back to Manual 1110 . Further detail about operating in these modes is shown in FIG. 11( b )-( d ) .
[0105] FIG. 11( b ) illustrates one exemplary operation of the Manual Mode 1120 , a mode that allows the operator complete control of the shot parameters. Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1122 . The controller begins the pre-infusion operation, and awaits subsequent bumps left before advancing the shot to the next phases of pressure ramp-up step 1124 , full pressure brew step 1126 , and pressure ramp-down step 1128 respectively. The shot is stopped at step 1129 at a sensed bump right. The brew parameters are retained within the computer temporary brew memory. Visual display 180 may display the current phase and parameters during the shot.
[0106] FIG. 11( c ) illustrates one exemplary operation of the Manual Program Mode 1130 , a mode that allows the operator limited control of the shot parameters. Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1132 . The controller automatically advances the shot to the next phases of pressure ramp-up step 1134 , full pressure brew step 1136 , and pressure ramp-down step 1138 . The shot is stopped at step 1139 at a sensed bump right. The operator may adjust the “blonding” of the shot at step 1136 with a left bump to truncate the shot pressure, and then may end the shot at the desired volume (if necessary) with a right bump at stop step 1139 . Visual display 180 may display the current phase and parameters during the shot.
[0107] FIG. 11( d ) illustrates one exemplary operation of the Volumetric Program Mode 1140 , a mode that allows the operator control of the start of the shot only. Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1142 . The controller then automatically advances the shot to each next phase at pressure ramp-up step 1144 , full pressure brew step 1146 , and pressure ramp-down step 1148 according to the program brew parameters in use. The shot is automatically stopped at step 1149 upon reaching the pre-programmed volume as sensed by the flowmeter. In this program mode, the operator may truncate the shot at any time with a bump right. The visual display 180 may display the current phase and parameters during the shot.
[0108] The functionality of the various program modes corresponds to the method flow steps as shown in FIG. 8 . For example, a sensed CCW actuation at step 810 with a shot brewing at step 820 which immediately ends the shot at step 822 . This corresponds to the right bumps at FIG. 11 steps 1129 and 1139 .
[0109] When the paddle is released, the save mode of operation then exits at exit step 940 . The espresso machine is then ready to enter the brew mode again with the newly saved and selected set of brew parameters. When a subsequent group control handle bump is sensed at step 806 , then a new programmed brew sequence is initiated according to this new second set of parameters. The espresso machine then automatically conducts the programmed sequence starting at step 812 to dispense the new dose of espresso.
[0110] Retrieving a Stored Set of Parameters for Use
[0111] FIG. 8 at state machine table 801 also illustrates a method for obtaining from storage memory a set of parameters for use, where the set of parameters has been previously stored in one of the page portions instead of the temporary brew memory. This functionality is enabled simply by cycling through the memory storage locations by means of scrolling with the group control head handle. In the FIG. 9 embodiment, the group control head handle is bumped right one or more times to cycle through the storage locations, up to six. When cycled, visual display 180 preferably highlights the particular location. A subsequent bump to the opposite left side then starts the shot using that selected recipe. The shot parameters are also transferred to the temporary brew memory during the shot, for subsequent saving and use.
Example
[0112] Some example settings for a page in computer storage memory appear in Table 1 below:
[0000]
Brew Group 2 (Volumetric Mode)
Program 1
Pre-infuse
4.0
Ramp Up
1.8
% of Shot Brewed
91%
Total Water Volume
350
[0113] A note from the morning barista says that they made a great shot earlier in the day and saved it in Brew Group 2 Program 1. We are currently using Program 2 on the second group, so the first step is to cycle to the Program 1 by bumping the group head control handle five times until Program 1 is highlighted on visual display 180 ′. Then we prepare a filter puck and bump left. The programmed sequence will run through 4 seconds of pre-infusion, ramp up for 1.8 seconds, and then run the pump until 91% of the total flow meter count of 350, corresponding to about 60 ml of water, has been dispensed. The pump will then shut off and the shot will finish at line pressure.
[0114] An espresso machine apparatus as described in FIGS. 1 through 6 comprises each of the elements that are necessary to perform the methods described above. An optional external programming controller 190 , described in FIG. 13 may be used in concert with the group control heads, controller, memories, and programmed sequences for additional flexibility in programming.
[0115] FIG. 13 shows an embodiment of the optional external programming controller 190 that may be used with the inventive espresso machine. Controller 190 is preferably handheld and communicatively connected to the controller 510 by wired or wireless means. Controller 190 includes three main features. Programmer display 192 displays information related to the stored programs. Programmer selection buttons 194 are arranged next to the display to enable the user to select particular items in display 192 . Programmer scrolling arrows 196 enable the user to adjust values of the displayed items.
[0116] If no useful set of brewing parameters yet exists in computer storage memory, or if it is desired to enter the values without brewing, one or more of the parameter set values may be more easily entered via the controller 190 . For example, the user wishes to adjust the volume of the shot on number 2 brew group, i.e. dosing unit. She scrolls with the scrolling arrows 196 until Brew Group 2 is displayed. The desired set of brew parameters resides in the memory storage location 1 , so she presses the button 194 that is adjacent that label. Then she presses the scrolling arrows to adjust the volume to the desired amount. Another press of the button 194 deselects the line and updates the set of brew parameters at that memory location. As previously described, this new set of brew parameters can be saved to any of the other memory locations in any of the other brew groups, and can be used with the group control head controls during the next brew. The entry of data using programmer 190 may also be conducted in concert with selection and saving of that data via the group control head operations as described above.
[0117] Modifications to the device, method, and displays as described above are encompassed within the scope of the invention. For example, various configurations of the plumbing and electrical systems which fulfill the objectives of the described invention fall within the scope of the claims. Also, the particular appearance and arrangement of the apparatus may differ.
[0000]
Table of Elements
Number
Name
100
Espresso machine
102
Espresso dosing unit
110
Group control head
110′
Second group control head
110″
Third group control head
150
Brew tank
160
Filter
170
Outlet spout
180
Visual display
180′
Second visual display
180″
Third visual display
190
External programming controller
192
Programmer display
194
Programmer selection buttons
196
Programmer scrolling arrows
200
Espresso machine
202
Steam tank
204
Pump
206
Control valve
208
Bypass control valve
210
Water source
250
Brew tank
250′
Second brew tank
250″
Third brew tank
260
Filter
300
Group control head
302
Base
314
Handle
316
paddle
324
Top plate
325
Pivot pin
340
Actuator
342
Magnet
350
Centering post
374
Proximity sensor board
375
First proximity sensor
376
Second proximity sensor
400
Idle position
410
Brew position
420
Control position
500
Espresso machine electrical system
502
Group head flow meter
504
Brew tank temperature sensor
510
Controller
520
Visual display
522
Pump control output
524
Control valve control output
526
Bypass valve output
530
Computer memory
532
Computer temporary brew memory
534
Computer storage memory
Computer storage memory page
Page left portion
Page right portion
540
Power supply
541-546
Computer storage memory storage locations
600
Operational display of programmed sequence
602
Shot timer display
604
Mode icon
606
Brew sequence phase display
608
Memory storage location icon
610
Save icon
620
Save mode display of brew parameter set transfer
620′
Second save mode display (not used)
620″
Third save mode display (not used)
622
Save left icon
624
Storage memory cycling icon
700
Espresso machine brewing sequence
702
Brewing start step
716
Brewing initiation step
717
Pre-infusion brew phase
720
Pressure ramp up phase
722
Full pressure brew phase
724
Pressure ramp down phase
726
Stop shot phase
727
End step
800
Method for providing hot water dose
802
Method start step
804
Providing an espresso machine step
806
sensing step
807
Monitoring step
808
mode decision step
810
actuation direction decision step
812
brew mode
814
shot brewing decision step
816
begin programmed sequence step
818
Proceed to next phase in sequence step
820
shot brewing decision step
821
Cycle recipe step
822
stop shot step
824
save into temporary memory step
900
Method for storing brewing parameters in an espresso machine
901
Saving method state table
902
Obtain brew parameters step
903
initial computer storage memory location step
906
Sense actuator direction step
908
Save to selected storage memory step
909
Group mode cycling step
910
Duration step
911
Duration step
912
Enter program and save mode of operation
914
scroll to the next available storage memory at step
940
Exit from program and save mode of operation
1000
Visual display state machine diagram, save mode
1001
Initial brew mode of operation
1002
Save last shot into computer temporary brew memory step
1004
enter save mode step
1006
change computer storage memory location step
1008
save to active computer storage memory step
1010
Exit save mode step
1102
Program mode adjustment state machine
1104
Manual mode
1106
Manual program mode
1108
Volumetric program mode
1110
Manual mode cycle
1120
Manual (M) mode of operation
1122
M start and pre-infusion step
1124
M pressure ramp-up step
1126
M full pressure brew step
1128
M pressure ramp-down step
1129
M stop step
1130
Manual Program (MP) mode of operation
1132
MP start and pre-infusion step
1134
MP pressure ramp-up step
1136
MP full pressure brew step
1138
MP pressure ramp-down step
1139
MP stop step
1140
Volumetric Program (VP) mode of operation
1142
VP start and pre-infusion step
1144
VP pressure ramp-up step
1146
VP full pressure brew step
1148
VP pressure ramp-down step
1149
VP stop step
1200
Groups display
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An espresso machine that includes a group control head for controlling the brewing and dispensing of espresso drinks. The group control head is in communication with a controller and memory. The combination is arranged to selectively record into the memory the brewing parameters during the dosing of espresso. A subsequent operation of the group control head then enables the controller to recall the recorded parameters such that the previous brewing conditions are replicated. Associated methods for recording the parameters under control of the group control head are also described.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cutting tools, and more particularly, to a method for extending the life of cutting tools having one or more cutting edges through shot peening.
2. Description of the Prior Art
Cutting tools are a necessary staple of the vast majority of manufacturing and repair facilities in operation today. While cutting tools, in the broadest sense, encompass such devices as grinding wheels, gas torch cutters, laser beam cutters and the like, the present invention is directed toward cutting tools that have one or more cutting edges, especially those that are designed for use in machines such as drills, drill presses, mills, lathes and the like. Representative examples of such cutting tools include drill bits, taps, mill cutters, broaches, turning cutters, form cutters and the like.
The important characteristic which is common to all of these cutting tools is that their cutting edges must be sharp and must be maintained sharp in order to satisfactorily function in their designed application. As the cutting edges begin to dull, a variety of problems evolve. For example, a sequence of smooth cuts is gradually replaced with jagged and scored surfaced cuts. Dullness increases the friction forces between the tool and the workpiece, increasing the strain on the cutting machine, as well as increasing the heat of both the cutting tool and the workpiece, both of which become increasingly more susceptible to breakage. As the cutting chips and shavings become more irregular, jams and sticking of the tool increases. The combination of the increased torque forces and the work hardening brittleness to which a dull cutting tool is exposed will quickly lead to complete tool failure. Scratches on a dull cutting tool turn into cracks and eventual complete tool failure. Finally, as the cutting tool dulls, the quality of the workpiece decreases, since dimensional tolerances become increasingly difficult to hold.
Because of the expense and poor quality resulting from the above problems, a constant vigilence is required to maintain the cutting edges of cutting tools sharp. Typically, as the cutting tool begins to dull, it is removed and precision ground to restore sharp cutting edges. While this is a costly operation, including either machine down time or the expense of an inventory of backup tools to minimize machine down time, it is less costly than poor quality workpieces and the replacement of expensive broken cutting tools. Consequently, extending the life of cutting tools, including the time between required resharpening operations, is an everpresent goal. Although modern technology has provided improved alloys for high speed and tool steel cutting tools, further improvement, especially at low cost, would be of significant value.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method for extending the life of cutting tools having one or more cutting edges which is simple, reliable, economical, which reduces tool breakage and improves workpiece quality, and which results in the cutting tools having lives many times the lives of existing tools, including the life between required resharpenings. The method comprises shot peening the surface of the cutting tool, including all cutting edges thereof, with substantially spherical shot peening media which comprises glass beads. Optimum results have been achieved with steel cutting tools.
The preferred shot peening media of glass beads has a Mil Spec size of from about G-9954A 3 to about G-9954A 13, and the peening is preferably conducted at an Almen intensity of from about 0.002 to about 0.010 A2.
Cutting tools shot peened in accordance with the method of the present invention uniformly exhibit lives on the order of from about 2 to over 20 times the lives of identical but unpeened tools, including the life between required resharpening.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention was the result of the surprising discovery that shot peening with generally spherical shot of glass beads dramatically extends the life of cutting tools with no adverse effect on the sharpness or uniformity of the cutting edges. It was discovered that although the cutting edges of the peened tools were initially slightly less sharp than the cutting edges of identical unpeened tools, after only a few cutting operation cycles, this status was reversed as the unpeened tool cutting edges dulled much more quickly. Heretofore, cutting tool manufacturers and the resharpening machinists would strive to provide as smooth and regular a surface on the cutting edges as possible. Although shot peening has been in widespread use for years to increase the fatigue life and prevent stress corrosion cracking of metal parts, a peened surface on the cutting edge of a cutting tool would be unthinkable, since it would be contrary to the accepted goal of achieving as smooth and regular a surface on the cutting edge as possible.
In performing the method of the present invention, conventional shot peening techniques and equipment are utilized, i.e., the surface of the tool, including the cutting edges, is bombarded with shot by a peening apparatus under controlled conditions. However, in the preferred embodiments, optimum results are achieved by utilizing specific sizes of the glass beads and specific Almen peening intensities. The preferred peening apparatus includes air blasting equipment which propel the shot media at the part under air pressure, utilizing either suction, direct pressure or gravity feed. Either wet or dry peening procedures may be utilized.
With respect to the shot peening media, the use of substantially spherical glass beads is critical to the success of the method of the present invention and the dramatic improvement to the life of the cutting tools. Irregular angular or abrasive media, such as employed in grit blasting, are totally unacceptable in the method of the present invention. Even generally spherical peening media other than glass beads, such as steel shot, are unsatisfactory. In the preferred embodiment, the glass beads have a Mil Spec size of from about G-9954A 3 to about G-9954A 13. Substantially larger beads tend to damage the cutting edges, while substantially smaller beads do not consistently provide significant improvement to tool life. Within the above range, the specific size election should be based on the size of any tool crevices or the spacing between cutting edges on multiple edged tools, such as taps and the like, to insure that the peening will reach all surfaces and not become trapped or lodged in the tool.
The peening process should be conducted under conditions that will yield substantially 100% coverage and saturation of the cutting tool surface. Under the generally accepted Almen shot peening intensity standard, which was developed by the General Motors Research Laboratories Division of General Motors Corporation, the various variables of shot peening are integrated into a single scale for measuring, specifying and duplicating shot peening intensities and results. All measurements are made on the standard Almen No. 2 gage, as shown in the SAE Manual on Shot Peening, AMS 2430 and MIL S-13165. In the present invention, when peening with glass beads in the above preferred size range, optimum results have been achieved with an Almen intensity of from about 0.002 to about 0.010 A2.
The method of the present invention has produced consistent improvement in life on a wide variety of cutting tools, such as taps, drill bits, broaches, cutting mills, shaper cutters, various turning and form tools and the like. The method has been especially effective on steel tools. A side by side comparison of cutting tools shot peened in accordance with the method of the present invention and identical but unpeened tools in the same cutting operation and equipment, on identical workpieces, dramatically demonstrates the value of the present method. In virtually every such test, the improvement in longevity of the peened tools is manyfold, ranging from a factor of about 2 to over 20.
The substantial and consistent increase in life of cutting tools peened according to the method of the present invention, which is simple and economical to perform, represents a significant contribution to the tool industry. In addition, the method and the peened tools also demonstrate a variety of other improvements and advantages. For example, the method is not limited to any particular physical size or configuration of cutting tool. Not only do the peened tools require less frequent resharpening than unpeened tools, in most cases the resharpening of the peened tools requires significantly less material removal than required with the unpeened tools, thereby adding to the longevity of peened tools. Under magnification, the peened surface of the tools has an "orange peel" like appearance. Since most machine operated cutting operations maintain coolant on the tool cutting edge, which is difficult with the conventional smooth tools, the shallow indentations of the peened tools act as small coolant reservoirs and thereby keep the cutting tool at a lower temperature with less galling, scoring and work hardening.
Another improvement of the peened tools is that peening provides a compressive stress layer at the surface, which reduces fatigue and cracking failures which are common in the case of the tensile stress surface of unpeened tools. Small scratches and cracks on the surface are less frequent, and, when they do occur, the compressive stress surface layer of the peened tools resists growth and inward propagation of the cracks.
Finally, when the economies of the low cost method of the present invention are combined with the substantial savings in resharpening and breakage down time and tool replacement costs, because of the extended life and superior properties of the peened tools, it is clear that the method and peened tools of the present invention represent a substantial advance in the cutting tool industry.
While the preferred embodiments of the present invention have been described and set forth, it will be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the present invention. Accordingly, the scope of the present invention is deemed to be limited only by the following appended claims.
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A method for extending the life of a cutting tool includes shot peening the surface of the tool, including all cutting edges thereof, with substantially spherical shot peening media of glass beads. Maximum life extension is achieved by optimizing the parameters of the peening process, including the Almen intensity and the shot size and uniformity. Cutting tools, especially steel tools, shot peened in accordance with the present method display many-fold increases in life.
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BACKGROUND OF THE INVENTION
a) Field of the Invention
The invention is directed to a subassembly for generating an optically active slit with a changeable slit width s, preferably for slit lamps, with two slit plates or slit jaws which are displaceable relative to one another at a straight-line guide and between which the slit is formed, wherein one of two guide paths is allocated to each slit jaw.
b) Description of the Related Art
In optical instrument engineering, it is frequently necessary to generate illuminated fields of different geometric shapes with a virtually uniform illumination. One shape of illuminated field that is very frequently required is a light slit which is adjustable in width and length with an exactly parallel limiting of the slit width. Precision guidance of the slit-shaping structural component parts and a high edge quality at the slit jaws are needed to generate a light gap of this kind with high-contrast, sharp image borders.
A preferred application for subassemblies for generating an optically active slit is the slit lamp, which is frequently used for ophthalmologic diagnosis. It comprises essentially a stereo microscope and a projection device, both of which are arranged so as to be movable on a carrying system and coordinated with one another. The projection device makes it possible to generate geometrically different light fields. It is coupled with the stereo microscope in such a way that the center of the illumination field plane generally coincides with the center of the observation plane.
For example, a slit width which is adjustable from “zero” to 14 mm in a continuous and sensitive manner is required for applications of the kind mentioned above, wherein “zero” signifies an absolutely tight closing of the slit. The length of the slit can be between 0.3 mm and 14 mm, for example; further, the slit must often be swivelable by at least ±90° about the optical axis.
A significant problem in slit-forming optical subassemblies continues to be that the function-related caused proximity of the light housing which contains the illumination source giving off heat causes temperature fluctuations which disadvantageously affect the parallelism of the slit and which require a slit jaw guide that still generates a light slit satisfying requirements with respect to quality in spite of the influence of temperature.
The slit jaw guides known from the prior art have straight guide elements based on sliding friction or rolling friction in which two slit jaws which are displaceable relative to one another for changing the slit width are pretensioned against a guide path arranged at the frame by means of correspondingly constructed sliding or rolling guide elements so as to be free of play.
A disadvantage in all of the known technical solutions in this respect is the transmission of thermal and mechanical influences to the slit jaws which still occurs to an undesirably high degree and the consequent unwanted influence on the slit parallelism which manifests itself, for example, in the inability of the slit to close absolutely tight. To this extent, in spite of the large number of solutions that are already known, there is still a need for development, the aim of which is to reduce the troublesome influences and their consequences.
OBJECT AND SUMMARY OF THE INVENTION
Based on this prior art, it is the primary object of the invention to further develop a subassembly of the type mentioned above for generating an optically active slit in such a way that the consequences of external influences on the parallelism of the light slit are further reduced.
According to the invention, it is provided in a subassembly for generating an optically active slit of the type mentioned above that the guide paths are formed at portions of a guide rail which project out freely from a clamping position at the frame in the displacement directions of the slit jaws.
Due to the fact that the guide rails project out freely, this guide rail can expand without hindrance under the influence of temperature in the displacement direction.
In a preferred constructional variant of the invention, the guide paths are formed at two portions of a guide rail which project in opposite directions in a cantilevering manner from a clamping position. It is therefore possible to compensate for changes in length through unimpeded longitudinal expansion of these two portions in opposite directions.
In another constructional variant of the invention, it is provided that the guide paths are formed at two portions of the guide rail which project in one direction from a clamping position, wherein the end portion of the guide rail located opposite to the clamping position is supported in a floating manner. This guarantees compensation of changes in length of the guide rail in this direction proceeding from the clamping position. The guide rail can expand in the displacement direction, whereas changes in its position vertical to the displacement direction are impossible.
Further, in an advantageous manner, means for bending the guide rail are provided in the middle between the clamping position and the opposite end portion which is supported in a sliding manner, wherein the alignment of the two guide paths can be corrected by this bending. When the rail is bent using these means and the relative alignment of the two guide paths is adjusted, the parallelism of the slit can be influenced in this way. Accordingly, an adjustment possibility is provided which can preferably be carried out for an optimal adjustment of the slit parallelism prior to mounting the subassembly, according to the invention, in an optical device, for example, in a slit lamp.
In this connection, a particularly preferred construction consists in that a threaded pin is provided as means for bending the guide rail, wherein a bending of the guide rail in the longitudinal direction of the slit is accomplished by advancing the threaded pin. For this purpose, the guide rail, the clamping means for the guide rail, and the threaded pin should be made from the same material with the lowest possible coefficient of expansion, preferably stainless steel, so that changes in length caused by temperature influences can be compensated.
In a further construction of the invention, it is provided that slides are located across from the guide paths and are outfitted either with sliding guides or rolling body guides, the slit jaws being fastened thereto. The rolling body guides can be constructed in such a way, for example, that they engage around the guide paths.
Alternatively, it can also be provided that V-grooves which slide against the guide paths are formed at the slides. In this connection, it is advantageous when tension springs and/or pressure springs are provided for generating a pretensioning force between the slides and the guide paths, wherein one end of the spring is fixed with respect to the frame and the other end of the spring is attached to one of the slides. This ensures that the V-grooves always make contact with the associated guide paths and are thus also always aligned in the guide direction.
In one construction, tension springs are provided for this purpose and are arranged in such a way that their spring force causes the pretensioning of the V-grooves against the respective associated guide path with a first component F 1 and, with a second component F 2 , causes a pretensioning of the respective slide against an actuating member which is used to adjust a distance between the slides in the displacement direction and accordingly serves for adjustment. In this way, the contact of the V-grooves against the guide path and the contact of the slide against the actuating member are ensured with a spring allocated to a slide and to a slit jaw, respectively. In addition the tension springs can be arranged in such a way that the spring force, with a third component F 3 , prevents a rotation of the slit jaws around the displacement direction as will be shown in detail in the embodiment example.
In an advantageous manner, rolling bearings can be provided in order to minimize the friction between the actuating member and the slides, the displacement movement being transmitted from the actuating member to the slides via the rolling bearings. The reduced friction at this location results in a reduction in the tilting moments which are directed to the slides during the rotation of the actuating member and which accordingly involve the risk of a faulty adjustment of the slit parallelism.
It is particularly advantageous when the attachment of the tension springs to the slides is provided at least approximately in the axis of the rolling bearing arrangement, which serves to reduce the friction between the slides and the actuating member.
In order to achieve an optimum slide pairing between the V-grooves and the guide paths, the surfaces of the V-grooves and/or the surfaces of the guide paths can be provided with a friction-reducing coating, for example, a DLC layer.
The invention will be described more fully in the following with reference to two embodiment examples. Shown in the accompanying drawings are:
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic top view of a first constructional variant;
FIG. 2 illustrates a section AA from FIG. 1;
FIG. 3 illustrates a section BB from FIG. 2;
FIG. 4 is a schematic view of a second constructional variant; and
FIG. 5 illustrates a section CC from FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the subassembly, according to the invention, for generating an optically active slit 1 with a changeable slit width s. The slit 1 is formed between two slit jaws 2 . 1 and 2 . 2 which are arranged so as to be displaceable in directions R 1 and R 2 .
The slit jaws 2 . 1 and 2 . 2 communicate, via associated slides 3 . 1 and 3 . 2 , to which they are attached, with an actuating member 4 which is provided with elliptic adjusting faces 4 . 1 and 4 . 2 and which is mounted so as to be rotatable about an axis of rotation 5 . The spacing between the elliptic adjusting faces 4 . 1 and 4 . 2 and the axis of rotation 5 can be changed rotating the actuating member 4 about the axis of rotation 5 .
When the actuating member 4 is rotated (e.g., manually) in such a way that this spacing increases, this change in distance is transmitted to the slides 3 . 1 and 3 . 2 via the outer races, the rolling bodies and the inner races (which are fixedly connected to the slides 3 . 1 and 3 . 2 ) of the ball bearings 6 . 1 and 6 . 2 , shown schematically, so that the slides 3 . 1 and 3 . 2 change their distance from one another and the width s of the slit 1 increases.
A precise straight-line guidance of the slides 3 . 1 , 3 . 2 is required in order to ensure the parallelism of the slit jaws 2 . 1 , 2 . 2 . This requirement is met by a guide rail 7 which is positioned at a frame 9 in a stationary manner by means of a clamping device 8 (see FIG. 2 ). As can be seen in FIG. 2, two guide paths 10 . 1 and 10 . 2 of equal length are formed at the guide rail 7 and cantilever out from the clamping position in opposite directions.
Alternatively, the slides 3 . 1 , 3 . 2 can be connected with the guide paths 10 . 1 , 10 . 2 by sliding assemblies as well as by rolling assemblies; the invention will be explained in the following with reference to a sliding assembly corresponding to one constructional variant.
In this case, the guide paths 10 . 1 , 10 . 2 have circular cross sections, while V-grooves which slide against the guide paths 10 . 1 , 10 . 2 are provided at the slides 3 . 1 , 3 . 2 . A relatively low-friction sliding assembly is achieved when, for example, the surface of the V-grooves and/or guide paths 10 . 1 , 10 . 2 are provided with a DLC layer. The groove base 11 of the V-grooves is shown in FIG. 2 in dashed lines.
FIG. 2 shows a side view of the slides 3 . 1 , 3 . 2 , the guide rod 7 with guide paths 10 . 1 , 10 . 2 , and the clamping device 8 , in which the guide rod 7 is clamped in the center.
The circular cross section of the guide rail 7 can be seen in FIG. 3 (section BB from FIG. 2 ). This guide rail 7 is mounted in the clamping device 8 (by a sliding fit virtually without play) and can be clamped in by a clamping screw (not shown).
Tension springs 12 . 1 and 12 . 2 are provided to ensure contact of the V-grooves at the guide paths 10 . 1 , 10 . 2 , each tension spring 12 . 1 and 12 . 2 being attached by one of its ends to a pin 13 (see FIG. 2 and FIG. 3 ). The pin 13 is arranged at the frame 9 and is stationary with respect to the frame. The tension springs 12 . 1 , 12 . 2 are attached by their opposite ends to pins 14 which are positioned approximately in the geometric center of the slides 3 . 1 , 3 . 2 . The inner races of the ball bearings 6 . 1 , 6 . 2 are also arranged on the pins 14 .
Therefore, each of the two tension springs 12 . 1 , 12 . 2 acts with a force component F 1 in the direction of the guide rail 7 and accordingly brings about a secure contact of the V-groove at the associated guide path 10 . 1 , 10 . 2 for each of the two slides 3 . 1 , 3 . 2 . Further, a spring force component F 2 acts in each instance in the displacement direction of the slides 3 . 1 , 3 . 2 , specifically, in such a way that the effective direction of the components F 2 is opposed to the adjusting directions R 1 and R 2 (see FIG. 1) and therefore the contact of the outer races of the ball bearings 6 . 1 , 6 . 2 is secured against the elliptic adjusting surfaces 4 . 1 , 4 . 2 . The elliptic adjusting surfaces 4 . 1 , 4 . 2 at the actuating member 4 form, in a side view, an elliptic curve 15 shown in dashed lines in FIG. 2 .
When the actuating member 4 is rotated in such a way that the distances between the elliptic adjusting surfaces 4 . 1 , 4 . 2 decrease toward the axis of rotation 5 , the components F 2 act as restoring forces by means of which the slides 3 . 1 , 3 . 2 are displaced opposite to directions R 1 and R 2 and the width s of the slits 1 is reduced.
The spring constant of the two tension springs 12 . 1 , 12 . 2 should be selected in such a way that the force components F 1 are of equal magnitude in all displacement positions of the slides 3 . 1 , 3 . 2 . A substantial advantage of such an arrangement consists in that the spring components F 1 and F 2 act symmetric to the slit jaws 2 . 1 , 2 . 2 and accordingly a tilting of the latter is ruled out.
Finally, FIG. 3 also shows that the effective forces of the tension springs 12 . 1 , 12 . 2 are directed in such a way that the slides 3 . 1 , 3 . 2 are acted upon by a tilting moment around the guide paths 10 . 1 , 10 . 2 which is brought about by a force component F 3 , this tilting moment being contained by a stop strip 15 . This prevents rotation of the slides 3 . 1 , 3 . 2 about the displacement direction.
In a construction of the invention according to FIG. 4, which differs from the previous example, guide paths 16 . 1 and 16 . 2 are provided at two portions of a guide rail 17 which is held so as to be stationary at the frame (e.g., by a press fit) at a clamping position 18 and which cantilevers in one direction from this clamping position 18 into the frame 9 .
In this respect, it can be seen from FIG. 4 that the end portion of the guide rail 17 located across from the clamping point which is stationary with respect to the frame is mounted so as to be displaceable in a sliding fit 19 . This arrangement ensures a change in length of the guide rail 17 caused by temperature influences because, in this case, a relative displacement takes place between the guide rail 17 and the frame 9 inside the sliding fit 19 .
As in the first example, slides 3 . 1 , 3 . 2 are allocated to the guide paths 16 . 1 , 16 . 2 . The straight-line guiding of the slides 3 . 1 , 3 . 2 and the slit jaws 2 . 1 , 2 . 2 at these guide paths 16 . 1 , 16 . 2 is achieved in a manner analogous to the first example.
According to FIG. 4, the slit 1 is oriented at right angles to the guide rail 17 . To this extent, it is easily conceivable that the parallelism of the slit 1 (assuming, of course, a high manufacturing accuracy of all parts of the subassembly) is ensured precisely when the guide paths 16 . 1 , 16 . 2 are aligned with one another. In a special construction of the invention, in order to enable optimal adjustment of this alignment prior to installing the subassembly in an optical device, a threaded pin 20 is fitted into the frame 9 as an adjusting element approximately in the middle between the clamping position 18 and the sliding fit 19 , wherein the advancing direction of the threaded pin 20 is represented by R 3 . Deviations can be corrected by advancing the threaded pin 20 , so that the parallelism of the slit 1 is also provided along with the adjusted alignment of the two guide paths 16 . 1 , 16 . 2 . Further, an automatic compensation for temperature influences is achieved when the materials for the guide rails 7 , the frame 9 and the threaded pin 20 are selected for an identical and also minimized coefficient of expansion.
Further, it can be advantageously provided that the V-grooves are not formed in a continuous manner at the slides 3 . 1 , 3 . 2 , but rather are relief-cut between their ends so as to prevent a tilting of the slides 3 . 1 , 3 . 2 in the displacement direction.
FIG. 5 shows the engagement of the threaded pin 20 on the guide rail 17 in a side view from FIG. 4 .
While the foregoing description and drawings represent the preferred embodiments of the present invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the true spirit and scope of the present invention.
REFERENCE NUMBERS
1 slit
2 . 1 , 2 . 2 slit jaws
3 . 1 , 3 . 2 slides
4 actuating member
4 . 1 , 4 . 2 elliptic adjusting faces
5 axis of rotation
6 . 1 , 6 . 2 ball bearings
7 guide rail
8 clamping device
9 frame
10 . 1 , 10 . 2 guide paths
11 groove base
12 . 1 , 12 . 2 tension springs
13 , 14 pins
15 stop strip
16 . 1 , 16 . 2 guide paths
17 guide rail
18 clamping position
19 sliding fit
20 threaded pin
21 curve
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A subassembly for generating an optically active slit with a changeable slit width s, preferably for slit lamps, with two slit jaws which are displaceable relative to one another at a straight-line guide and between which the slit is formed, wherein one of two guide paths is allocated to each slit jaw. In a subassembly for generating an optically active slit, the guide paths are formed at portions of a guide rail which project out freely in the displacement directions of the slit jaws from a clamping position which is fixed with respect to the frame. The guide rail can accordingly expand without hindrance in the displacement direction under the influence of temperature without the parallelism of the slit being affected thereby.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of application no. PCT/EP2015/066755 filed Jul. 22, 2015 which claims priority from EP 14178938.8 filed Jul. 29, 2014, the disclosures of both of which are incorporated herein by reference.
BACKGROUND
1. Technical Field
[0002] The present disclosure relates to a method and an apparatus for proving an integrity status of an outer packaging as well as for determining the integrity status of a suspect outer packaging. The disclosure further relates to a computer program for performing the mentioned methods as well as to a data carrier having a data structure stored thereon, which, after loading into a computer or a computer network, is capable of executing the methods.
2. Description of the Related Art
[0003] The determination of the integrity status of a packaging is a technology known from the cigarette industry, such as in EP 0 330 495 A2, EP 0 902 275 A1, EP 1 420 381 A1, DE 10 2008 062 370 A1, WO 2001/024141 A1, WO 2001/030654 A1, or WO 2001/079092 A1, where it is, generally, used for determining defects during manufacture of an outer packaging for cigarettes comprising a transparent folded wrapper, but may also be employed in other areas, in particular in the food, medical, pharmaceutical, and/or cosmetic industry as, for example, in U.S. Pat. No. 3,899,295, U.S. Pat. No. 5,515,159, US 2012/013734 A1, or U.S. Pat. No. 7,142,707 B2.
[0004] For this purpose, U.S. Pat. No. 5,515,159 discloses an on-line inspection of opaque, translucent and transparent elastomer sealed flexible and semi-rigid packaging seals, wherein, in case of highly reflective opaque seals of various elastomers and colors, low incident angle structured side lighting is used to locate and define the seal and highlight defects within the sealed area. For transparent, i.e. highly light transmissive seals, back lighting of the packaging is further provided in order to locate and classify defects within the seal boundaries. The images generated are used to determine whether the outer packaging is accepted, possibly accepted, or rejected based upon the quality of the seal area and the presence of any defects in the seal boundaries.
[0005] U.S. Pat. No. 7,142,707 B2 describes an apparatus comprising a computer component which receives at least one image of a packaging material, wherein the computer component employs an analysis of the image to determine a packaging integrity of the packaging materials by comparing optical features, such as transmittance, absorption, fluorescence excitation, or deformation of the packaging or of graphics, or by an identification of bright regions within the outer packaging, in particular by using low-angle incidence of radiation.
[0006] WO 2001/030654 A1 proposes to use at least one label, wherein the label comprises, in an encoded form, at least one characteristic feature of a packed article, in particular of a packed group of cigarettes, wherein the label will be destroyed when opening the outer packaging, such as for taking a cigarette, wherein the encoded form is compared with the characteristic feature in order to reveal falsifications by deviations or recurring identical matches. Alternatively, WO 2001/024141 A1 describes providing individual articles, such as each item in a group of cigarette, with characteristic, externally detectable markings, wherein the markings are encoded and applied to the outer packaging, in particular in form of a label, wherein a comparison between the externally detectable markings and the encoded form on the outer packaging allows determining its integrity.
[0007] EP 0 330 495 A2 discloses a packet inspection system being capable of high speed sensing and evaluation of packaging integrity. The system is capable of measuring predetermined parameters of an outer packaging, e.g. cigarette packages, comparing the measured parameters with predetermined values, evaluating from the measured parameters the integrity of the outer packaging and determining whether such an outer packaging is acceptable or, alternatively, should be rejected. Herein, the measured packaging is compared to a reference packaging to achieve a qualitative evaluation of the packaging structure with respect to wrapper centering alignment, wrapper placement skew, closure stamp alignment, closure stamp skew, flap closure, wrapper foil condition, and packaging shape. A similar inspection system is disclosed in EP 0 902 275 A1.
[0008] However, the known state of the art, on one hand, requires an additional piece, such as a seal, which may itself be subject to manipulation in order to demonstrate integrity of the outer packaging and/or, on the other hand does not allow pursuing the respective good over the whole supply chain.
SUMMARY
[0009] The present disclosure provides a method and an apparatus for proving an integrity status of an outer packaging as well as for determining the integrity status of a suspect outer packaging, which at least partially overcome the problems and shortcomings of such methods and devices known from the state of the art.
[0010] The present disclosure also provides a method and an apparatus for determining the integrity status of the packaging which allows pursuing the respective items covered within the outer packaging over the whole supply chain without any requirement to apply a separate piece for demonstrating its integrity, such as a seal, to the outer packaging in order to be able to detect a manipulation of the outer packaging.
[0011] Disclosed herein is a method and an apparatus for proving an integrity status of an outer packaging, a method and an apparatus for determining the integrity status of a suspect outer packaging, a computer program for performing one or more of the methods according to the present disclosure and by a data carrier having a data structure stored thereon, which, after loading into a computer or computer network, is capable of executing one or more of the methods according to the present disclosure. Preferred embodiments, which might be realized in an isolated fashion or in any arbitrary combination thereof, are described herein.
[0012] As used herein, the terms “have”, “comprise” or “include” or any arbitrary grammatical variations thereof are used in a non-exclusive way. Thus, these terms may both refer to a situation in which, besides the feature introduced by these terms, no further features are present in the entity described in this context and to a situation in which one or more further features are present. As an example, the expressions “A has B”, “A comprises B” and “A includes B” may both refer to a situation in which, besides B, no other element is present in A (i.e. a situation in which A solely and exclusively consists of B) and to a situation in which, besides B, one or more further elements are present in entity A, such as element C, elements C and D or even further elements.
[0013] Further, it should be understood that various terms used throughout this disclosure and claims should not receive a singular interpretation unless it is made explicit herein. By way of non-limiting example, the terms “item,” “modification,” “foil,” to name just a few, should be interpreted when appearing in this disclosure and claims to mean “one or more” or “at least one.” All other terms used herein should be similarly interpreted unless it is made explicit that a singular interpretation is intended.
[0014] Further, as used herein, the terms “preferably”, “more preferably”, “particularly”, “more particularly” or similar terms are used in conjunction with optional features, without restricting alternative possibilities. Thus, features introduced by these terms are optional features and are not intended to restrict the scope of the invention in any way. The invention may, as the skilled person will recognize, be performed by using alternative features. Similarly, features introduced by “in an embodiment” or similar expressions are intended to be optional features, without any restriction regarding alternative embodiments of the invention, without any restrictions regarding the scope of the invention and without any restriction regarding the feasibility of combining the features introduced in such way with other optional or non-optional features of the invention.
[0015] Generally speaking, the present methods and apparatuses are suitable for proving and determining an integrity status of an outer packaging. As further used herein, the term “outer packaging” refers to an enclosure which may at least partially, preferably completely, cover an item, such as a good or a product, in particular for storage, distribution, and sale. In particular contrast to other packages, such as an inner packaging, the outer packaging may be accessible and, especially, visible from the outside around the respective outer packaging. In this respect it may be mentioned that, particularly depending on the specific field in which the outer packaging is employed, the outer packaging may also be denoted by other terms which are commonly used for such kinds of objects, such as “package”, “packing”, “wrap”, “wrapper”, “wrapping”, “bundle”, sealing“, or “vacuumization”. Applying an outer packaging may be performed due to a number of different purposes, including but not limited to providing a protection for at least one item comprised within the outer packaging, such as a protection from mechanical, physical, chemical, biological or environmental interference, such as from shock, vibration, electrostatic discharge, radiation, dust, vapor, atmospheres, or contamination, or from interference with other substances, for improving transport properties, such as improved convenience, portion control, containment, or agglomeration of individual items, for providing a suitable substrate for a transmission of information, in particular by attaching respective labels to the outer packaging, as well as for improving security and marketing performances.
[0016] With particular regard to the present disclosure, the outer packaging may be considered as an original outer packaging as long as the outer packaging may be genuine and not tampered. In contrast hereto, a suspect outer packaging may be considered as an outer packaging which may or which may not be identical with the original outer packaging but which may have been tampered with for any reason, such as to remove at least one item from the outer packaging or to replace at least one of the original items by a counterfeit item which may allegedly create an impression as being identical to the original item. A willful tampering or manipulation may particularly occur in a case in which the at least one item comprised in the outer packaging may be of some esthetic or monetary value, such as with jewelry, watches, pieces of art, rare artifacts, microprocessors, or pharmaceuticals. In some cases it may be easy to identify a suspect outer packaging since the suspect outer packaging might differ with respect to any property from the original outer packaging, such as in a case where traces may be present which may be indicative of a breaking and a subsequent reclosing of the respective outer packaging. On the other hand, the tampering of the outer packaging may have been accomplished in a quality that the suspect outer packaging may not show any evidence, whether obvious or difficult to access, which would make it distinguishable from the original outer packaging in this way. Consequently, a suspect outer packaging might be one of a group consisting of the original outer packaging and of the tampered outer packaging.
[0017] As further used herein, the “item” may be any physical object which may at least partially, preferentially completely, covered by an outer packaging as described above and/or below. Hereby, it is of no particular relevance whether the item itself may be of any value or whether the item, such as a document or an inner packaging, refers to or comprises another item which may be of some value, either in a commercial view, a personal view, or any other view. In a number of cases the inner packaging of any kind may comprise at least one item. First, the item itself may be of a consistence, such as a gel, a liquid, a gas, or of any other form which may not exhibit a steady solid form, that a particular kind of inner packaging may be required for storing, transporting, trading, and any other action referring to the item. Second, the item may be furnished with any kind of inner packaging, for example, for any commercial or trading reason, such as for improving storability, durability, stability, or keeping properties of the item, for equipping the item with an inner packaging which comprises a specific style or design, particularly for transport or storage reasons, or for improving the optical appearance of the item such as for esthetic or trading reasons. Third, there may also be legal or statutory reasons which may require the item to be furnished with an inner packaging, such as for medical drugs. Particularly within the pharmaceutical industry, but not limited thereto, each substance which may comprise, within a first respect, a solid body, such as a powder, a pill, a tablet, or a preparation, within a second respect, a liquid, such as a liquid formulation, an emulsion, or a serum, or, within a third respect, a gas, such as an aerosol, are comprised in at least in one inner packaging, which may further be comprised itself in at least one additional packaging, which is usually referred to as the outer packaging as described elsewhere. Thus, the item may refer to the physical object itself, to a label, a document, or any other article which may accompany the physical object, or to at least the one inner packaging which may comprise the physical object. Consequently, the item may not only be selected from the physical object itself but also from an accompanying article or from any other object which may be employed as the inner packaging in form of a primary packaging for the physical object, such as a bottle, a syringe, a vial, an ampoule, a carpule, a blister, and/or in form of a secondary packaging such as a cardboard box, a folding box, or a hangtag. In this regard, it is of no relevance whether the inner packaging completely or only partially encloses the object.
[0018] With regard to the present disclosure, the at least one item may preferably also be arranged on at least one pallet. As used herein, the term “pallet” may refer to a primarily flat structure comprising at least one deckboard which is supported by at least two, but usually three or four, stringers, wherein the structure is configured for supporting at least one item, preferably a number of items which can be treated together as a so-called “bundle”, in particular for the purpose of providing a stable substrate whereon the item or the bundle of items may be located, stored or moved, such as by using a forklift or a pallet jack. In general, the pallet may comprise a mechanical stable material, in particular wood, metal, or a suitable plastic, cardboard or paper. In this preferred embodiment, wherein the at least one item is placed on the at least one pallet, the outer packaging may not only cover the at least one item but, additionally, may cover the at least one pallet at least partially, such as the top of the pallet adjoining to then location where the at least one item is placed. This kind of arrangement might be useful for further protecting and securing the at least one item. However, it is emphasized here that the present disclosure is equally applicable to items, such for food, medicals, pharmaceuticals, and/or cosmetics, which may be covered by the outer packaging without first being placed on at least one pallet.
[0019] In further accordance with the present disclosure, at least one foil is provided for manufacturing the outer packaging. As used herein, the term “foil”, which may also be denoted as a “film”, relates to a quasi-two dimensional body, wherein the quasi-two dimensional body may particularly exhibit a considerable extension in two dimensions, which are usually known as “length” and “width” of the foil, whereas the third dimension of the body, usually referred to as a “thickness” of the foil, exhibits an extension being much smaller than the considerable extension with respect to the other two dimensions. As a typical example, the thickness of a specific foil may, thus, be in the range from 1 μm to 100 μm, whereas the width may be in a range from 10 cm to 2.5 m while the length may range from 1 m to 100 m, in some cases practically only depending on the size of a so-called “endless tape” or “continuous tape”, which constitutes a foil being rolled-up for further use by unrolling the required portion. In order to be able to provide the foil as endless or continuous tape, the thickness of the foil may usually be required to stay below an experimentally determined value; otherwise it may not be possible to roll up the foil. Generally, the foil is selected from one or more of: a plastic foil, which might predominantly exhibit clear, lucent, or (semi-)transparent properties; a metal foil, preferably an aluminum foil, which might particularly show highly reflecting properties; a sheet of paper. However, other choices may be appropriate under specific circumstances.
[0020] Thus, the outer packaging is formed by using the at least one foil in order to at least partially, in particular completely, enclose the at least one item and, if applicable, also at least the top of the pallet on which the at least one item is placed. In some cases it might be advantageous to employ more than one foil to cover the respective item, such as in a case where the width of the foil turns out to be too small or where the thickness of a single foil may not be sufficient for providing enough stability of the outer packaging. In order to accomplish an optimal quality as possible of the outer packaging, in particular to further improve the stability of the complete packaging and, thus, to avoid an early opening, the at least one item, especially for larger items, may additionally be secured with at least one strapping which could be further affixed around the complete packaging comprising the at least one item and the corresponding outer packaging.
[0021] By forming the outer packaging through applying the at least one foil to the at least one item, at least one modification is introduced into the at least one foil. As used herein, the term “modification” of the at least one foil refers to a development of at least one feature within the foil which was not present in the foil prior to the modification. In a particular preferred embodiment, the at least one modification of the foil is introduced into the foil by at least one of wrapping, stretching, shrinking, or otherwise putting the foil around the at least one item and, if applicable, around at least the top of the pallet on which the at least one item is placed. Herein, the foil which may be used for covering the at least one item may be taken from a roll of foil, but the foil may equally be provided in the form of a pouch or sleeve. However, other kinds of foil may be feasible for specific purposes.
[0022] As used herein, the term “wrapping” refers to covering at least a part of the at least one item with a foil which is designated at least as a part of the outer packaging.
[0023] As further used herein, the term “stretching” or “stretch wrapping” refers to covering the at least one foil, in particular where the foil comprises a plastic foil, around the at least one item, wherein an inherent elastic recovery of the foil allows keeping the at least one item tight within the boundaries of the foil. For this purpose, the foil may comprise a linear low-density polyethylene, usually abbreviated to “LLDPE”, since LLDPE usually exhibits high adhesive properties together with a considerable tensile strength. However, other types of polyethylene (PE) or polyvinylchloride (PVC) may also be employed. In a particular preferred embodiment, a so-called “palletizer” may be used, i.e. an apparatus which provides automatic means, such as robotics, for placing the at least one item onto a pallet and, subsequently, covering the at least one item and, if applicable, at least the top of the pallet with the foil in form of a stretch wrap in order to provide the desired outer packaging.
[0024] In contrast hereto, the term “shrinking” or “shrink wrapping” refers to applying at least one foil, which particularly comprises a plastic foil, rather loosely around the at least one item and, subsequently, curing the plastic film with heat in order to accomplish a shrinking of the foil in a manner that it, preferentially tightly, covers the at least one item at least partially, in particular completely. For this purpose, heat may be applied with a heat gun, such as a hand-held gas or electric heat gun. Especially for a mass production, the at least one item at least partially covered with the film may be provided on a conveyor belt for passing through an appropriate heat tunnel. The plastic foil which may be used as shrink wrap usually comprises a polyolefin, but other polymers, such as PVC, PE, or polypropylene (PP), may also be employed. In particular for food, a coextrusion and a lamination which may comprise a number of different layers are preferably used as shrink wraps. The packaging may, thus, comprise a thin plastic film which may be used for covering items, such as food, for keeping them fresh over a longer period of time, in particular by using a shrink wrap. For covering food items, these kinds of packaging may also be denoted as “plastic wrap”, “food wrap”, “cling film”, or “cling wrap”.
[0025] As mentioned above, at least one label may be attached to the outer packaging. As used herein, a “label” refers to a substrate which is attached on the outer packaging and which may present data in alphanumeric, graphic or electronic form that is used for providing information which is related to the at least one item as comprised within the packaging and/or the outer packaging itself. The information as presented on the at least one label may include one or more of addresses, such as at least one sending and/or at least one receiving party, codes, such bar codes, data matrix codes QR codes, Electronic Data Interchange (EDI), identification codes or other product codes, such as a universal product code, a Serial Shipping Container Code (SSCC), Radio-Frequency Identification (RFID) labels, country of origin labels, registration marks, trademarks, symbols for product certifications, proof of purchase marks, notes providing conformance to a regulation, such as to a weight and measures accuracy regulation, e.g. a CE marking, environmental and/or recycling symbols, such as a recycling code, a resin identification code and/or a “Green Dot”, special information symbols for hazardous or dangerous goods, food contact material symbols, such as an oval-shaped EC identification mark, health marks for food safety, quality insurance signs, calibration and/or troubleshooting cues. As will be described below in more detail, at least one label attached to the outer packaging may equally be employed for storing at least one reference with regard to the original outer packaging for further use in a method for determining the integrity status of a suspect outer packaging.
[0026] The substrate of the label may preferably be shaped as an adhesive tag or sticker, as such comprising a thin sheet of paper or plastic affixed to a double-sided adhesive layer, which may be attached to the packaging by using a manual, a semi-automatic or, preferably, an automatic label dispenser. Preferably, the label may exhibit an optical contrast with regard to the packaging to which it is attached to, in particular by employing a thin sheet of a preferably white or bright substrate exhibiting the advantageous optical contrast to the material of the packaging which, in case of a plastic foil, might predominantly show clear, lucent, or (semi-)transparent properties, or in case of metal foil, preferably an aluminum foil, might particularly exhibit highly reflecting properties.
[0027] As already mentioned above, by a modification process comprising the forming the outer packaging through applying the at least one foil to the at least one item, the foil itself undergoes at least one modification. As a result of the modification process, the foil comprises at least one feature which is related to the modification as introduced by the modification process into the foil. According to a continuous observation of the modification process and its results as well as being particularly suited for being used in the methods according to the present disclosure, the at least one feature of the modification of the foil is preferably selected from one or more of:
at least one fold, i.e. an undulating shape, over at least one specific section of the outer packaging being introduced into the foil as a result of the modification; and/or at least one variation of a transparency and/or of a color of the at least one foil with regard to the respective property of the foil prior to the modification; at least one property of at least one edge, wherein the edge may be comprised within the outer packaging due to a respective wrapping of the foil around the at least one item; at least one stain which may, in general unintentionally, be introduced into at least one location on the foil by the modification; at least one variation of the features over at least one specific section of the outer packaging, in particular, if at least two features are present, at least one variation of the at least two features.
[0033] As used herein, the term “section” may actually refer to a part of the outer packaging, but, depending on the selected perspective, may also relate to one, two, or three partial or whole sides of the outer packaging as being recorded in a single picture.
[0034] With particular regard to the present disclosure, the term “fold” may refer to an undulated shape which might have developed in a part of the outer packaging, in particular after stretching or shrinking the foil which may, particular tightly, cover the at least one item as comprised by the outer packaging. Herein, the undulated shape may exhibit a sinusoidal, a wavelike or a rippled form particularly perpendicular with respect to a surface of the foil in a portion of the outer packaging. The ripples within the undulated shape may, in some case over a considerable area, form a regular sinusoidal variation of the at least one plastic film comprised within the packaging. However, overtones which might comprise a sequence of sine waves of different amplitudes as well as irregular patterns may also be observable within the areas where the undulation has developed.
[0035] Alternatively or in addition, the at least one foil used as the outer packaging may exhibit a variation with regard to the transparency and/or color of the foil when compared with the respective property of the foil before it underwent the modification. In particular due to a stretching and/or shrinking of the foil and depending on its inherent material properties during the modification process, the thickness of the foil may be slightly reduced within at least one specific area which may lead to a change of the optical properties of the foil within the specific area. Alternatively or in addition, the foil may be folded, pleated, creased, wrinkled, dragged or pushed together during the modification process which may result in a further change of the transparency and/or color of the foil. These kinds of changes are particularly obvious for a plastic foil but comparable features may also be observed in foils comprising a metal or a paper. Consequently, the transparency and/or the color of the foil which might be altered as a result of the modification may, thus, be observable as one of the features which particularly are suitable for the purpose of the present disclosure. However, further optical features, such as an observation of a phase and/or a polarization shift might as well be employed.
[0036] Alternatively or in addition, the at least one foil used as the outer packaging may exhibit at least one edge comprised within the outer packaging due to a respective wrapping of the quasi-two dimensional foil around the at least one three-dimensional item. With regard to the present disclosure, a location, a form, or a reflectivity of the edge may be suitable to be employed as the at least one feature of the modification. However, other properties of the edge may also be applicable for this purpose.
[0037] Alternatively or in addition, the at least one foil may exhibit at least one stain which may, in general unintentionally, be introduced into at least one location on the foil by touching and modifying the foil during manufacturing the outer packaging covering the at least one item. The outer packaging may, thus, exhibit at least one location where an amount of dirt, sweat, color residues, or a fingerprint, such as of a human fingertip or of a robot being employed within a palletizer, may be placed. With particular regard to the present disclosure, a location, a form, or a reflectivity of the stain may, further, suitably be employed as the at least one feature resulting from the modification. However, the stain may exhibit other properties which may also be applicable for this purpose.
[0038] Alternatively or in addition, the at least one variation of the features, whether previously mentioned or not, may be observable over at least one specific section of the outer packaging. This selection might preferably be applicable to distinguish contents of different sections of the outer packaging, such as sections in which a considerable number of various features may be observed, and other sections in which a only very few or no features may be present. As will be explained below in more detail, a density of features within a specific section may also be evaluated by applying respective evaluation methods to the respective section.
[0039] In a first aspect, the present disclosure relates to a method for proving an integrity status of an original outer packaging. As used herein, the term “proving” relates to acquiring and storing technical features which characterize the respective outer packaging in a manner that the outer packaging may, subsequently, be uniquely identifiable by using the stored characteristic technical features which relate to the outer packaging.
[0040] As further used herein, the “integrity status” of an outer packaging provides a value which defines whether a suspect outer packaging may be considered as the original outer packaging whose integrity is under question or not, i.e. an original or a tampered outer packaging. As further used herein, the outer packaging may be considered as the original outer packaging as long as the outer packaging itself may not be altered. Consequently, the method for determining the integrity status may, within a first respect, comprise a method for determining a verification of a suspect outer packaging or, within a second respect, comprise a method for determining a falsification of a suspect outer packaging, depending on the purpose and/or circumstances under which the method may be performed. In other words, the present method may be performed in a case in which it is desired to confirm the integrity of the suspect outer packaging. On the other hand, the present method may also be applied in a case in which the integrity of the suspect outer packaging may be discarded for any reason. Furthermore, the method may also be used under circumstances in which it may be desired to find an answer to an open question whether the outer packaging under investigation may be the true original outer packaging to be verified or whether the suspect outer packaging may be a tampered outer packaging pretending to be the original outer packaging.
[0041] In this regard, the present method may deliver a Boolean value which may be designated by TRUE or FALSE, by 1 or 0, or by any other designation and which may comprise the integrity status of the outer packaging determined by application of the present methods. Alternatively, the present method may deliver an absolute value or, more particular, a relative value, such as a percentage of accordance between two pictures under comparison, which may comprise an indication about the integrity status of the outer packaging determined by application of the present methods. For this purpose, it may be preferable to define a threshold, above which the integrity may be assumed and below which the integrity may be denied, or vice-versa. In addition, therefrom a result, for example, in form of a Boolean value as described above may be acquired. This value, whether Boolean or not, may further be employed by a user of the present methods for any purpose, e.g. as an entry into a specific database which may comprise such kind of values, for producing an optical signal or an audio signal or a signal of any other kind upon determining the suspect outer packaging to be a tampered outer packaging, or for separating an object which comprises the suspect outer packaging which may have been falsified by the method from an inspection line. However, the present method may be applied under various other circumstances and for any other purpose, which may particularly be based upon any specific need of the user.
[0042] According to the present disclosure, the method comprises the following steps step a) to c). Herein, the steps a) to c) are preferably performed in the given order, commencing with step a) and finishing with step c), still, other orders may be feasible. Further, it may be possible to perform two or more of the steps simultaneously or in an overlapping fashion. Further, it may also be feasible to perform one, two or more of the steps repeatedly, not depending on the fact whether other steps may be equally repeated. Further, additional steps may be comprised, irrespective whether the additional steps may or may not be mentioned in the following.
[0043] According to step a) of the present method for proving the integrity status of an original outer packaging, at least one picture of at least one section of the outer packaging is recorded. As further used herein, the “picture” may comprise an optical image of a section of the outer packaging which is recorded by using an optical system. Hereby, the picture may describe a one- or a two-dimensional representation comprising a number of pixels in each dimension which together form the picture of the respective section of the outer packaging, thus, constituting a basis for a further evaluation of the picture in order to analyze at least one reference to the at least one feature of the at least one modification of the at the least one foil with regard to the outer packaging comprising the at least one item.
[0044] In this regard, the proving and/or determining of the integrity may require a picture of the section of the outer packaging which may exhibit a reasonable quality and a sufficient resolution, which may be of particular importance for a further comparison of two distinct pictures, such as in step d) as described below, a comparison between a picture of the respective section of the suspect outer packaging and a hereto distinct picture of the supposed or alleged corresponding original outer packaging. Since in case of a poor quality and/or a low resolution of the picture of the section of the outer packaging, the present method may provide distorted results, such that a tampered outer packaging may be mistaken for the original outer packaging, it may, therefore, be necessary to ensure, before analyzing a recorded picture of the respective section of the outer packaging, that the picture may comprise a reasonable quality and resolution.
[0045] In particular for this purpose, it may be preferred to perform a transformation of the at least one picture as recorded for at least one section of the outer packaging. Herein, the term “transformation” may refer to at least one alteration of at least one element of the picture, such as a pixel or a further constituent of the picture, or the complete picture after the recording of the picture. In a particularly preferred embodiment, the transformation may comprise one or more of the following transformation processes:
adjusting the picture, in particular in a manner that the at least one recorded section of the outer packaging actually comprises at least one feature of interest of the at least one modification of the at the least one foil; rearranging a spatial orientation of the picture, in particular by aligning the picture in a manner that the at least one recorded section of the outer packaging comprising the at least one feature of interest constitutes a preferably rectangular shape, preferably as by spatially orienting the picture with respect to at least one recurring element, preferably by cropping at least one side of the picture, in particular, if applicable, by removing a part of the picture which shows the at least one pallet or a part thereof; removing a spatial distortion within the picture, in particular with respect to a perspective geometry, preferably as by employing known methods for eliminating distortions; performing a binary alteration of the picture, in particular by employing local binary patterns (LBP); performing a color classification transition in the picture, in particular by a transition from one color space to a further color space, such as from an RGB (red, green, blue) color space to an HSV (hue, saturation, value) color space.
[0051] In a preferred embodiment, a spatial orientation of the picture may be performed during the transformation process with particular regard to one or more of the following recurring elements: one or more edges of the outer packaging, which may, preferably, further be highlighted by respective marks, such as by a black, a white, or a color mark; a particular arrangement of at least one label, preferably of more than one label, on the surface of the outer packaging; one or more gaps between the at least two, but usually three or four, stringers which are adapted to support the at least one deckboard of the pallet. In this regard it may be preferable to rely on known features and, in addition, to employ a neural network which may be capable of both machine learning and pattern recognition.
[0052] By employing at least one of the mentioned transformation processes, a good comparability of at least two distinct pictures may, thus, be achieved. In addition, further mechanisms may be applied to ensure a good readability of the features comprised within the image, in particularly with regard to the contrast of the image. In the field of image processing various methods exist which may be applied to determine the quality of a given optical image, such as a detection of a blur of the image or a frequency analysis of the image.
[0053] In a preferred embodiment, the optical system employed for performing a method according to the present disclosure may comprise at least one element which may be selected from the group comprising: a camera, a flatbed scanner, a bar code hand-scanning device, a cell or a cellular phone, a laptop webcam, a smartphone, a tablet computer. However, any other optical system comprising a resolution which may be sufficient to resolve the characteristic features within the outer packaging may also be used.
[0054] According to step b), at least one reference to at least one feature of the at least one modification of the foil is analyzed in the picture. In this regard, the at least one feature may, preferably, be selected from one or more of: at least one fold within the outer packaging; at least one variation of a transparency and/or a color of the outer packaging; at least one property of at least one edge within the outer packaging; at least one stain as comprised within the outer packaging; at least one variation of the features over at least one specific section of the outer packaging.
[0055] According to the present disclosure, the at least one reference may be selected from one or more of: the at least one picture of the at least one section of the outer packaging, wherein the at least one section comprises the at least one feature; at least one quantity acquired for the at least one feature as comprised in the at least one picture of the at least one section of the outer packaging. Thus, the at least one reference may comprise the at least one picture in a form as recorded of the at least one section of the outer packaging, wherein the at least one feature of interest may be comprised. In a particular preferred embodiment, the at least one reference may, particularly, refer to the at least one picture after having performed a transformation of the at least one picture, wherein the transformation may comprise one or more of the transformation processes as described above, particularly in order to provide a good comparability of at least two distinct pictures, such as during the subsequent step d).
[0056] Alternatively or in addition, the at least one reference may, preferably, be derived from a quantity which may be related to the at least one feature developed in the outer packaging as a result of the at least one modification of the foil as described above and/or below in more detail. For this purpose, a numerical value for this quantity related to one or more features as developed in the outer packaging due to the modification of the foil may be employed, wherein the quantity may also be denoted as “individual imperfection profile” of the outer packaging. However, other denominations are possible.
[0057] In a preferred embodiment, the at least one quantity as acquired for the at least one feature is obtained from the picture of the at least one section of the outer packaging by using one or more of:
a threshold, in particular a limit below which respective characteristics, such as a color, in the picture may be disregarded; a feature extraction technique, in particular a Hough Transformation and/or a Watershed Filter, wherein the term “feature extraction technique” may generally relate to a method for reducing an acquired set of information into a reduced set of information in a manner that the reduced set comprises the desired feature; an edge detection operator, in particular a Canny Transformation or a filter according to Sobel, Prewitt, Roberts, Marr-Hildreth and/or Haralick, wherein the term “edge detection operator” may generally refer to a method for identifying at least one location in an image where a brightness or an intensity may change sharply and, thus, exhibits discontinuities; a texture classification technique, in particular applying local binary patterns (LBP), wherein the term “texture classification technique” may generally concern a method for extracting a shape, such as a mark or a stain, from a textured image; a process for approximating periodic features, in particular a Fourier analysis, more particular a Fast Fourier Transformation (FFT), wherein the periodic features may particularly be represented or approximated by a sum of at least one trigonometric function.
[0063] In this regard, it may be advantageous to select a specific section within the outer packaging which may exhibit a variation which might be above or below an average variation to be observable over at least one side of the outer packaging. Further, it might be especially useful to count the number of folds within the selected section and to identify its corresponding properties in more detail by employing the Canny Transformation and/or one or more of the above-mentioned filters. A similar procedure may be applicable to stains within the at least one selected section. Alternatively or in addition, at least two selected sections may be compared, in particular with regard to their corresponding transparency and/or color within the selected section which may be indicative of the respective thickness of the modified foil within the selected section. Alternatively or in addition, at least two selected sections may be compared, in particular with regard to a variation and/or density of features within the at least one selected section which may be indicative of a perturbation or a disturbance within the selected section. However, other kinds of deriving a numerical value for the quantity related to one or more features developed in the outer packaging as a consequence of the modification of the foil may be suitable.
[0064] As a result, the at least one reference to at least one feature of the at least one modification of the foil with respect to the original outer packaging has, thus, been acquired during step b). The at least one reference with respect to the original outer packaging is, during subsequent step c), stored as the integrity status of the original outer packaging for further use, in particular at some time in the future, in order to be employed to determine on this basis the integrity status of a suspect outer packaging.
[0065] In a particular preferred embodiment, the at least one reference with regard to the original outer packaging may be stored for further use by one or more of:
applying the at least one reference to the outer packaging, such as in a form of a code, e.g. a bar code, a data matrix code, a QR code, as applied to a label attached to the outer packaging as described above in more detail; generating a database record for the corresponding outer packaging, wherein the database record may at least comprise the at least one reference with regard to the original outer packaging and might, further, comprise a further reference to the original outer packaging, such as the SSCC code; if applicable, storing the at least one reference in a separate storage device, such as an RFID chip, a USB chip, or a magnetic stripe, wherein the separate storage device may be attached to the at least one pallet.
[0069] In a further preferred embodiment, the database record as generated during step c) may be transmitted to a database via one or more channels selected from: a wireless data transmission, a wire bound data transmission, a transmission via a computer network. Hereby, the exact details and manners of the transmission are of little relevance as long as the generated database record may be inserted into the database for further use during step d) of the method for determining the integrity status of the suspect outer packaging. In addition, by storing the further reference to the outer packaging, such as the SSCC code, too, it may, thus, be possible to easier identify the corresponding reference to the respective suspect outer packaging.
[0070] In a particularly preferred embodiment, the method for proving the integrity status of an outer packaging may be part of a packaging process for packaging the at least one item, irrespective whether being placed on a pallet or not, into an outer packaging. This kind of performance may particularly ensure that data which may later be required for a determination of the integrity status of the suspect outer packaging may be stored within the database with little or no time delay, preferably directly within the packaging line. Such an approach may particularly be useful for decreasing the manipulation of an outer packaging.
[0071] In a further aspect, the present disclosure relates to a method for determining the integrity status of a suspect outer packaging. The method according to the present disclosure comprises steps a), b) and d). These steps are preferably performed in the given order, commencing with step a) and finishing with step d), still, other orders may be feasible. Further, it may be possible to perform two or more of the steps simultaneously or in an overlapping fashion. Further, one or more steps may be performed repeatedly, depending or not whether other steps are equally repeated. The method may further comprise one or more additional steps, whether mentioned herein or not.
[0072] For further details to the method for determining the integrity of a suspect outer packaging, reference may be made to the disclosure of the method for proving the integrity of an original outer packaging, as disclosed above and/or below. In particular, both step a) related to recording a picture of a section of the outer packaging and b) related analyzing a reference to a feature of a modification of a foil in the picture have already been disclosed there. Accordingly, the at least one reference with respect to the suspect outer packaging is, thus, acquired. However, in contrast to the method for proving the integrity of an original outer packaging, the corresponding result of step b) may, during subsequent step d), be employed to determine the integrity status of the suspect outer packaging on this basis. With regard to the at least one reference, the disclosure of the method for proving the integrity of the original outer packaging, as disclosed above and/or below, may also be taken into account.
[0073] According to step d), the at least one reference with respect to the suspect outer packaging is compared with the at least one reference with respect to the original outer packaging as obtained during step b) within a comparing step. Hereby, a comparison of the at least one reference with respect to the suspect outer packaging with the at least one reference with respect to the original outer packaging allows determining the integrity status of the suspect outer packaging. As further used herein, “comparing” includes making a comparison between the at least one reference with respect to the suspect outer packaging with the at least one reference with respect to the original outer packaging with regard to their identity but also taking into account a tolerance level within which the integrity of the suspect outer packaging may be still assumed. Introducing a tolerance level may particularly allow taking into account inevitable adverse effects, such as deterioration, ageing, dirt, color residues or wear, which may affect the outer packaging during storage and/or transport.
[0074] As already described above in more detail, the at least one reference may be selected from one or more of: the at least one picture of the at least one section of the outer packaging, wherein the at least one section comprises the at least one feature; at least one quantity acquired for the at least one feature as comprised in the at least one picture of the at least one section of the outer packaging. Thus, the comparing according to step d) may comprise comparing the at least one picture of the at least one section of the suspect outer packaging with the at least one picture of the at least one section of the original outer packaging either in a form as recorded, or, in particularly preferred, after a transformation which comprises one or more of the transformation processes as described above has been applied to the respective pictures, particularly in order to provide a good comparability between the at least two distinct pictures. Alternatively or in addition, the comparing according to step d) may comprise comparing at least one quantity related to the at least one feature in the suspect outer packaging, such as the individual imperfection profile of the suspect outer packaging, with at least one quantity related to the at least one feature in the original outer packaging, such as the individual imperfection profile of the original outer packaging.
[0075] Since a further modification of the foil as comprised within the outer packaging may, thus, further modify the foil with regard to at least one reference and may, consequently, alter the at least one reference with respect to the outer packaging, a comparison according to step d) may indicate a tampering of the outer packaging in a time interval between the at least two distinct pictures which may be recorded for the same section of the corresponding outer packaging.
[0076] The present method for determining the integrity status of the suspect outer packaging may, further, comprise a transmission step by which, preferably after one or more of the method steps step a) or step b), data may be transferred to a data processing unit via a computer network in such a manner that the further steps, after the transmission, may be performed by the data processing unit, wherein the integrity status of the suspect outer packaging may be returned by the data processing unit. This transmitting step may particularly be performed by at least one control unit which may be adapted to perform or to have performed at least method step a) as well the data transmission. The control unit may comprise a computer or a micro-computer, wherein the micro-computer may be part of the optical system, of a system which may control the optical system, or of a system which may be in connection with the optical system. Which kinds of data are transmitted by the control unit to the data processing unit may particularly depend at which stage during the performance of the present method the actual data transmission takes place. As an example, after step a) the at least one picture of the at least one section of the outer packaging as recorded by the optical system may be transferred to the data processing unit on which the further steps b) and d) may be performed until the integrity status of the suspect outer packaging may be determined and returned to the at least one control unit. As a further example, steps a) and b) may be performed locally until the control unit may transmit the at least one reference determined for the suspect outer packaging to the data processing unit where only the remaining comparison step d) may be performed until the integrity status of the suspect outer packaging may be determined and returned to the at least one control unit. In this particular embodiment it might be advantageous that the database may be one or more of comprised within the processing unit or operationally connected to the data processing unit.
[0077] In a further aspect of the present disclosure, a proving apparatus for proving the integrity of an original outer packaging is disclosed. In this regard, reference may be made to the description above and/or below referring to the corresponding method. The proving apparatus comprises at least parts A) to C), which may be arranged in any suitable order. Further, additional parts may be comprised in the proving apparatus which are not mentioned in the following. The parts may be part of one combined apparatus or centralized unit or may be combined in different apparatuses or de-centralized units, wherein the apparatuses are adapted to interact in any suitable fashion, such as by wire-bound communication and/or wireless communication.
[0078] Herein, Part A) of the proving apparatus comprises a recording device being configured for recording at least one picture of at least one section of the outer packaging, whereas part B) comprises an analysis device configured for analyzing in the picture at least one reference to at least one feature of the at least one modification of the at the least one foil. Part C) of the proving apparatus comprises a storing device for storing the at least one reference with respect to the original outer packaging, wherein the storing device may comprise a label being attached to the outer packaging, a database device for generating a database record for the outer packaging, or, if applicable, a storage attached to the at least one pallet on which the at least one item may be placed. Hereby, the database record may comprise the at least one reference with respect to the original outer packaging as well as further reference to the outer packaging, such as an SSCC code. In a particularly preferred embodiment, the proving apparatus is configured to perform the method for proving the integrity of the original item as described above and/or below. For further details of the proving apparatus, reference may be made to the method for proving the integrity status of an original outer packaging as described elsewhere.
[0079] In a preferred embodiment, the proving apparatus may be part of a packaging apparatus for furnishing the at least one item with an outer packaging. This kind of embodiment may be particularly useful for strictly combining the packaging of the at least one item with the apparatus which generates the database record being related to the item. This arrangement may particularly allow ensuring that the at least one reference as stored on the item, in the database record and/or, if applicable, with the pallet may actually be related to the respective original outer packaging. Such a strong physical relationship of the mentioned devices may be particularly intended to reduce the risk of disappearing with relation to items of some value as comprised within the outer packaging.
[0080] In a further aspect of the present disclosure, a determining apparatus for determining the integrity status of a suspect outer packaging is disclosed. In this regard, reference may be made to the description above and/or below referring to the corresponding method as well as to the proving apparatus. According to the present disclosure, the determining apparatus at least comprises at least parts A), B) and D), which may be assembled in any suitable fashion. Further, additional parts may be comprised within the authentication apparatus which may or may not be mentioned in the following. The parts may be part of one combined apparatus or centralized unit or may be combined in different apparatuses or de-centralized units, wherein the apparatuses are adapted to interact in any suitable fashion, such as by wire-bound communication and/or wireless communication.
[0081] As described above for the proving apparatus, Part A) of the determining apparatus comprises a recording device being configured for recording at least one picture of at least one section of the outer packaging, whereas part B) comprises an analysis device configured for analyzing in the picture at least one reference to at least one feature of the at least one modification of the at the least one foil. However, in contrast to the proving apparatus, part D) of the determining apparatus comprises a comparing device configured for comparing the at least one reference with respect to the suspect outer packaging with the at least one reference with respect to the original outer packaging as stored as the integrity status of the original outer packaging for further use in a storing device according to part C) as described elsewhere in this description. By this comparison, the integrity status as defined above of the suspect outer packaging is determined. In a particularly preferred embodiment, the determining apparatus may be configured to perform the method for determining the integrity status of the suspect outer packaging as described above and/or below. For further details of the determining apparatus, reference may be made to the proving apparatus as well as to the method for determining the integrity status of a suspect outer packaging as described elsewhere.
[0082] In a particularly preferred embodiment, the determining apparatus may be further adapted to control the transmission of data to a data processing unit. In this regard, the transmission of the data may be performed via one or more transmission means selected from a wireless data transmission, a wire bound data transmission, and/or a transmission via a computer network. Further details concerning the data transmission, the data and the data processing unit may be found elsewhere in this description.
[0083] The present application further discloses and proposes a computer program, including computer executable instructions for performing both the method for proving the integrity of the original outer packaging and the hereto related method for determining the integrity status of the suspect outer packaging, when the program is executed on a computer or a computer network. Preferentially, the computer program may be stored on a computer readable data carrier. In this regard, the disclosure further describes a data carrier having a data structure stored thereon, wherein the data structure, after loading into a computer or a computer network, is capable of executing any or all methods as disclosed herein. As further used herein, a computer may comprise any device which may be capable of storing data and/or performing calculating steps and/or instructing steps. By way of example, this definition may not only include work stations and notebooks but also application-specified integrated circuits (ASICs) and field-programmable gate arrays (FPGAs).
[0084] Preferably, referring to the computer-implemented aspects of the present disclosure, one or more of the method steps or even all of the method steps of any or all methods disclosed herein may be performed by using a computer or a computer network. Thus, generally, any of the method steps including provision and/or manipulation of data may be performed by using a computer or a computer network. Generally, these method steps may include any of the method steps.
[0085] The disclosure further describes and proposes a computer program including computer-executable instructions for performing any or all methods according to the present disclosure in one or more of the embodiments enclosed herein when the program is executed on a computer or computer network. Preferentially, the computer program may be stored on a computer-readable data carrier. Thus, preferably, one, more than one or even all of method steps as indicated above may be performed by using a computer or a computer network, preferably by using a computer program.
[0086] The disclosure further describes and proposes a computer program product having program code means, in order to perform any or all methods according to the present disclosure in one or more of the embodiments enclosed herein when the program is executed on a computer or computer network. Preferentially, the program code means may be stored on a computer-readable data carrier.
[0087] Further, the disclosure describes and proposes a data carrier having a data structure stored thereon, which, after loading into a computer or computer network, such as into a working memory or main memory of the computer or computer network, may execute any or all methods according to one or more of the embodiments disclosed herein.
[0088] The disclosure further describes and discloses a computer program product with program code means stored on a machine-readable carrier, in order to perform any or all methods according to one or more of the embodiments disclosed herein, when the program is executed on a computer or computer network. As used herein, a computer program product refers to the program as a tradable product. The product may generally exist in an arbitrary format, such as in a paper format, or on a computer-readable data carrier. Preferentially, the computer program product may be distributed over a data network.
[0089] Finally, the disclosure proposes and describes a modulated data signal which contains instructions readable by a computer system or computer network, for performing any or all methods according to one or more of the embodiments disclosed herein.
[0090] Preferably, referring to the computer-implemented aspects of the disclosure, one or more of the method steps or even all of the method steps of any or all methods according to one or more of the embodiments disclosed herein may be performed by using a computer or computer network. Thus, generally, any of the method steps including provision and/or manipulation of data may be performed by using a computer or computer network. Generally, these method steps may include any of the method steps, typically except for method steps requiring manual work, such as providing the samples and/or certain aspects of performing the actual measurements.
[0091] The methods and devices according to the present disclosure are considerably distinguished from known methods and devices according to the state of the art and, thus, provide a number of advantages with regard to the state of the art. In addition to the well-known advantages of unit loads, particularly those which employ stretch wraps around palletized items, which are usually considered to be improved stability of products, more efficient handling and storage, some degree of dust and moisture protection, and some degree of tamper resistance and resistance to packaging pilferage, the present disclosure allows that the outer packaging itself may be used for determining the integrity of the outer packaging.
[0092] This further purpose may equally be employed for one or more items which may be covered in a plastic foil, such as cellophane, without being placed on a pallet.
[0093] In this regard, the present methods for proving and determining the integrity status of an outer packaging may, respectively, be employed for a fast and still reliable investigating of a plurality of outer packaging along the supply chain with respect to their integrity status and may, thus, help avoiding a willful tampering or manipulation in a case wherein the at least one item comprised in the outer packaging may be of some esthetic or monetary value, such as with jewelry, watches, pieces of art, rare artifacts, microprocessors, or pharmaceuticals. In contrast to the state of the art, the present methods for proving and determining the integrity status of an outer packaging may, respectively, are based on the observation that the outer packaging itself may comprise tamper-evident features which may be employed to help indicate tampering. Thus, in addition to other known measures which are commonly used for improved tamper resistance in order to deter the tampering of an outer packaging, the modifications introduced into the foil which, according to the present disclosure, constitute the outer packaging may advantageously be employed to help reducing risks of pilferage as well as theft and resale of items comprised in the corresponding outer packaging.
[0094] Summarizing the findings of the present disclosure, the following embodiments are preferred:
[0095] Embodiment 1: A method for proving an integrity status of an original outer packaging, wherein the outer packaging covers at least one item, wherein the outer packaging is formed by at least one modification of at least one foil provided for the outer packaging, wherein the proving comprises acquiring and storing at least one reference to at least one feature introduced by the at least one modification into the at the least one foil, wherein the outer packaging is uniquely identifiable by using the at least one reference, the method comprising the following steps:
a) recording at least one picture of at least one section of the outer packaging; b) analyzing in the picture the at least one reference to at least one feature introduced by the at least one modification into the at the least one foil; and c) storing the at least one reference with respect to the original outer packaging as the integrity status of the original outer packaging for further use, in particular in a method for determining the integrity status of a suspect outer packaging.
[0099] Embodiment 2: A method for determining an integrity status of a suspect outer packaging, wherein the outer packaging covers at least one item, wherein the outer packaging is formed by at least one modification of at least one foil provided for the outer packaging, wherein the outer packaging is suspect of a tampering, the method comprising the following steps:
a) recording at least one picture of at least one section of the outer packaging; b) analyzing in the picture at least one reference to at least one feature introduced by the at least one modification into the at the least one foil being suspect of a further modification by the tampering of the outer packaging; and d) comparing the at least one reference with respect to the suspect outer packaging with at least one reference with respect to an original outer packaging, in particular as stored for further use according to step c) of the preceding embodiment, by which comparison the integrity status of the suspect outer packaging is determined.
[0103] Embodiment 3: The method according to any one of the preceding embodiments, wherein the foil is selected from one or more of: a plastic foil, a metal foil, preferably an aluminum foil; a sheet of paper.
[0104] Embodiment 4: The method according to any one of the preceding embodiments, wherein the at least one modification of the at least one foil is introduced into the foil by at least one of wrapping, stretching, or shrinking the foil around at least the at least one item.
[0105] Embodiment 5: The method according to any one of the preceding embodiments, wherein the at least one feature of the at least one modification of the at the least one foil to which the at least one reference is related is selected over the at least one picture of the at least one section of the outer packaging from one or more of: at least one fold; at least one variation of a transparency and/or a color; at least one property of at least one edge; at least one stain; at least one variation of the feature, in particular with respect to a further feature.
[0106] Embodiment 6: The method according to the preceding embodiment, wherein the at least one fold comprises an undulated shape developed in a part of the outer packaging during the modification, wherein the undulated shape particularly exhibits a sinusoidal, a wavelike or a rippled form, wherein the undulated shape is preferably perpendicular to a surface of the foil in a portion of the outer packaging.
[0107] Embodiment 7: The method according to any one of the preceding two embodiments, wherein the at least one stain comprises at least one modification in at least one location on the outer packaging, wherein an amount of dirt, sweat, color residues, or a fingerprint, in particular of a human fingertip or of a robot being employed within a palletizer, is placed in the at least one location.
[0108] Embodiment 8: The method according to any one of the preceding embodiments, wherein the at least one reference is selected from one or more of: the at least one picture of the at least one section of the outer packaging, wherein the at least one section comprises the at least one feature; at least one quantity acquired for the at least one feature as comprised in the at least one picture of the at least one section of the outer packaging.
[0109] Embodiment 9: The method according to any one of the preceding embodiments, wherein a transformation of the at least one picture as recorded for at least one section of the outer packaging is performed.
[0110] Embodiment 10: The method according to the preceding embodiment, wherein the transformation comprises one or more of the following transformation processes: adjusting the picture of the at least one section of the outer packaging; rearranging a spatial orientation of the picture; removing a spatial distortion within the picture; performing a binary alteration of the picture; performing a color classification transition in the picture.
[0111] Embodiment 11: The method according to the preceding embodiment, wherein the adjusting of the picture of the section of the outer packaging is performed in a manner that the at least one section of the outer packaging comprises at least one feature of interest of the at least one modification of the foil.
[0112] Embodiment 12: The method according to any one of the two preceding embodiments, wherein the rearranging of the spatial orientation of the picture is performed by aligning the picture in a manner that the at least one recorded section of the outer packaging comprising the at least one feature of interest constitutes a preferably rectangular shape.
[0113] Embodiment 13: The method according to the preceding embodiment, wherein the rearranging of the spatial orientation of the picture is obtained by spatially orienting the picture with respect to at least one recurring element.
[0114] Embodiment 14: The method according to the preceding embodiment, wherein the recurring element is selected from one or more of: one or more edges of the outer packaging, wherein the edge is preferably highlighted by marks, in particular by a black, a white, or a color mark; an arrangement of at least one label on the surface of the outer packaging; at least one gap between stringers supporting at least one deckboard of a pallet.
[0115] Embodiment 15: The method according to any one of the three preceding embodiments, wherein the rearranging of the spatial orientation of the picture is performed by cropping at least one side of the picture.
[0116] Embodiment 16: The method according to the preceding embodiment, wherein the cropping of the at least one side of the picture comprises removing a part of the picture showing at least one pallet or a part thereof.
[0117] Embodiment 17: The method according to any one of the seven preceding embodiments, wherein the removing of the spatial distortion is performed with respect to perspective geometry, in particular by employing a method for eliminating distortions in an image.
[0118] Embodiment 18: The method according to the preceding ten embodiments, wherein the at least one quantity acquired for the at least one feature is obtained from the picture of the at least one section of the outer packaging by using one or more of: a threshold, a feature extraction technique, an edge detection operator, a texture classification technique, a process for approximating periodic features.
[0119] Embodiment 19: The method according to the preceding embodiment, wherein the feature extraction technique comprises a Hough Transformation and/or a Watershed Filter.
[0120] Embodiment 20: The method according to any one of the preceding two embodiments, wherein the edge detection operator comprises a Canny Transformation or a filter according to Sobel, Prewitt, Roberts, Marr-Hildreth and/or Haralick.
[0121] Embodiment 21: The method according to any one of the preceding three embodiments, wherein the texture classification technique comprises an application of local binary patterns (LBP).
[0122] Embodiment 22: The method according to any one of the preceding four embodiments, wherein the process for approximating periodic features comprises a Fourier analysis, in particular a Fast Fourier Transformation (FFT).
[0123] Embodiment 23: The method according to any one of the preceding embodiments, wherein the at least one reference is stored for further use by one or more of: applying the at least one reference to the outer packaging, in particular as a code, preferably as a bar code, a data matrix code, or a QR code, on a label attached to the outer packaging; generating a database record in a database which at least comprises the at least one reference; storing the at least one reference in a storage device, wherein the storage device is attached to at least one pallet.
[0124] Embodiment 24: The method according to the preceding embodiment, wherein the database record is transmitted to and/or retrieved from a database via one or more of: a wireless data transmission, a wire-bound data transmission, a transmission via a computer network.
[0125] Embodiment 25: The method according to the preceding embodiment, wherein a transmission of data to a data processing unit is performed via a computer network, wherein the further steps after the transmission are performed by the data processing unit, wherein the integrity status of the suspect outer packaging is returned by the data processing unit, wherein the data are preferably transmitted by at least one control unit, the control unit being adapted to perform or to having performed at least method step a), wherein the data transmission preferably takes place after one or more of the method steps step a) or step b).
[0126] Embodiment 26: The method according to any one of the two preceding embodiments, wherein a transmission of data to a data processing unit is performed via a computer network, wherein the further steps after the transmission are performed by the data processing unit, wherein the integrity status of the suspect outer packaging is returned by the data processing unit.
[0127] Embodiment 27: The method according to the preceding embodiment, wherein the data are transmitted by at least one control unit, the control unit being adapted to perform or to having performed at least method step a).
[0128] Embodiment 28: The method according to any one of the three preceding embodiments, wherein the at least one reference with respect to the original item is stored in a database, wherein the database is one or more of comprised within the data processing unit or operationally connected to the data processing unit.
[0129] Embodiment 29: The method according to the preceding embodiment, wherein the record of the database comprises a composite number containing the at least one reference and a further reference to the outer packaging.
[0130] Embodiment 30: The method according to any one of the preceding embodiments, wherein the at least one item is arranged on at least one pallet, wherein the outer packaging covers the at least one item and at least a part of the pallet.
[0131] Embodiment 31: The method according to any one of the preceding embodiments, wherein the item is selected from the group consisting of: a physical object; an accompanying article, such as a label, or a document; a primary packaging, such as a bottle, a syringe, a vial, an ampoule, a carpule, a blister; a secondary packaging, such as a folding box, a hangtag, a cardboard box.
[0132] Embodiment 32: The method according to any one of the preceding embodiments, wherein the method is part of a packaging process for packaging the at least one item.
[0133] Embodiment 33: A proving apparatus for proving an integrity status of an original outer packaging, wherein the outer packaging covers at least one item, wherein the outer packaging is formed by at least one modification of at least one foil provided for the outer packaging, wherein the proving comprises acquiring and storing at least one reference to at least one feature introduced by the at least one modification into the at the least one foil, wherein the outer packaging is uniquely identifiable by using the at least one reference, the proving apparatus comprising:
A) a recording device configured for recording at least one picture of at least one section of the outer packaging; B) an analyzing device configured for analyzing in the picture the at least one reference to at least one feature introduced by the at least one modification into the at the least one foil; C) a storing device for storing the at least one reference with respect to the original outer packaging as the integrity status of the original outer packaging for further use, in particular in a determining apparatus for determining the integrity status of a suspect outer packaging.
[0137] Embodiment 34: The proving apparatus according to the preceding embodiment, wherein the proving apparatus is configured to perform the method for proving the integrity status according to any one of the preceding embodiments referring to a method for proving the integrity status of on original outer packaging.
[0138] Embodiment 35: The proving apparatus according to the preceding embodiment, wherein the proving apparatus is part of a packaging apparatus for packaging the at least one item.
[0139] Embodiment 36: A determining apparatus for determining an integrity status of a suspect outer packaging, wherein the outer packaging covers at least one item, wherein the outer packaging is formed by at least one modification of at least one foil provided for the outer packaging, wherein the outer packaging is suspect of a tampering, the determining apparatus comprising:
A) a recording device configured according to the embodiment referring to a proving device; B) an analyzing device configured according to the embodiment referring to a proving device; D) a comparing device configured for comparing the at least one reference with respect to the suspect outer packaging with at least one reference with regard to an original outer packaging, in particular as acquired from Part C) according to the preceding embodiment, by which comparison the integrity status of the suspect outer packaging is determined.
[0143] Embodiment 37: The determining apparatus according to the preceding embodiment, wherein the determining apparatus is configured to perform the method for determining the integrity status according to any one of the preceding embodiments referring to a method for determining an integrity status of a suspect outer packaging.
[0144] Embodiment 38: The determining apparatus according to any of the preceding embodiments referring to an apparatus, wherein the recording device comprises an optical system, wherein the optical system comprises at least one element which is selected from the group consisting of: a camera, a flatbed scanner, a bar code hand-scanning device, a laptop webcam, a cell phone, a smartphone, a tablet computer.
[0145] Embodiment 39: The determining apparatus according to any one of the preceding embodiments referring to a determining apparatus, wherein the determining apparatus is adapted to control a transmission of data to a data processing unit, wherein the transmission of the data is performed via one or more of: a wireless data transmission, a wire-bound data transmission, a transmission via a computer network.
[0146] Embodiment 40: A computer program including computer-executable instructions for performing the methods according to any one of the preceding method embodiments, when the program is executed on a computer or computer network.
[0147] Embodiment 41: A data carrier having a data structure stored thereon, wherein the data structure, after loading into a computer or computer network, is capable of executing the methods according to any one of the preceding method embodiments.
[0148] Embodiment 42: A computer or computer network comprising at least one processor, wherein the processor is adapted to perform the method according to one of the embodiments described in this description.
[0149] Embodiment 43: A computer loadable data structure that is adapted to perform the method according to one of the embodiments described in this description while the data structure is being executed on a computer.
[0150] Embodiment 44: A computer program, wherein the computer program is adapted to perform the method according to one of the embodiments described in this description while the program is being executed on a computer.
[0151] Embodiment 45: A computer program comprising program means for performing the method according to one of the embodiments described in this description while the computer program is being executed on a computer or on a computer network.
[0152] Embodiment 46: A computer program comprising program means according to the preceding embodiment, wherein the program means are stored on a storage medium readable to a computer.
[0153] Embodiment 47: A storage medium, wherein a data structure is stored on the storage medium and wherein the data structure is adapted to perform the method according to one of the embodiments described in this description after having been loaded into a main and/or working storage of a computer or of a computer network.
[0154] Embodiment 48: A computer program product having program code means, wherein the program code means can be stored or are stored on a storage medium, for performing the method according to one of the embodiments described in this description, if the program code means are executed on a computer or on a computer network.
[0155] Further optional features and embodiments will be disclosed in more detail in the subsequent description of preferred embodiments. Therein, the respective optional features may be realized in an isolated fashion as well as in any arbitrary feasible combination, as the skilled person will realize. The scope of the invention is not restricted by the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0156] The above mentioned and other features of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description taken in conjunction with the accompanying drawings, wherein several embodiments are schematically depicted in the Figures.
[0157] FIG. 1 schematically depicts a well-known process for furnishing a number of items on a pallet with a foil in order to provide an outer packaging;
[0158] FIG. 2 presents a schematic overview over features of an outer packaging;
[0159] FIG. 3 shows a schematically overview over a preferred embodiment of a proving apparatus for proving an integrity of an original outer packaging; and
[0160] FIG. 4 presents a schematic layout of a preferred embodiment of a determining apparatus for determining an integrity status of a suspect outer packaging.
[0161] Corresponding reference characters indicate corresponding parts or functionally comparable elements throughout the several views. Although the exemplification set out herein illustrates embodiments of the invention, the embodiments disclosed below are not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise forms disclosed.
DETAILED DESCRIPTION
[0162] FIG. 1 schematically depicts a well-known process for furnishing a number of items 110 which are placed on a pallet 112 by employing a foil 114 in order to provide an outer packaging 116 which, in this preferred example, covers both the items 110 and at least the top part 120 of the pallet 112 . However, it is emphasized here that the present disclosure is equally applicable when the number of items 110 , such as food, medicals, pharmaceuticals, and/or cosmetics, may only be covered by the foil 114 in order to provide the outer packaging 116 without any requirement to be placed on the pallet 112 .
[0163] In this particular example, the foil 114 which is being used for providing the outer packaging 116 is a transparent plastic foil 118 which is, preferentially, taken from a roll 122 of so-called endless or continuous tape by unrolling a required portion of the foil 114 . According to the present disclosure, however, other kinds of foil, such as a metal foil, preferably an aluminum foil, or a sheet of paper, are equally applicable. By forming the outer packaging 116 through applying the foil 114 in order to cover at least the items 110 , at least one modification 124 is introduced into the foil 114 , wherein the modification 124 of the foil 114 causes a development of one or more features 126 within the foil 114 which were not present in the foil 114 prior to the modification 124 .
[0164] Further, in this particular example, the modification 124 of the foil 114 is introduced here into the foil 114 by one or more of wrapping, stretching, or shrinking the foil 114 around the items 110 and the top 120 of the pallet 112 on which the items 110 are placed. In this regard, the plastic foil 114 , 118 is preferably first wrapped around the items 110 as well as the top 120 of the pallet 112 by covering the items 110 and the top 120 of the pallet 112 with the foil 114 and, subsequently, stretched by employing an inherent elastic recovery of the plastic foil 114 , 118 which allows keeping the items 110 as well as the top 120 of the pallet 112 tight within the boundaries of the plastic foil 114 , 118 . Especially for a mass production, a palletizer, i.e. an apparatus providing automatic means, such as robotics, for placing the items 110 onto the pallet 112 and, subsequently, covering the item 110 and the top 120 of the pallet 112 with the plastic foil 114 may be employed for providing the desired outer packaging 116 .
[0165] Alternatively, the plastic foil 114 , 118 may rather loosely applied around the items 110 and the top 120 of the pallet 112 and, subsequently, cured with an application of heat in order to accomplish a shrinking of the plastic foil 114 , 118 in a manner that it completely, preferentially tightly, covers the items 110 and the top 120 of the pallet 112 . Especially in mass production, the items 110 and the pallet 112 on which the items 110 are placed may be provided for achieving this purpose on a conveyor belt for passing through an appropriate heat tunnel.
[0166] As already mentioned above and irrespective of the actual process as applied for performing the modification 124 , the modification 124 of the foil 114 causes a development of one or more features 126 within the foil 114 which were not present in the foil 114 prior to the modification 124 and which will be explained with regard to FIG. 2 in more detail.
[0167] In addition, one or more labels 128 may be attached to the outer packaging 116 , wherein the labels 128 provide an optical contrast with regard to the outer packaging 116 . For this purpose, the labels 128 are attached onto the outer packaging 116 for presenting data in alphanumeric, graphic or electronic form for providing information generally being related to the items 110 as comprised within the outer packaging 116 . Herein, the information may include addresses, bar codes, identification codes or other product codes, in particular an SSCC code, RFID labels, country of origin labels, registration marks, trademarks, symbols for product certifications, proof of purchase marks, notes providing conformance to a regulation, information symbols for hazardous or dangerous goods, food contact material symbols, quality insurance signs, calibration and/or troubleshooting cues, and others.
[0168] FIG. 2 presents a more detailed schematic overview over the various features 126 as comprised within one side 129 of the outer packaging 116 which may, preferably, be used in the methods according to the present disclosure. As a result of the modification 124 of the plastic foil 114 , 118 , the plastic foil 114 , 118 , which constitutes the outer packaging 116 comprises in this particular example, a number of folds 130 are introduced into the plastic foil 114 , 118 in an undulating shape over at least one specific section of the outer packaging 116 . Further, the plastic foil 114 , 118 , which here constitutes the outer packaging 116 , comprises in this particular example a variation 132 of a transparency and color of within at least one specific section of the outer packaging 116 with regard to the respective property of the plastic foil 114 , 118 prior to the modification 124 . Furthermore, edges 134 have been formed within the outer packaging 116 in this particular example mainly due to the wrapping of the plastic foil 114 , 118 around the items 110 and the top 120 of the pallet 112 . Moreover, stains 136 in the form of a fingerprint 138 have, unintentionally, been applied in this particular example onto at least one location on the plastic foil 114 , 118 which constitutes the outer packaging 116 after the modification 124 . However, other kinds of features 126 , such as stains 138 arising from sweat or from color residues, such as from unintentionally touching a human being or a colored object, respectively, may result from the modification 124 , too.
[0169] FIG. 3 schematically displays a preferred embodiment of a proving apparatus 140 which is particularly configured for performing the method for proving the integrity status 142 of an original outer packaging 116 . Herein, the proving apparatus 140 comprises a camera 144 as an example of an optical system which is employed as a recording device 146 being configured for recording one or more pictures 148 of one or more sections 150 at one or more sides 129 of the outer packaging 116 . In this respect, it may particularly be useful to record a picture of four sides 129 of the outer packaging 116 which are perpendicular to the pallet 112 . Alternatively, it may be sufficient to record only a picture of a single side 129 of the outer packaging 116 which comprises the majority of the features 126 .
[0170] Further, the proving apparatus 140 comprises an analysis device 152 which is configured for analyzing the pictures 148 of the sections 150 for retrieving at least one reference to one or more features 126 as introduced during the modification 124 of the plastic foil 114 , 118 which constitutes the outer packaging 116 . For this purpose, the pictures 148 of the sections 150 are transferred from the recoding device 146 to the analysis device 152 by a transmission line 154 which may be wire-bound, wire-less or within a computer network. Accordingly, at least one of the pictures 148 of the sections 150 may be used as the at least one reference. Herein, a transformation of the pictures 148 may be performed, wherein the transformation may comprise one or more of the following transformation processes: adjusting the picture of the at least one section of the outer packaging; rearranging a spatial orientation of the picture; removing a spatial distortion within the picture; performing a binary alteration of the picture; performing a color classification transition in the picture.
[0171] Alternatively or in addition, from a quantity which is related to the features 126 as developed in the outer packaging 116 as a result of the modification 124 of the plastic foil 114 , 118 , an individual packaging profile 156 of the outer packaging 116 may be derived as a corresponding numerical value which may constitute or contribute to the at least one reference.
[0172] In a preferred embodiment as employed in this example, the individual imperfection profile 156 of the outer packaging 116 is acquired by employing a process for approximating periodic features, such as the number of folds 130 as introduced into the plastic foil 114 , 118 in an undulating shape over at least one specific section of the outer packaging 116 , in particular by employing a Canny Transformation or a filter according to Sobel, Prewitt, Roberts, Marr-Hildreth and/or Haralick. For this purpose, it may be advantageous to select the sections 150 within the outer packaging 116 in a manner that they exhibit a variation being above or below an average variation observable over one or more sides 129 of the outer packaging 116 .
[0173] As a preferred example, the number 158 of the folds 130 within the selected section 150 of the outer packaging 116 may be counted. In addition, further corresponding properties of the folds 130 , such as a frequency of the undulating shape, may be identified in more detail by applying a Fourier Transformation, more particular a Fast Fourier Transformation (FFT), of the respective sections 150 Similarly, a number of the stains 136 , such as the number of the fingerprints 138 , within the selected section 150 of the outer packaging 116 may be counted.
[0174] As a further example, two or more sections 150 on the outer packaging 116 may be compared with each other with regard to their corresponding transparency and/or color within the sections 150 in order to record the respective variation 132 which may be indicative of the corresponding thickness of the plastic foil 114 , 118 within the sections 150 after the modification 124 .
[0175] As mentioned above in more detail, other kinds of deriving the individual imperfection profile 156 from the respective features 126 in the outer packaging 116 may be applied, such employing one or more variation of the features 126 over one or more sections 150 in the picture 148 of the outer packaging 116 .
[0176] Further, the proving apparatus 140 comprises a storing device 160 for storing the at least one reference, in particular a transformation of at least one of the pictures 148 and/or the individual imperfection profile 156 , for further use.
[0177] In a first example (not depicted here), the storing device 160 may comprise a label 128 which is attached to the outer packaging 116 and which is configured for carrying the respective information.
[0178] However, in the example as shown here, the individual imperfection profile 156 is transferred to the storing device 160 by means of a further transmission line 162 , which may be wire-bound, wire-less or within a computer network, wherein the storing device 160 is adapted for generating a database record 164 in a database 166 , wherein the database record 164 is related to the outer packaging 116 under investigation. In this particular example, each database record 164 comprises at least an identifier as a further reference 168 and the individual imperfection profile 156 , wherein both the further reference 168 , which may comprise an identification number of the outer packaging 116 , and the individual imperfection profile 156 are related to the outer packaging 116 in a manner that they allow uniquely identifying both the outer packaging 116 and its integrity status 142 over the complete supply chain.
[0179] In further first example (also not depicted here), the storing device 160 may comprise a physically separate storage device, preferably an RFID chip, a USB chip, or a magnetic stripe, which may be attached to the at least one pallet 112 , wherein the at least one reference may be stored in the storing device 160 for further use.
[0180] FIG. 4 schematically depicts a preferred determining apparatus 170 which is particularly configured for performing the method for determining the integrity status 142 of a suspect outer packaging 116 . In this particular example, the determining apparatus 170 also comprises the camera 144 as the recording device 146 being adapted for recording one or more pictures 148 of one or more sections 150 at one or more sides 129 of the outer packaging 116 .
[0181] Further, the determining apparatus 170 again comprises the analysis device 152 being configured for analyzing the pictures 148 of the sections 150 for retrieving at least one reference to one or more features 126 as introduced during the modification 124 of the plastic foil 114 , 118 constituting the outer packaging 116 . Also here, the pictures 148 of the sections 150 are transferred from the recoding device 146 to the analysis device 152 by the transmission line 154 . Accordingly, at least one of the pictures 148 of the sections 150 may be used as the at least one reference. Herein, a transformation of the pictures 148 may be performed, wherein the transformation may comprise one of the transformation processes as described above in more detail. Alternatively or in addition, from a quantity which is related to the features 126 as developed in the outer packaging 116 as a result of the modification 124 of the plastic foil 114 , 118 , an individual packaging profile 156 of the outer packaging 116 may be derived as a corresponding numerical value which may constitute or contribute to the at least one reference.
[0182] In contrast to the proving apparatus 140 , the determining apparatus 170 further comprises a comparing device 172 which is configured for comparing the at least one reference with respect to the suspect outer packaging 116 , in particular the at least one transformation of the pictures 148 and/or the least the individual packaging profile 156 , with the at least one reference with respect to the original outer packaging 116 , in particular the at least one transformation of the pictures 148 and/or the individual packaging profile 156 of the original outer packaging 116 , which have been stored for further use in the storing device 160 as described above. As already mentioned above, the comparison is preferably performed in a manner that it takes into account any tolerance levels within which the integrity of the suspect outer packaging may be still assumed, wherein the tolerance levels consider inevitable adverse effects, such as deterioration, ageing, dirt, color residues, or wear, which may affect the outer packaging 116 during its storage and/or transport.
[0183] By this comparison the integrity status 142 of the suspect outer packaging 116 is finally determined. Since a further modification of the plastic foil 114 , 118 which constitutes the outer packaging 116 usually further modifies the plastic foil 114 , 118 with respect to the features 126 comprised within the at least one reference with respect to of the outer packaging 116 , in particular in the at least one transformation of the pictures 148 and/or in the least the individual packaging profile 156 . Thus, the pictures 148 and the individual imperfection profile 156 of the outer packaging 116 are very likely to be altered so that, consequently, a the comparing device 172 may provide a result being indicative of a tampering of the outer packaging 116 in the time interval between the two or more distinct pictures 148 which have been recorded for the same section 150 of the corresponding outer packaging 116 .
LIST OF REFERENCE NUMBERS
[0000]
110 item
112 pallet
114 foil
116 outer packaging
118 plastic foil
120 top of pallet
122 roll of foil
124 modification
126 feature
128 label
129 side
130 fold
132 variation
134 edge
136 stain
138 fingerprint
140 proving apparatus
142 integrity status
144 camera
146 recording device
148 picture
150 section
152 analysis device
154 transmission line
156 individual packaging profile
158 number of folds
160 storing device
162 transmission line
164 database record
166 database
168 further reference
170 determining apparatus
172 comparing device
[0217] While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.
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A method and apparatus for proving an integrity status of an outer packaging. The outer packaging covers an item and includes a modification of a foil provided for the outer packaging. A picture of a section of the outer packaging is recorded and a reference to a feature of the modification of the foil is analyzed. The integrity status of the original outer packaging is proved by storing the reference with respect to the original outer packaging for further use, wherein the outer packaging is uniquely identifiable by using the reference. The integrity status of suspect outer packaging is determined by comparing the reference of the suspect outer packaging with the reference of the original outer packaging. This allows using the outer packaging itself to be used for determining its integrity and may, thus, support avoiding a willful tampering or manipulation of the outer packaging.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of application Ser. No. 60/830,049, filed Jul. 11, 2006, which is incorporated herewith.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of administering medicine. Specifically, the present invention relates to monitoring patient compliance with a prescribed treatment regarding the time of consumption, frequency and amount of medicine taken.
BACKGROUND OF THE INVENTION
[0003] Patient compliance is critical in the effective use of pharmaceuticals. The term “patient compliance” within the pharmaceutical industry refers to taking the proper type and amount of a medication at the proper time interval.
[0004] When new drugs are tested, compliance is extremely important in determining the effectiveness and side effects of drugs being tested. If patients skip doses, an effective drug may be mistakenly determined to be ineffective because it was not taken properly. Thus, millions of dollars of developmental costs as well as FDA approval may be lost by an otherwise effective drug due to lack of patient compliance. Conversely, negative side effects may not become evident during testing if patients do not take medication regularly enough to produce the negative side effect. The result could be that a potentially dangerous drug will be approved for use by the public. Drug recalls, negative publicity and lawsuits are all potential detriments which could be suffered by the companies involved in marketing a drug, as a result of lack of patient compliance.
[0005] Patient compliance is an important factor in determining effectiveness and side effects of new drugs, it also critical in the determination of proper dosage of a new drug. When patients don't take the prescribed amount of medication at the proper time, a new drug could be released into the market with recommendations for an improper dose. This may lead to lack of effectiveness, greater occurrence of side effects, and increased drug interactions.
[0006] While most interested parties would agree that compliance is extremely important, there are not many widely used systems for insuring patient compliance. Pre-printed fold-over blister cards are common in the clinical trial industry. Cards are printed with easy to understand graphics and text instructing the patient exactly what medication to take at the designated time. Slowly, such pre-printed cards are making their way into the commercial/retail marketplace with great success.
[0007] Easy to read instructions are a critical first step, yet they do little to provide actual patient compliance information back to the physician, clinician, or other involved party. Despite the fact that cards may have an area to write-in information about the time of dosing, patients often forget or may write false information in order to avoid criticism from the health care provider. It is possible that many individuals will skew information to show greater compliance as a means to achieve acceptance and avoid disapproval as well as possible termination as a participant in a clinical trial.
[0008] While there are some materials which pertain to the field of medication disbursement and recording information, such devices generally involve elaborate systems for dispensing the medication. Existing products attempt to control the dispensing of medication. Such systems are too complex to be cost effective, are too limiting with regard to the type of medications dispensed, may require repackaging of product into their dispensing system, tend to provide unreliable data, may not be child resistant, and can be perceived as too controlling by the patient.
[0009] U.S. Pat. No. 6,529,446 B1 to de la Huerga provides a good example of an elaborate system for dispensing medication. Exact time of dispensing is recorded via doors that open in the top of a system. While such a system has the potential of working, it is not portable, and is too large, awkward and expensive to be cost effective and convenient. Furthermore, any system such as this that controls or overtly monitors medication by opening doors or compartments can be perceived as overly controlling.
[0010] Attempts to include circuitry into blister cards can have two major drawbacks. First the cost of such a system is high. Each card may need to be manufactured with radio frequency ID chips, batteries or extensive circuitry wiring. Such high tech systems are delicate and may malfunction in normal conditions. Bending such a card could result in the computer recording doses taken when only a wire has been broken inside the card. False data will be an inevitability involved in such a systems and quickly invalidate patient data from a clinical trial. Thus, there is a need for a device which can monitor patients' adherence to medication regimens and is inexpensive. There is also a need for a device that is far less complex than other devices currently available.
SUMMARY OF THE INVENTION
[0011] The present invention is an apparatus for monitoring patient compliance in the administration of medication. The apparatus includes a recording device for recording data related to administration of said medication to a patient, a collecting device and an electronic transmitting device for transmitting, via an electronic link, data to the collecting device. The data is related to administration of the medication and includes time and date of administration. The data may consist of many types of data such as patient identification information, medication identification information, dose consumed, reported side effects, severity of reported side effects, delays in consumption of said medication, text notes by said patient, and text notes by any other individual.
[0012] The medication and the apparatus are attached to a blister card and the device alerts a patient to the time of the next dosage of the medication.
[0013] Other objects, features and characteristics of the present invention, as well as the methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description with reference to the accompanying drawings, all of which form a part of this specification.
BRIEF DESCRIPTION OF THE FIGURES
[0014] A further understanding of the present invention can be obtained by reference to a preferred embodiment set forth in the illustrations of the accompanying drawings. Although the illustrated embodiment is merely exemplary of systems for carrying out the present invention, both the organization and method of operation of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention.
[0015] FIG. 1 is a diagram depicting a blister card embodiment of the present invention.
[0016] FIG. 2 is a diagram depicting a reminder device in accordance with an embodiment of the present invention.
[0017] FIG. 3 is a diagram depicting the transfer of information from the compliance monitoring device in accordance with an embodiment of the present invention.
[0018] FIG. 4 is a diagram depicting the changing of battery and reuse of the compliance monitoring device in accordance with an embodiment of the present invention.
[0019] FIGS. 5A & 5B are diagrams depicting a patient compliance monitoring system using a portable monitoring device in accordance with an embodiment of the present invention.
[0020] FIG. 6 is a diagram depicting the identification method to determine which medicine is taken in accordance with an embodiment of the present invention.
[0021] FIG. 7 is a flow chart depicting the steps taken when a patient enters side effect information in accordance with an embodiment of the present invention.
[0022] FIG. 8 is a flow chart depicting the steps taken when a patient delays the taking of a dose of medication in accordance with an embodiment of the present invention.
[0023] FIGS. 9 & 10 are diagrams depicting a patient compliance monitoring system meant to accommodate complex drug regimens in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] A detailed illustrative embodiment of the present invention is disclosed herein. However, techniques, systems and operating structures in accordance with the present invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiment. Consequently, the specific functional details disclosed herein are merely representative, yet in that regard, they are deemed to afford the best embodiment for purposes of disclosure and to provide a basis for the claims herein which define the scope of the present invention.
[0025] Moreover, well known methods and procedures for both carrying out the objectives of the present invention and illustrating the preferred embodiment are incorporated herein but have not been described in detail as not to unnecessarily obscure novel aspects of the present invention.
[0026] The present invention is a device for recording data (i.e. time, date and type of medication taken) related to patient compliance with drug regiments. Under clinical testing condition or when medication is administered to a patient in a hospital, the container in which the medicine is administered would contain an electronic device capable of recording the date and time when the device is activated, as well as any other relevant information, and transmitting such data to a central computer (i.e. server).
[0027] When a patient is given a drug the patient would activate the data recording device when taking the drug, by pressing a button on the device, the device would then record the time and date at which the patient consumed the medication and transmit this data to a data storing server. Such data can be reviewed by any relevant medical professional (i.e. doctor, testing technician, etc.) from a computer to ensure that a patient is compliant with medication regimens designed to either treat a patient or test a medication.
[0028] Referring to FIG. 1 , the device of the present invention is shown. The device includes a blister card 101 a time and date recording device 103 which is attached to blister card 101 . A simple button 102 for recording events is attached to device 103 . The device 103 includes an alarm or reminder signal, such as a noise emitted by speaker 106 or light emitted by LED 104 that would indicate that the next dose of medication is due or overdue. Button 102 is used for event recording and has a protective cover 107 to prevent accidental event recording. Thus, the patient would have to slide or flip the protective cover 107 to expose the button 102 and then depress the button 102 to record that they have taken their medication. The blister card 101 would have clearly printed instructions 105 for the use of the time and date recording device 103 as well as the dosing instructions 108 for the medicine.
[0029] Rather than writing the time of dispensing the medication on the blister card 101 , the patient will simply press the button 102 to record this event. Because the patient has no ability to alter the time/date on the device 103 , they can not record information other than the actual time and date of each event.
[0030] Compliance with a schedule can be further increased with the addition of a reminder signal. The lighting of LED 104 with the speaker 106 emitting an audible alarm would remind the patient that it is time to take the medication. For example, a LED 104 that glows green 10 minutes before the exact prescribed time of dosing, indicating that it is now OK to take the medication, this could be combined with three audible beeps to attract attention.
[0031] If the patient has not already pressed the button 102 to record the event at the time of the dose, the speaker 106 would beep 5 times. The LED 104 would then turn to blinking orange 15 minutes after the recommended time of dosing. After a certain time period, when the dose should be skipped, the LED 104 would blink red. Printed instructions 105 on the card would direct the patient to respond to different colors of LED 104 and different audible signals emitted by speaker 106 . One example would be that the patient would press the button 102 to reset the device and skip the dose and leave the dose in the card 101 . Each medication or clinical trial could have its own customized design as to the precise compliance requirements. The signaling methods could be adjusted to cater to the needs of a particular study, without departing from the spirit of the present invention.
[0032] Shown in FIG. 2 is a reminder device 200 . The reminder device 200 alerts the patient that it is time to take the medication. In this embodiment of the invention, the time and date recording device 103 is separate from the reminder device 200 .
[0033] The time and date recording device 103 is adhered to the blister card as in FIG. 1 , while the reminder device 200 is separate and portable as in FIG. 2 . The portable component, namely reminder device 200 , could provide the same type of audible reminder through a speaker 206 as the blister card 101 shown in FIG. 1 .
[0034] Instead of the LED 104 , a liquid crystal screen 201 could be used to display the exact amount of time until the next dose, or the amount of time until the dose is overdue. Only the device 103 adhered to the card would have the time/date recording button 102 . This would reduce the ability of the patient to record an event unless they have the blister card 101 with the medication in their hand. The two devices synchronize with each other by means of radio frequency communication, or the reminder device 200 could simply have an alarm reset button 202 which would not record any actual time/date information.
[0035] FIG. 3 shows the transfer of information from the compliance monitoring device. Once the blister card 101 has been used by the patient, it would be returned to the appropriate health care provider for analysis. As discussed with respect to FIG. 1 , the recording device 103 includes a time and date recording button 102 , a protective cover 107 , LED 104 . The device also includes a RF communication means 300 , optical signal transmission means 303 , and a wire socket 301 .
[0036] The device 103 has a simple wire socket 301 to hook up wiring to the device 103 . The patient downloads the information on device 103 to a computer for analysis by an electronic means such as radio frequency communication means 301 , optical signal transmission means 303 (i.e. infrared LED), or by wire connection 302 to wire socket 301 . Because the device 103 is not hidden inside the blister card 101 , the data can be recovered by any conventional means. Other devices must rely on RFID transmission because they have been designed with no means to connect wires. Any other conceivable method of data transfer may be used without departing from the spirit of the present invention.
[0037] FIG. 4 shows the changing of battery and reuse of the compliance monitoring device. The electronic device 103 includes: a time and date recording button 102 , a protective cover 107 , LED indicators 104 and an audible alarm 106 . Device 103 is designed to adhere to the card 101 during the time when the patient is in possession of the card 101 . Once the data is recovered from the device 103 , it is possible for the device 103 to be removed from the card 101 , have a battery replaced and be reused on another card in the future. A flanged thermoformed blister 401 is used to adhere the electronic device 103 to the blister card 101 , which contains dosage instructions 108 . A die cut hole 404 in the top half of the blister card 101 will allow the flanged thermoformed blister 401 to be inserted at the time of sealing of the card 101 . The ability to reuse the device 103 through several different cards will aid in cost reduction when utilizing the present invention. Even a device which is more expensive to manufacture becomes less costly when it is used multiple times over its life cycle.
[0038] In yet another embodiment of the invention, as depicted in FIGS. 5A & 5B , the present invention uses more elaborate means to instruct the patient, and has a broader range of possible uses. In this configuration, more sophisticated electronic devices will be utilized. As shown in FIGS. 5A & 5B , the recording device is a small computerized device 500 , with a screen 501 to display information, and data input means 502 , such as a scroll wheel and buttons. Screen 501 can also be a touch screen for convenient data input.
[0039] Any other data input means maybe used without departing from the spirit of the present invention. It is possible that the computerized device 500 could be existing technology such an existing Personal Digital Assistant (PDA).
[0040] This device 500 could be configured to record multiple medication regimens. In such a scenario, it is preferred that the device 500 not be adhered to the container, whether it is a blister package 101 or a pill bottle 509 . A method for reliably recording that the medication was present at the time of the event recording may be used. This could be established by the use of RFID tags 503 on or in each medicine container, the printing of barcodes 504 on the container, such as blister card 101 or pill bottle 509 , wire socket 301 , or the use of an alphanumeric code system 506 .
[0041] With the RFID system, the card 101 containing the RFID tags 503 would need to be within the reading range of the computerized device 500 , for the device 500 to acknowledge the medication and to record the event of the dispensing of that medication. With printed barcodes 504 , the computerized device 500 would be equipped with a LED barcode reader 507 or a camera system to read the barcode 504 . Wire hookup would entail a simple chip 508 possessing a socket 301 attached to the pill bottle 509 or blister package 101 , and the data recording device to have a socket 301 capable of receiving the same type of wire connection 302 as the chip 508 , thus verifying the presence and type of medication as well as identifying the medication.
[0042] In an alphanumeric system, the container would have information on it such as alpha numeric code 506 or the prescription number. The user would key in the number from the package in order to verify that they are indeed looking at the package. In this scenario, patients would be instructed not to copy down the alphanumeric code 506 elsewhere.
[0043] As shown in FIG. 6 , the identification of which particular pill taken would be recorded when used with a blister card 101 or a similar container. In operation, a tab 601 would be removed from the back of the individual dose at the time of dispensing as shown in steps A & B in FIG. 6 . This tab 601 could have a unique RFID tag 503 , barcode 504 , or alphanumeric code 506 on it. The user would record the identification of the pill which is taken in the same manner as in FIGS. 5A and 5B (i.e. RFID scanning, barcode scanning, etc.). Thus, when the dispensing event is recorded, the exact location on the blister card 101 of the medication is also recorded. Therefore, there would be a unique identifier for each dose.
[0044] The portable electronic data recording device 500 will allow more information to be recorded by the patient, and thus increase the amount of information to the healthcare provider. Because of the interactive nature of a PDA or similar device, the patient could be asked questions about their health at regular intervals, such as at the time of dosing of medication. Through software programming, the questions could be adapted to the responses of the patient.
[0045] FIG. 7 shows a flow chart of the steps taken when a patient enters side effect information. These reports could be followed up with further questions in order to get more detailed information about the negative event. For example, the patient first records the dose taken in step 701 . The system asks if there are any negative effects in step 702 . If the patient responds no, the input process would end in step 703 . However, if the patient's response is yes in step 702 the system would prompt for the type of side effect. The patient would choose from a list of side effects such as: dizziness 704 , upset stomach 705 , and drowsiness 706 . Then in step 707 , the system would ask a follow up question related to a described side effect, such as “is the participant experiencing blurred vision?” If the patient answers “no”, the process ends in step 703 . If the patient answers “yes” to step 707 , the patient would be further asked to describe the severity of the symptoms in step 708 A on a scale of 1-5 708 B. The system would further issue patient instructions such as “discontinue this medication now and call your physician immediately” in step 709 if necessary, or if not end the inquiry process in step 703 .
[0046] By asking the questions at time of the event, the patient can provide more accurate responses to the questions than if they were to wait until their next doctor's appointment. Furthermore, when necessary, the system would follow-up with more in-depth questions thus providing more feedback to the physician. By having the system ask a number of predetermined questions closer to the event, important questions will be asked. When the information is downloaded to the healthcare provider, problems could be flagged for follow up, thus reducing the possibility that a serious side effect or problem will be overlooked. Recording of the exact time line of positive effects of a drug can be critical information for the physician or clinician.
[0047] FIG. 8 shows a flow chart depicting the steps taken when a patient delays the taking of a dose of medication. The system aids the patient in establishing a dosing regimen that works for their individual lifestyle. For example, a message would issue informing the user that it is time to take a medication in step 801 . The user may then either: take the medication in step 802 , delay the dose in step 803 , or override the dose in step 804 . If the patient takes the dose at the prescribed time the adjustment process ends in step 805 . If the patient chooses to delay the dose, a time frame of delay is chosen in step 809 , and the time of future doses is shifted in step 810 by the appropriate time frame.
[0048] If the patient overrides the dose in step 804 the patient may choose to inform the system that the medication will be taken later in step 806 . This may be done outside of observation. Once the patient returns to the testing facility or observation area the time when the patient ingested the medication is recorded in step 807 . Then that particular dose is flagged as an overridden dose in step 808 .
[0049] Patients with too many dose overrides could be identified and reviewed. In the case of a clinical trial, non-compliant participant's data could be reviewed and/or removed from the drug study. In the general population, physicians would be alerted to the lack of patient compliance as part of their overall assessment of the patient's condition.
[0050] This system can also be used to instruct patients how to handle missed or skipped doses. Because the system knows how long it has been since the last dose, it could instruct the patient to take double the medication, skip a dose, or set up an accelerated dosing pattern to get the patient back on the proper schedule. The exact choice for such handing of missed doses would be pre-programmed into the system by the health care provider and can be tailored to the particular medication taken.
[0051] It is also contemplated that drug interaction of existing medications could be uploaded into the system, and that all medications would be checked against each other to reduce the possibility of interaction.
[0052] Yet another embodiment of the device is depicted in FIGS. 9 and 10 . This embodiment is especially useful in assisting individuals who are: elderly, visually impaired, mentally impaired, or individuals who are on complex drug regimens. This embodiment would incorporate elaborate dosing instructions for the patient.
[0053] The system shown in FIG. 9 includes a medicine bottle 509 possessing a RFID tag 503 , a RFID reader mat 902 possessing a wire connection 302 , a computerized device 500 possessing a wire socket 301 capable of coupling with wire connection 302 and displaying instructions 904 relevant to the medication in bottle 509 . The pharmacist would dispense medication in a bottle 509 with a RFID tag 503 on it. The system would prompt the patient at the time of dosing. The patient would place the medicine containers on a RFID reader mat 902 , the system would audibly speak the name of the prescription using speaker 903 , indicating the number of pills to be taken at that time. Instructions 904 confirming amount of medicine in each dose would be large and easy to read.
[0054] The system in FIG. 10 includes a medicine bottle 509 possessing a barcode 504 , computerized device 500 possessing a wire socket 301 capable of coupling with wire connection 302 and displaying instructions 904 relevant to the medication in bottle 509 , the pharmacist would dispense medication in a bottle 509 including a barcode 504 . The system would prompt the patient at the time of dosing. The patient would scan the barcode using barcode scanner 507 , the system would then audibly speak the name of the prescription using speaker 903 , indicating the number of pills to be taken at that time. Instructions 904 confirming amount of medicine in each dose would be large and easy to read.
[0055] Confirmation of dosing can be received via voice recognition. The system would also be able to warn patients of mixed up medicine containers between individuals in a household. Thus a wife would be less likely to take a husband's medication because all medication would be identified by system prior to dispensing.
[0056] Additionally, the electronic device which monitors compliance can be read by the doctor at regular check-up intervals. If the device was hooked up to a central computer at the user's home or at the pharmacy, non-compliance could be identified and automatic emails to the physician and/or responsible caregivers (i.e. family) would be generated to alert them that the patient has exceeded some minimum compliance requirement. An example would be that if a patient misses 3 or more doses in a week and their caretaker and the physician are alerted via email, text message or other electronic means. By downloading the compliance data to a home PC or other device with internet access, such non-compliance would be detected quickly, before health consequences occur.
[0057] Up to the minute recording of medication is critical to emergency care givers responding to patients in medical crisis. Information about the previous 48 hours of medication is of utmost importance in such cases. In such a scenario, the EMT would simply have to bring the medication computer to the emergency room to read a full record of the patient's current medications, dosing levels and time of dosing.
[0058] Elaborate dosing regimens such as AIDS drugs and diabetes medication would be excellent uses of the present invention. It is contemplated that the system could easily interface with blood glucose readers to record critical blood sugar levels as well as to record the medication taken. This could include user input data for injected insulin as well as recoding information about current health conditions.
[0059] By recording this data in one device, data analysis would be greatly simplified, with trends and statistical factors more accurately identified. Even though complex regimens would be most important for this system, it could be used by anyone on a drug therapy to help boost compliance and aid in the convenience of medication dispensing.
[0060] Once data is downloaded, it can be analyzed by software to determine the compliance rate of a given patient. Coupled with medical records, compliance can be factored into the effectiveness rating of the drug. With this critical information, bad data may be eliminated from drug studies leading to more accurate evaluations of drugs under review.
[0061] In the case of the consumer, the physician may encourage stronger adherence to the dosing instructions before changing a medication. The result could be greater effectiveness of preferred medications; thus reducing the reliance on more dangerous medications, surgeries, or other intrusive therapies. In an environment where information is critical to accurate decision making, accurate dosing information and compliance to the prescribed regimen is critical. A simple, low cost, easy to use device can greatly aid in the flow of information back to the health care provider.
[0062] While the present invention has been described with reference to the preferred embodiment and alternative embodiments, which have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, such embodiments are merely exemplary and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. The scope of the invention, therefore, shall be defined solely by the following claims. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention. It should be appreciated that the present invention is capable of being embodied in other forms without departing from its essential characteristics.
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An apparatus for monitoring patient compliance in the administration of medication includes a recording device for recording data related to administration of said medication by a patient, a collecting device and an electronic transmitting device for transmitting, via an electronic link, data to the collecting device. The data is related to administration of the medication and includes time and date of administration. The data may consist of many types of data such as patient identification information, medication identification information, dose consumed, reported side effects, severity of reported side effects, delays in consumption of said medication, text notes by said patient, and text notes by any other individual.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods for hydrolyzing oat husks to provide D-(+)-xylose, and through subsequent treatment, if desired, xylitol, lignin and cellulose.
2. Description of the Prior Art
D-(+)-xylose and its hydrogenation product, xylitol, are of considerable industrial significance. For example, xylose can be employed for various purposes in the foodstuffs industry, while xylitol has proved to be a very good sweetener for diabetics. Varieties of deciduous timber, such as beech and chestnut, are used almost exclusively as the starting material for the industrial manufacture of xylose. The yields are about 10-12% (compare, for example, German Pat. No. 912,440). It is a significant disadvantage of these processes that the wood material which remains, so-called cellolignin, has hitherto been incapable of practicable industrial utilization and that the process mentioned only gives moderate yields of xylose.
German Pat. No. 834,079 has disclosed the production of xylose from oat husks. Oat husks contain about 38% of pentosan while, for example, beechwood and birchwood only contain 24-25% and maize cobs contain about 28% of pentosans. In this process the oat husks are heated to boiling with 0.08% strength ammonia or are extracted with benzene/alcohol. Thereafter, the usual hydrolysis under pressure is carried out with 0.2 to 0.5 % strength H 2 SO 4 at 125°C. Further working up is not carried out. In the pretreatment with NH 3 , 4 kg of NH 3 , as an 0.08% strength solution, are used per 1,000 kg of oat husks. However, 17 kg of NH 3 would be necessary to split off the acetic acid. Furthermore, under the conditions mentioned in German Pat. No. 834,079, it is likely that hardly any splitting off, and hence removal, of the acetic acid, which accounts for approximately 6% of the weight of the oat husks, takes place.
There is therefore a need for a process which, firstly, permits complete utilization of the starting material, and secondly, gives a higher yield of xylose so that the process is economical.
SUMMARY OF THE INVENTION
The subject of the present invention is a process for the hydrolysis of oat husks to provide D-(+)-xylose which is characterized in that the hydrolysis is carried out with alkali metal hydroxide or alkali metal chlorite in a first stage and with a mineral acid in a second stage. The xylose can be recovered as such or converted in situ to xylitol. The solid residue by-product of the aforesaid process for the hydrolysis of oat husks, following removal of the lignin content thereof, is readily convertible to cellulose.
As a result of the use of alkali metal hydroxide or alkali metal chlorite in the first process stage of the process according to the invention, the (chemically) bonded acetic acid present in the oat husks is split off. In addition, the crystallization-inhibiting nitrogen-containing substances and other concomitant substances, about the nature of which nothing is known as yet, go into solution, while the pentosan is not attacked by the alkali metal hydroxide or alkali metal chlorite. The acetic acid can be distilled off and can, if desired, be isolated from the distillate by extraction with a suitable solvent.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
If alkali metal hydroxide is used in the first stage, then sodium hydroxide and potassium hydroxide, but especially sodium hydroxide, are preferred. The process can be carried out, for example, in aqueous solution. When working under normal pressure, the concentration of the alkali metal hydroxide can be, for example, 0.6-4% by weight, based on solvent and alkali metal hydroxide. The preferred concentration range is 0.6-3, in particular, 1-2% by weight. The temperature is 15-100°C, preferably, 25°-60°C.
By way of example, 1.2% strength aqueous NaOH at room temperature dissolves almost 20% of the oat husk material, the acetic acid is split off and the residue contains 50.5% of pentosan. 2% strength NaOh at 50°C dissolves 38% of the oat husk material and the residue contains 46.6% of pentosan; 3% strength NaOh at 50°C dissolves 40% of oat husk material and the residue contains 31% of pentosan; 4% strength NaOH at 60°C. dissolves about 45% of oat husk material and the residue contains 30% of pentosan.
If the process is carried out under pressure it is possible to use, for example, alkali metal hydroxide concentrations of 0.3 to 1.5% by weight, preferably of between 0.5 and 1.0% by weight. In that case, the most advantageous concentration is 0.66% by weight. The pressure is preferably up to 3 atmospheres gauge and the temperature is preferably up to 125°C. The pressure is in general generated autogenically in the autoclave. If the process is carried out under pressure with 0.66% strength NaOH, 25-27% of the interfering materials are dissolved and the residue contains 50% of pentosan.
If the hydrolysis in the first stage of the process according to the invention is carried out with alkali metal chlorite, the potassium salt or sodium salt, but especially the sodium salt, is again used for preference. The concentration of the chlorite in the solvent, which is preferably water, is up to 10% by weight, 2 to 6% by weight being preferred. The pH value of the reaction mixture is initially adjusted to be alkaline, preferably at least 11. Thus, in contrast to the usual reactions with alkali metal chlorite, the treatment is not carried at an acid pH value already from the start. During the hydrolysis, the pH value drops to about 4-5. The process is carried out without use of pressure and the temperature is preferably between 15° and 60°, especially between 30° and 55°C. The oat husks lose approximately 11% of their weight and have a white-yellowish appearance, the acetic acid has been split off and the pentosan content of the residue has risen to 49.8%. Since the amount of NaClO 2 consumed is only as much as corresponds to the acetic acid split off, the reaction solution can be reused several times after replacing the NaClO 2 consumed, which must always be present in exess.
After removing the acetic acid by filtration, the oat husks treated in the first stage are hydrolyzed, in a manner which is in itself known, with a dilute mineral acid at elevated temperatures with or without use of pressure.
This process can be carried out, for example, with H 2 SO 4 , HCl or HBr, for example, in water, but preferably with H 2 SO 4 . When working without pressure, preferably 1.5-6.0% strength by weight HCl or HBr or 1.5-6.0 % strength by volume H 2 SO 4 and a liquid to solid ratio of 3- 6 parts by volume is used. An elevated temperature, preferably 50°-125°C is employed, and in that case, about 2 to 4 hours are required for the second stage of the process according to the invention.
When working under pressure, a pressure of up to 4 atmospheres gauge, in particular 1-3 atmospheres gauge, is used preferentially, and the temperature is preferably 125°-135°C. The acid concentration is preferably 0.2-0.6% by weight HCl or HBr or 0.2-0.6% by volume of H 2 SO 4 and the ratio of liquid to solid should preferably be from 4:1 to 7:1 volumes/weight of solids. The time required is approximately 1-2 hours.
After completion of the second stage of the process, the batch is filtered. The liquid can be processed to give xylose or directly to give xylitol. If sulphuric acid has been used in the second stage, the mixture can be neutralized with calcium oxide, calcium carbonate or, preferably, barium carbonate, in the calculated amount. In that case, after removing the precipitate, a xylose solution which can be reduced directly to xylitol, is obtained, while hitherto it has been necessary to concentrate the solution or pass it over ion exchangers to remove acetic acid. The yield of pure xylose is up to 25% and further proportions of xylose, namely up to 10%, can be isolated from the mother liquor.
The process according to the invention results in splitting of the bonds of the lignin to the polysaccharides in the oat husks, without the lignin undergoing a further polymerization, as is the case in the known hydrolysis processes. The lignin can easily be dissolved out of the filtration residue from the second stage of the process according to the invention, by washing with an organic solvent such as methanol or acetone, temperatures of 10°C up to the boiling point of the solvent being suitable. As much as 90% of the lignin is dissolved out at room temperature. The lignin is then obtained as a yellowish-brownish powder which is also dissolved by various other solvents. The substance is thermoplastic and very reactive and is used as the base material for industrially utilizable products, such as dyestuffs and pesticides. Yet further amounts of lignin can be dissolved by treatment with methanol under pressure.
Suprisingly, the residue remaining after the methanol treatment can be hydrolyzed to an almost white cellulose even at waterbath temperature (approximately 88° to 95°C) using dilute alkali metal hydroxide solution, preferably NaOH, for example using 1-4% strength NaOH, while in other circumstances boiling under pressure at up to 180°C is necessary. The cellulose is obtained in a yield of approximately 70% and can be obtained in a pure white form by brief customary bleaching.
The residue can also be treated with alkali and H 2 O 2 instead of with alkali.
A third embodiment is to treat the residue with dilute alkali metal chlorite solution, especially with sodium chlorite solution. Here, in contrast to the known processes which are carried out in the acid range, an alkali chlorite solution which has been adjusted to a basic pH value, especially to a pH value of at least 11, is employed. In this way, the residue is very easily hydrolyzed, giving pure white finely fibrous cellulose in a yield of approximately 85%. This cellulose can easily be pulverized and can, inter alia, be used as so-called foodstuff-grade cellulose.
EXAMPLE 1
1 kg of oat husks are left to stand with 4 l of 1.2% strength NaOH solution for 24 hours at room temperature, with frequent shaking and mechanical working, and while following the decreasing titre of the solution. The mixture is then suction-filtered and the residue is well washed with H 2 O until the solution which passes through, and which is initially turbid, has become clear. A determination of the residue shows 50.5% of xylose (pentosan content conversion by calculation, to the pentose). The residue is furthermore now free from nitrogen.
The filtrate is acidified with sulphuric acid and the acetic acid from the distillate is determined; it is found that the oat husks contain from 5.8 to 6% of acetic acid.
1.2 l of 3% strength by volume H 2 SO 4 are added to 300 g (calculated as solids) of the residue, the liquid being completely absorbed. Thereafter, the mixture is heated in an oil bath for 2 hours to 120°-125°C under reflux, and in the course thereof soon becomes mobile. After suction filtration and thorough pressing-out, the residue is rinsed with water; the filtrate is brown-yellow and on standing some sediment forms, and for this reason the filtrate is clarified with kieselguhr and decolorized with active charcoal and the solution, which retains a greenish-yellowish tinge, is neutralized with the calculated amount of BaCO 3 and concentrated in vacuo at 45°C until it is slightly syrupy. After seeding and standing in the cold, crystallization occurs. The cyrstals are filtered off and briefly washed with 85% strength methanol. Pure xylose is obtained in a yield of 75.5 g. Further proportions are isolated in an amount of approximately 15 g, from the mother liquor by fractionation with methanol and isopropanol.
The mother liquor which thus remains is still a mixture of D-xylose, L-arabinose and glucose, which is difficult to separate.
As was to be expected, the distillate contains no further acetic acid.
To ascertain what amounts of xylose were converted to furfuraldehyde during the hydrolysis process, a determination of the distillate is carried out with 2,4-dinitrophenylhydrazine; this shows that about 1.5% of the xylose produced has reacted further to give furfuraldehyde.
The hydrolysis residue is washed with methanol until the latter becomes colorless, and then weighs 160.1 g and still contains 12.1% of pentosan, so that approximately 124 g of this substance have passed into the hydrolysis liquid. The brown-yellow methanol filtrate, which still contains H 2 O from the moist hydrolysis residue, is evaporated, in the course of which the lignin precipitates after the methanol has evaporated, and is filtered off. The aqueous filtrate still contains residual xylose and can be worked up.
To isolate cellulose, 150 g of this residue are left to stand, without acidification, with 20-50 g of 80% strength sodium chlorite dissolved in 1.4 l of H 2 O. After some time, the mass swells up and loss of color occurs. The substance is then stirred at approximately 40°C until it has become light in color. It is then filtered off, washed with H 2 O until the odor of ClO 2 has disappeared, and dried.
A pure white flocculent substance, which is very easy to grind, remains in a yield of almost 90%.
A further 100 g of the hydrolysis residue treated with methanol are warmed with 700 ccs of 2% strength NaOH for 2 hours on a waterbath at approximately 95°C, filtered off on a glass frit and rinsed with H 2 O until the initially dark brown filtrate has become colourless. The remnants of alkali are removed with 1 % strength acetic acid.
Here again, a flocculent, slightly brownish-colored cellulose is produced, which is immediately turned white by a customary bleaching agent. The yield is 70% since the alkali metal hydroxide solution also dissolves out pentosan constituents which are still present, which is not the case using hydrolysis with NaClO 2 .
EXAMPLE 2
1 kg of oat husks and 6 l of 0.66 % strength NaOH (40 g) are heated to 125°C over the course of 40 minutes at 0.9 to 1.3 atmospheres gauge and then allowed to cool, and the solids are filtered off, using a fiber fleece, and are washed well. The residue amounts to approximately 750 g and contains 48.5% of pentosan.
If the oat husks are heated in the autoclave under the same conditions, but only to 105°C, a residue of 876 g, containing approximately 43% of pentosan, is obtained.
600 g of this residue, 4 l of H 2 O and 24 ccs of concentrated H 2 SO 4 are heated for 90 minutes to 134°C in a stirred autoclave, stirring being readily possible from 70°C upwards. After filtration, washing with H 2 O and treatment with methanol, the residue amounts to 283.7 g and only retains 8.1 % of pentosan.
The acid filtrate is neutralized with the calculated amount of BaCO 3 while stirring, and is clarified with active charcoal. After evaporation under reduced pressure at 45°C until slightly syrupy, approximately 25% of pure xylose crystals can be isolated; a further 6% can be obtained from the mother liquor.
100 g of the hydrolysis residue treated with methanol are stirred with 1 l of 1.2% strength NaOH for 1 hour at 90/92°C on a waterbath, and after being left to stand overnight, the mixture is filtered through a glass frit. The residue is washed with hot water until the alkalinity has disappeared, and is dried. It consists of white cellulose, the methoxy content of which is about 0.5 to 0.6%. The yield is about 73 g.
EXAMPLE 3
100 g of oat glumes are mixed with a solution of 30 g of NaClO 2 in 500 ccs of H 2 O; the pH value is 11. The mixture is warmed to 50°C for 2 hours on a waterbath, while stirring; in the course of this, the pH value drops to 4 and the color of the reaction mixture changes from brownish to yellow. The acetic acid is split off and liberates ClO 2 , which then reacts further. After cooling, the mixture is filtered and the residue is well rinsed with water. The yield is about 89 g, and the material contains approximately 49.1 % of pentosan and 2.5% of OCH 3 groups. The materials containing nitrogen have been removed.
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A process for the hydrolysis of oat husks is carried out with alkali metal hydroxide or alkali metal chlorite in a first stage and with mineral acid in a second stage to provide D-(+)-xylose. The xylose can be recovered as such, or converted in situ to xylitol. The solid residue by-product of the aforesaid process for the hydrolysis of oat husks, following removal of the lignin content thereof, is readily convertible to cellulose.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to sliding means that have been extensively used in machines and instruments as diverse as semiconductor manufacturing apparatus, machine tools, industrial robots, conveyors and others. It is more particularly concerned with a sliding means with built-in moving-magnet linear motor, in which an exciting winding is arranged in a stationary bed while a magnet is installed in a moving table.
[0003] 2. Description of the Prior Art
[0004] In recent years, multi-axis stages and moving mechanisms employed in the diverse technical fields as described above have required more and more sliding means, which are compact or slim in construction and light in weight, and moreover able to operate with high propulsion, high speed and high response to provide high speed travel and accurate position control for works, tools, articles and instruments. Linear motors commonly used in the sliding means involve two broad types. The first, called moving-coil linear motor, has a stator of field magnet mounted on a stationary bed, and moving-armature coils arranged on a table movable lengthwise of the bed in space one after another such that they lie a preselected phase angle. The second, called moving-magnet linear motor, has a stator of armature windings arranged lengthwise over the entire length of a bed, and a moving-field magnet of permanent magnet arranged on a table movable in a sliding manner along the length of the bed.
[0005] Japanese Patent Laid-Open No. 322232/1996 discloses a linear motor installed in a knitting machine to drive a knitting needle in reciprocating motion. The liner motor is comprised of a plurality of built-in moving-coil liner motor units each of which has a moving assembly composed of a backing plate made therein a window, a resilient sheet member fixed on any one side of the backing plate with adhesive, and exciting windings, for example three windings, arranged on any one surface of the sheet member in a manner to be partly accommodated in the window. The exciting winding is made in the form of flat ellipse where the axial direction of the winding extends thickness-wise of the linear motor unit. The moving assembly is arranged for linear movement between stator assemblies confronting one another, each of which is composed of a backing plate made of ferromagnetic material such as steel, and a plurality of permanent magnet, for example six pieces arranged on the backing plate in juxtaposition along the traveling direction of the moving assembly. The construction in which the exciting windings are accommodated in the associated window in the backing plate reduces the overall thickness or height of the moving assembly. Linear displacement-measuring means is composed of a linear scale extending along the moving direction of the moving assembly, and a sensor head installed on any one of the confronting stator assemblies.
[0006] A moving-magnet brushless dc linear motor is disclosed in Japanese Patent Laid-Open No. 298946/1989, in which a semiconductor rectifier is arranged for each coil, and two sets of three-phase coil groups are arranged to provide a linear motor of three-phase conduction system.
[0007] A sliding means adapted to be used for machine tools and industrial robots is disclosed in Japanese Patent Laid-Open No. 266659/1997, which is a senior application of the present applicant. The prior sliding means includes a driving source made of an electromagnetic linear actuator and a built-in moving-magnet uniaxial linear motor to control with precision a position of a driven article. With the prior sliding means cited just above, an electromagnetic linear actuator is arranged between a moving table and stationary bed of steel or magnetic material and at least any one of the table and the bed is constructed to serve a part of magnetic circuit of the electromagnetic linear actuator, concretely the function of either magnet yoke or coil yoke. The prior sliding means has no need of providing separately yokes for establishing magnetic circuit, which might make the sliding means bulky, thus reduced in the number of parts required, and made inexpensive in production cost and slim in construction.
[0008] The sliding means disclosed in the above Japanese Patent Laid-Open No. 266659/1997 will be explained below, with referring to FIGS. 14 and 15. A sliding means 51 with an built-in linear motor is composed of a stationary bed 52 and the moving table 53 , both of which are made of magnetic material such as steel to serve the function of magnetic circuit, or magnet yoke and coil yoke, thereby rendering the linear motor small or compact in size. The sliding means 51 with built-in linear motor has the stationary elongated bed 52 , and the moving table 53 mounted on the bed 52 for linearly reciprocating movement lengthwise of the bed 52 by virtue of linear motion guide units 54 . The linear motion guide units 54 are comprised of two track rails 55 arranged on the bed 52 in parallel with each other, and four sliders 56 fitting over the associated track rail 55 for sliding movement. In the linear motion guide units 54 , load raceway areas are provided between confronting raceway grooves, one of which is formed on lengthwise sides of the track rails 55 while the counterpart is formed on the sliders 56 . The sliders 56 are allowed to move with smooth along the track rails 55 as rolling elements run through the load raceway areas. The table 53 is bored with holes 58 through which screws fit to fix a work on the table 53 . An end block 61 and a connector block 62 are secured to the lengthwise opposing ends of the bed 52 , each to each end, with fixing bolts 63 , 64 to define a tolerable range of operating stroke of the table 53 . The bed 52 is made with holes 65 through which bolts 66 fit to anchor the bed 52 to a platform.
[0009] An armature 70 , which is a primary side of the sliding means 51 , is comprised of a coil board 71 and eight pieces of armature windings 72 arranged on the underside of the coil board 71 in juxtaposition along the moving direction of the table 53 . The bed 52 is recessed lengthwise at 73 on the upper surface thereof, where the armature 70 is accommodated through an insulating film 74 . Hall-effect elements 75 are arranged on the coil board 71 in conjunction with the armature windings 72 , each to each winding. The Hall-effect elements 75 are to issue a signal in response to an amount of magnetic flux created by a secondary field magnet 90 , which is detected when the field magnet 90 approaches the Hall-effect elements 75 . Excitation of the armature windings 72 is controlled depending on the signal issued out of the Hall-effect elements 75 . The armature 70 is jointed to the bed 52 by means of machine screws 76 fitting through spacers 77 , which make abutment at their opposing ends against both the bed 52 and the coil board 71 at locations offset widthwise of the bed 52 between any two adjacent armature windings 76 from one another.
[0010] The bed 52 is also made with a recess 79 at the underside opposite to the upper recess 73 . A driving board 80 is received in the lower recess 79 through an insulating film 81 . The driving board 80 is to apply electricity to the armature windings 72 , and mounted with a driving circuit 82 composed of diverse electronic components. The driving board 80 is connected with the coil board 71 via connectors 83 , 84 extending through a hole 85 bored vertically through the bed 52 . In addition, the lower recess 79 in the bed 52 is closed with a cover 86 .
[0011] The field magnet 90 , which is the secondary side of the linear motor, is installed in a recess 92 formed in the table 53 and secured to the underside of the table 53 . The field magnet 90 is composed of platy magnets 91 arranged such that unlike poles (N, S) on the platy magnets 91 alternate along the moving direction of the table. The table 53 mounted with the platy magnets 91 provides a magnet yoke forming a part of magnetic circuit, while the bed 52 provides a coil yoke for each armature winding 72 , which also forms a part of magnetic circuit. When the preselected current is applied to each armature coil 72 , a thrust force is created between the primary and secondary sides on the basis of Fleming's rule to drive the table 53 integral with the secondary field magnet 90 in a sliding manner by virtue of the linear motion guide units 54 .
[0012] To determine the reference position of the table 53 with respect to the bed 52 , a Hall-effect element 97 is installed inside the second armature winding 72 from the left. The reference position may be identified by a signal issued at a time when the Hall-effect element 97 has detected the leftmost platy magnet 91 in the field magnet 90 . Besides, two Hall-effect elements 98 , 99 are attached to the coil board 71 inside the leftmost and rightmost armature windings 72 , each to each winding, to provide limit sensors that ensure keeping the table 53 from travelling over the tolerated range of moving stroke. Each Hall-effect element 98 , 99 , when the table 53 has traveled over the tolerated range of the operating stroke, may respond to any associated pole at the leftmost and righ-tmost extremities of the field magnet 90 to issue a signal reporting the accidental event where the table has run away from the desired stroke. In order to monitor the relative location of the table 53 to the bed 52 in the sliding means 51 , the table 53 is provided at one lengthwise side thereof with a magnetic linear scale 95 in which unlike magnetic poles (N, S) are arranged alternately with a fine pitch along the moving direction of the table 53 , while the bed 52 has a sensor head 96 responsive to the magnetic scale 95 .
[0013] In the sliding means 51 with built-in linear motor constructed as stated earlier, there is employed a system in which electric conduction is controlled every each armature winding 72 and, therefore, both the driving board 80 and the driving circuit 82 are built in underneath the bed 52 . This system makes the sliding means complicated and bulky in construction. Besides, the linear scale is made of magnetic scale.
[0014] In a sliding means with built-in moving-magnet linear motor in which a table is arranged on a bed for sliding movement, the bed having supported thereon an armature winding while the table being mounted with a field magnet on a surface confronting the bed so that the current flowing through the armature winding interacts in an electromagnetic manner with magnetic flux created by the field magnet to drive the field magnet together with the table, it has been desired to make the sliding means light in operation, simple and slim in construction, light in weight and much more precious in position control of the table to the bed. To this end, there are problems to be solved in conduction system for the armature winding, material for the field magnet, design of the high resolving-power encoder and fixing means for the sensor cords.
[0015] Summary of the Invention The present invention has as its primary object to overcome the problems as described just above and more particular to provide a sliding means with built-in moving-magnet linear motor, in which conduction system for armature windings, material of field magnets, design of a high resolving-power encoder and fitting means for sensor cords are improved to render a stationary bed much more slim or thin in construction, thus reducing the overall height of the sliding means. Thus, the present invention contemplates to develop a sliding means with built-in moving-magnet linear motor, which is made simple or compact in construction, light and smooth in operation, and improved in operating speed and response ability of the table movement, thereby making it possible to ensure the high accuracy of position control of the moving table to the bed.
[0016] The present invention relates to a sliding means with built-in moving-magnet linear motor, which is comprised of a bed of magnetic material, a table of magnetic material arranged movable lengthwise of the bed in a sliding manner with respect to the bed, a field magnet arranged on a surface of the table, which opposes to the bed, the field magnet having unlike poles alternating in polarity in a moving direction of the table, an armature winding installed on a surface of the bed, which confronts the field magnet of the table, and a means for monitoring a position of the table with respect to the bed, wherein the three armature windings are provided to carry a three-phase current, each to each phase, so that the three-phase current flowing in the armature windings interacts with magnetic flux created by the field magnet to produce an electromagnetic force to drive the table along the bed in a sliding manner with a desired position control.
[0017] In an aspect of the present invention, there is provided a sliding means in which the field magnet has five poles for the three armature windings. With the sliding means stated earlier, a armature assembly is composed of only three armature windings, which are the minimum for a linear motor unit, while the field magnet has the least five poles. This construction makes it possible to reduce the sliding means in size to the commercially available minimum.
[0018] According to the sliding means of this invention, the armature windings carry a three-phase current and, therefore, there is no need of providing on-board driving circuits underneath the bed as in the prior construction in which conduction systems are individually prepared for every armature winding. Thus, the sliding means may be reduced in overall height.
[0019] Now considering the modified sliding means in which the field magnet has, for example four poles, the moving stroke of the table, effective in keeping high propulsion, becomes reduced by one pole. Moreover, since the poles at forward and aft ends of the field magnet are unlike in polarity, the Hall-effect ICs, limit sensors and before-the-origin sensors must be set in compliance with unlike poles and correspondingly the construction becomes complicated. As opposed to the modification stated earlier, when the field magnet has six poles, the moving stroke of the table, effective in keeping high propulsion, becomes extended by one pole. Nevertheless, the table is inevitably rendered long by the length of one pole and correspondingly the bed is extended lengthwise. Thus, this modification of the field magnet makes the sliding means bulky in size.
[0020] With the sliding means constructed according to the present invention, the moving stroke of the table may be kept in the minimum range enough to ensure the high propulsion, and also the field magnet has like poles at the forward and aft ends thereof so that the Hall-effect ICs, limit sensors and before-the-origin sensors can be set with ease. This is effective in providing the sliding means desirable in both function and compactness.
[0021] For the sliding means of the present invention, the field magnet is preferably made of a permanent magnet of rare earth such as neodymium, which is effective in raising flux density, thereby providing high propulsion (=current×flux density). This makes it possible to ensure much high-speed movement, responsibility and accurate position control.
[0022] In another aspect of the present invention, there is provided a sliding means in which the position monitoring means is an optical encoder composed of an optical linear scale secured on the table and a sensor element installed in the bed in opposition to the optical linear scale. The optical encoder stated above is improved in resolution and less vulnerable to change in distance between the scale and the sensor element as compared with the prior magnetic encoder, thus ensuring the highly accurate position control of the table. With the optical encoder employed for the position monitoring means, the optical linear scale is arranged on the underside of the table while the sensor element is installed in the bed. Thus, there is no sensor cord or line moving in conjunction with the operation of the sliding means. The construction is effective in keeping the sliding means itself low in the occurrence of dust and dirt, thus realizing clean environment. Employment of the optical encoder rather than the magnetic encoder results in improvement in resolution and high accuracy.
[0023] In the sliding means of the present invention, the current flowing in the armature windings interacts with the magnetic flux created by the field magnet to produce an electromagnetic force, for the sake of which the field magnet is allowed to move together with the table serving as the magnet yoke by virtue of the linear motion guide units with respect to the bed serving as the coil yoke. The relative arrangement of the armature windings with the field magnet according to the present invention serves well to establish the efficient electromagnetic reaction despite realizing significant space saving.
[0024] In another aspect of the present invention, there is provided a sliding means wherein the armature winding is composed of a resinous core molded in a form of rectangle, and turns wound around the core. The core of molded resin serves well to preserve the shape of the armature winding.
[0025] In a further another aspect of the present invention, there is provided a sliding means in which the table is provided with an origin mark to define an origin of the table, while the bed is made with a limit sensor to detect the poles at forward and aft ends of the field magnet and a before-the-origin sensor to monitor the origin mark, both the sensors being placed at forward and aft ends of the bed along the moving direction of the table. Both the limit sensors and before-the-origin sensors are to sense any one of the forward and aft ends of the field magnet, thus making it possible to control the position and stroke of the table relatively to the bed.
[0026] In another aspect of the present invention, there is provided a sliding means in which the bed has an end block at any one of the forward and aft ends thereof in the moving direction of the table, and has a connector block at another of the forward and aft ends, the connector block having an electric power cord to be connected to the armature windings and a sensor line to be connected to the position monitoring means. Moreover, elastic stoppers are mounted on the blocks, each to each block, to buffer collision with the table. If the table were moved beyond the tolerated stroke range with respect to the bed, the elastic stopper inside the end block or the connector block would buffer the collision with the table to protect the sliding means against breakage.
[0027] In another aspect of the present invention, there is provided a sliding means in which a moving stroke of the table with respect to the bed is defined in such a range that forward and aft ends of the table remain at most between centers of forward and aft coil sides of the armature windings. That is to say, the table is allowed to move over the armature windings without deviating from the forward and aft outermost coil sides of the armature windings. In this way the current conducting through the armature windings may interact at the most efficiency with the magnetic flux produced by the field magnet. This makes it possible to continue keeping the high propulsion of the table.
[0028] In a further another aspect of the present invention, there is provided a sliding means in which the field magnet is mounted on forward and aft ends thereof with end plates, each to each end, of magnetic material to keep the magnetic flux created by the field magnet against magnetic leakage. As the end plates keep the magnetic flux established in the field magnet from leakage out of the forward and aft ends of the table, anything approaching the table may be protected against magnetic affection.
[0029] In another aspect of the present invention, a sliding means, in which the table fits on the bed in a lengthwise sliding manner by virtue of a linear motion guide unit, which is composed of track rails provided on the bed and a slider mounted on the bed for sliding movement and having thereon the table.
[0030] In another aspect of the present invention, there is provided a sliding means in which the field magnet is at most equal in height to the linear motion guide unit while the armature winding is accommodated in a recess formed in the bed between the track rails. Moreover, the armature windings are installed in juxtaposition along the sliding direction of the table in the recess formed in the bed. Thus, the bed may be made as slim as possible so that the sliding means is made much reduced in overall height. The track rails for the linear motion guide units are arranged on widthwise opposing sides of the recess in parallel with each other whereby the table is allowed to move steady along the bed. The encoder may be arranged on the bed and table sidewise outside any one of the linear motion guide units.
[0031] In a further another aspect of the present invention, there is provided a sliding means in which the armature windings are attached to a coil board that is secured to the bed to close the recess, and the armature windings are each formed in a flat shape and fixed in juxtaposition in the moving direction of the table to a surface of the coil board, which is exposed to the recess. The armature assembly of the armature windings with the coil board is made as thin or slim as possible in thickness to be snugly accommodated in the recess.
[0032] The sliding means constructed as stated earlier, as being made as compact as possible in size, realizes space saving in production, storage, conveying, installation and use thereof. Moreover, the sliding means of the present invention makes for an improvement in working environment, and further providing position control mechanism that is suitable for clean room and high in propulsion, operating speed and responsibility.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] [0033]FIG. 1 is a top plan view showing a preferred embodiment of a sliding means with built-in moving-magnet linear motor in accordance with the present invention:
[0034] [0034]FIG. 2 is a front elevation of the sliding means shown in FIG. 1:
[0035] [0035]FIG. 3 is a cross-sectional view of the sliding means, taken along the plane I-I of FIG. 1:
[0036] [0036]FIG. 4 is a top plan view of the sliding means shown in FIG. 1, with a moving table being removed:
[0037] [0037]FIG. 5 is rear elevation of the moving table used in the sliding means of FIG. 1:
[0038] [0038]FIG. 6 is a side elevation, viewed from the left side, of the table shown in FIG. 5:
[0039] [0039]FIG. 7 is a rear elevation showing an armature assembly in the sliding means of FIG. 1:
[0040] [0040]FIG. 8 is a front elevation of the armature assembly shown in FIG. 7:
[0041] [0041]FIG. 9 is a rear plan view showing a coil board used in the armature assembly of FIG. 7:
[0042] [0042]FIG. 10 is a diagram illustrating waveforms of currents changing with time, which are supplied to the armature windings:
[0043] [0043]FIG. 11 is a schematic illustration explaining the operation of the sliding means shown in FIGS. 1 to 9 , in which an upper part shows the event where the table is going to move rightwards at the leftmost end of stroke range, while a lower part is another event the table is going to move leftwards at the rightmost end of stroke range:
[0044] [0044]FIG. 12 is a schematic illustration explaining the operation of the sliding means shown in FIGS. 1 to 9 , where a three-phase current flowing through the armature windings serves to drive the table leftwards at an arbitrary position:
[0045] [0045]FIG. 13 is an illustration showing the same operation found in FIG. 12, in which the table is driven leftwards:
[0046] [0046]FIG. 14 is a top plan view showing a conventional sliding means: and FIG. 15 is a view in section along the plane II-II of FIG. 14 showing the conventional sliding means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Preferred embodiments of a sliding means with built-in moving-magnet linear motor according to the present invention will be explained hereinafter in detail with reference to the accompanying drawings.
[0048] Referring to FIGS. 1 to 9 , a sliding means 1 is mainly comprised of an elongated steel bed 2 of rectangular shape in top plan view, secured to any stationary machine or instrument, and a steel table 3 of rectangular shape mounted on the bed 2 for linearly sliding movement lengthwise of the bed 2 by virtue of linear motion guide units 4 . The linear motion guide units 4 are composed of a pair of track rails 5 secured to the bed 2 with fixing screws so as to extend lengthwise of the bed 2 in parallel with one another, and sliders 6 fitting over and conforming to the track rails 5 , two sliders to each rail, for sliding movement relatively of the track rails 5 . The table 3 , since affixed to the sliders 6 of the linear motion guide units 6 , is allowed to move as the sliders 6 run along the track rails 5 . The table 3 is fastened on the sliders 6 with screws 23 drilled into the sliders 6 to the extent where the tops of their screwheads are buried below the top surface of the table 3 . With the present sliding means 1 shown in FIGS. 1 and 4, the bed 2 is made with holes 7 through which bolts stretch to clamp the bed 2 together with any stationary base, while the table is bored with threaded holes 8 into which screws are driven to secure any work thereon. The sliding means is, as shown in FIG. 2, made in a flat construction reduced in overall height.
[0049] Each slider 6 has, for example, a casing, a pair of end caps attached on froward and aft ends of the casing respectively, and end seals mounted on the outer surfaces of the end caps, each to each cap, and clamped together with the end caps to the casing. Besides, the end caps are provided with grease nipples. The casing is made with raceway grooves confronting raceway grooves on widthwise-opposing, lengthwise-extending sides of the track rails 5 . The confronting raceway grooves define between them parts of recirculating passages through which rolling elements contained therein are allowed to run in a row. The recirculating passages consist of load raceway grooves formed in the casing to define load raceways in conjunction with the raceway grooves on the track rails 5 , return passages formed in the casing and turnarounds formed in the end caps to connect the load raceways with the return passages. Thus, the sliders 6 are allowed to move with smooth on and along the track rails 5 as the rolling elements in the recirculating passages run through the load raceways defined between the casing and the track rails.
[0050] As seen from FIGS. 3 and 4, the bed 2 is made on the upper surface thereof with a recess 9 extending between the widthwise-opposing linear motion guide units 4 along the moving direction of the table 3 . Snugly fitted in the recess 9 is an armature assembly 10 of stator side, which is comprised of a coil board 11 and armature windings 12 affixed to the coil board 11 . A moving element of a field magnet 13 made of a rectangular 5-pole permanent magnet is mounted underneath the table 3 in opposition of the armature assembly 10 . The sliding means 1 operates on linear motor action in which a three-phase current flowing through the armature windings 12 will interact electromagnetically with a magnetic flux created by the field magnet 13 , driving the table 3 in a sliding manner towards a desired position. Control means and driver means for the control means and a power source are installed outside the sliding means 1 . An optical encoder 14 for monitoring a position of the table 3 with respect to the bed 2 is composed of an optical linear scale 15 arranged along the moving direction of the table 3 underneath the table 3 , and a sensor element 16 fitted in the bed 2 about midway of the bed 2 in opposition to the optical linear scale 15 .
[0051] Fixed to any one of the lengthwise opposing ends of the bed 2 by tightening fixing means such as bolts with internal hexagonal-socket head is an end block 17 serving as a limiter to keep the table 3 from shooting outside the end of the bed 2 owing to the movement beyond the tolerated range of operating stroke. The end block 17 is mounted on a side thereof facing the table 3 with a stopper 18 of elastic body such as urethane rubber. A connector block 19 is attached to another end of the bed 2 by means of the same fixing means as in the end block 17 . Besides serving as a limiter to keep the table 3 from shooting outside the end of the bed 2 owing to the movement beyond the tolerated range of operating stroke, the connector block 18 may serve to guide an electric power line for supplying electric power to the armature windings 12 to energize the linear motor, a signal line 21 for the detection element, and a sensor cord 22 for delivering a signal monitoring a position of the table 3 relatively to the bed 2 , without possible disconnection. The sensor cord 22 is connected to a controller unit, which is to supply electric power for energizing the linear motor through the signal line 21 , depending on position information issued via the sensor cord 22 . The connector block 19 is also mounted on a side thereof facing the table 3 with a stopper 20 of elastic body of urethane rubber. These stoppers 18 , 20 provide buffers for protecting the slider 6 from a collision that might occur when the slider 6 comes close to the limit of its stroke.
[0052] Attached on an underside 30 of the table 3 is a field magnet 13 composed of five rectangular poles 24 , which are arranged in such a manner that unlike poles alternate with each other along the moving direction of the table 3 . According to the embodiment shown here, the field magnet 13 is a permanent magnet made of rare earth such as neodymium, and so on, in which N-poles are placed at forward and aft ends thereof. The table 3 is made of magnetic material of steel to serve as a magnet yoke allowing the magnetic flux created by the field magnet 13 to permeate through there. Thus, there is no need of preparing separately the magnet yoke to be attached to the table 3 , and therefore the moving element of the linear motor may be made compact or slim in construction.
[0053] The field magnet 13 is provided on the forward and aft ends thereof with steel-made end plates 25 for the prevention of flux leakage. The end plates 25 keep the magnetic flux established in the field magnet 13 from leakage out of the forward and aft ends of the table 3 , protecting anything approaching the table 3 against magnetic affection. Each end plate 25 is equal in width to about half of a coil-side width d, shown in FIG. 7, of the armature winding 12 , for example 2.5 mm width, and also equal in thickness to the field magnet 13 . As an alternative, the end plates 25 are integrally with the table 3 . The fore-and aft optical linear scale is attached to the underside 30 of the table 3 at the lengthwise side thereof opposing to the sensor element 16 in the bed 2 , while an origin mark 28 is mounted in opposition to the side surface of the sensor element 16 to an L-bracket 27 , shown in FIG. 3, neighboring the linear scale 15 in an attitude normal to the underside 30 of the table 3 . A magnet is embedded in the center of the origin mark 28 to issue a signal reporting the origin or reference position to the sensor element 16 .
[0054] The armature assembly, as shown in detail in FIGS. 7 to 9 , is comprised of a coil board 11 of level thin sheet, and three flat armature windings 12 for three-phase current arranged in juxtaposition along the moving direction of the table 3 on the underside 31 of the coil board 11 and secured thereto with adhesive. The armature assembly 10 is accommodated in the recess 9 in the bed 2 in such a relation that the armature windings 12 are arranged in opposition to the field magnet 13 . Each armature winding 12 is made in the form of three-phase coreless coil, which includes a core 33 of molded resin and turns 32 looped around the core 33 in the form of rectangle. Hall-effect elements or Hall ICs 34 to detect the magnetic poles, for example N-poles on the field magnet 13 are fixed to the coil board 11 in opposition to the field magnet 13 midway between the forward and aft coil sides of each armature winding 12 . The Hall-effect ICs 34 are to detect any specific pole, for example N-pole to identify the position of the field magnet 13 , depending on what Hall-effect ICs have detected the specific pole at the beginning when the electric source has been turn on, thereby to control the electric current to the armature windings 12 in light of the detected position of the field magnet 13 .
[0055] Limit sensors 35 to respond to the poles or N-poles 24 of the field magnet 13 are attached to the underside of the coil board 11 at any one lengthwise side thereof. The limit sensors 35 serve as detection elements where the N-poles at the forward and aft ends of the field magnet 13 are monitored to keep the table 3 against overrunning the tolerated range. In addition, a sensor 36 , which will be called “before-the-origin sensor”, is arranged nearby just before any one of the limit sensors 35 along the moving direction of the table 3 . The before-the-origin sensor 36 serves as a detection element to monitor any N-pole of the forward and aft ends of the field magnet 13 for decelerating the table 3 to make the origin mark 28 on the table 3 align with the origin embedded in the side of the sensor element 16 . On the underside 31 of the coil board 11 , there are formed terminals 37 for wiring a power source line for the armature windings 12 , and signal lines for the Hall-effect ICs 34 , limit sensors 35 and before-the-origin sensor 36 . Moreover, the coil board 11 is made with holes 38 in which bolts fit to mount the coil board 11 to the bed 2 . The coil board 11 constructed as shown in FIGS. 3 and 4 is accommodated in the lengthwise-extended recess 9 in the bed 2 , and affixed to the bed 2 by screwing flush bolts through the holes 39 into the bed 2 .
[0056] The bed 2 is made of magnetic material of steel such as, for example ferromagnetic material: S45C so as to serve as the coil yoke for the armature assembly 10 . Since there is no need of providing separately coil yokes, the stator side of the linear motor may be reduced in size. This makes it possible to render the linear motor much compact or slim in construction. Besides, an insulating film 40 is inserted between the bed 2 and the armature coils 12 placed in the recess 9 .
[0057] The following explains how the sliding means 1 operates. That is to say, when the armature winding 12 carries current, a rotation of magnetic flux generated around the coil sides of the armature winding interacts with the magnetic flux that exists always in perpendicular direction across the air gap between the field magnet 13 and the bed 2 serving as the coil yoke. Thus, the armature windings 12 experience a horizontal force according to the Fleming's rule. With the reaction, the moving element of the field magnet 13 is forced to drive the table 3 . The current supplied to the armature winding 12 is turned over correspondingly to the direction of the magnetic flux, which is desired in compliance with the moving direction of the field magnet 13 . Eventually the table 3 is allowed to move in a sliding manner to the desired position. The acceleration control depending on the amount of current is combined with detection of the current position by the optical encoder 14 to realize accurate position control of the table 3 in the sliding direction. Moreover, the driving speed and position control of the table 3 is accomplished by combining the sliding means 1 with control system including personal computers, sequencers and drivers.
[0058] Referring to FIG. 10 there is illustrated changing with time of current supplied to the armature assembly 10 of the sliding means 1 . The current to the armature assembly 10 , as seen from FIG. 10, is a three-phase current of U-, V- and W-phases that are 120° in the electrical angle out of phase. The numbers on the abscissa indicate the magnification of a half-wavelength for each phase. Next, FIGS. 11 to 13 show operating events of the sliding means 1 . In FIG. 11, the upper part shows the event where the table 3 is going to move rightwards at the leftmost end of stroke range, while the lower part is another event the table 3 is going to move leftwards at the rightmost end of stroke range. In either event, the table 3 is controlled such that the rightmost end 3 a thereof is invariably kept just above the center of the right-ward coil side 12 a of the rightmost armature winding 12 while the leftmost end 3 b thereof is kept just above the center of the leftward coil side 12 b of the leftmost armature winding 12 . That is to say, the table 3 is allowed to move over the juxtaposed armature windings 12 without deviating from the forward and aft outermost coil sides 12 a, 12 b. In this way the current conducting through the armature windings 12 may interact at the most efficiency with the magnetic flux produced by the field magnet 13 . This makes it possible to continue keeping the high propulsion of the table 3 .
[0059] [0059]FIGS. 12 and 13, respectively, explains how the table 3 at an arbitrary position moves leftward when the armature windings 12 carry three-phase current. With the event shown in FIG. 13, the leftmost armature winding 12 is placed just below a boundary between the adjacent unlike poles in the field magnet 13 and the current becomes zero. In the event in FIG. 12, all the six coil sides of the armature windings 12 carry current. In FIG. 13, although only four coil sides carry current, the propulsion may be kept high independent of the number of the alive coil side of the armature windings 12 because the flux density becomes great at the center of each pole 24 and the amount of current also varies in compliance with the position of the poles 24 . Even when it is tough to keep the propulsion high, the moving stroke of the table 3 may be set over the stroke shown in FIGS. 12 and 13, such that the coil side of any armature winding 12 is permitted deviating outside the poles 24 .
[0060] Now assuming a pole width in the field magnet 13 is Wm, as will be seen from FIG. 12, a pole pitch Pm is equal with Wm: Pm=Wm, an interval Bc between the centers of the opposing coil sides of any armature winding 12 is equal to the pole width Wm: Bc=Wm, and a coil pitch Pc of the armature winding 12 is 4/3 Wm: Pc=4/3 Wm. A widthwise length Lm of the field magnet 13 , shown in FIG. 5, is made substantially equal with a distance Lp, shown in FIG. 7, between the centers of widthwise opposing coil ends of any armature winding 12 . In accordance with the embodiment stated earlier, for example the pole width Wm is 15 mm, and a stroke St of the table 3 , refer to FIG. 11, is 25 mm. A length Lf of the field magnet 13 is 75 mm, the total length Lt of the table 3 including the forward and aft end plates 25 of 2.5 mm in thickness per a plate becomes 80 mm. Moreover, the sliding means 1 constructed as stated here is, for example 14 mm in height H indicated in FIG. 3, 145 mm in fore-and-aft length L in FIG. 1 and 60 mm in width B in
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A sliding means with built-in moving-magnet linear motor is provided, realizing high-speed operation and much response ability of a table to a stationary bed, and also accurate position control of the table to the bed. With the sliding means of this invention, armature windings carry a three-phase current while a driving circuit is transferred to the external driver to make the bed slim in construction. Thus, the sliding means is reduced in overall height. A field magnet of rare earth permanent magnet is effective in raising flux density, thereby providing high propulsion for the table. An encoder to monitor a position of the table is an optical encoder having an optical linear scale, which contributes to improvement in accurate monitoring. The construction in which the armature windings connected to cords, lines, and so on are placed on the stator side has no fear of causing dust and dirt, thus realizing clean environment.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a boat propulsion system for being replaceable to a rudder controlling moving direction and enhancing power transmission during the boat is moved.
2. Prior Art
Boat propulsion systems are known as primary power for moving boats. The power can be adjusted to different levels by marine engine in order to control moving speed of a boat, and if cooperate with a rudder, the boat can turn port or starboard.
However, a boat's movement is generally affected by varied reasons such as kinds of propellers, rudders and positions where they are mounted on. Though the propellers and rudders can make the boat move and turn, they still suffer from several drawbacks as described below:
1. unstable power transmission-a propeller is generating vortex by way of rotating blades, and the vortex facilitates the boat move, however, the vortex may affect the power transmission and result in unstable transmission. 2. over-big turning radius-a boat can change its moving directions by utilizing a rudder swinging; the rudder operates based on the “Bernoulli Theory”, that is, an equation that relates the fluid pressure and velocity acting along the surface of a wing. It also can apply to a boat's rudder. The rudder is a curved shape while the opposite side is relatively flat. Thus, when fluid passes over the rudder, that stream over the curved side is squeezed into a smaller area than that stream passing the relatively flat side. Thus, a higher pressure exists on the relatively flat surface of the rudder and a lower pressure on the curved surface. As the hydraulic pressure difference generated between the two surfaces of the rudder, a boat can turn according to variation of an angle given by the rudder swinging. However, such a turning of boat requires relatively big radius, and it causes the boat cannot turn flexibility. 3. more time to make a turn-as described above, a big turning radius, of course, requires more time to complete the process of turning.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a boat propulsion system having a plurality of positive displacement pumps for generating uniform jet-flow of fluid as the thrust power source and thus can enhance power transmission efficiency and stability.
Another object of the present invention is to provide a boat propulsion system for controlling moving direction and requiring smaller radius and being able to replace a conventional rudder.
To achieve the above object, a boat propulsion system in accordance with the present invention includes a plurality of positive displacement pumps which having high discharge head and having inlets and outlets therein and a controlling panel having circuits, wherein the pumps are mounted on the bottom of a boat and driven by a motive power. By means of different positions of the outlets in each pump and different arrangement of each pump and cooperating with using the controlling panel, the boat can therefore move toward desired directions.
Other objects, advantages and novel features of the present invention will be drawn from the following detailed embodiment of the present invention with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an perspective view of a boat propulsion system in accordance with a preferred embodiment of the present invention, and the boat propulsion system is mounted on a boat;
FIGS. 2 and 3 are schematic views of two types of pumps;
FIG. 4 is a plan view of a transmission apparatus being pivotally connected with the pumps;
FIG. 5 is a plan view of a layout of inlets and outlets of the pumps.
FIGS. 6-10 are schematic views illustrating the boat moving forwardly, turning right, turning left, moving backwardly and turning round; and
FIGS. 11-13 are schematic views of another embodiment illustrating the boat moving forwardly, turning right, turning left, moving backwardly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 to 5 , a boat propulsion system 1 in accordance with the first embodiment of the present invention comprises: a plurality of positive displacement pumps 2 mounted on a bottom of a boat 9 , a controlling panel 3 , and a transmission apparatus 4 . Referring to FIG. 1 , a motive power 90 of the boat 9 is disposed at the rear of the boat, and the controlling panel 3 is set nearby a steering wheel 91 having circuits therein (not shown) for switching on or off each pump 2 . The controlling panel 3 further has controlling buttons with signs, shapes or descriptions for different functions such as forward button 30 , backward button 31 , turning left button 32 , turning right button 33 , and turning around button 34 , 35 .
Referring to FIGS. 2 and 3 , the pumps 2 are driven by the motive power 90 . Each pump 2 comprises a housing 20 having a driving chamber 21 , an inlet 201 and an outlet 202 therein, both the inlet 201 and outlet 202 communicating with the driving chamber 21 . A first gear rotor 22 and a second gear rotor 23 are assembled in the driving chamber 21 and are engaged with each other. In FIG. 2 , the inlet 201 is positioned perpendicularly to the outlet 202 , whereas in FIG. 3 , the inlet 201 is positioned horizontally to the outlet 202 with opposite direction. By way of different positions of the outlets 202 in each pump 2 and cooperate with different arrangement of each pump 2 in order to make the boat 9 move or turn, and thus the boat 9 turns requiring smaller radius. A remarkably feature is that through a full compression by the first and the second gear rotor 22 , 23 , a flow of the fluid is in a positive displacement and is pressurized by the first and the second gear 22 , 23 whereby the pump 2 generates high discharge head and therefore efficiently transports the fluid. Furthermore, the flow of the fluid generated by the pumps 2 turns to a jet-flow that the liquid is discharged uniformly during the meshing rotation of the first and second gears and thus can prevent from generating unnecessary vortex to affect the boat 9 thereby can reduce a loss of the power transmission.
Referring to FIG. 4 , the transmission apparatus 4 is driven by the motive power 90 and pivotally connected to each of the pumps 2 for transmitting power at a steady speed or a discrepant speed in order to drive each of the pumps to generate the thrust of the boat 9 . The transmission apparatus 4 includes a bevel gear set 40 and four gear sets 41 , 42 , 43 , 44 , wherein the bevel gear set 40 is pivotally mounted to the motive power 90 and driven by the motive power 90 . The bevel gear set 40 is further coupled with two driving shafts 901 , 902 respectively at different sides thereof for transmitting the power to each of the four gear sets 41 , 42 , 43 , 44 . Each gear set 41 , 42 , 43 , 44 is respectively coupled with driven spindles 410 , 420 , 430 , 440 in series. The driven spindles 410 , 420 , 430 , 440 are respectively connected to the first gear rotor 22 of each pump 2 thereby to drive the second gear rotor 23 as the first gear rotor 22 is rotating. Therefore, the transmission apparatus 4 can transmit the power from the motive power 90 to far portions of the boat 9 and cooperate with the controlling panel 3 can drive each pump 2 optionally. Alternatively, the transmission apparatus 4 of the present invention is adoptable with different assembly, by way of example, it can cooperate with clutch or add a gear sets to change the direction of transmission, or add a motive power or other power plant to increase the transmission.
Referring to FIGS. 5 to 10 , the four pumps 2 are mounted on a bottom of the boat 9 , wherein two of the pumps are mounted respectively on the fore part and the aft part of the boat 9 , which are equipped with the inlet 201 and the outlet 202 being horizontal to each other, wherein the outlet 202 of the fore pump 201 is positioned toward the front side of the boat 9 whereas the outlet 202 of the aft pump 201 is positioned toward the stern side of the boat 9 . The rest of the two pumps 201 are mounted respectively on the left and the right side of the boat 9 and both are equipped with the inlet 201 and the outlet 202 being perpendicular to each other. The left pump 201 is positioned close to a mid-part of the boat 9 (preferably positioned over the mid-part of the boat 9 for turning quickly). With respect to FIGS. 6 to 10 is shown the boat 9 can move in different directions only by pressing the forward button 30 , the backward button 31 , the turning left button 32 , the turning right button 33 or the turning around button 34 , 35 . For example, a user can press the forward button 30 for moving forwardly, or press the forward button 30 and the turning left button 32 for turning the boat 9 (as shown in FIG. 8 ).
Referring to FIGS. 11 to 13 , an alternate embodiment of a boat propulsion system 1 is illustrated, a boat 9 having three driving motors 8 (replaceable by other motive power) which drive three pumps respectively (not shown). The three driving motors 8 are arranged in a triangular position. The pumps mounted on the left and the right sides of the boat are close to mid-part of the boat and outlets of the two pumps are positioned respectively toward the left and the right side. The other pump is mounted aft and an outlet thereof is positioned at a stem side of the boat. By way of controlling the rotation speed and rotation direction of each of the motors 8 through a controlling panel and cooperate with multiple inlets and outlets which are positioned at different directions, the boat can move and turn under controlling. With further reference to FIG. 11 illustrates the boat moving forwardly or backwardly; FIG. 12 illustrates the boat turning rightward; FIG. 13 illustrates the boat turning leftward.
While the preferred embodiment of the invention has been set forth for the purpose of disclosure, modifications of the disclosed embodiment of the invention as -well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention.
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A boat propulsion system includes a plurality of positive displacement pumps which having high discharge head and having inlets and outlets therein and a controlling panel having circuits, wherein the pumps are mounted on a bottom of a boat and driven by a motive power. By means of different positions of the outlets in each pump or different power transmission of each pump and cooperating with using the controlling panel, the boat can therefore move toward desired directions and enhancing power transmission by the pumps are drawn uniform flow when the boat is moved.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 61/552,732, filed on Oct. 28, 2011, and of German patent application No. 10 2011 084 438.4, filed Oct. 13, 2011, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for producing a component for connecting structures, a method for producing a structural arrangement and a device for producing a component.
[0003] FIG. 1 shows a detail from an aircraft designated 100 in general. The aircraft 100 comprises a landing flap 102 . FIG. 1 shows the landing flap 102 counter to the flight direction of the aircraft 100 . The landing flap 102 is shown once in a dashed view, which corresponds to its unloaded state. The landing flap 102 is furthermore shown by a continuous line, which corresponds to its state shown greatly exaggerated and deformed because of air loads 104 . The landing flap 102 is connected by means of two flap carriages 106 , 108 to a wing 110 , which is only schematically indicated. The flap carriages 106 , 108 allow an adjustment of the landing flap 102 with respect to the wing 110 from a flight position into a take-off or landing position, the take-off and landing position serving to increase the lift. In the wingspan direction, in other words from left to right in FIG. 1 , one flap carriage 106 is configured as a fixed bearing and the other flap carriage 108 as a loose bearing. The flap carriages 106 , 108 are in each case connected by an eye-pin connection 112 to the landing flap 102 .
[0004] It is known to configure the eye of a respective eye-pin connection 112 in the form of a fitting, which is manufactured from metal and is connected, in particular riveted, to the landing flap 102 . For example, DE 10 2007 011 613 A1 shows a fitting made of metal for load introduction.
[0005] There is increasingly a need to also produce load introduction elements, such as, for example, the above-described eye of the eye-pin connection 112 , from fibre composite materials, for example carbon fibre plastics material (CFRP), in order to save further weight and assembly costs. US 2010/0148008 A1 describes a corresponding load introduction element made of fibre composite material, which is produced by an RTM (resin transfer moulding) method.
SUMMARY OF THE INVENTION
[0006] An idea of the present invention is to disclose a method for simple production of a component, in particular the load introduction element described above, a method for simple production of a structural arrangement and a device for simple production of the component.
[0007] Accordingly, a method is provided for producing a component for connecting structures at crossing regions thereof, having the following steps: depositing first and second fibres on an underlay, in such a way that a respective first fibre has an offset in the longitudinal direction of the first or second fibre with respect to a respective second fibre, connecting the first and second fibre along an overlap region, in which the first and second fibres overlap, and pivoting the first and second fibres with respect to one another to form the component.
[0008] Furthermore, a method is provided for producing a structural arrangement, in particular for an aircraft or spacecraft, having the following steps: providing a first structure, providing a second structure, which forms a crossing region with the first structure, producing a component by the method according to the invention and connecting the first and second structure in the crossing region by means of the component.
[0009] Furthermore, a device is provided for producing a component for connecting structures at crossing regions thereof, in particular for carrying out the method according to the invention, with an underlay, a depositing mechanism to deposit the first and second fibres on the underlay, in that a respective first fibre has an offset in the longitudinal direction of the first or second fibre with respect to a respective second fibre, a connecting mechanism to connect the first and second fibres along an overlap region, in which the first and second fibres overlap, and a pivoting mechanism for pivoting the first and second fibres with respect to one another to form the component.
[0010] The idea on which the present invention is based on the finding that a component with an approximately cruciform cross-section can easily be produced, in which the first and second fibres are pivoted relative to one another. After the pivoting, the first fibres intersect with the second fibres at a crossing point. The first fibres then extend, for example, substantially horizontally through the crossing point and the second fibres extend, for example, substantially perpendicularly. If the component thus provided is integrated in a structural arrangement, in particular in the landing flap described at the outset, the latter can provide two substantially mutually independent load paths through the crossing point: the first load path leads along the first fibres and the second load path leads along the second fibres.
[0011] The use of the methods and the device is not restricted to the field of air or space travel. For example, these may also be used in the area of producing bridges, multi-storey buildings, masts, roofs or other planar supporting structures.
[0012] “Fibre” preferably comprises both a single fibre and a fibre tow of individual fibres.
[0013] Advantageous configurations of the invention emerge from the subordinate claims.
[0014] The first and second fibres are preferably deposited parallel to one another on the underlay. If, in the present case, “parallel” is referred to, deviations from this of up to 30 degrees, preferably up to 10 degrees, still more preferably up to 2 degrees, are also meant.
[0015] According to a preferred configuration of the method according to the invention, it is provided that the first fibres are connected to one another in a first projection region, in which they project in the longitudinal direction over the second fibres, and/or the second fibres are connected to one another in a second projection region, in which they project in the longitudinal direction over the first fibres. This produces a stable structure of first fibres, which can be pivoted against a second structure made of second fibres.
[0016] According to a preferred configuration of the method according to the invention, it is provided that the first and second fibres are connected to one another in the overlap region along a centre line, which is arranged centrally in relation to a total extent of the first and second fibres in the longitudinal direction, and/or the first fibres are connected to one another in the first projection region along a first line parallel to the centre line and/or the second fibres are connected to one another along a second line parallel to the centre line and opposing the first line in relation to the centre line. This type of fastening of the fibres can be produced easily, in particular in an automated manner, because it is substantially linear.
[0017] According to a preferred configuration of the method according to the invention, it is provided that the first and second fibres are connected to one another in the overlap region, the first fibres are connected to one another in the first projection region and/or the second fibres are connected to one another in the second projection region by means of stitching, weaving, braiding or gluing. The stitching, weaving, braiding and gluing can easily be automated.
[0018] According to a preferred configuration of the method according to the invention, it is provided that at least one stitching, weaving or braiding fibre is fed through a gap in the underlay. For example, a lower fibre (“bottom thread”) can thus easily be fed.
[0019] According to a preferred configuration of the method according to the invention, it is provided that the gluing takes place by means of a thermoplastic strand, a fibre sheathed at least in portions with a thermoplastic material, or an adhesive strip. The thermoplastic strand, the fibre and the adhesive strip may, for example, be easily laid along the first or second line and/or the centre line in order to thereby glue them to the first and/or second fibre.
[0020] According to a preferred configuration of the method according to the invention, it is provided that the first and second fibres are pivoted with respect to one another in such a way that the latter have an angle of 30 to 90 degrees, preferably 60 to 90 degrees, more preferably 80 to 90 degrees, still more preferably 90 degrees, with respect to one another, and/or the pivoting of the first and second fibres with respect to one another is brought about by means of a curved guide element, past which the first and/or second fibres are guided. As a result, the component can easily be produced with a cruciform cross-section.
[0021] According to a preferred configuration of the method according to the invention, it is provided that the underlay is configured as a conveyor belt, on which the first and second fibres are deposited. By means of the conveyor belt, the first and second fibres can move past the connecting mechanism in an automated manner, so an efficient method is ensured.
[0022] According to a preferred configuration of the method according to the invention, it is provided that the first and second fibres are in each case cut to length from continuous material before the depositing. As a result, the efficiency of the method can also be increased.
[0023] According to a preferred configuration of the device according to the invention, it is provided that the underlay has a plurality of parts, which, between them, define at least one gap, through which at least one stitching, weaving or braiding fibre can be fed to connect the first and/or the second fibre.
[0024] According to a preferred configuration of the device according to the invention, it is provided that the connecting mechanism is set up to connect the first fibres to one another in a first projection region, in which they project in the longitudinal direction over the second fibres, and/or to connect the second fibres to one another in a second projection region, in which they project in the longitudinal direction over the first fibres. For this purpose, the connecting mechanism may be guided, in particular, by a robot hand.
[0025] According to a preferred configuration of the device according to the invention, it is provided that the connecting mechanism comprises at least one stitching needle, by means of which the first fibres, second fibres and/or the first and second fibres can be stitched to one another.
[0026] According to a preferred configuration of the device according to the invention, it is provided that the pivoting mechanism has a curved guide path to guide the first and/or second fibre past and to pivot them. The guide path is, in particular, configured as a guide rail.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention will be described in more detail below on the basis of embodiments with reference to the accompanying figures of the drawings, in which:
[0028] FIG. 1 shows a detail of an aircraft;
[0029] FIG. 2 shows a schematic view of a structural arrangement comprising a component;
[0030] FIG. 3 shows a perspective view of a device for producing the component from FIG. 2 in a first state;
[0031] FIG. 4 shows the view from FIG. 3 in a second state of the device;
[0032] FIG. 5 shows the view from FIG. 4 in a third state of the device;
[0033] FIG. 6 shows a section through a thermoplastic strand;
[0034] FIG. 7 shows a section through a fibre sheathed with a thermoplastic material; and
[0035] FIG. 8 shows a section through an adhesive strip.
[0036] Identical reference numerals in the figures denote identical or functionally identical components, unless indicated otherwise.
DETAILED DESCRIPTION OF THE INVENTION
[0037] FIG. 2 shows a partially perspective view of a structural arrangement 200 according to an embodiment kept comparatively general.
[0038] The structural arrangement 200 is, for example, a component of the landing flap 102 shown in FIG. 1 and therefore a component of the aircraft 100 . Basically, the structural arrangement 200 may, however, be a component of any flap or aerofoil wing.
[0039] In the present case, the three spatial directions that are orthogonal to one another are designated X, Y and Z. This serves merely for better understanding of the spatial arrangement of the various components with respect to one another. In the case of the landing flap 102 , X designates the oncoming flow direction, Y the wingspan direction and Z the vertical direction.
[0040] The structural arrangement 200 comprises a substantially closed box structure 202 indicated by dashed lines in FIG. 2 . By “substantially closed” it is meant that the box structure 202 has no or only comparatively small apertures in its outer walls 204 . The front outer wall 206 is shown as transparent in FIG. 2 to reveal the view of the interior 208 of the box structure 202 . The outer walls 204 , 206 , according to one embodiment, form the outer skin of the landing flap 102 .
[0041] The structural arrangement 200 furthermore comprises a component 210 , which is composed of first and second fibres 212 , 214 , wherein, for the sake of better understanding, only one such individual first fibre 212 and an individual second such fibre 214 are shown in the YZ-plane. The component 210 may comprise any desired number of such fibres 212 and 214 arranged next to one another in the X-direction. The first and second fibres 212 , 214 are designated by short dashes in opposing directions to distinguish them better. A respective first fibre 212 extends, for example, in a horizontal XY-plane, while a respective second fibre 214 extends, for example, in a vertical XZ-plane. A respective first fibre 212 and a respective second fibre 214 therefore extend, according to the embodiment, perpendicular to one another.
[0042] A respective first fibre 212 and a respective second fibre 214 are connected to one another at a crossing point 216 . The fibres 212 , 214 are stitched, woven, braided or glued to one another at the crossing point 216 . It is furthermore shown in FIG. 2 that a respective first fibre 212 has a first and second portion 218 , 220 , the portions 218 , 220 being connected to the lower outer wall 204 , which extends in the XY-plane, of the box structure 202 . Stated more precisely, the first portion 218 of the first fibre 212 is integrated in a first portion 232 of the outer wall 204 and the second portion 220 of the first fibre 212 is integrated in a second portion 233 of the outer wall 204 , in particular glued in. For this purpose, the portions 232 , 233 of the outer wall 204 are in each case fork-shaped. However, a different type of fastening of the portions 218 , 220 on or in the outer wall 204 of the box structure 202 is also conceivable.
[0043] A respective second fibre 214 forms an inner web 222 , which projects upwardly into the interior 208 of the box structure 202 , and an outer web 224 , which extends downwardly outside the box structure 202 . The inner web 222 is connected to a support element 234 of the structural arrangement 200 . The support element 234 is, for example, configured as a rib, which is connected to the box structure 202 . The support element 234 may, for example, also be configured as a beam or transverse web. The inner web 222 is preferably integrated in the support element 234 , in particular glued in.
[0044] The outer web 224 has a fastening point 226 to introduce a first load 230 into the outer web 224 . The fastening point 226 is, in particular, configured as an eye, but may also be configured as a different structural load transmission device, such as, for example, a riveting or gluing. A corresponding axis of the eye 226 is designated by the reference numeral 228 .
[0045] The second fibre 214 guides the first load 230 introduced at the fastening point 226 from the fastening point 226 into the support element 234 . The first fibre 212 simultaneously transmits the second load 235 between the first and second portions 232 , 233 of the box structure 202 . Therefore, two substantially mutually independent load paths are provided. For example, bending loads 235 in the outer wall 204 are guided by means of the first fibres 212 through the crossing point 216 , while—substantially unaffected thereby—the holding forces 230 introduced at the eye 226 by means of the flap carriage 106 , 108 are guided into the support element 234 . Despite the fibre composite mode of construction, the eye 226 is therefore effectively prevented from peeling off in the coupling region 216 by the uninterrupted first and second fibres 212 , 214 .
[0046] The outer wall 204 , with the rib 234 , forms a crossing region 236 , in which the component 210 is preferably glued. The gluing of the portions 218 , 220 of the component 210 in the outer wall 204 of the box structure 202 may take place in different ways: the completely or partially cured portions 218 , 220 can be cured with the wet outer wall 204 . Furthermore, the completely or partially cured portions 218 , 220 can be structurally glued to the completely or partially cured outer wall 204 . Furthermore, the dry portions 218 , 220 can be infiltrated together with the dry outer wall 204 and cured. Furthermore, the wet portions 218 , 220 (prepregs) can be glued to the wet outer wall 204 (prepreg).
[0047] Furthermore, the inner web 222 of the component 210 is preferably also glued into the rib 234 (or a beam or transverse web) in one of the ways as described above for the portions 218 , 220 . The outer web 226 can also be glued into a rib, not shown.
[0048] Other possibilities of connecting the component 210 to the outer wall 204 and rib 234 are conceivable, for example bolting or screwing.
[0049] FIGS. 3 to 5 show a plurality of states when producing the component 212 from FIG. 2 by a stitching method. Furthermore, FIGS. 3 to 5 show various components of a device 300 for carrying out the method.
[0050] First and second fibres 212 , 214 are deposited parallel to one another on a conveyor belt 302 , moving in the conveying direction F, of the device 300 , see FIG. 3 . A respective fibre 212 , 214 is preferably configured as a “fibre tow” of individual fibres. The designations 2k to 24k are, for example, prevalent here. A respective fibre 212 , 214 is preferably deposited dry, i.e. without a thermoplastic or thermosetting matrix, although a depositing of wet fibres 212 , 214 is in no way ruled out.
[0051] The device 300 furthermore comprises a reel 301 with continuous material 303 , a cutting mechanism 305 and a depositing mechanism 304 . The fibres 212 , 214 are cut to length from the continuous material 303 by means of the cutting mechanism 305 and thereafter deposited on the conveyor belt 302 by means of the depositing mechanism 304 , in particular a robot.
[0052] The fibres 212 , 214 preferably in each case have the same length and, after depositing, extend in the direction 306 transverse to the conveying direction F.
[0053] The transverse direction 306 therefore corresponds to the longitudinal direction of the fibres 212 , 214 . The deposited fibres 212 , 214 in each case have an offset 308 in the transverse direction 306 with respect to one another. This produces a first and second projection region 310 , 312 . The first projection region 310 only has ends of the first fibres 212 and the second projection region 312 only has ends of the second fibres 214 .
[0054] FIG. 4 shows how the ends of the first fibres 212 are stitched together in the projection region 310 . A corresponding connecting mechanism of the device 300 comprises a needle 400 and a stitching fibre 402 . The stitching takes place, for example, along a line 404 . Moreover, the ends of the second fibres 214 are stitched together in the second projection region 312 . A corresponding connecting mechanism of the device 300 comprises a needle 406 and a stitching fibre 408 . The stitching takes place, for example, along a line 410 .
[0055] Between the two projection regions 310 , 312 , the first and second fibres 212 , 214 form an overlap region 412 , in which they overlap in the transverse direction 306 . The first and second fibres 212 , 214 are stitched together in the overlap region 412 , in particular along a centre line 414 . The centre line 414 is arranged centrally in relation to a total extent 416 of the fibres 212 , 214 in the transverse direction 306 . A corresponding connecting mechanism in the form of a needle and a stitching fibre is designated by the reference numerals 418 and 420 . The lines 404 , 410 , 414 are preferably parallel to one another.
[0056] The movement of the needles 400 , 406 , 418 is indicated in each case by a double arrow. A respective upper stitching fibre 402 , 408 , 420 (“top thread”) is preferably connected to a corresponding lower stitching fibre 421 , 423 , 425 (“bottom thread”). For this purpose, the conveyor belt 302 is preferably formed from a plurality of parts 422 , 424 , 426 , 428 , which form gaps 430 , 432 , 434 between them, through which a respective lower stitching thread 421 , 423 , 425 can easily be fed.
[0057] After this, the second fibres 214 are pivoted relative to the first fibres 212 about the centre line 414 , i.e. about the stitching fibre 420 , as indicated by the arrows in FIG. 5 . A respective first fibre 212 then preferably forms, with a respective second fibre 214 , an angle 500 of 90 degrees. A component 210 is therefore formed, which thereafter is integrated in the crossing region 236 of the structural arrangement 200 , see FIG. 2 , in particular as described above. The pivoting takes place, for example, by means of a pivoting mechanism of the device 300 in the form of a curved guide rail 501 , which gradually rotates the second fibres 214 relative to the first fibres 212 . The first fibres 212 may, for example, be moved onwards supported on horizontal guide rails 502 of the device 300 , while the second fibres 214 pivot. The guide rails 500 , 502 are only shown partially for the sake of greater clarity. For rotation, the first and second fibres 212 , 214 can be lifted from the conveyor belt 302 , which is why this is not shown in FIG. 5 .
[0058] Instead of stitching, the first and second fibres 212 , 214 can be woven or braided together by means of fibres 402 , 408 , 420 .
[0059] The first and second fibres 212 , 214 can furthermore alternatively be glued to one another, in particular by means of a thermoplastic strand 600 (see FIG. 6 ), a fibre 702 sheathed with thermoplastic material 700 (see FIG. 7 ) or an adhesive strip 800 (see FIG. 8 ). FIGS. 6 to 8 show a cross-sectional view, in each case.
[0060] In an embodiment which is not shown, a first thermoplastic strand, a first sheathed fibre or a first adhesive strip extends along the first line 404 and connects the first fibres 212 . A second thermoplastic strand, a second sheathed fibre or a second adhesive strip extends, for example, along the second line 410 and connects the second fibres 214 . A third thermoplastic strand, a third sheathed fibre or a third adhesive strip extends, for example, along the centre line 414 and connects the first and second fibres 212 , 214 to one another.
[0061] Although the invention was described in the present case with the aid of preferred embodiments, it is not in any way restricted thereto, but can be modified in diverse ways. In particular, the embodiments and configurations described for the methods according to the invention can be applied accordingly to the device according to the invention, and vice versa. Furthermore, “a” does not rule out a plural in the present case.
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The present invention pertains inter alia to a method for producing a component for connecting structures at crossing regions thereof, having the following steps: depositing first and second fibres on an underlay in such a way that a respective first fibre has an offset in the longitudinal direction of the first or second fibre with respect to a respective second fibre; connecting the first and second fibre along an overlap region, in which the first and second fibres overlap; and pivoting the first and second fibres with respect to one another to form the component.
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PRIORITY CLAIM UNDER 35 U.S.C. §119(e)
[0001] This patent application claims the priority benefit of the filing date of provisional application Ser. No. 62/318,789 having been filed in the United States Patent and Trademark Office on Apr. 4, 2016 and now incorporated by reference herein.
STATEMENT OF GOVERNMENT INTEREST
[0002] The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon.
TECHNICAL FIELD OF THE INVENTION
[0003] This invention relates generally to the field of portable drying and sanitizing for is multiple personal articles, such as boots, gloves, and helmets, using an airflow stream that is either ambient temperature or heated, and/or ozone infused.
BACKGROUND OF THE INVENTION
[0004] In order to dry personal equipment and to prevent the problems associated with storing dampened gear, personnel have taken such mundane steps as spreading their damp items out on the floor or hanging them on racks after each use, and then returning them to the container. In more aggressive efforts, they have taken the steps of removing their damp items from their containers, and then use standard or specialized equipment to dry them, and then returning them to the container. There have been numerous blowing and drying devices invented for the purpose of drying shoes, boots, mittens and gloves. For example, see U.S. Pat. No. 4,768,293 issued to Kaffka, U.S. Pat. No. 4,198,765 issued to Miyamae, U.S. Pat. No. 4,145,602 issued to Lee. U.S. Pat. No. 3,645,009 25 issued to Ketchum. U.S. Pat. No. 3,417,482 issued to Peet, U.S. Pat. No. 3,154,392 issued to Littman. U.S. Pat. No. 2,614,337 issued to Darbo, and U.S. Pat. No. 2,443,695 issued to Russell, all of which are discussed in U.S. Pat. No. 5,720,108 issued to Rice. There have also been several specialized bags, devices, or containers developed to dry and sanitize athletic equipment or clothing. Some are small and portable, some are large and stationary, some are hard sided and some are made of flexible material. Of these, some are intended to dry the items while others only sanitize them. Most of these known prior art systems for treating damp or wet items have some common characteristics, but none incorporate all of the characteristics one would desire.
[0005] Tactical military activities as well as active athletic sports such as hockey, football, lacrosse, and the like, require specialized equipment and specific clothing for use in completing the mission or playing the game and for protecting the person. Such clothing and equipment items are usually not worn constantly but are transported in some sort of a portable container such as a sports bag or specially container. During vigorous use such clothing and equipment items tend to become damp or wet by either the player's perspiration, or, and also, by being exposed to wet weather or environmental conditions. After an event is completed, if such damp or wet gear is left in a closed container, the gear tends to be acted upon by bacteria and mold, and as a result, becomes foul smelling and rank, and subject to deterioration. Research has shown that such odors are a byproduct of bacteria and mold that grow readily in the moist, dark, generally stagnant, environment inside the closed container. Some of the resulting bacteria may also become a source for infections when they come into contact with an open cut or abrasion on the body of a user the next time the gear is worn. In addition, items left inside a closed container dry so slowly that they may still be wet or damp the next time they are removed from the closed container.
OBJECTS AND SUMMARY OF THE INVENTION
[0006] It is therefore a primary object of the present invention to provide a highly portable, self-contained, multiple-item drying system that directs an anti-bacterial air flow stream through a series of separate flexible, expandable, conduits (hoses) to provide an efficient, inexpensive, uncomplicated drying, sanitizing, deodorizing, and heating apparatus.
[0007] A particular object of the invention is provide a drying system that is readily adaptable to a variety of articles.
[0008] A further object of the invention is to provide the combined effects of both ultraviolet light and ozone entrained air to ensure antibacterial drying of articles.
[0009] Another object of the present invention to provide a drying system that is capable of drawing operating power from a variety of sources.
[0010] Other objects and various implementations made possible by this design approach will become apparent in the detailed description of the invention to follow.
[0011] In a preferred embodiment of the present invention, a system for drying and sanitizing a plurality of diverse articles, comprises a source of forced air; a plurality of conduits having a first end and a second end for channeling the forced air; a manifold for directing the forced air into the first end of each of the plurality of conduits; an ultraviolet light emitting source located at second end of at least one of the plurality of conduits; and an attachment means located at the second end of at least one of the plurality of conduits for attaching the conduits to the articles so as to direct forced air and ultraviolet light into the articles.
[0012] In another embodiment of the present invention, a method for drying and sanitizing a plurality of diverse articles, comprises the steps of generating a stream of forced air; directing the stream of forced air into each of the plurality of articles; warming the forced air prior to directing; and illuminating that portion of each of the plurality of articles onto which said forced air is directed, with ultraviolet light.
[0013] Briefly stated, the invention provides a highly portable, self-contained, multiple-item drying system that directs an antibacterial warmed air flow stream through a series of separate flexible, expandable, conduits (hoses) to provide an efficient, inexpensive, uncomplicated drying, sanitizing, deodorizing, and heating apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of an exemplary embodiment of an individual gear dryer system air blowing assembly and an exemplary manifold with air conduit hoses routed to exemplary individual articles intended for treatment.
[0015] FIG. 2 is a perspective view of an exemplary embodiment of an individual gear drying system air blowing assembly.
[0016] FIG. 3 is a perspective side view of an exemplary embodiment of an individual gear drying system air blowing assembly showing the intended direction of airflow through the system.
[0017] FIG. 4 is a perspective view of an exemplary manifold without air conduit hoses, attached to an exemplary common portable hair drying apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring to FIG. 1 and FIG. 2 concurrently, the present invention includes an air blowing assembly 10 consisting of; a housing enclosing an internal fan or blower (see FIG. 3, 150 ), a rechargeable battery 40 , a battery charging power supply (see FIG. 3, 180 ), an ozone generator (see FIG. 3, 160 ), the various switches needed for controlling the system 60 , 70 , 80 , 90 and ports 20 , 30 for the electrical power required by the system, and a separate attachment consisting of; a manifold 110 with attached hoses 120 and attached to the distal end of the hoses 120 , ultraviolet light emitting diodes (UV-LED) for anti-bacterial effect 135 , and spring activated clamping clips 130 . The housing may be constructed of metal or plastic or other appropriate material.
[0019] Referring to FIG. 3 , the housing includes an air intake opening 50 which may include a screening or filtering device intended to keep out debris such as vegetation, pollen, sand, and insects. Connected internally to the air intake opening is a plenum 90 ) that directs the flow of air across and through heat sinks 170 that are associated with the battery 40 and power supply/battery charging system 180 , through the anti-bacterial ozone generator 160 , through the fan 150 or blower, and out of the housing through a port 100 , which has normally attached to it a manifold (see FIG. 1, 110 ) separating the airflow into five flexible conduit hoses (see FIG. 1, 120 ).
[0020] Still referring to FIG. 3 , the invention may be operated with the anti-bacterial ozone generation unit 160 either on or off. The invention includes a rechargeable battery 40 capable of powering the blower 150 , the ozone generator 160 , and the UV-LED's (see FIG. 1, 135 ). The invention further includes an (preferably industry standard International Electrical Code (IEC) 60320 C13 type) electrical cord (not shown) and receiving socket (see FIG. 2, 20 ) enabling the unit to be operated from alternating electrical current as found in common U.S. household electrical outlets, as well as recharging the battery from the same electrical source, or a direct current source such as a solar panel or automotive 12 or 24 volt electrical system. In a preferred embodiment the system power supply 180 electrical input section will be of an automatically sensing and setting type able to detect the input voltage level and frequency and automatically providing the proper output voltage regardless of input type.
[0021] Referring again to FIG. 1 , Coupled to the housing air outlet port 100 is a five port manifold 110 which connects a plurality (five) of flexible hoses 120 that are intended to direct the flow of output air to item(s) 140 to be dried, warmed and disinfected. The distant end of each hose segment contains a clip 130 which allows it to be fastened to the article to be treated, to prevent the hoses from becoming dislodged, and to direct the end of the hose in a direction which targets the flow of air to a particular location, such as into the toe box of a boot, or inside the fingers of a glove. Each hose also contains a pair of electrical wires encased into and running longitudinally down its length to provide power to an UV-LED for generating anti-bacterial light 135 attached to or embedded into the hose at its distal end. The power to the UV-LEDs 135 can be selected either on or off via a switch 80 mounted upon the system housing 10 . The removable manifold 110 is of such a size and circular shape as to allow it to be slid over the end of commonly found, portable, hair dryers, commonly referred to as a blow dryer, enabling the use of the manifold and hose subsystem removed and apart from the subject system air blowing assembly housing 10 .
[0022] Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
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A highly portable, self-contained, multiple-item drying system that directs an antibacterial warmed air flow stream through a series of separate flexible, expandable, conduits (hoses) to provide an efficient, inexpensive, uncomplicated drying, sanitizing, deodorizing, and heating apparatus.
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INTRODUCTION
The present invention relates generally to an improved delivery assistance device and more particularly to a magnetic vibrator sub-assembly for vibratory feed devices that has fixed flat springs for use in surface mount electronic assembly applications.
BACKGROUND OF THE INVENTION
The continued miniaturization of electronic components for use in electronic devices has given rise to a need for self-contained component feeder assembly units which are ready to mount into an existing work envelope for use with pick and place robotics machinery whenever and wherever reliable component parts delivery is required. In particular, electronic component feed devices used in the robotic assembly of integrated circuit boards and like electronics applications must provide steady and dependable delivery of parts to a given work site. Furthermore, it is extremely important that each part be correctly oriented and strategically aligned so that it can be properly interfaced with other systems including pick and place machinery and like robotics to ensure that each part is where it should be when it should be and is oriented as it should be so that an efficient production line can be maintained. It is for these reasons that existing vibratory feeders were designed.
However, some of the major problems with existing vibratory feed devices are the frequent misorientation or misalignment of critical parts and the frequent and expensive downtime required to change dedicated vibratory feeder platforms when switching from the delivery of one type of circuit board component to a different type of component for continued assembly of the same or a different circuit board. The different or substitute components are usually of different sizes and shapes and thus, the prior art uses dedicated platforms which are generally made to accommodate only a limited quantity of sizes and shapes of component parts. Therefore, the time lost to production includes both the manual switching of dedicated platforms as well as the programming adjustment of the X and Y coordinates of the automated pick and place or robotic machinery to properly locate and pick up the newly selected different component parts.
Accordingly, a serious need exists in industrial electronics assembly lines and particularly with integrated circuit chip applications for a new and improved vibratory parts delivery device, which saves time and money while increasing productivity and enhancing the reliability and dependability of such machines and thereby enables them to contribute more to the overall efficiency of the assembly production line.
It has been found, and will hereinafter appear in greater detail, that the sub-assembly of the present invention not only solves the prior art problems but provides a reliability and precision heretofore unobtainable by prior art devices.
BRIEF SUMMARY OF THE INVENTION
The present invention involves a unique magnetic vibrator sub-assembly for a vibratory feed device that has flat springs interposed in a fixed position between the lower and upper members of the sub-assembly to provide increased stability and remove the need for incremental spring adjustments. Thus, the present invention provides for fast, efficient exchange of interchangeable top platforms to be affixed to a semipermanent upper member of the present invention without disturbing the three-dimensional, X, Y or Z location settings for the component parts presented by the vibratory feed device to the automatic or robotic pick and place machinery. More particularly, the present invention provides an improved in-line, vibratory feed device having fixed position flat springs which enable delivery of small component parts such as those used in electronic assembly operations while also providing a high pick point accuracy in delivery that is completely repeatable not only from part to part in a single operation, but also from one assembly operation to another involving different parts and different, interchangeable top platforms.
The novel structure of the present invention involves the interconnection of a lower member and an upper member of the vibratory sub-assembly by a pair of flat springs operatively interposed therebetween. The flat springs are angularly disposed between and support the upper member in spaced, generally parallel superposed relationship above the lower member. The springs are connected to both the lower and upper members in rabbet-type indentations such that the springs are confined by retaining barriers abutting the top, bottom and lateral edges of the springs. Furthermore, as described generally in my previous patent (U.S. Pat. No. 5,184,716) which involved cylindrical springs, an electromagnetic coil is similarly attached to the lower member of the sub-assembly of the present invention to alternately flex and release the flat springs of this sub-assembly. Thus, the coil, which cycles between creating a magnetic attraction force and then presenting no attraction force, alternately magnetically attracts the upper member (i.e. pulls it downward) and then releases it to allow the springs to return the upper member upward to its normal position. This action imparts a forward-only impulse motion to the component parts placed on the upper member or a top platform attached thereto. The forward only motion eventually propels the component parts to the preselected pick point in proper orientation for pick up by the automated or robotic pick and place machinery.
Accordingly, a principal object of the present invention is to provide a new and improved magnetic vibrator sub-assembly for a vibratory feed device for electronic component parts which has improved reliability in the delivery and orientation of the parts transported thereby.
Another object of the present invention is to provide an improved vibrator sub-assembly having flat springs attached to and interposed between the lower and upper members of a vibrator sub-assembly to increase stability and accuracy in the delivery of small component parts for electronic assembly operations.
These and still further objects as shall hereinafter appear are readily fulfilled by the present invention in a remarkably unexpected manner as will be readily discerned from the following detailed description of an exemplary embodiment thereof especially when read in conjunction with the accompanying drawings in which like parts bear like numerals throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an isometric view of a vibratory feed device having a magnetic vibrator sub-assembly embodying the present invention operatively associated therewith;
FIG. 2 is a side elevation of the magnetic vibrator sub-assembly of FIG. 1; and
FIG. 3 is an exploded isometric view of the magnetic vibrator sub-assembly shown in FIGS. 1 and 2,
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the attached drawings, a description of the preferred embodiment of the present invention, its assembly and operation will now be presented.
The present invention relates generally to in-line vibratory feed devices, an example of which is identified in FIG. 1 by the general reference numeral 10. This invention more particularly involves the mounting and orientation of first and second springs 12 and 14 on magnetic vibrator sub-assembly 15 so as to ensure stability and accurate, repeatable three-dimensional positioning of a top platform 16 which is mounted on sub-assembly 15.
FIG. 1 shows a magnetic vibrator sub-assembly 15 having a top platform 16 (shown in dashed lines) attached thereto. Sub-assembly 15 is also attached to a base 17 (also shown in dashed lines). A complete vibratory feed device 10 generally comprises a base 17, a sub-assembly 15 and a top platform 16. Top platform 16 is preferably adjustably configurable to receive a wide variety of component parts (not shown) which are to be delivered to automatic or robotic pick and place machinery (also not shown). Base 17 is used to mount the present invention in a preselected assembly line location.
Sub-assembly 15 has a lower member 18 to which are attached (either directly or indirectly) springs 12 and 14 which, in turn, support an upper member 20. A vibratory electromagnetic coil assembly 21 is also mounted upon lower member 18 as shown in FIGS. 1 and 2. The coaction of springs 12 and 14 with coil assembly 21 to move component parts will be described further below.
As shown most clearly in FIG. 2, spring 12 is attached directly to front end 22 of lower member 18 and supports leading end 23 of upper member 20. Similarly, spring 14 is disposed on lower member 18 near its rear end 24 and is also attached directly to and thereby supports trailing end 25 of upper member 20. Also as shown in FIG. 2, it is preferable for springs 12 and 14 to be attached at certain predetermined interior angles Θ 1 and Θ 2 measured between the substantially horizontal plane of lower member 18 and the planes of springs 12 and 14. Note, Θ, and Θ 2 may but need not be equal and measure from about 5° to 85°.
In one practice of the present invention, springs 12 and 14 may be connected directly to ends 22, 23 and 24, 25 of lower and upper members 18 and 20, respectively, although in the preferred embodiment, as shown in FIGS. 1-3, the mounting of springs 12, 14 involves the use of two substantially rectangular blocks, herein referred to as first and second spring banks 26 and 27, respectively. Spring banks 26, 27 are used to attach springs 12 and 14 to lower and upper members 18 and 20. More specifically, spring bank 26 is attached directly to and depends from upper member 20 by suitable fastening means 28 while spring bank 27 is attached to lower member 18 by suitable fastening means 29 such as screws, bolts and the like. As shown in FIG. 3, a channel 30 is formed on the lower surface of spring bank 27 while a corresponding groove 31 is formed on lower member 18 in registry with channel 30. Channel 30 and groove 31 coact to receive and contain power cable 32 which extends from coil assembly 21 to a suitable power source (not shown).
As mentioned above, springs 12 and 14 are mounted at preselected angles Θ 1 and Θ 2 which, as shown in FIG. 2, are established and maintained by the coaction of the slanted connection edges at or near the front and rear edges of lower and upper members 18 and 20. As shown in FIGS. 1-3, two of these slanted connection edges; front edge 33 located on front end 22 of lower member 18 and edge 34 on trailing end 25 of upper member 20 are each formed directly on lower and upper members 18 and 20, respectively. The other two connection edges 35 and 36 are formed on spring banks 26 and 27, respectively.
The slanted connection edges are formed substantially as shown having preselected interior acute angles corresponding to angles Θ 1 and Θ 2 . Again, Θ 1 and Θ 2 may but need not be equal and generally measure from about 5° to 85°. Also as shown, it is preferable to have springs 12 and 14 slanted such that the top ends of springs 12 and 14 are disposed above and rearward relative to the lower ends thereof.
The preferred embodiment of sub-assembly 15 also has rabbet-type indentations formed in the slanted connection edges associated with lower and upper members 18 and 20. These indentations, in coaction with multiple protruding barriers, provide greater accuracy and stability in positioning springs 12 and 14 for interconnecting lower and upper members 18 and 20 for repeatable, consistent and steady in-line operation of feeder device 10. It is preferable, as shown in the attached drawings, that these indentations be formed in spring banks 26, 27, and lower and upper members 18 and 20 leaving several protruding retaining barriers as described below. In particular, and as is most clearly shown in FIG. 3, lower member 18 has a front end slanted connection edge 33 which is indented relative to a protruding lower retaining barrier 40 and two protruding side barriers 41 and 42. Side barriers 41 and 42 are oriented substantially parallel to each other on opposite lateral sides of lower member 18. They are also generally perpendicular to lower retaining barrier 40. Thus, when mounted on connection edge 33, the lower, substantially squared end of flat spring 12 abuts against retaining barriers 40-42 with its bottom edge 44 abutting against barrier 40 and first and second lower lateral edges 45, 46 abutting against lateral side barriers 41 and 42, respectively. In this way, spring 12 is made more stable as mounted so that there can be no possible undesirable unsteady, side to side or rotating motion. Further, when removal and reattachment or replacements of the springs or other structural members are necessary, retaining barriers 40-42 assist in accurately repositioning spring 12 to its original three-dimensional spatial location so that the pick and place machinery cooperatively coacting with vibratory feed device 10 will not have to be readjusted to conform to a new pick point location.
Similar retaining barriers are formed directly on spring bank 26 to define a similar rabbet-type indentation as again is most clearly shown in FIG. 3. This indentation supports the upper substantially squared ends of first and second arms 48 and 49 of spring 12 such that two top retaining barriers 50 and 51 abut against upper edges 52 and 53 of first and second arms 48, 49 of spring 12. Meanwhile, first and second side retaining barriers 54 and 55, which are generally perpendicular to top retaining barriers 50 and 51, abut against and thereby secure first and second upper lateral edges 56, 57 of spring 12. Thus, spring 12 is confined within the rabbet-type indentation on spring bank 26 and thereby secured to upper member 20 such that spring 12 cannot move upwards or laterally relative to upper member 20.
A similar arrangement of rabbet-type indentations is used on trailing end 25 of upper member 20 and on spring bank 27 to rigidly secure spring 14 to both upper member 20 and lower member 18. Thus, spring 14 is also made stable with no undesirable unsteady, side to side or rotational motion.
As described above, lower and upper members 18 and 20 are operatively connected to each other by flat springs 12 and 14. The upper, lower and lateral sides of each spring are substantially squared or rectangularly shaped while each spring has a "U"-shaped cut out from the upper edge to a spaced relationship with the lower edge. Thus, each spring in the preferred embodiment has two arms, (such as arms 48 and 49 of spring 12) the tops of which are attached to the slanted connection edges of upper member 20. Similarly, the springs are mounted at their lower ends to the slanted connection edges of lower member 18. Springs 12 and 14 are mounted such that they fit securely into the rabbet-type indentations on the corresponding slanted edges. Screws, bolts or like attachment means may be used to secure these connections. Preferably, one or more cover members 58 are used to further secure these spring connections.
In operation of a vibratory feed device 10, a top platform 16 is attached to upper member 20 while lower member 18 is attached to a base 17. Top platform 16 is capable of receiving small component parts of the type used in the manufacture and assembly of electronic circuit boards particularly as such parts are to be picked up and maneuvered by automated or robotic assembly pick and place machinery (not shown). Top platform 16 is attached directly to upper member 20 as described above by any of several conventional methods including the use of screws or bolts 59 as shown in FIG. 3. Dowel pins 60 are also used for the attachment of top platform 16 to upper member 20 and are inserted into corresponding holes in both upper member 20 and top platform Dowel pins 60 assist in securely and properly aligning top platform 16 during the installation of screws or bolts 59 while also being useful to absorb vibrational stresses occurring during the vibrational operation of device 10. Otherwise, these stresses would be absorbed solely by the screws or bolts 59 and thereby cause an undesirable loosening or failure thereof.
When sub-assembly 15 is attached to and between top platform 16 and base 17 in the manner described, a vibratory feed device 10 is assembled. Device 10 may then be demountably mounted in a predetermined work space in cooperative association with existing robotic pick and place machinery as generally described above. As is generally known in the art, one or more anti-static tubes or other delivery means (not shown) may then be disposed on top platform 16 relative to one or more guide lanes and elevator braces (neither shown) which are attached to top platform 16. An example of a similar arrangement is set forth in my previous patent, U.S. Pat. No. 5,184,716. More specifically, the anti-static tube(s) (or other delivery means) are held in position by one or more elevator and/or hold down braces which are adjustably attached to top platform 16 to deliver a supply of component parts passed through said anti-static tube(s) to predetermined pick points in said one or more guide lanes.
In use, device 10 operates by supplying electric power to coil assembly 21 which alternately energizes and de-energizes a magnetic field that alternately attracts and releases upper member 20. An armature plate 61 may optionally be attached to the undersurface of upper member 20 immediately above coil assembly 21 to focus the magnetic attraction and release action described above. The force of the magnetic attraction causes upper member 20 to move vertically downward and, due to the angled orientation of springs 12 and 14, slightly rearwardly toward rear end 24 of lower member 18. Springs 12 and 14 are forced or flexed against their normally biased position during this attraction motion. During the de-energizing part of the alternating power cycle as applied by coil assembly 21, the electromagnetic attraction is switched off and upper member 20 is released from this downward pull. Flexed springs 12 and 14 are thus allowed to respond by returning to their normally biased, unforced position and thus provide the impetus required to return upper member 20 to its original uninfluenced position. Each movement has a preferably small amplitude, and is controllable to provide a variety of consistent amplitudes and frequencies. Continuous and rapid repetition of this alternating motion imparts a vibrational linear motion to upper member 20 and thus also to top platform 16, thereby moving any component parts placed thereon linearly in the desired direction, preferably from rear to front, to eventually place them at the proper pick point of the associated guide lane on top platform 16 so that the component parts are where they can each be picked up by the aforementioned automated or robotic pick and place machinery. The stability and accuracy provided by the spring positioning in the rabbet-type indentations generates a greater reliability and consistency in delivery of the aforementioned small component parts to the proper pick point interface with manufacturing and assembly pick and place machinery.
Note, it is foreseeable that upper member 20 could be integrally formed with top platform 16 in one inseparable piece such that the functions of each are met by a single member. Similarly, lower member be could be integrally formed with base 17 such that they, too, are inseparable. Thus, a sub-assembly 15 comprising such member would be coextensive with and would identically embody vibratory feed device 10 without a detachable base 17 or top platform 16.
It is, of course, also foreseeable that a wide variety of combinations of spring connections using either fewer or more spring blocks may be used with the present invention and are thus intended to be included within the scope of this disclosure. More specifically, any number of spring blocks are foreseeably usable in different embodiments including for example, no blocks where the springs are attached directly to the front and rear ends of the upper and lower members.
From the foregoing, it is readily apparent that a new and useful embodiment of the present invention has been herein described and illustrated which fulfills all of the aforestated objects in a remarkably unexpected fashion. It is of course understood that such modifications, alterations and adaptations as may readily occur to the artisan confronted with this disclosure are intended within the spirit of this disclosure which is limited only by the scope of the claims appended hereto.
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A magnetic vibrator sub-assembly for a vibratory feed device is described which provides uniform directional motion to component parts placed on its upper member through coaction of the upper member with an alternately energized electromagnetic field and restorative spring forces. The structure of the present invention involves the interconnection of a lower member and an upper member by one or more flat springs. The flat springs are angularly disposed between and support the upper member in superposed spaced, generally parallel relationship above the lower member. The springs are connected to both the lower and upper members in rabbet-type indentations such that the springs are confined by retaining barriers above, below and on the lateral edges of the springs. An electromagnetic coil is attached to the lower member and is employed to alternately flex and release the flat springs by alternately magnetically attracting (i.e., pulling down) and releasing the upper member. This action imparts a forward-only impulse motion on the component parts delivered to and placed on the upper member. The forward-only motion eventually propels the component parts to the desired pick point in proper orientation for pickup by automated or robotic pick and place machinery coacting therewith in an electronics assembly application.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/769,946, filed Feb. 2, 2004, now U.S. Pat. No. 7,000,483 the entire contents of which are incorporated herein by reference, which claims the benefit of U.S. provisional patent application 60/444,545 filed Feb. 3, 2003, the entire contents of which are incorporated herein by reference, and claims the benefit of U.S. provisional patent application 60/468,728 filed May 7, 2003, the entire contents of which are incorporated herein by reference.
BACKGROUND
The invention relates to inflatable manometers. Manometers are often used in medical procedures to monitor pressures in apparatus such as inflatable cuffs or manual resuscitators for a patient. For example, it is desirable to maintain the internal pressure of a tracheal tube cuff below 30 cmH 2 O. Existing manometers are typically costly and can be a vehicle for disease transmission, rendering widespread use of such manometers prohibitive. Accordingly, there is a need in the art for a low cost, accurate manometer for medical applications (e.g., single-patient use disposable) and other applications.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the invention include an inflatable manometer having an air cell. The air cell has a concavity formed therein. The concavity has two edges, or other geometric features, wherein increased pressure within the air cell causes contraction of the concavity moving the two edges closer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B depict inflatable manometers in embodiments of the invention.
FIG. 2 depicts the manometer of FIG. 1A as pressure increases.
FIG. 3 depicts an inflatable manometer in an alternate embodiment of the invention.
FIG. 4 depicts the manometer of FIG. 3 as pressure increases.
FIG. 5 depicts an inflatable manometer in an alternate embodiment of the invention.
FIG. 6 depicts the manometer of FIG. 5 as pressure increases.
FIGS. 7A and 7B depict inflatable manometers in alternate embodiments of the invention.
FIG. 8 depicts an inflatable manometer in an alternate embodiment of the invention.
FIG. 9 depicts the manometer of FIG. 8 as pressure increases.
FIG. 10 depicts an inflatable manometer in an alternate embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1A depicts an inflatable manometer 10 in an embodiment of the invention. Manometer 10 includes an air cell 12 coupled to a fluid inlet 14 . The manometer serves as an air cell pressure transducer that indicates pressure of the fluid which may be gas, liquid, etc. The air cell 12 is formed by two sheets of material sealed along seal 16 . In one embodiment, the sheets of material are thermoplastic material and are sealed using known techniques such as heat sealing, ultrasonic welding, etc. The sheets of material are not limited to thermoplastic materials and may be implemented using any flexible material such as rubber, glued paper, etc. The air cell 12 is generally circular and includes a concavity 18 in the shape of a triangular wedge. It is understood that the air cell 12 and concavity 18 may have shapes other than those depicted in FIG. 1A . FIG. 1B depicts an alternate manometer similar to that shown in FIG. 1A , but having differently shaped concavity 18 .
A scale 20 is also formed from the same sheets defining the air cell 12 and includes indicia 22 representative of pressure. The scale 20 and indicia 22 may be formed by molding the indicia 22 into thermoplastic sheets (e.g., heat stamping) or printing the indicia 22 . The scale 20 is positioned proximate to edge 24 of concavity 18 . The scale 20 can be designed for different real units of measure, e.g., PSI. In alternate embodiments, scale 20 is affixed to air cell 12 and moves relative to a stationary indicator.
FIG. 2 depicts manometer 10 of FIG. 1A as pressure in air cell 12 increases. As the air cell 12 is inflated, the two edges that define the concavity 18 will contract towards each other in response to increasing internal fluid pressure. The pressure within the air cell 12 is represented by the position of edge 24 relative to scale 20 . Thus, the size and shape of the air cell 12 , concavity 18 and scale 20 are designed to provide an accurate indication of pressure.
Inlet 14 may be coupled to a tube in fluid communication with a chamber for which pressure monitoring is desired. Alternatively, manometer 10 may be secured on a sidewall of a chamber with inlet 14 in fluid communication with the chamber. The seal 16 around inlet 14 may be secured to the chamber wall (e.g., heat sealed to thermoplastic chamber) to provide an integrated manometer.
FIG. 3 depicts an alternate manometer 30 . Manometer 30 includes an air cell 32 and a fluid inlet 34 . The manometer 30 indicates pressure of the fluid which may be gas, liquid, etc. The air cell 32 is formed by two sheets of material sealed along edges 36 . Interior seals 38 define a number of rectangular sub-cells 40 , each having a concavity 42 at each end defined by seals 36 . In one embodiment, the sheets of material defining air cell 32 are thermoplastic material and are sealed using known techniques such as heat sealing, ultrasonic welding, etc. The sheets of material are not limited to thermoplastic materials and may be implemented using any flexible material such as rubber, glued paper, etc.
Air cell 32 and inlet 34 are positioned within a housing 50 having a first and second sheet sealed along the periphery encasing the air cell 32 and inlet 34 . The first and second housing sheets may be thermoplastic material and are sealed using known techniques such as heat sealing, ultrasonic welding, etc. A scale 52 is also formed on the housing 50 and includes indicia 54 representative of pressure. The scale 52 and indicia 54 may be formed by molding the indicia 54 into thermoplastic sheets (e.g., heat stamping) or printing the indicia 54 . The scale 52 is positioned proximate to a distal end 56 of air cell 32 . The scale 52 can be designed for different real units of measure, e.g., PSI.
FIG. 4 depicts manometer 30 as pressure in air cell 32 increases. As the air cell 32 is inflated, rectangular sub-cells 40 expand into cylindrically shaped cells, thereby reducing the length of the air cell 32 in a linear direction. The pressure within the air cell 32 is represented by the position of distal end 56 relative to scale 52 . The distal end 56 of the air cell 32 may be colored to more easily determine the position of the end of the air cell 32 relative to the scale 52 . Thus, the size and shape of the air cell 32 and scale 52 are designed to provide an accurate indication of pressure.
Inlet 34 may be coupled to a tube in fluid communication with a chamber for which pressure monitoring is desired. Alternatively, manometer 30 may be secured on a sidewall of a chamber with inlet 34 in fluid communication with the chamber. The seal around inlet 34 may be secured to the chamber wall (e.g., heated sealed to thermoplastic chamber) to provide an integrated manometer.
FIG. 5 depicts another manometer 60 in an alternate embodiment. Manometer 60 includes an air cell 62 and a fluid inlet 64 . The manometer 60 indicates pressure of the fluid which may be gas, liquid, etc. The air cell 62 is formed by two sheets of material sealed along edges 66 . The shape of seal 66 defines a number of sub-cells 68 , each having a concavity 70 . The sub-cells are in fluid communication with each other, and inlet 64 . The concavity 70 in FIG. 5 is a triangular wedge, but it is understood that other geometries may be used. In one embodiment, the sheets of material defining air cell 62 are thermoplastic material and are sealed using known techniques such as heat sealing, ultrasonic welding, etc. The sheets of material are not limited to thermoplastic materials and may be implemented using any flexible material such as rubber, glued paper, etc.
Air cell 62 and inlet 64 may be positioned within a housing 72 having a first and second sheet sealed along the periphery encasing the air cell 62 and inlet 64 . The first and second housing sheets may be thermoplastic material and are sealed using known techniques such as heat sealing, ultrasonic welding, etc. A scale 74 is also formed on the housing 72 and includes indicia 76 representative of pressure. The scale 74 and indicia 76 may be formed by molding the indicia 76 into thermoplastic sheets (e.g., heat stamping) or printing the indicia 76 . The scale 74 is positioned proximate to a distal end 78 of air cell 62 . The scale 74 can be designed for different real units of measure, e.g., PSI.
FIG. 6 depicts manometer 60 as pressure in air cell 62 increases. As the air cell 62 is inflated, sub-cells 68 contract at concavity 70 , as described above with reference to FIG. 2 , thereby reducing the length of the air cell 62 in a linear direction. The pressure within the air cell 62 is represented by the position of distal end 78 relative to scale 74 . The distal end 78 of the air cell 62 may be colored to more easily determine the position of the end of the air cell 62 relative to the scale 74 . Thus, the size and shape of the air cell 62 and scale 74 are designed to provide an accurate indication of pressure.
FIG. 7A depicts a manometer 80 in an alternate embodiment of the invention. Manometer 80 is similar to manometer 10 in FIG. 1A and similar components are labeled with the same reference numerals. Manometer 80 includes an indicator 82 extending from edge 24 of concavity 18 . Rather than scale 20 formed in the sheet defining the air cell 12 , manometer 80 includes a scale 84 printed on a separate card 86 . The manometer 80 and the printed scale 84 may be encased within a transparent housing 88 . The housing 88 includes an opening to access the fluid inlet 14 to the manometer 80 . FIG. 7B depicts an alternate manometer similar to that shown in FIG. 7A , but having differently shaped concavity 18 .
FIG. 8 depicts a manometer 90 in an alternate embodiment of the invention. The manometer 90 is formed from two sheets sealed together (e.g., thermoplastic sheets sealed together) to define an air cell 91 and an inlet 96 for fluid. The sheets of material are not limited to thermoplastic materials and may be implemented using any flexible material such as rubber, glued paper, etc. Inlet 96 is in fluid communication with a chamber for which pressure monitoring is desired. Manometer 90 includes two concavities 92 and 94 , having differing characteristics. The concavities 92 and 94 have different widths so that each notch will close at different pressures. It is understood that other characteristics of concavities 92 and 94 may be varied including length, width and shape. The manometer 90 may also include a single concavity rather than two concavities. The single concavity may correspond to a minimum pressure that should be maintained or a maximum pressure that should be avoided. The distal end 98 of the manometer 90 may serve as a fluid outlet so that manometer 90 may be positioned inline in a pressure system to indicate pressure of a chamber connected to outlet 98 .
FIG. 9 shows manometer 90 as pressure increases in air cell 91 . As shown in FIG. 9 , the opening of concavity 92 with the smaller width closes at a first predetermined pressure while concavity 94 has started to contract. Concavity 94 with the larger width has started to contract and closes at a second pressure. This allows an operator to determine that air cell 91 has been inflated to a pressure between two limits without requiring a scale indicating a numerical pressure value. Manometer 90 may be used in a variety of applications including indicating pressure of pilot balloons associated with tracheal devices.
The inlet in the manometers of FIGS. 1-9 may be eliminated and the air cell pressurized with a fluid and sealed. In this embodiment, the manometer indicates ambient pressure in response to a difference between ambient pressure and pressure in the air cell.
FIG. 10 depicts an inflatable manometer in an alternate embodiment of the invention. The manometer 10 is similar to that shown in FIG. 1 and includes an outlet 15 in air cell 12 . In this embodiment, the manometer 10 serves as a flowmeter to indicate a pressure differential between inlet 14 and outlet 15 . In this configuration, the manometer may be used to indicate positive pressure, negative pressure or fluid flow. As long as the pressure within the manometer chamber 12 is positive to inflate the chamber 12 and cause edge 24 to move relative to scale 20 .
While the invention has been described with reference to exemplary 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 essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed for carrying out the invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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An inflatable air cell pressure transducer. The air cell has a concavity formed therein. The concavity has two edges, wherein increased pressure within the air cell causes contraction of the concavity moving the two edges closer.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved position regulation system.
Generally speaking, the position regulation system of the present invention is of the type comprising a digital incremental measuring apparatus with a direction discriminator for the evaluation of measuring signals having 90° phase shift. Such system contains two relatively movable objects, one of which is provided with a drive.
From German Pat. No. 2,758,525, published June 28, 1979, there is known to the art a digital incremental measuring apparatus with a direction discriminator, which serves to determine the relative position of two objects displaceable relative to one another. Since the resolution capacity of such measuring apparatuses is limited by the grid constant of the employed precision scale and by the counting frequency of the counters, the speed of advance of the relatively movable objects is increased so as to avoid a high resolution scale graduation. In order to achieve this, an up-down or forwards-backwards counter with a direction discriminator is used, which counts the signals which have a 90° phase shift and are supplied by a scanning head sensing the scale graduation. Such signals are counted according to the principle of single evaluation, i.e. only the edge of the pulse corresponding to a change of the 90°-signal is counted, whereas the 0°-signal has the value 1. Then a division into any number of coded intermediate values is carried out by means of a circuit whose internal structure is not disclosed in the aforementioned patent. Thus, the graduation scale can be coarser in production to the factor by which the number of intermediate values is larger than the number of the measuring signals.
Such measuring apparatus is not suitable for a position regulation system containing two objects which are displaceable relative to one another and one of which objects has an incremental scale with a very fine graduation, such as 10 μm, since the required high resolution of the measuring apparatus and the great length of the incremental scale would require counters with high capacity and a great circuit complexity.
SUMMARY OF THE INVENTION
Therefore, it is a primary object of the present invention to provide a new and improved arrangement of a position regulation system containing a digital incremental measuring apparatus with a direction discriminator, which does not require high-capacity counters and high circuit complexity even with high resolution and great length of the incremental scale used.
Now in order to implement this object and others which will become more readily apparent as the description proceeds, the position regulation system of the present development is manifested by the features that the discriminator delivers a number of measuring pulses for each relative direction of movement of both objects, wherein each of such measuring pulses corresponds to one pulse edge of the measuring signals. The output of the discriminator is connected in circuit with an interrupt logic which is connected to a computer having a program and memory register means. The course of the program is interrupted by each output pulse of the interrupt logic, and the output pulses from the interrupt logic serve for updating an actual value in the memory register means. These output pulses, following the interruption of the program of the computer, forming a set value/actual value difference and from such difference a positioning magnitude which is transmitted to a positioning element controlling the drive of the driven object.
According to the invention, the position regulation system therefore is not provided with a measuring apparatus containing a direction discriminator which operates according to the principle of single evaluation, but rather with a discriminator which via an interrupt logic feeds a computer. On the basis of a comparison between the set value and the actual value, such computer delivers the positioning or adjustment magnitude for a positioning or adjustment element connected with the drive. Thus, the position regulation system can be used, for instance, for a gear grinder at which the incremental scale has a graduation of only 10 μm, which leads to a high number of measuring signal pulses at the output of the scanning head. This number is still doubled by the discriminator which, depending on the direction of motion, i.e. up or down on the scale, delivers four measuring pulses for every increment of the scale. Since each measuring pulse corresponds to a covered distance, the measuring pulses of each direction of motion need to be added or subtracted. For the position regulation system according to the invention no counters or only short counters are needed for detecting long distances with a high resolution, since the pulses are simply stored in memory or storage registers, the content of which then corresponds to the covered distance, i.e. the actual value of the position.
According to a further aspect of the invention the computer can be constructed to contain at its output side a digital to analogue converter (D/A-converter) which delivers the positioning magnitude for the position. The computer furnishes the positioning or adjustment magnitude in the form of an analogue value which can be directly processed by the normally used analogue positioning or adjustment elements.
As a further feature of the invention the interrupt logic can possess a time clock input, by means of which there likewise can be interrupted the course of the program in the computer. The measuring pulses arriving at the interrupt logic between such interruptions constitute a measurement for the displacement speed of the driven object, and a signal representative of the displacement speed of the object is transmitted to the digital to analogue converter as a second positioning magnitude. This second positioning magnitude constitutes a measure for the displacement speed of the driven object. Moreover, there can be provided an apparatus or means for differentiating the displacement speed of the driven object. Such differentiating means deliver as a third positioning magnitude the acceleration of the object. Both of these positioning or adjustment magnitudes enable the regulation system to advance to positions at a preselected speed or with preselected acceleration.
Still a further design of the position regulation system contemplates arranging an intermediate storage or memory between the discriminator and the interrupt logic. This intermediate storage or memory stores measuring pulses arriving during the time clock interruptions and the interrupt logic processes such measuring pulses. There is thus prevented the loss of any of the incoming measuring pulses during such time clock interruptions.
Also, there can be provided an external computer which determines priorities between the three positioning magnitudes. Hence, it is possible, for instance, for processing reasons, to give priority either to the positioning magnitude for the displacement speed, since at a gear grinding machine there is desirable, for example, a quick advance for the roughing work while the exact position is not important, or to the positioning magnitude for the position, since for the finishing work the exact position is important.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings which depict an exemplary embodiment of the invention described hereinafter in greater detail and wherein:
FIG. 1 is a block circuit diagram of the position regulation system according to the invention; and
FIG. 2a and FIG. 2b are respective diagrams illustrating the mode of operation of a discriminator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a block circuit diagram of a position regulation system wherein the incremental measuring apparatus for measuring the actual value is designated in its entirety by reference character 1, the regulator or control in its entirety by reference character 2, a positioning or adjustment element by reference character 3 and a drive by reference character 4. The incremental measuring apparatus contains an incremental scale 1a, e.g. a precision scale which can have a graduation of 10 μm at a gear grinding machine. However, the position regulation device described herein is not limited to such machines or to machine tools in general, but may be applied in any case where a high resolution is required for long travel or displacement paths of objects to be moved. The incremental scale 1a is attached to a carriage or slide which is driven by drive 4. Arranged opposite the incremental scale 1a is a scanning or sensing head 1b which scans the graduation marks of the scale and delivers for every graduation marking or line two measuring signals A and B (FIG. 2) which have a phase shift of 90°. In one direction of motion of the object to be moved, indicated by +x in FIGS. 2a and 2b, the measuring signal A leads the measuring signal B by 90°, while in the opposite direction, indicated by -x in FIGS. 2a and 2b, the measuring signal B leads the measuring signal A by 90°.
The scanning or sensing head 1b is provided with two outputs, by means of which the measuring signals A and B are transmitted to a discriminator 5.
The discriminator 5 doubles the pulses of the two measuring signals A, B by generating a defined measuring pulse for every ascending and descending pulse edge or flank of the signals A and B, whereby separate pulses are generated for each direction of motion or there are generated non-separated movement pulses UP/DOWN and separate direction pulses UP, DOWN. In FIGS. 2a and 2b the measuring pulses for the direction of motion +x, i.e. in upward direction of the incremental scale 1a with reference to a zero-mark or graduation line 1c, are designated by UP, while for the direction of motion -x, i.e. downwards with reference to the zero-mark or graduation line 1c, they are designated by DOWN, or UP/DOWN and UP and DOWN respectively.
The discriminator 5 transmits these measuring pulses to an interrupt logic 6 via separate channels which are designated by UP or DOWN, or by UP/DOWN and UP and DOWN respectively. The interrupt logic 6 is connected to a computer designated in its entirety by reference character 7.
The computer 7 comprises a microprogram 71 which can be exchanged, when necessary, a central processing unit CPU 72, a memory or storage register 73 and, if necessary, a digital to analogue converter 74. Furthermore, such computer 7 comprises data busses 75. The measuring pulses UP, DOWN need to be added to subtracted in order to determine the actual positional value reached, since every pulse corresponds to a certain distance covered or displacement path. For this purpose the measuring pulses trigger by means of the interrupt logic 6 an interruption of the computer program running in the computer 7, according to the direction of motion, i.e. +x or -x. A memory or storage in the storage or memory registers 73, for instance memory or storage I, is incremented or decremented, so that the content of the memory or storage I corresponds to the distance covered. The memory can therefore be regarded as a software-counter for the actual value. As occasion demands, i.e. according to the number of pulses to be counted, several storages or memories I, II, III . . . can be interconnected with each other by means of the microprogram 71 so that appreciable "counter lengths" can be achieved.
The positional set or reference point is stored in the storage or memory register 73, for instance in the storage or memory IV, where it has been loaded through an interface 8 which is connected to the computer 7. Whenever there is no interruption in the computer 7 by entering UP or DOWN measuring pulses, the set point/actual value difference is determined under the control of the microprogram 71 and transmitted to the digital to analog converter 74. Such converter 74 delivers an analogue signal us which constitutes the positioning magnitude and such is transmitted to the positioning element 3 in order to adjust the object to the exact position by means of the drive 4. In addition to the measuring pulses, the interrupt logic 6 receives a null pulse, which determines the location of the scanning head 1b with reference to the incremental scale 1a.
The interrupt logic 6 is further provided with a time clock input 50 connected to a here not further illustrated but conventional clock generator and serving for time clock interruptions in periodical intervals. Thus, the speed of movement of the scale can be determined by means of the displacement paths stored in the memory register 73 and the differences of such displacement paths since the last time clock interruption, or the acceleration of the scale can be determined by means of a differentiator included, for instance, in the microprogram 71. In the digital to analogue converter 74 the values for speed and acceleration are converted into analogue signals uv and ug, respectively. By means of such signals the positioning element 3 can be controlled so as to advance the object to a given position at a certain speed or with a certain acceleration, as the case may be.
By means of the interface 8 the program of computer 7 can be exchanged by means of an external computer 9. Therefore, if necessary, other program parts or programs can be fed into the microprogram storage 71 which have other or additional functions, e.g. regulation or control algorithms. Furthermore, the memory content of computer 7 can be displayed through the interface 8 and the external computer 9. Through the interface 8 and the external computer 9 it is furthermore possible to achieve a synchronization with external processes by means of feedback or reporting back messages, such as, for instance, position has been reached, or, speed has been reached.
The regulator 2 offers the possibility of detecting and controlling a plurality of independent movements. For this purpose it is only necessary to provide for an appropriate number of additional channels, each of which contain an incremental measuring apparatus, a drive and a positioning element, and to connect them to the discriminator 5, as indicated by broken lines for a second channel in FIG. 1.
As mentioned, the digital to analog converter 74 can be omitted if the positioning element or the evaluation circuits receiving the positioning magnitude can process the latter in digital form.
If so desired, the interrupt logic 6 can be provided with an intermediate memory or storage 10 which during time clock interruptions stores measuring pulses coming from the discriminator 5 so that these do not get lost.
The external computer 9 can be used for determining priorities among the three positioning magnitudes. This can be desirable, for instance, for the machining of workpieces, since for the roughing work a quick advance is needed while the position is not important and priority is therefore given to the positioning magnitude uv over the positioning magnitude us, whereas for the finishing work priority would be given to the positioning magnitude us over the positioning magnitude uv.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly,
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A position regulation system containing a digital incremental measuring apparatus. The use of a discriminator and a computer allows the detection of long distances with high resolution, without counters or with only very short counters. The system is capable of automatically advancing to certain positions at a preselected speed or with preselected acceleration and of accordingly determining priorities for the positioning or adjustment magnitudes used for the advance.
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This application is a divisional of U.S. patent application Ser. No. 09/245,158, filed Feb. 4, 1999, now U.S. Pat. No. 6,272,929.
FIELD OF INVENTION
The present invention relates to pressure transducers and more particularly to an improved high pressure piezoresistive transducer which is suitable for use in hostile environments and a novel, advantageous method for making the same.
BACKGROUND OF THE INVENTION
Kulite Semiconductor Products, Inc., the assignee herein, has previously made and patented a method for fabricating high pressure piezoresistive transducers using both longitudinal and transverse piezoresistive coefficients U.S. Pat. No. 5,702,619, entitled “Method of Fabricating a High-Pressure Piezoresistive Transducer”, filed Sep. 30, 1996, and assigned to the assignee herein, the entire disclosure of which is hereby incorporated by reference. Therein, a basic sensor is formed from a piece of single crystal silicon to which sensors are dielectrically bonded on one surface and the other surface of the silicon is bonded to a glass support member. In those structures the piezoresistive elements were formed on the surface of the transducer that is directly exposed to the pressure media. Additionally, electrical contacts and lead wires are also exposed to the media.
This structure is undesirable in some situations, where exposure of the piezoresistive elements, electrical contacts and lead wires to the media shortens the life expectancy of the pressure transducer. Accordingly, it is an object of the present invention to provide a high pressure transducer less sensitive to the media.
SUMMARY OF INVENTION
A pressure transducer including: a silicon substrate including: a first surface adapted for receiving a pressure applied thereto, an oppositely disposed second surface, and a flexing portion adapted to deflect when pressure is applied to the first surface; at least a first sensor formed on the second surface and adjacent to a center of the flexing portion, and adapted to measure the pressure applied to the first surface; at least a second gauge sensor formed on the second surface and adjacent to a periphery of the flexing portion, and adapted to measure the pressure applied to the first surface; a glass substrate secured to the second surface of the silicon wafer.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a diagram of the approximate shape of a diaphragm with the resistor placement according to the present invention.
FIG. 2 illustrates a top view of a glass support to which the diaphragm of FIG. 1 is mounted according to the present invention.
FIG. 3 illustrates a cross-section A—A of FIG. 2 .
FIG. 4 illustrates the mounting of the diaphragm/support assembly to a header according to the present invention.
FIG. 5 illustrates a cross-section of a diaphragm/support and header according to the present invention.
FIG. 6 illustrates a perspective view of gauge placement according to the present invention.
FIG. 7 illustrates a side view of a sensor assembly as described in U.S. Pat. No. 5,614,678.
FIG. 8 illustrates a stress diagram for the sensor of FIG. 7 .
FIG. 9 illustrates a sensor assembly according to the present invention.
FIG. 10 illustrates a stress diagram for the sensor of FIG. 9 .
DETAILED DESCRIPTION OF INVENTION
Referring now to the numerous figures, wherein like references refer to like elements of the invention, FIG. 1 illustrates a diagram of the approximate shape of a diaphragm with the resistor placement according to the present invention.
According to the present invention, piezoresistive elements are placed on a side of the silicon structure 10 isolated, or away, or opposite from a media. Preferably, two elements or gauges, 15 , 20 are located near a center of flexing portion 25 of the silicon member 10 , while two additional members or gauges 30 , 35 are located just inside the flexing portion 25 area.
Contact areas 40 on the silicon structure 10 are sealed to a glass support structure 45 in a non-flexing area (complement of flexing area 25 ). Referring now also to FIGS. 2 and 3, holes 50 are provided in the glass support structure 45 to access the various contact areas 40 of the silicon structure 10 associated with sensors 15 , 20 , 30 and 35 . Additionally, a small depression 55 to allow the flexing area portion 25 of the silicon structure 10 to deflect is provided. The sensor network (sensors 15 , 20 , 30 and 35 ) and contact areas 40 are preferably dielectrically isolated from the silicon structure 10 in the same manner as U.S. patent application Ser. No. 09/047,548, entitled “Compensated Oil-Filled Pressure Transducers” filed Mar. 25, 1998, the entire disclosure of which is also incorporated by reference hereinto, including the seal of the glass to a rim structure and to the contact areas 40 .
Referring now also to FIGS. 4 and 5, the apertures, or holes, 50 in the glass structure 45 are preferably partially filled with a metallic frit 60 (and or an epoxy metal frit for example) and small copper balls 65 are inserted in the back areas of the apertures 50 (also see FIG. 9 ). The sensor-glass support structure (collectively 10 and 45 ) is then mounted to either a polymide structure 70 or ceramic structure with plated through holes 75 into which the exposed portions of the copper balls 65 will seat.
Contact can be made between the balls 65 and plated through holes 75 with a solder or braze. If a polymide structure 70 is used, the sensor structure can be secured with an epoxy or like material, while if a ceramic structure 70 is used the mounting may be made using a glass type frit. However, both mounting surfaces contain lead outs, or metallizations 90 to a series of holes 80 , sized in such a way to conform to the position of pins 95 on a header 85 preferably secured utilizing tapered glass 100 .
The composite structure ( 10 , 45 and 70 ) is then mounted on the header 85 allowing the interconnects and the composite structure ( 10 , 45 and 70 ) to be electrically connected to the pins of the header 85 . When pressure is applied from the side of the silicon not containing the sensor network, i.e. opposite thereof, the central portion of the silicon structure 10 deflects giving rise to a tensile surface strain in the center of the flexing member 25 , while the exterior portions of the flexing member 25 will be put in compression.
Referring now also to FIG. 6, methods of finite analysis were used to elucidate the various stresses within the plane of the silicon structure 10 (directions 105 and 110 ) and normal to it (direction 115 ). This analysis shows that the region of compressive surface stress in the flexing portion 25 where the sensor may be placed is very narrow. This is because the compressive normal stress in the center of the flexing region 25 is zero, but rises to its largest value at the outer edge of the flexing member 25 , and because of the negative sign of the transverse gage factor in the < 110 > direction is negative. If the outer gauge is in this region, the change in resistance will be positive [(−1)×(−1)] and there will be no output.
In general, each gauge sees three different stresses: a longitudinal stress in the plane of the diaphragm (direction 110 ), a transverse stress in the plane of the diaphragm (direction 105 ), and a transverse stress perpendicular to the diaphragm (direction 115 ). These stresses serve to change the resistivity of the gauge through piezoresistive effects. In general this change in resistivity can be broken down into a change for each separate stress, namely: Δ R R = σ x π x + σ y π y + σ z π z ( 1 )
where σ is the stress is one of the three directions and Π is the piezoresistive coefficient in that same direction.
By appropriate choice of crystallographic orientation, one skilled in the art can ensure the coefficient in the longitudinal in plane ( 110 ) and transverse out of plane ( 115 ) are equal in magnitude and opposite in sign, while the coefficient for the transverse in plane ( 105 ) is very close to 0. This leads for a final result for the change in resistance to be: Δ R R = σ long ( π 44 2 ) - σ tran ( π 44 2 ) ( 2 )
By finite element analysis one can compute the transverse and longitudinal stresses that the gauges see and therefore choose the locations which yield the maximum change is resistance for a given load condition.
Referring now also to FIGS. 7-10, therein is illustrated a not to scale drawing and a graph of the relevant stresses for both a conventional high pressure sensor (FIGS. 7-8) and the new leadless one (FIGS. 9 - 10 ). FIGS. 7 and 9 are for reference only and should be used to clarify FIGS. 8 and 10. FIGS. 8 and 10 illustrate the transverse and longitudinal stresses in the appropriate part of the diaphragm. FIGS. 8 and 10 also have marked the approximate locations for the placement of the gauges.
Referring first to FIG. 7, therein is illustrated a conventional pressure transducer including supports 120 , diaphragm 125 and gauges 130 .
It can be seen from FIGS. 8 and 10 that for each sensor there are two gauges which will see a negative change in resistance and two which will receive a positive change in resistance. By combining these four gauges in a wheatstone bridge as set forth in U.S. Pat. No. 3,654,579, entitled “Electromechanical Transducers and Housings” filed May 11, 1970, is assigned to the assignee hereof, also herein incorporated by reference, one can to achieve the desired change in voltage.
This new structure has a number of unanticipated advantages. The position of both the inner and outer gages was only learned by computation using finite element analysis and would be different for each geometry of the sensor but the large difference in surface stress distributed from the top to the bottom surface of the silicon was not anticipated. However, the use of the finite analysis still makes possible the fabrication of a miniature sensor.
By putting the sensing network on the side of the silicon away from the media and using glass support structures with access holes to reach the contacts, it makes possible the construction of a “leadless” structure without fine gold wires and ball bonds as is illustrated in pending U.S. patent application Ser. No. 09/160,976 entitled “Hermetically Sealed Ultra High Temperature Silicon Carbide Pressure Transducers and Method for Fabricating Same” filed Sep. 25, 1998. It also makes possible higher temperature application of the device since the contact material in the apertures is sealed from any high temperatures, hostile environment while still retaining all of the advantages of the structure disclosed in pending U.S. patent application Ser. No. 09/160,976 entitled “Hermetically Sealed Ultra High Temperature Silicon Carbide Pressure Transducers and Method for Fabricating Same” filed Sep. 25, 1998. Additionally, the use of a separate mounting surface for the sensor structure makes possible the use of a header specifically designed for high pressure while still employing a miniature sensor.
Having described the preferred embodiment of this invention, it is evident that other embodiments incorporating these concepts may be used. Accordingly, although the invention has been described and pictured in a preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the detail of construction in combination and arrangement of parts may be made without departing from the spirit and scope of the invention as here and after claimed. It is intended that the patent shall cover by suitable expression in the appended claims, the whatever features of patentable novelty exist in the invention disclosed.
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A pressure transducer including: a silicon substrate including: a first surface adapted for receiving a pressure applied thereto, an oppositely disposed second surface, and a flexing portion adapted to deflect when pressure is applied to the first surface; at least a first sensor formed on the second surface and adjacent to a center of the flexing portion, and adapted to measure the pressure applied to the first surface; at least a second gauge sensor formed on the second surface and adjacent to a periphery of the flexing portion, and adapted to measure the pressure applied to the first surface; a glass substrate secured to the second surface of the silicon wafer.
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[0001] This application is a continuation-in-part of U.S. application Ser. No. 09/450,871 filed on Nov. 29, 1999 and claims priority from Provisional Application Ser. No. 60/119,871, filed Feb. 2, 1999.
BACKGROUND OF THE INVENTION
[0002] It is known in the art of pole manufacturing that the suitability of a pole for a given purpose depends upon the materials from which it is constructed. Pole designs have been restricted by the fact that selection of the material for construction previously required a tradeoff with respect to a number of certain key desirable characteristics of the pole. Among the key characteristics are strength, resilience, weight, length, durability, resistance to environmental conditions, and the ease of transportation and erection. Optimal pole design has been confounded because materials which provide superiority in one characteristic generally have corresponding disadvantages in other characteristics.
[0003] Perhaps the oldest known method in the art of pole construction is the use of wooden poles, such as those commonly used for telephone lines. However, many modern pole uses require longer lengths than are practical, or even possible, with wood. While shorter length poles constructed of wood are relatively inexpensive and easy to erect, wood poles become increasingly more expensive as the desired length increases. Furthermore, wood poles are highly susceptible to rot, insect infestation, and bird attack. Known methods of preventing these latter problems present their own difficulties in that the chemicals used to treat the wood may leach out into the surrounding soil, causing environmental hazards. Finally, optimal construction of wooden poles requires that the pole be of one piece of uncut wood. This creates difficulties in transporting and erecting long poles, and it obviously limits the maximum pole length to the height of available trees from which the poles are made.
[0004] Metal pole construction has also long been known in the art. However, metal poles also have disadvantages. Although relatively strong and capable of being constructed in sections for ease of transportation and erection, metal poles have limited durability in that they are susceptible to rusting and other chemical deterioration. This is primarily because the moisture, chemicals, and abuse that a typical pole receives at its base abrade any resistant coatings and lead to rapid rusting and deterioration of the metal structure. Metal poles experience an acute problem in locations near roadways, marine environments, industrial plants, and aggressive soils. For example, the salt used to prevent ice accumulation on the roads inevitably comes into contact with the pole, accelerating its deterioration. Other chemicals commonly spilled onto roadways can easily be splashed onto metal poles, accelerating the deterioration. Marine environments are also very aggressive and substantially limit the life of a metal pole.
[0005] Further, metal poles implanted directly into the ground or with closely surrounding vegetation are subjected to constant moisture accumulation both underground and within the first few feet of the base. While separately preparing a foundation onto which a metal pole may be secured addresses the underground deterioration, this does not solve the problem of salt and chemical splash, abuse, or moisture at the ground line vicinity of the pole. Further, such foundations built on site have the disadvantage of being of variable quality depending on the skill of the designer, the worker, and the actual soil conditions. Likewise, the necessity for the design and construction of a separate foundation structure adds significantly to the time and expense required to erect such a pole. Attachment to such foundation presents a critical structural weak point. Bolts used for attachment of the pole to the base are themselves subject to environmental degradation. Additionally, the bolts and mechanical fasteners represent a weak point because of the imposed fatigue loads and thus the potential for failure in shear or tension. The bolts may also pull out under stress if they are not adequately embedded in the foundation.
[0006] The use of concrete poles has also been known in the prior art. The strength and durability of concrete poles is superior to other materials. Concrete poles also solve the problem of susceptibility to roadside conditions and moisture. However the greater weight of concrete poles precludes the use of very long poles. The weight causes problems both for transportation and for ease of installation. Methods have been devised for transporting concrete poles to the construction site in sections to address the weight problem. See, for example, U. S. Pat. No. 5,285,614 issued to Fouad, which is hereby incorporated by reference, and which describes a splicing mechanism for concrete poles to address the weight and length restrictions. However, the greater weight of concrete poles has significantly impeded their widespread use.
[0007] A new improvement in the art is the use of hybrid pole construction, where the advantages of two different types of poles can be utilized. However, a hybrid pole approach has engendered its own set of problems, not the least of which is the method for securing the upper steel or other lightweight material pole to the concrete base pole and the method for manufacturing the pole in a manner that permits the pole to support high loads while reducing pole weight. The most efficient way to manufacture a strong concrete pole is by centrifugally casting the pole. The centrifugal action compacts the concrete mix, making it denser and thus stronger. The hollow core results in a lighter weight pole as well as saving on the cost of raw materials. The smooth, circular cross-section of the concrete base pole makes it easier to embed into the ground, is the most efficient shape for wind-loading minimization, and is the easiest to centrifugally cast. A lightweight, hollow steel or other lightweight material upper pole, on the other hand, generally is stronger and provides greater torsion resistance if it has a multisided cross-section than if it has a circular cross-section. So far, there has been no pole design that takes advantage of all the most favorable characteristics of both types of materials in a hybrid construction.
SUMMARY OF THE INVENTION
[0008] It is an object of one preferred embodiment of this invention to provide a centrifugally-cast concrete pole base that is reinforced, prestressed, and post-tensioned and that has two different cross-sectional shapes in order to permit it to readily receive a multi-sided upper pole section. This permits the mounting of much taller metal, fiberglass, or other material poles on the concrete pole base in one or more pole sections so as to reach the desired height while utilizing all the best design characteristics of each individual material.
[0009] It is also an object of the present invention to provide for taller poles that are economical to manufacture and install, in terms of time, labor, and materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a perspective view of a preferred embodiment of a hybrid pole made in accordance with the present invention, where the pole in the foreground depicts the concrete base section only, and the other two poles are completely constructed;
[0011] [0011]FIG. 2 is an enlarged, broken away perspective view of the upper portion of the concrete base of FIG. 1 after removal from the manufacturing molds and before the reinforcing post-tensioning strands have been tensioned;
[0012] [0012]FIG. 3 is an enlarged, broken away perspective view of the top of the concrete pole section of FIG. 2 after a steel bearing plate has been inserted and post-tensioning of strands has been applied;
[0013] [0013]FIG. 4 is a broken away side view of the transition section of the assembled pole of FIG. 1, showing a hollow multi-sided steel pole telescopically mounted over the multi-sided upper portion of the concrete base, with the bottom part of the steel pole partially in section;
[0014] [0014]FIG. 5 is a perspective view of the hardware for the centrifugal casting of the concrete pole base of FIG. 1, including an insert for the transition from circular cross-section to a multisided cross-section, as well as the end anchor plates used for prestressing the steel mold;
[0015] [0015]FIG. 5A is an enlarged perspective view of the left end of the mold of FIG. 5, including steel reinforcing strands and cage and the anchor end plate;
[0016] [0016]FIG. 6 is a schematic, broken away side view, partially in section, of the top of the concrete base pole shown in FIG. 3, showing both pretensioned and post-tensioned strands;
[0017] [0017]FIG. 7 is a broken away perspective view, partially in section, of the uppermost part of an alternative embodiment of a concrete base pole made in accordance with the present invention, prior to post-tensioning, and including a channel or keyway used to non-rotationally secure the upper pole (not shown) to the concrete pole;
[0018] [0018]FIG. 8 is a broken away perspective view of the top of the concrete pole section of FIG. 7 after post-tensioning;
[0019] [0019]FIG. 9 is a broken-away, perspective side view of a multi-sided pole, having a circular cross-section bottom portion, mounted over the concrete base of FIG. 8;
[0020] [0020]FIG. 9A is a section taken along the line 9 A- 9 A of FIG. 9;
[0021] [0021]FIG. 10 is a view along the section 10 - 10 of FIG. 7;
[0022] [0022]FIG. 11 is a view along section 11 - 11 of FIG. 7;
[0023] [0023]FIG. 12 is a broken away side view of another embodiment of the present invention, wherein a multisided cross-section pole is being mounted onto a circular-cross-section concrete pole;
[0024] [0024]FIG. 13 is a perspective view of the left end of the mold, similar to the view of FIG. 5A, except that it is for yet another embodiment of the present invention, showing two sets of reinforcing strands and cages and an end plate;
[0025] [0025]FIG. 14 is a view, similar to that of FIG. 11, but for the double cage embodiment depicted in FIG. 13; and
[0026] [0026]FIG. 15 is an enlarged view of the detail area 15 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] [0027]FIGS. 1-4 show a first preferred embodiment of a hybrid construction pole 100 made up of a concrete base pole 102 , and a hollow, multi-sided metal pole section 104 mounted atop and overlapping part of the concrete base pole 102 . The concrete base pole 102 defines a first or lower end 106 and a second or upper end 108 . The concrete base pole 102 further defines an outer surface 110 and an inner surface 112 (See FIG. 2), since the concrete base pole 102 is hollow. The concrete base pole 102 has a continuous longitudinal taper along its outside surface 110 such that the outside diameter of the concrete base pole 102 is largest at the bottom end 106 , and smallest at the top end 108 .
[0028] The concrete base pole 102 is manufactured by centrifugally casting, using the hardware assembly 114 shown in FIGS. 5 and 5A. This hardware assembly includes two identical semicircular cross-section mold halves 116 which, when assembled, together will form a tapered shape having a circular cross-section, which is wider at the bottom end 118 and narrower at its top end 120 . The mold halves 116 (preferably made of steel) are made up in sections, each section having end flanges 117 , at both ends, and the abutting end flanges 117 are bolted together to form the full length of the mold. Each mold half 116 also has side flanges 119 , and the upper and lower mold halves 116 are bolted together at their side flanges 119 to form the tapered-cylinder mold. Inside the tapered cylindrical shape formed by the two identical semicircular mold halves 116 are two identical semicircular sleeve inserts 122 . These semicircular sleeve inserts 122 are substantially shorter than the two semicircular mold halves 116 (in this preferred embodiment the sleeve inserts 122 are approximately 4 feet long), and the sleeve inserts 122 are also of slightly smaller diameter than the mold halves 116 and have the same taper such that, when the sleeve inserts 122 are bolted into the mold halves 116 , they fit snugly inside the mold halves 116 . The sleeve inserts 122 are mounted at the top end 120 of the respective mold halves 116 such that the upper end of the sleeve inserts 122 is exactly even with the upper end 120 of the cylinder formed by the assembled mold halves 116 .
[0029] The sleeve inserts 122 have an outer surface 124 and an inner surface 126 . In this preferred embodiment, the inner surface 126 defines a multisided, polygonal shape which, in this case, is a dodecagon or twelve-sided figure. End plates 128 , 130 lie adjacent to the respective ends 118 , 120 of the mold. As shown in FIG. 5A, the reinforcing strands 139 extend through holes 140 in the end plate 130 . The same is true of the other end, which is not shown in this view. The reinforcing strands 139 that are tensioned are held in position by chucks 142 , and this tension holds the end plates 128 , 130 on the ends of the mold. As will be noted in FIG. 5A, an additional ring 144 is located outside the end plate 130 in order to provide sufficient space for all the chucks 142 . The additional ring 144 rests on the lower tier of chucks 142 . It should also be noted that not all the reinforcing strands 139 are tensioned by the chucks 142 . These strands may be post-tensioned, as will be explained below, or they may not be tensioned at all.
[0030] The casting assembly 114 is, then, essentially a tapered, cylindrical shape, a multisided insert at the narrow end, and end anchor plates at both ends, which are secured to the cylindrical shape with reinforcing strands 139 extending along the interior of the mold and projecting out at the ends.
[0031] In the manufacture of the centrifugally-cast concrete pole 102 , the cage of reinforcing spiral wires and prestressing strands is prepared as is shown in FIGS. 5A and 7 . To accomplish this, a coil of reinforcing wire 137 is placed in the lower mold half 116 . The end plates 128 , 130 are temporarily clamped to their respective end flanges 117 by means of large C-clamps (not shown). Reinforcing strands 139 are then fed through the end plate 130 , through the inside of the coil of reinforcing wire 137 which is lying on the mold half 116 , and through the other end plate 128 , such that the reinforcing strands 139 are extending out past the bottom 118 of the mold half 116 , and they are also extending out past the top 120 of the mold half 116 . The coil of reinforcing wire 137 is tied with wire ties to the reinforcing strands 139 at intervals along the length of the pole and is stretched out, so that it surrounds the strands 139 from the top 120 to the bottom 118 of the mold half 116 , forming a spiral cage around the strands 139 , as is known in the art.
[0032] The reinforcing strands 139 form a cylindrically-shaped bundle, with each strand 139 extending through its respective opposed holes in the end plates 128 , 130 . As is best shown in FIGS. 6 and 11, some of the strands 139 have a sheath 132 surrounding the strand starting at the end proximate to the upper end 120 of the mold half 116 and extending for a desired length, such as four or five feet, fifteen feet, or whatever length the designer thinks is desirable for post-tensioning. The sheaths 132 are located at and project out of the narrow end 120 of the mold half 116 . The sheaths 132 are preferably made of plastic tubing or other similar material and have an inside diameter which will freely allow the axial movement of the reinforcing strands inside the sheaths 132 . The purpose of these sheaths 132 will be explained later. While these drawings show the sheaths 132 on every other strand, the designer may insert the number and arrangement of sheaths as is desired for the proper post-tensioning. However, the sheaths 132 should be placed symmetrically so that the post-tensioning will be uniformly distributed at the end of the pole.
[0033] The reinforcing wire 137 (which is now no longer in a coil but is rather in a spiral) is secured to the reinforcing strands at several points along the length of the mold. The end result is a cage, formed of reinforcing strands 139 running lengthwise and inside of a spiral of reinforcing wire 137 , with the reinforcing strands 139 and the reinforcing wire 137 being secured to each other (preferably with wire ties) along the length and circumference of the cage.
[0034] Once the bottom mold half 116 , the end plates 128 , 130 , and the cage made up of spiral wire 137 and straight strands 139 , some with casing 132 , is assembled, some of the strands 139 are pre-tensioned (preferably the strands that are not encased by sheaths 132 ) by fastening one end relative to the mold with a chuck 142 , pulling the other end with a certain desired amount of tension, and then fastening the other end relative to the mold using another chuck 142 , as is well known in the art. Once the chucks 142 are in place, the tensioning holds the end plates 128 , 130 onto the ends of the mold, and the C-clamps (not shown) are removed. Concrete is then placed along the entire length of the mold half 116 , through the wire cage, such that the concrete mix fills the trough formed by the mold half 116 and the end plates 128 , 130 . Additional concrete is placed toward the narrower end 120 of said trough such that the concrete level actually crowns above what would be a full-trough level. The trough is now closed by assembling the other half of the sleeve insert 122 to the upper mold half 116 , installing the upper mold half 116 over the lower mold half 116 , and bolting the side flanges 119 together.
[0035] At this point, there is an entire cylinder assembly consisting of mold halves 116 with sleeve inserts 122 , and inside these is a reinforcing strand cage made up of a cylindrical bundle of strands 139 , in which some strands have a plastic sheath 132 at the narrower end 120 of the assembly, and a spiral wound reinforcing wire which has been secured to the axially aligned reinforcing strands. Concrete has been placed into the horizontal cylinder assembly so it is approximately half full as the cylinder lies on its side (with its longitudinal axis perpendicular to the force of gravity). End plates 128 , 130 have been installed at the first and second ends 118 , 120 of the cylinder assembly, and the desired strands 139 have been prestressed.
[0036] This entire assembly is then placed on a spinner that rotates the assembly around its longitudinal axis until the concrete material has been evenly distributed by the centrifugal forces along the walls of the assembly, forming an interior void, and the concrete mix has hardened due to consolidation. The centrifugal action will also cause a slight migration of the concrete along the longitudinal axis of the assembly, from the narrower end to the wider end of the tapered cylinder. It is in order to counter the effects of this migration that concrete was placed to a higher level (until it actually crowned over what would be the flush level) in the narrower end of the trough.
[0037] The spinning of the assembly around its longitudinal axis accomplishes the centrifugal casting, wherein centrifugal forces acting on the concrete sling the concrete against the walls of the assembly and at the same time compact the concrete, resulting in a denser, stronger concrete than one simply statically poured but not subjected to centrifugal action. The entire assembly is then removed from the spinner and is allowed to remain undisturbed for a desired curing period. Once the concrete has cured sufficiently, the chucks 142 securing the pre-tensioned strands to the end plates 128 , 130 are then removed; this releases the steel mold and transfers the tension in the pre-tensioned strands to apply a compression force along the entire length of the concrete pole 102 , thus applying the prestress forces to the concrete to increase its load carrying capacity and reduce its susceptibility to cracking.
[0038] Once the end plates 128 , 130 have been removed, the mold halves 116 and the sleeve inserts 122 are also removed, and the ends of all pre-tensioned strands (those which did not have a sheath) extending out at the narrow top end 120 of the assembly are cut off. All ends of all the strands extending out the bottom end 118 are cut off. A ring-shaped bearing plate 134 (see FIGS. 3, 6, and 8 ) is then installed at the upper end of the pole 102 , with all ends of the post-tensioning strands 139 (those which have the sheath) sticking out through holes in the circular bolt pattern of the plate 134 . The majority of the length of these post-tensioning strands is embedded, and thus secured, in the cured concrete below the sheaths 132 . The end of each post-tensioning strand proximate to the narrow end 108 has been encased by the sheath 132 so it is free to move axially, as the sheath 132 has protected and separated the strand from bonding to the concrete. Once the bearing plate 134 is in place, the ends of the encased strands 139 extending out are tensioned with the desired amount of force and secured against the plate 134 , using securing devices 141 known in the industry. Thus, the plate 134 , pushing against the strands in order to keep said strands in tension, will exert a compression force on the concrete, at the end of the pole that fits inside the upper pole section and that bears the most force from the upper attachment pole section 104 . This is also the area of the concrete pole which has the multisided cross-section. This post-tensioning of the concrete at the upper end makes the concrete stronger in this area and capable of resisting the high internal forces that develop when an upper pole 104 is mounted on the concrete base pole 102 and is subjected to external loads.
[0039] As may be understood by anyone skilled in the art, the specific configuration of the reinforcing cage, the number, relationship, and ratio of sheathed-to-unsheathed strands, and the pre-tensioning and post-tensioning forces applied, if any, may vary, depending on the specific requirements and design calculations of the application. While the bearing plate 134 is shown here as a single plate, it could also be made in various configurations, such as providing a smaller, individual plate for each strand to be post-tensioned, for example.
[0040] [0040]FIG. 4 shows a broken-away portion of a pole 100 at the bottom of the upper hollow pole portion 104 . It can be seen in this view that the cross-section of the concrete base pole 102 in its upper portion has a multi-sided polygonal shape and corresponds with the cross-section of the hollow upper pole 104 , so that the upper pole 104 readily telescopes over the lower pole 102 . The upper portion of the base pole 102 and the lower portion of the upper pole 104 are tapered so that, as the upper pole 104 is lowered onto the base pole 102 , it reaches a position in which there is a tight fit between the upper pole 104 and the base pole 102 . At that point the upper pole 104 stops, leaving a strip 102 A of the multi-sided portion of the concrete pole that is not encased by the upper pole 104 . The mating polygonal shapes of the upper pole 104 and base pole 102 prevent the pole portions from rotating relative to each other.
[0041] [0041]FIG. 15 shows an enlarged, detailed view of the area 15 encircled in FIG. 4, in which the upper metal pole section 104 is shown partially in section. The wall of the metal pole 104 is shown to include an outer surface 160 , and an inner surface 162 . The end portion 164 of the metal pole 104 , which slides over the concrete base 102 , includes a chamfer on its inner surface 162 , having a rounded contour. The inner surface 162 of the bottom portion 164 of the metal pole 104 preferably is curved in a substantially parabolic shape, so that it is tangent to the substantially vertical concrete base wall in the area where it contacts the concrete base and then curves away from the concrete base at an increasing angle. In this case, the angle a at the bottom end of the inner surface 162 is approximately 45° from a line perpendicular to the wall of the concrete base, which means that it is also approximately 45° from the substantially vertical wall of the concrete base 102 A, while the angle β where the curved surface 162 approaches the wall of the concrete base 102 A is substantially less than 45°. This shape may be achieved by making a double chamfer or by other known means. This rounded chamfer provides a smooth side to slide and rest against the concrete base 102 A, so there are no sharp edges to cut into the concrete base 102 A, which could weaken the concrete base 102 A. By protecting the concrete base 102 A against being cut by the upper pole 104 , the concrete base is not weakened, and therefore can support the applied design loads. This curved shape also shifts the inner surface of the bottommost edge 166 of the metal pole outwardly as much as possible, making it easy to slip the metal upper pole portion 104 over the concrete base 102 A.
[0042] [0042]FIGS. 7-9A show an alternate embodiment of the present invention. In this embodiment, the transition from circular cross-section base pole to multisided cross-section upper pole is achieved by the upper pole 104 ′. The tapered concrete base pole 102 ′ has a circular cross-section throughout its full length. At the top of the concrete pole 102 ′, and extending axially downwardly along one side of the outer surface 110 of the concrete pole 102 ′, is a groove or keyway 136 . The upper pole 104 ′ has a projection 136 A on its inner surface that serves as a key, which is received in the keyway 136 to prevent the upper pole from rotating relative to the lower pole, as shown in FIG. 9A. If the upper pole 104 ′ is made of metal, the key may be a metal bar that is welded in place. If the upper pole 104 ′ is made of fiberglass, the projection may just be a molded part of the pole. The key is of such dimensions that it will slide into and fit snugly into the keyway 136 . The upper pole 104 ′ is first aligned with the concrete base pole 102 ′ such that the key 136 A attached to the inner surface of the upper pole 104 ′ is lined up with the corresponding keyway 136 in the concrete pole 102 ′. The upper pole 104 ′ is lowered onto the base pole 102 ′ until it reaches a position in which there is a tight fit between the upper pole 104 ′ and the base pole 102 ′. The key 136 A and keyway 136 , acting cooperatively, provide a positive alignment of the upper pole 104 ′ and the base concrete pole 102 ′, and further will not allow for rotation of the upper pole 104 ′ relative to the concrete pole 102 ′ once the two poles have been mated.
[0043] [0043]FIG. 9 shows a broken-away portion of the upper pole 104 ′, which fits over the base pole 102 ′. The upper pole 104 ′ has a hollow multisided polygonal cross-section in its upper portion and a transition to a hollow circular cross-section 104 A in its lower portion, which conforms to the shape of the concrete base 102 ′.
[0044] [0044]FIG. 12 shows another alternative embodiment. In this embodiment, the lower pole 102 ′ has a circular cross-section from top to bottom as in FIGS. 7-9A, and the upper pole 104 has a multi-sided polygonal (i.e. 12-sided) cross-section from top to bottom as in the first embodiment. The upper pole 104 in this embodiment must be made of a deformable material, such as metal. In this case, the hollow upper pole 104 is lowered onto the base pole 102 ′ until it reaches a position in which there is a tight fit between the upper pole 104 and the base pole 102 ′. The upper pole 104 is then forced further down over the concrete base pole 102 ′, resulting in a friction fit and a distortion of the multisided cross-section of the upper pole 104 in the area where it is contacting the concrete pole 102 ′, such that the multisided cross-section of the upper pole 104 ′ becomes rounded. Essentially, the upper pole 104 is being deformed and re-shaped by the lower concrete pole 102 ′ due to jacking of the two parts together and, as it does so, the cross-sectional profile of the lower portion of the upper pole 104 ′ adopts the more circular cross-sectional profile of the concrete pole 102 ′, so that it approaches the shape shown in FIG. 9. This friction fit between the lower concrete pole 102 ′ and the upper pole 104 will not allow for rotation of the upper pole 104 relative to the concrete pole 102 ′ once the two poles have been mated.
[0045] [0045]FIGS. 13 and 14 show yet another embodiment for a concrete base 202 of the present invention. In this embodiment, the concrete base 202 is made stronger in order to handle higher structural loadings. This is accomplished by a combination of additional reinforcing steel embedded in the centrifugally cast concrete base 202 , and a thicker cast concrete wall. In order to physically accommodate the additional reinforcing steel, a second cage 204 is added inside the first cage 206 .
[0046] In the manufacture of the centrifugally-cast concrete pole 202 , the inner cage 204 of reinforcing wires and prestressing strands is prepared very much in the same manner as has already been described with reference to the first embodiment 102 , as is shown in FIGS. 5A and 7. Namely, a coil of reinforcing wire 137 is placed in the lower mold half 116 . However, in addition, a second, larger diameter coil of reinforcing wire 237 is also placed in the same lower mold half 116 , surrounding the first coil 137 . The purpose of this second coil 237 will be explained shortly. The end plates 128 , 130 are temporarily clamped to their respective end flanges 117 by means of large C-clamps (not shown). Two sets of elongated reinforcing strands 139 , extending in the lengthwise direction of the pole, are then fed through the end plate 130 , through the inside of their respective coils of reinforcing wire 137 , 237 , and through the other end cap 128 , as was explained earlier. Each coil of reinforcing wire 137 , 237 is stretched out and tied to its respective elongated reinforcing strands 139 , forming inner and outer cages 204 , 206 . As was described earlier, and as best shown in FIGS. 6 and 11, some of the strands 139 have a sheath 132 surrounding the strand starting at the end proximate to the upper end 120 of the mold half 116 and extending for a desired length, for post-tensioning. The sheaths 132 project out the narrow end 120 of the mold half 116 . While these drawings show the sheaths 132 on every other strand, the designer may insert the number and arrangement of sheaths as is desired for the proper post-tensioning. However, the sheaths 132 should be placed symmetrically so that the post-tensioning will be uniformly distributed at the end of the pole. Once the bottom mold half 116 , the end plates 128 , 130 , and the cages 204 , 206 made up of spiral wires 137 , 237 , and their respective straight strands 139 are assembled, some of the strands 139 are pre-tensioned as described earlier. At this point in the manufacturing process, the inner cage 204 lies suspended inside the outer cage 206 , as shown in FIGS. 13 and 14.
[0047] Once the chucks 142 are in place, the tensioning holds the end plates 128 , 130 onto the ends of the mold, and the C-clamps (not shown) are removed. Concrete mix is then placed along the entire length of the mold half 116 , through the wire cages 204 , 206 , such that the concrete mix fills the trough formed by the mold half 116 and the end plates 128 , 130 . Additional concrete mix is placed toward the narrower end 120 of said trough such that the concrete level actually crowns above what would be a full-trough level. The trough is now closed by assembling the other half of the sleeve insert 122 to the upper mold half 116 , installing the upper mold half 116 over the lower mold half 116 , and bolting the side flanges 119 together.
[0048] This entire assembly is then placed in a spinner that rotates the assembly around its longitudinal axis until the concrete has been distributed by the centrifugal forces along the walls as described earlier. Immediately after an initial spin cycle, which is usually a few minutes, the wall thickness is measured. If the measured cast concrete wall thickness is short of the targeted wall thickness, then additional concrete is added to the assembly via an opening 208 (See FIG. 5) in the second, narrower end 120 of the cylinder assembly 114 and is spread out as evenly as possible in the first section of the mold 116 . The entire assembly is then spun a second time for a few minutes at full rpm, and then it is spun a third time for an additional few minutes at {fraction (2/3)} of full rpm. Upon completion of this third spinning cycle, the wall thickness is checked once again to ensure that the actual wall thickness is within the desired tolerance. As an example, the first spin may take ten minutes, and the second and third spins may each take five minutes.
[0049] As described earlier, the entire assembly is then removed from the spinner and is allowed to remain undisturbed. Thereafter, the pre-tensioned strands may be released from their chucks and cut off, and the strands within sleeves may be post-tensioned as described earlier. The procedure for using this heavier-wall-thickness cast concrete base 202 is similar to that described for the original cast concrete base 102 of the first embodiment, including the procedure for post-tensioning, if required, with the only added complexity being that there are now more strands. This heavier-walled concrete base 202 , with its more extensive metal reinforcing, results in a structurally stronger concrete base.
[0050] While a 12-sided polygonal shape has been shown here as a preferred embodiment, other similar shapes could be used, such as a six-sided (hexagon), eight-sided (octagon), ten-sided, twelve-sided, 18-sided, or other polygons. Also, the casting methods and reinforcement arrangements shown here may be used for other cross-sectional shapes of poles as well, such as for a base that has a circular cross-section throughout its height. It will be obvious to those skilled in the art that many other modifications may be made to the embodiments described above without departing from the scope of the present invention.
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This invention relates to pole structures used for supporting transmission and distribution lines, lighting and communications systems, highway signs, traffic signals, and the like. More specifically, this invention relates to a new and useful design of a multi-sectioned pole, with at least one telescoping upper section made of metal or another similar lightweight material and a base section composed of concrete or similar material that can be directly embedded into the ground without the need for baseplate-type foundations, or other preparatory work.
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BACKGROUND
In the field of electronics, conductive and/or insulating features are formed on a substrate through photo-lithographic techniques. Essentially, an optical image that represents one or more patterns to be formed onto the substrate is directed onto a layer of photo resist that has been coated onto the substrate. A projection camera projects the optical image onto the photo resist layer from light that has been patterned in accordance with a mask.
In general, a primary measure of an electronic device's sophistication is its smallest feature size. The smallest feature size of an electronic device is largely determined by the sophistication of the lithography techniques and/or equipment employed in the device's manufacture. In particular, the shorter the wavelength of the light that is processed by the photo-lithographic equipment's projection camera optics, the smaller the smallest achievable feature size becomes.
Thus, in general, the smaller the wavelength of the light that is processed by the projection camera's optics, the more sophisticated the projection camera is deemed to be. Presently, considerable work is being done in the development of photo-lithographic equipment that processes light in the Extreme Ultra Violet (EUV) spectra (a range approximately from 10 to 14 nm). Part of the challenge in designing EUV photo-lithographic equipment is designing that portion of the equipment that “pre-conditions” the EUV light prior to illuminating the mask and the entrance pupil of the projection camera.
FIG. 1 shows a simplistic depiction of the cross section of the “shape” of light as it is reflected from the mask at a “ring field” projection camera. According to the depiction of FIG. 1 , the light travels substantially along the z axis through arc 101 . According to one EUV approach, the arc 101 of the EUV light has a radius R between 116 mm and 124 mm over an angle θ of approximately 30°. Moreover, at least for EUV light, the illumination of the light over the arc 101 is supposed to be highly uniform (e,g., on the order of only 1% variation across the arc 101 ).
A condenser is used to form light into the appropriate shape and uniformity at the projection camera entry pupil. The condenser can usually be viewed as containing two components: 1) a collector; and, 2) an illumination system. The collector is designed to collect photons from a light source. The illumination system crafts the light from the collector into the appropriate shape for illuminating the mask (arc field) and illuminating the entrance pupil of the projection camera.
An exemplary condenser originally described in U.S. Pat. No. 6,195,201 B1 (hereinafter, “Koch et. al.”) is shown in FIG. 2 . The collector 201 includes a light source 203 and a collection mirror 204 . The collection mirror 204 directs the light it collects into the illumination system 202 . The illumination system 202 includes a pair of faceted mirrors 205 , 206 . The faceted mirrors 205 , 206 effectively break down the light from the collector 201 into a plurality of beams that are recombined by relaying mirrors 207 , 208 so as to form light of the proper shape and uniformity at the mask plane 209 of the projection camera.
A problem with EUV condensers is their expense. The cost of an EUV condenser is largely a function of the amount of photon energy that its light source emits. That is, the more photon energy that a light source emits, the more expensive the condenser.
DRAWINGS
The present invention is illustrated by way of example, and not limitation, in the figures of the accompanying drawings in which like references indicate similar elements and in which:
FIG. 1 shows EUV light shaped to enter a mask plane of a projection camera;
FIG. 2 (prior art) shows a condenser that processes light for entry to a projection camera;
FIG. 3 shows a first embodiment of a collector for an LPP EUV source;
FIG. 4 shows a second embodiment of a collector for an LPP EUV source;
FIG. 5 shows a third embodiment of a collector for an LPP EUV source;
FIG. 6 shows a fourth embodiment of a collector for an LPP EUV source;
FIG. 7 shows a first embodiment of a collector for a discharge source;
FIGS. 8 a , 8 b show a second embodiment of a collector for a discharge source;
FIG. 9 shows a third embodiment of a collector for a discharge source; and,
FIG. 10 shows that a faceted collector mirror can eliminate a mirror in an illumination system;
FIG. 11 shows a reflective mask lithography system.
DETAILED DESCRIPTION
In order to reduce the cost of an EUV condenser, more efficient collectors should be designed. By designing collectors that are capable of directing more photon energy from the light source into the illumination system, the amount of light energy needed from the source can be reduced; which, in turn, should lower the cost of the condenser as a whole because less expensive EUV sources can be used.
Two types of EUV light sources that are presently in common use are Laser Produced Plasma (LPP) sources and discharge sources. FIGS. 3 though 6 show designs for efficient EUV collectors that include an LPP source; and, FIGS. 7 through 9 show designs for efficient EUV collectors that include a discharge source. A discussion of these designs immediately follows.
Collector with LPP EUV Source
FIGS. 3 through 6 show designs for efficient EUV collectors that include an LPP source. According to the designs of FIGS. 3 through 6 , efficiency is improved over prior art LPP sourced EUV collectors through then collection of light over, approximately, a sphere that surrounds the LPP source. Prior art LPP sourced EUV collectors (such as the source 203 of Koch et al. shown in FIG. 2 ) are believed to only collect light over, approximately, no more than a hemisphere resulting in less collected photon energy than the designs observed in FIGS. 3 through 6 .
Another feature of the collector designs of FIGS. 3 through 6 that prior art LPP sourced EUV collectors are not known to exhibit is that they each collect light from the source that travels from the source in opposite directions. Both the spherical nature of the collection range and the collection of light traveling from the source in opposite directions is apparent from an analysis of each of the drawings observed in FIGS. 3 through 6 .
Specifically, note that each of the collector designs of FIGS. 3 and 4 have two mirror stages whose reflecting surfaces face one another. That is, for example the collector design of FIG. 3 has a first mirror 301 whose reflective surface 303 faces the reflective surface 304 of a second mirror 302 . Similarly, the collector design of FIG. 4 has a first mirror 401 whose reflective surface 403 faces the reflective surface 404 of a second mirror 402 . Each of the mirror pairs 301 , 302 and 401 , 402 represent the first highly reflective surface that light from the LPP EUV source 305 , 405 impinges upon.
Referring to FIG. 3 , light from the source 305 is drawn radiating in four different arcs 306 , 307 , 308 , 309 . Note that, in demonstrating the approximately spherical collection range of the collector, arcs 306 and 308 correspond to oppositely traveling light from the LPP source 305 and arcs 307 and 309 correspond to oppositely traveling light from the LPP source 305 . Also, again demonstrating the spherical collection range of the collector, the pair of applicable coordinate axis shown in FIG. 3 indicate that the design is symmetrical about the z axis.
According to the design of FIG. 3 , light propagates from the source 305 and reflects off of mirrors 301 and 302 . Light that reflects off of mirror 302 reflects into grazing incidence mirror 310 . Light that reflects off of mirror 301 reflects back onto and off of mirror 302 and then into grazing incidence mirror 310 . From grazing mirror 310 the collected light is directed toward the illumination system of the condenser.
The near grazing incidence angle of light (e.g., less than or equal to as 15° when measured against the reflective surface of the mirror 310 ) as it passes into grazing mirror 310 permits a high collection angle for each of mirrors 301 and 302 (e.g., in a range of 75° to 90°). The grazing incidence mirror 310 also conditions the illumination beam for the downstream mirrors of the illumination system. Also, related embodiments may only collect over approximately a hemisphere rather than a sphere (e.g., just mirror 302 is employed and not mirror 301 ).
In an embodiment, in order to ensure efficient reflectivity off of mirrors 301 , 302 , the angle of incidence at each of mirrors 301 , 302 for non reflected light emanating from the source 305 is “normal” or “near normal” (e.g., less than or equal to 15° when measured against a ray that is normal to the reflecting surface of the mirror) across most, if not all, of the surface area of mirrors 301 , 302 ). Graded reflective coatings on the mirror surfaces may permit more severe angles of incidence.
In an embodiment, the reflecting surface 303 of mirror 301 is approximately elliptical and the reflecting surface 304 of mirror 302 is approximately spherical. Mirror 302 may also be larger than mirror 301 . In other or same embodiments, the collection angle for both mirrors 301 , 302 ranges from 25° to 90°. Each of mirrors 301 and 302 may be annular to make room for the source 305 and any other fixtures. In the alternative, the surfaces may be biconic as used in lens optimization software design tools with the purpose of elongating the source image.
The optical design of FIG. 4 is similar to that of FIG. 3 , except that a third mirror 406 is inserted between mirrors 401 , 402 so as to eliminate the grazing incidence mirror 310 . That is, light propagates from the source 405 and reflects off of mirrors 401 and 402 . Light that reflects off of mirror 402 reflects off of mirror 406 . Light that reflects off of mirror 401 reflects back onto and off of mirror 402 and then off of mirror 406 . From mirror 406 the collected light is directed toward the illumination system of the condenser.
Again, in an embodiment, in order to ensure efficient reflectivity off of mirrors 401 , 402 , the angle of incidence at each of mirrors 401 , 402 for non reflected light emanating from the source 405 is “normal” or “near normal” (e.g., less than or equal to 15° when measured against a ray that is normal to the reflecting surface of the mirror) across most, if not all, of the surface area of mirrors 401 , 402 . Also, again, graded reflective coatings on the mirror surfaces may permit more severe angles of incidence.
In an embodiment, the reflecting surface of mirror 401 is approximately elliptical and the reflecting surface of mirror 402 is approximately spherical. Mirror 402 may also be larger than mirror 401 . In other or same embodiments, the collection angle for both mirrors 401 , 402 ranges from 45° to 85°. Each of mirrors 401 and 402 may be annular to make room for the source 405 and any other fixtures.
FIG. 5 shows another collector embodiment for an LPP EUV source. Like the designs of FIGS. 3 and 4 , the collector design of FIG. 5 is capable of an approximately spherical collection range. Here, light traveling from the source will impinge upon each of reflecting elements (e.g., mirrors) 550 , 551 , 552 and 553 . Reflecting element 554 receives light from each of reflecting elements 552 and 553 . Reflecting element 552 receives light from reflecting element 551 and reflecting element 553 receives light from reflecting element 550 . Reflecting element 554 forms output light 556 . Reflecting elements 550 , 551 , 552 and 553 can be elliptical or nearly elliptical, spherical or nearly spherical, conical or nearly conical or biconical or nearly biconical.
FIG. 6 shows another collector embodiment for an LPP EUV source. Again, the collector design of FIG. 6 can collect light over an approximately spherical (rather than hemispherical) collection range. The light paths associated with the collector of FIG. 6 are most easily understood in reference to axis 612 and 613 . Specifically, axis 612 and 613 can together be viewed as: 1) breaking down a first reflecting element into regions 602 , 604 and 606 ; and 2) breaking down a second reflecting element into regions 603 , 605 , 607 .
Light that impinges upon regions 602 and 603 directly from source 601 form reflected beams 613 and 614 , respectively. These beams focus to focus point 610 . Light that impinges upon regions 604 and 605 directly from source 601 form reflected beams that pass through focus point 611 and continue forward to form reflected beams 615 and 616 . Reflected beam 615 impinges upon reflecting surface 608 and converges after its reflection at focal point 610 . Similarly, reflected beam 616 impinges upon reflecting surface 609 and converges after its reflection at focal point 610 .
Note also a degree of stability against movement of the source 601 is likely to result from the perspective of image 610 because a number of light beams that experience an odd number of reflections in reaching source 610 will be compensated for by a number of light beams that experience an even number of reflections in reaching source 610 .
Light that impinges upon region 606 directly from the source 601 reflects back to regions 603 and 605 . The light that reflects to region 603 behaves as described above for region 603 , and, the light that reflects to region 605 behaves as described above for region 605 . Similarly, light that impinges upon region 607 directly from the source 601 reflects back to regions 602 and 604 . The light that reflects to region 602 behaves as described above for region 602 , and, the light that reflects to region 604 behaves as described above for region 604 . Note that the diagram in FIG. 6 is a cross section of the overall collector. Here, it is expected that the embodiments may be constructed where this cross section is preserved over a plurality if not all angles of view.
According to at least one implementation, regions 602 and 603 are part of the same annular reflective component. In combination, regions 604 and 605 may also be formed from a same, second annular reflective component that is coupled next to the annular component that forms regions 602 and 603 . Alternatively, regions 604 and 605 may be formed with different reflective components with respect to one another; and/or, may be formed from the same reflective component that forms regions 602 and 603 (either as a whole or respectively). Regions 606 and 607 may be part of the same reflective component that regions 604 and 605 are formed with (either as a whole or respectively); or, may be formed with different components from those that form regions 604 and 605 . Regions 606 and 607 may also be formed from the same annular reflective component or may be separate with respect to one another.
Collector with Discharge EUV Source
Known prior art collectors that collect EUV energy from a discharge source collect the EUV light at high “grazing” angles of incidence. Grazing angles of incidence can have poor collection efficiency given that they only collect at a collection angle no more than 45°. As such, in order to enhance the efficiency of a discharge source collector, a “normal” or “near-normal” angle of incidence is used at the collector's reflective surfaces. FIGS. 7 through 9 show designs for efficient EUV collectors that include a discharge source. A discussion of each immediately follows.
The design of FIG. 7 is similar to that of FIG. 4 except that mirror 401 is removed. Here, discharge EUV sources generally emit more light energy than LPP sources. As such, the collection optics need not approximately surround the source as was discussed with respect to the collector designs of FIGS. 3 through 6 . Moreover, discharge sources tend to be larger in size than LPP sources; and, as a consequence, surrounding the source with collection optics may not be practicable.
According to the design of FIG. 7 , light from a discharge source 701 is reflected at near normal incidence (e.g. at or less than 15° when measured against a ray that is normal to the reflecting surface of mirror 702 ) off of mirror 702 onto mirror 703 ; which, in turn, reflects the light toward the illumination system of the condenser. In an embodiment, the collection angle of mirror 702 ranges from 45° to 85°. Also, as depicted by the coordinate axis, the collector is symmetrical about the z axis. Mirrors 702 and 703 may be annular to make room for the source 701 and any other fixtures.
FIG. 8 a shows a top view and FIG. 8 b shows a side view of another collector design for a discharge source. According to the design of FIGS. 8 a and 8 b , light from discharge source 801 is reflected at near normal incidence (e.g. at or less than 150 when measured against a ray that is normal to the reflecting surface of mirror 802 ) off of a first mirror 802 toward a second mirror 803 from which it is reflected at near normal incidence toward the illumination system. Referring to the top view depiction in FIG. 8 a , the first mirror 802 is tilted so as to direct its reflected light past the source 801 on its way toward mirror 803 without being obscured by the source 801 (i.e., the source is not in its way).
Here, because the side view of FIG. 8 b shows a continuous collection angle from about +75° to −75°, reflected light from mirror 802 needs to be directed off the side of the source 801 (as shown in FIG. 8 a ) in order to be directed past the source 801 . Moreover, because of the continuous collection angles through their middle, mirrors 802 and 803 may be non annular (i.e., there does not exist a need to make room for the source 801 or other fixtures through the middle of the mirrors 802 , 803 ).
The approach of FIGS. 8 a and 8 b show the first mirror 802 being smaller than the second mirror 803 . FIG. 9 shows a top view of an alternative design to that of FIGS. 8 a and 8 b where the first mirror 902 is larger than the second mirror 903 . Here, FIG. 9 can be directly compared against FIG. 8 a . Again, mirrors 902 , 903 have a continuous collection angle through their middle. As such, reflected light from mirror 902 needs to be directed off the side of the source 901 in order to be directed past the source 901 . Moreover, because of their continuous collection angles, mirrors 902 , 903 may be non annular.
In both the designs of FIGS. 8 a,b and 9 , light is directed past the source 801 , 901 by the first mirror 802 , 902 to allow for a wider total collection angle at the first mirror 802 , 702 .
Faceted Collector Mirrors
Koch et al. (discussed in the background) reveals that a faceted mirror can be used in the collector. The reflective surface of a faceted mirror is made of smaller discrete reflective surfaces that are positioned to break an incident beam into a plurality of smaller beams. FIG. 10 shows a faceted mirror having arc shaped discrete surfaces. In alternate approaches the discrete surfaces may be square, hexagonal or some other tilted surface.
Presently, it has been realized that the use of faceted mirrors in the collector can be used to reduce the number of optical components in the illumination system; and, moreover, the use of faceted mirrors can be used to compensate for variations in the source's illumination properties. FIG. 10 demonstrates the former and further discussion of FIG. 3 demonstrates the later.
FIG. 10 can be compared directly with FIG. 2 . Recall that FIG. 2 shows a condenser system taught by Koch. Although Koch discloses that the collector mirror 204 can be faceted, Koch does not teach that the use of the faceted collector mirror can result in the elimination of optical components within the illumination system. Comparing FIGS. 2 and 10 , note that faceted mirror 206 has effectively been eliminated from the illumination system in the condenser design of FIG. 10 . That is, condenser 1001 is similar to the condenser design shown in FIG. 4 a of the present application and the illumination system 1002 includes a faceted mirror 1005 and relaying mirrors 1007 , 1008 .
Recall that the original purpose of the illumination system is to effectively break down the light from the collector into a plurality of beams in order to form light of the proper shape and uniformity at the mask plane and also to properly fill the entrance pupil of the projection camera. With one or more of the mirrors 1010 , 1011 , 1012 in the collector 1001 being faceted, the illumination system 1002 receives light from the collector 1001 already broken down into a plurality of beams.
As such, one of the faceted mirrors in the illumination system (notably mirror 206 ) can be eliminated. The elimination of the reflecting mirror improves the collection efficiency of the condenser as a whole because the light will experience one less reflection and reflections are less than 100% efficient (i.e., a reflection involves some light loss, so with each reflection along the optical channel the amount of light that is lost through the channel increases).
Referring back to FIG. 3 , if mirrors 301 and/or 302 are faceted, they assist in the breaking down the light from the source 305 into a plurality of beams. However, because light that impinges upon mirror 301 directly from the source will experience one more reflection than the light that impinges upon mirror 302 directly from the source, there can be an opposite image magnification imposed as between the light that reflects off of mirror 302 directly from the source 305 and the light that reflects off of mirror 302 from mirror 301 .
As a consequence it is possible to stabilize (in terms of position) the source image 311 created by the collector. That is, because of the opposite magnification (e.g., “positive” and “negative”) from the different beams of light, should the source 305 “move”, the beams that are magnified positively will move in one direction while beams that are magnified negatively will move in the opposite direction. As such, the position of the source image 311 should remain somewhat fixed as a consequence of the built-in compensation. Similar compensation techniques can be achieved with discharge source collectors having one or more faceted mirrors.
For any of the mirrors described above, the materials that could be used to form their respective reflective surfaces may include: Gold, Aluminum, Platinum, Chromium, Nickel, Molybdenum, Silicon, Beryllium, Palladium, Tungsten, Ruthenium, Rhodium, Lithium.
A reflective mask lithography system 1100 is shown in FIG. 11 . According to the design of the reflective mask lithography system of FIG. 11 , a source and collection optics (such as any of those described above) 1101 directs light to a reflective mask 1102 that is held in place by some type of mechanical fixture 1105 . Reflected light from the mask is directed into a projection camera 1103 that projects the reflected light onto a wafer 1104 that is being processed. The wafer 1104 is typically coated with some kind of photo resist. Depending on the type of photo resist (i.e., positive or negative), the light that is projected onto the photo resist will either be hardened or weakened so that specific features may be formed on the wafer.
In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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A collector that includes a laser produced plasma (LPP) extreme ultra violet (EUV) light source and a first optical path from the source to a mirror. The mirror is the first mirror that light emitted from the source and traveling along the first optical path impinges upon. The collector also includes a second optical path from the source to another mirror. The other mirror is the first mirror that light emitted from the source and raveling along the second path impinges upon. The mirror and the other mirror are oriented relative to the source such that light from the source traveling along the first optical path travels in a direction opposite to light traveling from the source along the second optical path. A collector having a discharge extreme ultra violet (EUV) light source.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention—involving bookbinding methods and image-forming systems for binding the spine endface of sheet blocks having been collated into bundles to finish the bundles into booklets—relates to a method and device for inserting foldout printing leaves into a bookbinding-processed sheet bundle.
2. Description of the Related Art
Generally, this kind of image-forming system is known in the art to have a bookbinding unit connected to an image-forming unit such as a printer and the like to collate printed sheets into a sheet bundle and bind a spine edge of the sheet bundle using adhesive or the like. A system configuration that folds sheets conveyed from an image-forming apparatus using predetermined specifications such as a single fold or a gate fold and the like and collates the sheets is known.
For example, Japanese Unexamined Pat. App. Pub. No. 2005-335262 discloses an image-forming system in which sheets on which images have been formed in an image-forming apparatus (printed sheets) are conveyed to a bookbinding unit and are collated and stacked into bundles in the bookbinding unit, and in which an adhesive paste is applied to the spine-portion endface of the sheet bundles and the sheet bundles are encasing-bound with cover sheets, and afterwards the sheet bundles in book-bound form are finished by trimming true the head, tail, and fore-edge portions.
Further, Japanese Unexamined Pat. App. Pub. No. 2006-076779 discloses a finisher that folds in half or thirds printed sheets produced in an image-forming unit, collates and stacks the sheets, and staple-binds them. Then with this sheet folding unit, both single-folding, whereby a sheet is folded over substantially in half, as well as Z-folding, whereby in divisions into thirds a sheet is folded inward and then is folded outward back onto itself, are proposed. It is to be noted that by the sheet folding unit in this document, a trim-cutting configuration for trimming true the periphery of staple-bound sheets is neither disclosed nor even suggested.
Meanwhile, in image-forming units or printing systems such as just described, foldout leaves are sometimes inserted into the sheets (bundles) bookbinding-processed into booklet form. When, for example, foldouts such as table-of-contents leaves, advertising leaflets, or errata leaves (correction leaves) are to be fit into booklets, the method adopted traditionally has been to interject-insert such leaves following the bookbinding process.
Thus, as just noted, in bookbinding and finishing systems that form predetermined images on sheets, and collate and stack the sheets and bind together their spine-portion edges, foldout leaves are sometimes inserted in post-bookbinding-process booklets. Conventionally, foldout leaves are printed separately from the book-forming sheets, and they are interject-inserted into the booklets. Consequently, a problem with inserting interjection leaves such as table-of-contents leaves, advertising leaflets, or errata/correction leaves is that it requires the considerable labor of producing images on the leaves, and of the interjection operation, etc., which therefore raises the job costs.
Particularly with conventional bookbinding methods that insert foldout leaves after the bookbinding process, because inserting a foldout leaf between specific pages with images demands an extremely complex operation, foldout leaves are inserted between arbitrary pages. Accordingly, inserting printed leaves corresponding to a specific image page, such as errata tables or supplementary explanations relating to the image page, has presented difficulties.
BRIEF SUMMARY OF THE INVENTION
Therefore, the inventors came upon the idea of forming images on large-sized sheets with predetermined image data and simultaneously printing foldout images an outside a region (a blank portion of the sheet) of a predetermined size when sequentially forming images on sheets of predetermined sizes based on a series of image data. Then, an area formed with the foldout image is folded by sheet folding means, and then the bookbinding process is applied to the sheet bundle. Then, when trimming true edges using trimming means, the foldout image area is cut free. With this, it is possible to insert a foldout leaf to correspond to a predetermined image on a page in a bound sheet bundle without requiring any special processes.
An object of the present invention is to provide an image-forming system and bookbinding method that can easily insert a foldout leaf in the bookbinding processes of collating and stacking sheets formed with images and binding the spine edges.
Furthermore, the present invention provides an image-forming system that can insert a foldout leaf such as a correction table and the like between predetermined pages of a bound sheet bundle simultaneously to the bookbinding process.
The present invention employs the following configuration to attain the aforementioned objects. The bookbinding method that collates sheets formed with images into a sheet bundle and binds a spine portion to form a booklet has an image-forming step for sequentially forming images on a plurality of sheets based on predetermined image data; a folding step that folds the sheets formed with images at the image-forming step; a stacking step that collates into a sheet bundle sheets formed with images at the image-forming step and/or sheets folded at the folding step; a bookbinding step that binds a spine portion of the sheet bundle collated at the stacking step; and a trimming step that trims at least a fore-edge portion of the sheet bundle bound at the bookbinding step.
Also, at the image-forming step, images are formed on one or a plurality of a series of sheets to be formed with images by setting a foldout-image area on the fore-edge portion. Next, in the folding step, the foldout image area is folded at a folding-back fold location. Also, at the trimming step, the foldout-image area is cut free by cutting the folding position thereby placing the folded portion into the sheet bundle.
Next, at the trimming step, edges of the bound sheet bundle, excluding the bound spine portion, are trimmed. This step trims true the head and tail portions of the sheet bundle, then trims the fore-edge portion last.
In the image-forming step, a series of images are formed by setting an image area on a predetermined size of sheet and images are formed in parallel on a sheet of a size larger than this predetermined size by setting an image area and a foldout image area thereupon. Next, at the folding step, the foldout-image area is folded at a folding-back fold location. That folding position is set to substantially match the fore-edge portion of the sheet of a predetermined size.
A data processor that has a series of image data and at least one foldout image data, image-forming means that forms images on sheets based on image data from the data processor, sheet folding means for folding sheets from the image-forming means, stacking means that collates and stacks sheets from the image-forming means, bookbinding means that binds a spine portion of the sheet bundle conveyed from the stacking means, trimming means for trimming at least a fore-edge portion of the sheet bundle bound by the bookbinding means, and control means for controlling the image-forming means, the sheet folding means and the trimming means are provided.
The control means is configured (1) to control the image-forming means to sequentially form images on sheets based on the series of image data and to form images of at least one selected image data on the same sheet in parallel to the folded-image data; (2) to control the sheet folding means to fold the sheet with the foldout image formed at a folding-back fold location; and (3) to control the trimming means to trim at a position to cut free the folding position.
The control means controls the image-forming means to form images on sheets of a predetermined size based on the series of image data and to print at least one of the selected image data and folded-image data on a sheet of a larger size than the image data of the predetermined size. The foldout image is formed at the outside of the sheet of a predetermined size.
The control means sets the folding position to a position where it is not cut by the trimming means when the sheet formed with images based on the series of image data is being folded. Furthermore, the control means is configured to control the sheet folding means when folding back the foldout image to set that folding position to a position where it is cut free by the trimming means.
The trimming means has sheet bundle orientation deviation means that changes the posture of the bound sheet bundle by gripping it. The sheet bundle orientation deviation means is configured to change the posture of the sheet bundle by gripping the area of the sheet to be inserted where foldout image is formed.
The present invention has the following effects because the system to which it is applied forms images on sheets based on a series of image data, and simultaneously forms a series of image data and foldout images based on folded-image data on one or a plurality of sheets, folds and binds the foldout image area of the sheet, then trims the folding position of the foldout-image area.
It is possible to insert a foldout leaf such as a table of contents, advertisement or bookmarker and the like without needing special paper insertion work (processes) because the foldout image is formed at the same time as the series of images, and the folding position is cut free after the bookbinding process.
Particularly, it is possible to fold a foldout image between predetermined pages and to accurately fold a corrections table or supplementary explanation into necessary pages (conventionally a difficult process) because foldout images are formed simultaneously on predetermined image sheets, and the folding position is cut free after the bookbinding process. Therefore, there is a wide application of use for foldout images. It is possible to diversify bookbinding styles and editing work.
Also, the present invention provides a system configuration that collates and binds sheets formed with images, and trims true three edges, excluding the spine binding edges, after the bookbinding process, and does not require special mechanisms. With the present invention, it is possible to create foldout leaves using ordinary bookbinding processes (mechanisms), and this makes for a low-cost bookbinding process.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an explanatory view of an overall configuration of an image forming system equipped with the bookbinding apparatus of the present invention;
FIG. 2 is an explanatory view of a sheet folding unit in the system shown in FIG. 1 ;
FIG. 3 is an explanatory view of a configuration of a bookbinding unit in the system of FIG. 2 ;
FIGS. 4A to 4D are explanatory views of examples of folding specifications in the system shown in FIG. 2 ; FIG. 4A shows a gate fold; 4 B shows a Z fold; 4 C shows ¼ Z fold; 4 D shows a foldout image;
FIGS. 5A to 5D are explanatory views of cutting the sheet bundle in the system shown in FIG. 3 ; FIG. 5A shows cutting a fore-edge portion of the sheet bundle; FIG. 5B shows cutting the fore-edge of the sheet bundle when the cover sheet is shorter than the inner leaves of sheets; 5 C shows cutting the fore-edge of the sheet bundle when the cover sheet is longer than the inner leaves of sheets; and FIG. 5D is a plan view of the sheet bundle, showing head, tail, and fore-edge trim lengths, and their correspondence to a larger-size sheet on which a foldout image is printed, and having been folded as in FIG. 4D and cut along the fore-edge fold to finished sheet size.
FIGS. 6A and 6B are schematic diagrams of an adhesive application means in the system shown in FIG. 3 ; 6 A shows an adhesive container; 6 B shows an application operation;
FIG. 7 is a schematic diagram of cover sheet binding means; sheet bundle orientation deviation means; and trimming means in the system shown in FIG. 3 ;
FIG. 8 is a block diagram of a configuration of a control unit in the apparatus shown in FIG. 1 ;
FIG. 9 is a flowchart of the bookbinding operation in the apparatus shown in FIG. 1 ; and
FIG. 10 is a flowchart of the bookbinding operation in the apparatus shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Overall Structure
A preferred embodiment of the present invention will now be explained based on the drawings provided. FIG. 1 is an overall view of a configuration of the image-forming system according to the present invention; FIG. 2 is a view of a configuration of the sheet folding unit; and FIG. 3 is an explanatory view of a configuration of the bookbinding unit.
Image-Forming System Configuration
The image-forming system shown in FIG. 1 is composed of an image-forming unit A that forms images on sheets; a sheet folding unit B that folds sheets formed with images into predetermined shapes; and a bookbinding unit C that performs a bookbinding process on sheets fed from these units. A finisher unit D is linked downstream of the bookbinding unit C. These units are disposed to convey sheets from with images at the image-forming unit A sequentially downstream to the sheet folding unit B, the bookbinding unit C and then to the finisher unit D. The sheet folding unit B folds sheets using predetermined specifications such as a single fold or in thirds, then sends the folded sheet to the bookbinding unit C. The bookbinding unit C collates into sheet bundles folded sheets or sheets fed from the image-forming unit A and then binds the spine edge of the sheet bundle. For that reason, a bookbinding means 55 such as an adhesive binding means or stapler binding means is disposed in the bookbinding unit C. Trimming means 65 is disposed downstream of this bookbinding means 55 to trim and align three sides of a bound sheet bundle, excluding the spine portion thereof.
Each unit will be described in detail below. However, a feature of the present invention is that the image-forming unit A, the sheet folding unit B, and the bookbinding unit C are disposed downstream in that order. An image data processor 18 d is provided in the image-forming unit A shown in FIG. 1 . A series of image data da 1 and foldout image data da 2 are prepared in the processor 18 d . In other words, the image data processor 18 d is a memory means (for example, a hard disk), and image data da 1 that finishes the bookbinding process and foldout image data da 2 that is inserted into the sheet bundle after bookbinding process are stored therein. In addition to that, it is also acceptable to configure the image data processor 18 d to transfer the image data da 1 and foldout image data da 2 from an external device (such as a PC).
Images are formed sequentially using the image data da 1 specified by the operator on a predetermined size at the image-forming unit A. The present invention forms images of one or a plurality of image data da 1 on a series of sheets in parallel to forming foldout images with the foldout image data da 2 at the same time. For that reason, foldout images are formed on sheets (hereinafter referred to as folding sheets) of a size larger than the predetermined size of sheet specified by the operator. For example, to form an image of image data da 1 on a JIS standard A4 size sheet (297 mm×210 mm), an image is formed using an A3 (420 mm×297 mm) size sheet and the sheet is folded. The foldout image is formed outside of the area of the predetermined size of sheet (see FIG. 4D ).
The present invention folds the sheet formed with a foldout image as described above at the sheet folding unit B. The foldout image is folded inward or outward at the folding back position. In other words, the foldout image is formed outside of the front edge of the finished size on a sheet larger than the predetermined size (finished size). The folding position is formed in the outside of the finished size.
The predetermined size of sheet and the folding sheet are collated into a bundle in the stacking tray 41 . Then, adhesive is applied to the spine of the sheet bundle or the sheet bundle is stapled to form a booklet. Three sides of the bound sheet bundle, excluding the spine portion, are trimmed true by the trimming means 65 .
The present invention cuts away the foldout image area of the folding sheet at the folding position when the sides are being trimmed. The folding position of the folding sheet is arranged within the trimming region when trimming the booklet. Therefore, the foldout image formed on the folding sheet is inserted into a predetermined page after the trimming and finishing process.
Furthermore, when folding the sheet formed with images according to the image data da 1 into a half or ⅓ folds at the sheet folding unit B, the present invention sets the folding position to be inside the cutting position so it is not cut when cutting using the trimming means 65 , and sets the folding position within a cutting amount to be cut when cutting the folding position of the folding sheet with the trimming means 65 .
Also, as shown in FIG. 1 , the image-forming unit A is equipped with an image-forming means 20 that sequentially forms images on sheets based on predetermined image data da 1 , and feeding means 2 that feeds sheets thereto. Also, the sheet folding unit B is equipped with a sheet folding means 21 that folds sheets formed with images. The bookbinding unit C is equipped with collecting means 41 that collates and stacks sheets fed from the image-forming means 20 directly or via the sheet folding means 21 ; cover sheet binding means 60 that covers the collated sheet bundle and binds a cover sheet thereto; and trimming means 65 that trims three edges of the sheet bundle bound with the cover sheet to align the edges. An inserter unit (feeding apparatus) E is disposed upstream of the cover sheet binding means 60 on an image-forming system having such a configuration, and in some cases the finisher unit D is disposed downstream of the bookbinding unit C. The inserter unit E feeds the cover sheet to the cover sheet binding means 60 ; the finisher unit D is equipped with a finishing means 39 , such as stapling means that staples sheets, hole-punching means, and stamping means and the like, that aligns sheets fed from the image-forming means 20 or the sheet folding means 21 into a sheet bundle without the bookbinding process, and a discharge tray 37 .
With such a system configuration, images are sequentially formed on sheets using image data da 1 stored in a data storage unit provided in the image-forming unit A, or sent thereto, and these sheets are folded, collated and collected. Thereafter, the collated sheet bundle is covered by a cover sheet to form a booklet. After the bookbinding process, a finishing process to cut three sides of the sheet bundle, excluding the spine portion of the sheet bundle is possible. (Hereinafter, this is called a bookbinding operation.) At the same time, it is possible to feed sheets formed with images to the finisher unit D passing through the bookbinding unit C without their undergoing the bookbinding process and to be finished at the finisher unit with a process such as stapling, stamping, or hole-punching. (Hereinafter, this is called a finishing operation.) For that reason, in addition to folded sheets fed from the sheet folding unit B are sent to the collecting means 41 , and a sheet conveyance path 38 is provided to convey the sheets to the finishing means 39 . Therefore, it is possible to select whether sheets formed with images are sent either to the collecting means 41 via the sheet folding unit B for the bookbinding operation, or to the finisher unit D for the finishing operation.
The present invention has a feature to automatically execute processes with this system configuration from the image-forming process to the finishing process with the “print-out mode,” “folding mode,” “bookbinding mode,” and “finishing mode.” These modes can be set using a mode setting means 72 , as described below, for example, but here the processes of each mode will now be explained.
Print-Out Mode
In this mode, sheets formed with images at the image-forming unit A are stacked on a discharge tray. This mode forms images on sheets of a size specified by the image data da 1 in the same way as with an ordinary copier or printer, or of a size specified using an input means (a control panel 71 described below), and stacks and stores the sheets in the discharge tray. The system shown in FIG. 1 stores the sheets in the discharge tray 37 equipped on the finisher unit D at the furthest downstream side.
Folding Process Mode
In this mode, sheets formed with images at the image-forming unit A are finished into a booklet, or folded for the finishing process. Bookbinding folding specifications, staple folding specifications, and the letter folding specifications can be specified for the sheet folding method. Note that the system shown in FIG. 1 is configured so that a sheet folding process folds sheets fed from the image-forming unit A according to the specified folding specifications, and stores folded sheets in a folded sheet storage tray 29 (see FIG. 2 ), that is separate to bookbinding and finishing processes. Therefore, it is possible for the system to be set to bookbinding, finishing, or to sheet folding operations on sheets formed with images.
The present invention has a feature to determine the folding position N to fold the sheet according to the type of each final finishing process, of “bookbinding, finishing, and sheet-folding” when the system is set for the “folding process mode.” In other words, a folding position computing means 73 that sets the folding position N when the sheet folding means 21 disposed in the sheet folding unit B folds the sheet is composed to determine the folding position N using a first control mode and a second control mode.
The first control mode sets the folding position N for the sheet when the “bookbinding finish” is set. This control sets the folding position N so that the folded edge of the folded sheet is not cut when a sheet bundle covered with a cover sheet bound by the bookbinding finish is being trimmed for alignment. For that reason, the folding position computing means 73 is composed to set the sheet folding position N based on a virtual trimming length by computing the trimming length for bookbinding finish as the virtual trimming length.
This virtual trimming length is computed in the following way, using initial setting conditions (setting values) for example for image forming. First, with the initial settings, the finishing mode selection, the sheet size selection and the image-forming area (page layout) are set. When supplying the cover sheet for the bookbinding finishing from the inserter unit E, the operator specifies the size of the cover sheet on the control panel 71 . The virtual trimming length first determines the horizontal direction of the sheet from the page layout setting. The cover sheet, the longitudinal length L of the inner leaves of sheets, and the lateral length R are compared to set the trimming position based on the shortest sheet. This is to trim the sheets based on a small sized sheet to align the cover sheet and all the leaves of inner sheets (the sheet bundle).
To explain this based on FIGS. 5A and 5B , FIG. 5A shows a case where the cover sheet Sh is shorter compared to the inner leaves of the sheet bundle Sn; at that time, a minimum trimming length Δx is set based on the cover sheet Sh. FIG. 5B shows a case where the inner leaves of the sheet bundle Sn are shorter compared to the cover sheet Sh; at that time, a minimum trimming length Δx is set based on the inner leaves of the sheet bundle Sn.
Note that the comparison of the length between spine bound edge and fore-edge portion edge is calculated by [(sheet length−bundle thickness t)/2] for the cover sheet. In other words, to cover and bookbinding the inner leaves of the sheet bundle Sn with the cover sheet Sh, the cover sheet Sh is folded to form the spine cover at the central portion. The spine cover sheet width at this time substantially matches the thickness of the inner leaves of sheets of the bundle.
However, the spine cover sheet width (the thickness t of the sheet bundle of inner leaves) is determined when images are formed on the inner leaves of sheets to be aligned, and the sheet bundle is aligned in the stacking means. On the other hand, the sheet folding process can be applied on the first sheet. Here, the present invention has a feature to find that “bundle thickness (hereinafter called presumed bundle thickness”) t when computing the virtual trimming length, from (1) a tolerable maximum bookbinding thickness, or (2) a number of sheets that were formed with images. The former is set in advance from the apparatus configuration (for example, a maximum gripping amount of a gripping conveyance means 47 , described below) of the bookbinding unit C. The latter is determined by multiplying an average sheet thickness (paper thickness) by the number of sheets to be printed that is known by the initial page layout settings.
Therefore, as shown in FIGS. 5A and 5B , the virtual trimming length is computed by subtracting the minimum trimming length ΔX from the short length of either the length of the inner leaves of sheets or the cover sheet length, for the longitudinal length L in the head to tail direction. The minimum trimming length Δx is subtracted from the shorter length by comparing the [(cover sheet length−presumed bundle thickness]/2] as the cover sheet lateral length (Shr) to the lateral length (Snr) of the inner leaves of sheets for the fore-edge direction horizontal length R.
Note that in this case, the minimum trimming length Δx is set in advance based on an amount of position slippage generated in the sheets in the process for sheets formed with images at the image-forming unit A to be collated and stacked in the bookbinding unit C and covered with a cover sheet. In other words, the minimum trimming length Δx is set from the amount of mis-alignment of the head, tail and open side that is generated in the cover sheet Sh and the inner leaves of sheets of the sheet bundle Sn that were bound by the cover sheet binding means 60 , described below.
Next, the second control mode sets the folding position N for the sheet when “finishing•sheet folding” are set. This control calculates the folding position according to the preset folding specifications such as a half fold, a standard gate fold, and ⅓ Z-fold and the like which are described below. In such a case, the folding position computing means 73 is configured to calculate the folding position N from the folding specifications and the sheet size (the default value). The configuration of each of the above will be described below.
Bookbinding Mode
This mode stacks and collates in stacking means 41 sheets fed from the image-forming unit A and dispenses adhesive (or adhesive tape) for example to the sheet bundle. Then, this sheet bundle is covered and bound by a cover sheet, and three sides, excluding the bound spine portion, of the sheet bundle are cut for alignment. A portion of the sheets stacked in this stacking means 41 are folded by the sheet folding means 21 . Then, the sheet bundle formed into a cut and aligned booklet is stored in a storage stacker 67 .
Finishing Mode
This mode conveys sheets from the image-forming unit A directly into a processing path (hereinafter referred to as a finishing path 39 a ) via the bookbinding unit C after being folded at the sheet folding unit B. After undergoing a finishing process by the finishing means 39 , such as a stapling means, stamping means or a hole-punching means and the like prepared in this path, the sheets are conveyed out to the discharge tray 37 .
Image-Forming Unit Configuration
The following will now explain the image-forming unit A shown in FIG. 1 . The image-forming unit A can adopt a variety of structures of a copier, printer or printing machine. The drawing shows an electrostatic printing system. This image-forming unit A has a feeding unit (feeding means) 2 , printing unit 3 , discharge unit 4 and control unit in the casing 1 . A plurality of cassettes 5 corresponding to sheet sizes is prepared at the feeding unit (feeding means) 2 . Sheets of the size specified by the control unit are fed to the sheet feed path 6 . A registration roller 7 is equipped at the sheet feed path 6 . After the leading edge of the sheet is registered by this roller, it is fed at a predetermined timing to the downstream printing unit.
A static electric drum 10 is equipped at the printing unit 3 . A print head 9 , a developer 11 and a transfer charger 12 are disposed around this drum 10 . The print head 9 is composed of a laser emitter, for example, to form electrostatic latent images on the electrostatic drum 10 . Toner ink adheres to the latent image at the developer 11 , and this is transferred and printed on the sheet at the transfer charger 12 . The printed sheet is the fixed at the fixer 13 and discharged to the discharge path 17 . A discharge outlet 14 formed in the casing 1 and a discharge roller 15 are disposed at the discharge unit 4 . Note that the symbol 16 in the drawing represents a recirculation path. A printed sheet from the discharge path 17 is turned over from front to back at the switchback path and fed to the registration roller 7 to be formed with images on its backside. In this way, a sheet formed with images on one side or both sides is conveyed from the discharge outlet 14 by the discharge roller 15 .
Note that the symbol 20 in the drawing is a scanner unit (image-forming means). This optically reads original images to print using the print head 9 . As is generally known in the art, the scanner is composed of a platen 18 where an original sheet is set; a carriage 20 a that scans the original image along the platen 18 ; and an optical reading means (for example, a CCD device) 20 b that photo-electrically converts optical images received from the carriage 20 . The drawing shows an original feeding apparatus 19 that automatically feeds the original sheet to the platen, installed over the platen 18 .
Sheet-Folding Unit Configuration
The following will now describe the configuration of the sheet folding unit B. The sheet folding unit B is composed of a folding unit B 1 and a folded sheet stacker B 2 . A conveyance inlet 24 a linked to a discharge outlet 14 of the image-forming unit A is equipped in the sheet folding unit B, and a sheet conveyance path P 1 that sends sheets from the conveyance inlet 24 a to the bookbinding unit C, described below, is connected to traverse the apparatus. A folding process path P 2 and a sheet feed path P 3 from the inserter unit E are branchingly connected to the sheet conveyance path P 1 .
Sheet Folding Specifications
The following will now explain the folding specifications performed by the sheet folding unit B 1 . Folding sheets in half or in thirds are the types of folds (folding specifications) that are commonly applied with the image-forming system described above. Each type of sheet fold will now be explained.
Single Fold
This creases or folds a sheet conveyed out from the image-forming unit A at substantially the half position of the length of the direction of conveyance. Although not shown, the sheet is folded in half at a central position. The folded ends of sheets can then be bound by stapling or gluing and the like to form a closed-end document. Furthermore, if holes are punched into the folded sheets, they can be used in a variety of document organizing methods, such as filing. The folding position computing means 73 that sets the folding position N uses the first control mode for the bookbinding operation, and the second control mode for the finishing and sheet folding operations.
Gate Fold
In this folding method, the sheet is folded at desired positions (for example at ⅓ positions) of the leading edge and the trailing edge of the sheet in the length direction. The two end panels, specifically, the leading and trailing ends of the sheet, are mutually folded inward over a middle third panel. As shown in FIG. 4A , the leading end side of the sheet (in direction of sheet conveyance) is folded at a ⅓ position of the sheet, then the trailing end is folded over that panel at a ⅓ position of the sheet. A gate-folded sheet can be inserted into an envelope as a letter.
Therefore, with this folding specification, folded sheets are stored a folded sheets in a sheet storage tray 29 equipped on the sheet folding unit B. In such a case, the folding position computing means 73 sets the folding position with the second control mode.
Z-Fold
In this folding method, the sheet is folded at desired ⅓ positions of the leading edge and the trailing edge of the sheet in the length direction of sheet conveyance. Specifically, the leading and trailing ends of the sheet are folded in opposite directions. The leading edge of the sheet is folded inward, and the trailing edge of the sheet is folded outward. If a sheet is folded at ⅓ positions as shown in FIG. 4B , it can be inserted into an envelope as a letter. If the sheet is folded at a half position inward, and a ¼ position is folded outward, the sheet can be used for filing. Note that the sheet can be folded for any kind of use by adjusting the inner folding position (N 1 in the drawing) and outer folding position (N 2 ) when apply such a Z fold. For example, if the inner folding position N 1 is set to ⅓ of the sheet length L, leaving a binding margin at the spine portion, bookbinding is possible. If the folding back position (outer folding position) N 2 of the edge is adjusted, it is possible to project the folded back portion so that a letter head portion of the sheet is facing outward so as to be visible.
Specifically, as shown in FIGS. 4( b ) and 4 ( c ), by adjusting the outer folding position N 2 so that a relationship of L 2 <L 3 exists, the folded back portion can be projected to the outside of the folded sheet. Also, if the outer folding position N 2 is adjusted so that a relationship of L 2 >L 3 exists, the folded back portion can be pulled inside the folded sheet. When in the bookbinding finish mode, the folding position computing means 73 that sets the folding position N at that time sets the folding position using the first control mode; when in the finishing process mode or sheet folding mode, it sets the folding position using the second control mode.
Folding Unit Configuration
The structure of the folding unit B 1 will be now explained with reference to FIG. 2 . The folding process path P 2 is linked to the sheet conveyance path P 1 interposed by a path switching flapper 24 ; the folding roller mechanism (the sheet folding means, and that applies below) 21 is disposed in the folding process path P 2 . A folded sheet path 23 branched in a T-shape is furnished to the folding process path P 2 at a central position of the path, and a switchback path 22 is furnished downstream at a leading end of the folding process path P 2 . The folding roller mechanism 21 is furnished at the path branching point. The folding roller mechanism 21 shown in the drawing is composed of a first roller 21 a , a second roller 21 b , and a third roller 21 c . The first and second rollers 21 a and 21 b are in mutual contact to nip the sheet; the second and third rollers 21 b , and 21 c are also in mutual contact to nip the sheet. Therefore, a first folding process is executed at the nipping point (the first folding unit) between the first and second rollers 21 a , and 21 b , and a second folding process is executed at the nipping point (the second folding unit) between the second and third rollers 21 b , and 21 c.
A conveyance roller 25 that conveys the sheet is disposed in the folding process path P 2 ; the folding roller mechanism 21 is positioned downstream of the conveyance roller. A switchback roller 22 f that is capable of both forward and reverse rotations and a sheet sensor SS 1 are disposed in the switchback path 22 downstream of the folding process path P 2 . The sensor SS 1 detects the leading edge of the sheet fed downstream ( FIG. 2 ) by the switchback roller 22 f . After the sensor detects the leading edge of the sheet, the switchback roller 22 f further conveys the sheet a predetermined amount and then stops. Then, the central portion of the sheet is bowed by the conveyance roller 25 continuing to rotate, thereby causing the bowed ¼ position of the sheet to enter the nipping point of the first folding unit Np 1 of the folding roller mechanism 21 . Next, the switchback roller 22 f is driven in reverse thereby backing up the leading edge of the sheet. At the same time as that reverse drive, the conveyance roller 25 continues to feed the trailing edge of the sheet. These two actions cause the sheet to enter nipping point between the first and the second rollers 21 a and 21 b . These rollers pull the sheet downstream into the folded sheet path 23 .
On the other hand, a trailing edge registration stopper 25 S is provided downstream of the conveyance roller 25 to calculate the folding position based on the trailing edge of the sheet. After the trailing edge of the sheet is fed past the registration stopper 25 S by the switchback roller 22 f , the switchback roller 22 f rotates in reverse thereby abutting the trailing edge of the sheet against the registration stopper 25 . This causes the sheet to form a bow based on the sheet's trailing edge position. The bowed portion advances into the nipping point Np 1 of the first and second rollers 21 a , and 21 b (the first folding unit).
Thus, the first folding process is executed based on the trailing edge of the sheet. Note that the sheet stopper mechanism is composed of a flapper-shaped stopper 25 S. This stopper 38 is configured to retract from the path when the sheet advances downstream in the folding process path P 2 , and to advance back into the path when the sheet is being conveyed upstream to stop the trailing edge of the sheet. This stopper that registers the trailing edge of the sheet can also be composed of the conveyance roller 25 as a switchback roller capable of forward and reverse rotations. Switchback roller 22 f at the leading end of the path can also be configured for position registration.
Sheets whose folding positions are calculated by either their leading edge or their trailing edge when supplied to the first folding unit are folded by the first and second folding rollers 21 a , and 21 b , and then conveyed into the folded sheet path 23 . A sheet detection sensor S 2 and movable stopper 23 are disposed in the folded sheet path 23 . The movable stopper 23 S is configured to move into the folded sheet path 23 to register the leading edge position of the sheet according to the sheet size and folding specifications. The leading edge of the folded sheet fed by the first and second rollers 21 a , and 21 b abuts the movable stopper 23 S and is registered. This also forms a bow in the trailing edge side. This bow causes the sheet to advance into the nipping point between the second 21 b and third roller 21 c so the trailing edge side of the sheet is folded. A first discharge path P 4 is disposed downstream of the nipping point (the second folding unit) Np 2 of the second and third rollers 21 b and 21 c . Sheets folded at the first and second folding units Np 1 , Np 2 are conveyed out to the first discharge path P 4 . Note that in the event that the sheet does not require a second folding, for example if only a single fold is applied to the sheet, the movable stopper 23 retracts to a non-operational, standby position so that the sheet can be conveyed out to the first discharge path P 4 without being folded at the nipping position of the second and third rollers 21 b and 21 c.
The first discharge path P 4 is equipped with a conveyance out rollers 27 b . These rollers nip the folded sheet and convey it to downstream. A folded sheet storage tray 29 and a second discharge path P 5 are disposed downstream of the first discharge path P 4 interposed by path switching member 29 f . Conveyance rollers 27 c are disposed at proper intervals in the second discharge path P 5 to convey a folded sheet to the sheet conveyance path P 1 .
Inserter Configuration
As described above, a printed sheet is conveyed in from the image-forming unit A to the folding unit B 1 but in addition to this, a sheet can be selectively conveyed from the inserter E for the folding process. As shown in FIG. 1 , the inserter B 3 is composed of a feeder tray 28 a where sheets such as cover sheets or a divider sheet can be set; a separating means 28 b that separates and feeds one sheet on the tray at a time; and the paper feed path P 3 that guides the separated sheet to the sheet conveyance path P 1 . The separating means 28 b is ordinarily composed of a friction roller (paper feed roller) and separating roller; a registration roller 28 c is disposed downstream thereof.
Therefore, it is possible to guide a sheet from a different printing process, not supplied from the image-forming unit A, or to set a cover sheet in the feeder tray 28 a to insert in front and behind sheets. It is also possible to set divider sheets in feeder tray 28 to insert the dividers into the sheet conveyance path P 1 for insertion between the pages at appropriate times.
Sheet Folding Operation
The following will now explain actions of the sheet folding unit B configured as described above. The present invention has the possibility of trimming a folding position N when trimming to align the edges of sheets bound in the bookbinding process when a sheet has been applied with a Z-fold, when applying the bookbinding process at the bookbinding unit C, on sheets folded into a Z-fold at the sheet folding unit B. The present invention has a feature of setting the sheet folding position N according to the trimming amount. The following will explain folding operations to fold a sheet into a Z-fold at the sheet folding unit B.
The control unit 59 of the sheet-folding unit B is composed of a control CPU. The control unit 59 can be integrated to the control unit 70 of the image-forming unit A or the control unit 75 of the bookbinding unit C, or it can be furnished separately to the sheet-folding unit B. A ROM 74 that stores folding execution programs and a RAM 77 that stores control data are provided in the control unit (control CPU) 59 . The folding execution program (ROM) 74 executes folding processes with the folding specifications described above by controlling the conveyance roller 25 of the folding process path P 2 , the conveyance out rollers 27 b , the folding roller mechanism 21 and the movable stopper 23 S. This folding process execution program (ROM) 74 selects whether to move the folded sheet fed into the first discharge path P 4 from the first discharge outlet 27 a to the folded sheet storage tray 29 or to move the folded sheet from the second discharge path P 5 to the bookbinding unit C according to the folding specifications, at the same time as executing a folding process described above. The drawings show sheet sizes of A4 or letter size. The sheet is conveyed from the first discharge path P 4 and is stored in the folded sheet storage tray 29 for gate fold folding specifications. For other folding specifications, the sheet is conveyed out from the second discharge path P 5 to the bookbinding unit C.
When a gate fold is applied to the sheet, the control unit (control CPU) 59 discharges the sheet from the discharge outlet 14 of the image-forming unit A facing downward. The sheet is handed over and conveyed into the folding process path P 2 in the manner indicated by arrow a in FIG. 2 . Next, the sheet passes through the folding roller mechanism 21 and advances into the switchback path 22 downstream. At the point where the leading edge of the sheet is conveyed a predetermined amount downstream, the switchback roller 22 f is driven in reverse while the conveyance roller 25 is stopped. At that point, the trailing edge of the sheet is restrained by the conveyance roller 25 , and the center of the sheet is bowed in the direction of the nipping point Np 1 between the first and second rollers 21 a and 21 b . The sheet is nipped between the both rollers, and the first folding process is executed therebetween. By adjusting the distance between amount of feeding of the switchback rollers 22 f and the nipping point N 2 , the outside folding position N in FIGS. 4( b ), ( c ) is set.
Specifically, the sheet sensory detects the leading edge of the sheet, the control CPU 59 rotates the switchback roller 22 f in reverse after an estimated amount of time after that signal for the sheet folding position N 2 to reach the nipping point Np 1 . At that time, the leading edge of the sheet is folded between the second rollers 21 a , 21 b at the folding position N 2 facing outward.
In this way, the sheet folded to face outside is fed to the folded sheet path 23 by the first and second rollers 21 a , 21 b . At this time, the CPU 59 moves the movable stopper 23 S using a drive motor, not shown, to align the distance of the sheet folding position and the nipping point Np 2 to the inner folding position N 2 (see FIG. 4 ) set according to the sheet size.
Therefore, the leading edge (the folded position) of the sheet folded by the first folding unit Np 1 abuts the movable stopper 23 S and the center portion of the sheet is nipped between the first and second rollers 21 b , 21 c . The printed surface of the sheet is folded inward by the second and third rollers 21 b , 21 c and the distance between the nipping point Np 2 and the movable stopper 23 S is set to L 2 of the length of the sheet, shown in FIG. 4 . Therefore, the leading edge of the sheet faces outward and the trailing edge of the sheet is Z-folded inward. Sheets folded in this manner are fed from the second discharge path P 5 to the bookbinding unit C where the bookbinding process is performed.
Bookbinding Unit Configuration
The following will now explain the bookbinding unit C that is attached to the image-forming unit A. The bookbinding unit C is composed of a stacker 40 that stacks and aligns printed sheets into bundles; an adhesive applicator means (the bookbinding means) 55 that applies adhesive to the sheet bundle conveyed from the stacker 40 ; and cover sheet binding means 60 that binds the cover sheet to the sheet bundle applied with adhesive, in the casing 30 .
Conveyance Path Configuration
A conveyance path 31 having a conveyance inlet 31 a linked to the discharge outlet 14 of the image-forming unit A is provided in the casing 30 , and the intermediate sheet conveyance path 32 and cover sheet conveyance path 34 are linked from this conveyance path 31 via the path switching flapper 36 . The bookbinding path 33 is linked to the cover sheet conveyance path 34 via the stacker 40 , and a finishing path 39 is connected to the cover sheet conveyance path 34 . The bookbinding path 33 is disposed to traverse the apparatus longitudinally in a substantially vertical direction, and the cover sheet conveyance path 34 is disposed in a direction to traverse the apparatus in a lateral direction.
The bookbinding path 33 and the cover sheet conveyance path 34 mutually intersect (orthogonally); the cover sheet binding means 60 , described below, is disposed in the intersection. The conveyance path 31 configured as described above is linked to the discharge outlet 14 of the image-forming unit A to receive printed sheets from the image-forming unit A. Sheets printed with content information (the leaves of sheets), and sheets printed with a title and the like to be used as a cover sheet (hereinafter referred to as a cover sheet) are conveyed out from the image-forming unit A. This conveyance path 31 is branched into the intermediate sheet conveyance path 32 and the cover sheet conveyance path 34 , and sort printed sheets to convey them into each path by the use of a path switching flapper 36 .
Stacker Configuration
The stacking tray 41 arranged at the discharge outlet 32 b of the inner sheet conveyance path 32 stacks and stores sheets from the discharge outlet 32 b in a bundle. As shown in FIG. 2 , the stacking tray 44 is composed of a tray member disposed in substantially horizontal posture; a forward and reverse rotating roller 42 a and conveyance guide 42 b are furnished thereabove. Also, printed sheets from the discharge outlet 32 b are guided to the stacking tray 41 by the conveyance guide 42 b and are stored by the forward and reverse rotating roller 42 a . The forward and reverse rotating roller 42 a feeds the printed sheet to the leading edge of the stacking tray 41 with a forward rotation. When rotated in reverse, the trailing edge of the sheet is pushed against an aligning member 43 disposed at the trailing edge of the tray (the right edge of FIG. 1 ) to become aligned. A sheet side aligning means, not shown, is equipped on the stacking tray 41 to align both edges of the printed sheet stored in the tray to reference positions. With this configuration, printed sheets conveyed from the inner-sheet conveyance path 32 are sequentially stacked in the stacking tray 41 and aligned into a bundle shape.
Sheet Bundle Conveyance Means Configuration
Gripping conveyance means 47 are furnished in the bookbinding path 33 to convey a sheet from the stacking tray 41 to a downstream adhesive application position F. As shown in FIG. 3 , the gripping conveyance means 47 turns the sheet bundle stacked on the stacking tray 41 from a horizontal posture to a vertical posture, then conveys the sheet bundle to the adhesive application position F by conveying it along the bookbinding path 33 disposed in a substantially vertical direction. For that reason, the stacking tray 41 moves from a stacking position (solid lines in FIG. 3 ) to the hand-over position (dashed line in FIG. 3 ), and hands over the sheet bundle to the gripping conveyance means 47 prepared at this hand-over position.
Adhesive Application Unit Configuration
An adhesive application means 55 is disposed in the adhesive application position F of the bookbinding path 33 . As shown in FIG. 6( a ) the adhesive application means 55 is composed of an adhesive container 56 that stores hot-melt adhesive; an applicator roller 57 ; and a roller rotating motor MR. Adhesive is stored in the adhesive container's 56 liquid adhesive storage chamber. This adhesive impregnates the applicator roller 57 and is applied to a spine edge of the sheet bundle. The symbol 56 S in the drawing is the temperature sensor. This maintains a predetermined temperature for liquefaction of the adhesive in the container. Also, heating means 50 , such as an electric heater or the like, is embedded in the adhesive container 56 . The adhesive container 56 is supported on a guide rail 52 of the apparatus frame to move along the tail edge of the sheet bundle. A drive motor MS installed on the apparatus frame is connected to the adhesive container 56 . Therefore, drive motor MS reciprocates the adhesive container 56 between a home position HP and a return position RP where the return operation is started along the sheet bundle.
Cover Sheet Binding Means Configuration
The cover sheet binding means 60 is disposed in the cover sheet binding position G of the bookbinding path 33 . As shown in FIG. 7 , the cover sheet binding means 60 is composed of a spine support plate 61 , cover sheet folding plates 62 , and folding rollers 63 . The cover sheet conveyance path 34 described above is disposed in the cover sheet binding position G, and conveys cover sheets from the image-forming unit A or the inserter unit E. The spine support plate 61 is composed of a plate-shaped member that backs-up the cover sheet and is able to advance into and retract from the bookbinding path 33 . The inner sheet bundle is joined in an upside-down T-shape to the cover sheet supported on the spine support plate 61 . The cover sheet folding plates 62 are composed of a pair of left and right side pressing members. Drive means, not shown, are composed to come together and separate to fold and form the backside of the cover sheet joined in an upside-down T-shape. The folding rollers 63 are composed of are composed of a pair of rollers that finish the cover by sandwiching the sheet bundle joined with the cover sheet.
Bundle-Attitude Biasing Means Configuration
A bundle-attitude biasing means 64 that turns the sheet bundle over from head to tail, and trimming means 65 that cuts the edges of the sheet bundle are disposed in the trimming position H positioned downstream of the folding rollers 63 . The bundle-attitude biasing means 64 turns the covered sheet bundle fed from the cover sheet binding position F to a predetermined direction (or posture) and conveys the sheet bundle downstream to the trimming means 65 or the storage stacker 67 . The trimming means 65 trims the fringes of the sheet bundle to align the edges. Therefore, the bundle-attitude biasing means 64 is equipped with rotating tables 64 a , 64 b that grip and turn the sheet bundle fed from the folding rollers 63 . As shown in FIG. 7 , the rotating tables 64 a , 64 b are established on the unit frame 64 x installed on the apparatus frame to rise and lower. The pair or rotating tables 64 a , 64 b that sandwich the bookbinding path 33 are rotatably supported on bearings in the unit frame 64 x ; one of the movable rotating tables 64 b supported to move in a sheet bundle thickness direction (a direction orthogonal to the bookbinding path 33 ). Spinning motors Mt 1 , Mt 2 are furnished in the bookbinding path 33 for the rotating tables 64 a , 64 b to change the posture of the sheet bundle. A grip motor Mg is provided for the movable side rotating table 64 b to move in the left and right directions of FIG. 7 .
Therefore, the sheet bundle guided to the bookbinding path 33 is gripped by the pair of left and right rotating tables 64 a , 64 b , then the posture of the sheet bundle is changed by the turning motors Mt 1 , Mt 2 . For example, the sheet bundle with its spine portion conveyed downward is rotated 180 degrees and fed to downstream discharge rollers 66 with the fore-edge portion facing downward. The sheet bundle is sequentially rotated 90 degrees to turn the sheet bundle's head and tail and fore-edge portion at a downstream trimming position H to enable the trimming of three edge directions of the sheet bundle. Note that a grip sensor (not shown) is provided on the rotating table 64 b of the movable side. This detects that the sheet bundle has been securely gripped between the left and right side rotating tables 64 a , 64 b . After detection, the rotating tables 64 a , 64 b are configured to revolvingly drive. Also, the unit frame 64 x raises and lowers the sheet bundle along the bookbinding path 33 using an elevator motor MA. This is to configure a jog mechanism to offset a predetermined amount the sheet bundle fed by the discharge rollers 66 and convey the sheet bundle to a trimming position H when trimming edges of the sheet bundle, and to set the trimming width at the trimming position H by that feed amount.
Note that the bundle posture changing means 64 is configured to change the posture of the sheet bundle by gripping insertion image areas when gripping the sheet bundle with folded sheets inserted therein. This is to prevent the folded sheets from falling.
Trimming Means Configuration
Trimming means 65 are provided downstream of the bundle posture changing means 64 . As shown in FIG. 7 , the trimming means 65 is composed of trimming edge pressing member 65 b that pressingly supports the trimming edge of the sheet bundle to a blade-edge bearing member 65 a and a trimming blade unit 65 c . The trimming edge pressing member 65 b is disposed in a position that opposes the blade-edge bearing member 65 a disposed in the bookbinding path 33 , and is composed of a pressing member that moves in an orthogonal direction to the sheet bundle by drive means, not shown. The trimming blade unit 65 c is composed of a flat, blade-shaped trimming blade 65 x and a cutter motor MC that drives that blade. The trimming means 65 with this configuration cuts a predetermined amount around the edges, excluding the spine of the sheet bundle that has been made into a booklet (hereinafter referred to booklet sheets), to align the edges.
In the trimming to align the booklet sheets, the head portion of the booklet sheets is cut with the trimming amount Lc 1 , as shown in FIGS. 5C and 5( d ), then the rotating table 64 b is turned 180 degrees to cut the tail portion of the booklet sheets with the trimming amount Lc 2 . These trimming amounts Lc 1 , Lc 2 , are calculated by Lc 1 =Lc 2 [[(inner sheet size)−(finished size)]÷2], for example. Next, the rotating tables 64 a , 64 b are rotated 90 degrees to cut the fore-edge portion with the trimming amount Lc 3 . The trimming amount Lc 3 is calculated by Lc 3 =(inner sheet size)−(finished size), for example.
On the other hand the cover sheet trimming amount is calculated in the same way as described above. The trimming amount Ld 3 of the foe-edge portion of the cover sheet is calculated by Ld 3 =[[(inner sheet size)−(bundle thickness)]÷2−(finished size)], for example. The trimming amount Ld of the cover sheet and the trimming amount Lc of the inner sheets are calculated for each, and the longer of the two is set to the trimming position to execute the trimming process. The trimming amount computing means 78 , described below, is configured in this way.
Finisher Configuration
The bookbinding unit C is arranged in the finishing unit D. The finishing path 39 is connected to cover sheet conveyance path 34 for the finishing unit D and a finisher, such as a staple unit, punch unit, and stamp unit or the like, is disposed in the finishing path 39 a . Printed sheets are received from the image-forming apparatus A via the cover sheet conveyance path 34 and stapled, punched or applied with a mark, then conveyed to the discharge tray 37 . It is also possible not to apply any finishing process on printed sheets and to store them in the discharge tray 37 directly from the image-forming apparatus A.
Control Means Configuration
The configuration of the control means in the apparatus described above will now be explained with reference to FIG. 8 . The present invention described above is configured to calculate the folded position according to the trimming amount when sheets are folded to a Z-fold, when the system is set to a mode for bookbinding sheets conveyed from the image-forming unit. FIG. 8 is a block diagram to assist in describing the conveyance of the control means. As shown in FIG. 1 , in the system that connects the image forming unit A, the sheet folding unit B and the bookbinding unit C, a control panel 71 and mode selection means 72 are furnished on the control unit CPU 70 equipped on the image forming apparatus A, for example. A control CPU 75 is provided in the control unit of the bookbinding unit C. This control CPU 75 calls up a bookbinding execution program from the ROM 76 and executes each process in the bookbinding path 33 .
This control CPU 75 receives a finishing mode instruction signal, job end signal, sheet size information, and other information and command signals required in the bookbinding process from the control CPU 70 of the image-forming unit A. On the other hand, sheet sensors Se 1 to Se 6 are arranged in the positions shown in FIG. 3 to detect the sheets (sheet bundle) conveyed to the conveyance path 31 , bookbinding path 33 , and cover sheet conveyance path 34 . Detection signals from the sheet sensors Se 1 to Se 6 are transmitted to the control CPU 75 ; the control CPU 75 is provided with “folding operation control unit 75 a ;” “stacking operation control unit 75 b ;” “adhesive application operation control unit 75 c ;” “cover sheet operation control unit 75 d ;” “trimming operation control unit 75 e ;” “stack operation control unit 75 f ;” “folding predetermined position calculating means 73 ;” and “trimming amount calculation means 78 .” The bookbinding process is executed according to the flowchart shown in FIG. 9 .
Trimming Amount Calculation Means Configuration
The trimming amount calculation means 78 is configured in the control CPU 75 , and calculates the amount of the edges of the sheet bundle to trim after the bookbinding process. For that reason, the trimming amount calculation means 78 receives the folding specifications information and sheet size information set by the mode on the image-forming unit A from the control unit 70 of the image-forming unit A.
To explain this with reference to FIG. 8 , the trimming amount calculation means 78 receives size information of the inner leaves of sheets not folded (hereinafter referred to as inner sheets) and size information of the cover sheet from the control unit 70 on the image-forming unit A.
On the other hand, the trimming amount calculation means 78 receives the bookbinding finishing size information transferred from the image-forming unit A. This finishing size is specified from either of the trimming conditions of whether the size information is what the operator selected such as JIS standard A5 size and the like for example, or a preset trimming amount of “αmm (it is acceptable for the operator to specify 5 mm, for example).
The trimming amount calculation means 78 calculates the (1) inner sheet trimming amounts (hereinafter called the length) Lc 1 , Lc 2 and Lc 3 according to the trimming conditions above from that information. The calculating method is as described above when the finishing size is specified. (2) Next, the trimming amount calculation means 78 calculates the cover sheet trimming amount Ld 1 (head), Ld 2 (tail), and Ld 3 (fore-edge portion). In such a case, the bundle thickness of the inner sheets is considered.
Next, the trimming amount calculation means 78 compares the inner sheet trimming amount Lc and cover sheet trimming amount Ld with the head, tail and fore-edge portion sides to set the longest of the inner sheet and cover sheet to the actual trimming amount. Note that such calculation of the trimming amount differs according to the system configuration. For example, if the size of sheet specified by the image-forming unit A is not prepared, and the bookbinding process is executed by printing on a size of sheet that is larger than the specified size and the excess portions are trimmed, it is necessary for the operator to specify “finished size.”
Configuration of Folding Position Calculating Means
Next, the folded position calculation means 73 is configured in the control CPU 75 , and calculates the folded position of the sheets folded at the sheet folding unit B. To explain with reference to FIG. 8 , when folding a sheet to a Z-fold, the folded position calculation means 73 calculates the inner-facing folding position N 1 and the outer-facing folding position N 2 , as described above. The length L 1 to the spine edge and inner-facing folding position and the length L 3 to the front edge portion and outer-facing folding position are calculated. This calculation is done using L 1 =L 3 [[(sheet size)−(binding amount)÷3] when the folding specifications are set to a Z-fold. If the folding specifications are set for ¼ Z-fold, this calculation is done using L 1 =[(sheet size)÷2], and L 3 =[(sheet size)÷4]. The present invention has a feature to set the actual folding position from the above calculation values of L 1 , L 3 , and the trimming amount (Lc or Ld described above).
In other words, when L 1 (the length of the spine edge and the inner-facing folding position) is smaller than the length of the bookbinding finishing size, the calculated folding length is set to the inner-facing folding position N 1 . Also, when this L 1 is L 1 ≧bookbinding finishing size, this is set to L 1 =(bookbinding finishing size−β). Note that β is set to a preset, arbitrary value, considering discrepancy of the trimming position. By setting to this, the inner-facing folding position N 1 (see FIG. 4 ) is set to a size smaller than the bookbinding finishing size, and the folding position will not be cut off when performing the subsequent trimming process.
Explanation of Bookbinding Operation
Next, the bookbinding process operations using the control CPU 75 will now be explained with reference to the flowchart block diagram of FIGS. 9 and 10 . Image forming conditions and a finishing mode are set (St 001 ) using the control panel 71 on the image-forming apparatus A. “Print-out mode,” “bookbinding mode,” “staple mode,” “marking mode,” “hole-punching mode,” and “jog mode” can be set as the finishing mode, for example. At the same time as this, folding specifications whether to fold the sheet are set according to the sheet size. When the system is set to “bookbinding mode” using the mode setting, the present invention specifies whether to implement “fold-printing” or “fold which image.”
In the print-out mode, a sheet formed with an image does not undergo the bookbinding process or the finishing, and is conveyed out to the discharge tray 37 (equipped on the finisher unit D shown in the drawings) and stored. With the bookbinding mode, sheets formed images are aligned and stacked, then joined with a cover sheet and stored in the storage stacker 67 . Also, in the staple mode, sheets formed with images are stapled by a stapling unit equipped in the finisher unit D; in the marking mode, a mark is applied; in the hole-punching mode, holes are punched in the sheets; and in the jog mode, sheets are sorted. Each of these modes is executed by the finisher unit D, and then the finished sheets are stored in the discharge tray 37 .
The following will now explain a finishing mode when the “bookbinding mode” is selected and fold-printing is specified. When each mode for finishing is set (St 001 ), the control CPU 75 executes each finishing mode specified when the system is set to a mode other than the “bookbinding operation.” When the “bookbinding operation” is set, the control CPU 75 determines whether trimming was specified (St 003 ).
When the “trimming process” is specified, the control CPU 75 determines whether “fold-printing” was set, though not shown, and if it is not set, the system executes the normal order of operations of forming images, aligning and stacking, bookbinding, and trimming. On the other hand, if “fold-printing” is specified, the control CPU 75 calculates a virtual trimming length (St 004 ). When the apparatus is configured to cover the sheet bundle with a cover sheet, this virtual trimming length calculates the trimming position (see the trimming line in FIG. 4D ) when trimming to finish the sheet bundle using the sheet size of the inner leaves of sheets, the cover sheet size and virtual thickness size, and the minimum trimming amount (Δx). The virtual sheet bundle thickness at this time is found using the “maximum tolerable booklet thickness” preset according to the apparatus configuration, or the scheduled number of sheets to print (“the number of inner leaves of sheets”דaverage paper thickness”). This virtual trimming length is to set the folding position when folding sheets. The present invention executes a first control mode and a second control mode, described below, according to the virtual trimming length when performing the folding operation.
Next, the control CPU 75 determines whether it is a “folding specification image.” (St 005 ). Images are formed according to the specified printing conditions (St 006 ) when folding specification images are used. In the forming of images, image data da 1 and foldout image data da 2 are read out from the image data processor 18 d , and the series of image data da 1 and foldout image data da 2 is printed in parallel at the same time. At this time, the control CPU 75 prints foldout images to outside (the fore-end portion of the sheet) the trimming line based on the previously calculated virtual trimming length. Next, the control CPU 75 executes the folding operation on the printed sheet using the sheet folding means 21 . The folding position at that time is set to outside the trimming line so the folding position is trimmed based on the virtual trimming length (St 007 ). In other words, the folding position of the sheet folding means is set (second control mode) to within the region of the trimming amount of the virtual trimming means. The sheet is folded at the folding position set in this way. Next, the foldout images are formed and the control CPU 75 sends the folded sheet to be stacked in the stacker 40 , described below.
On the other hand, when the system is not set to “folding specification image,” the control CPU 75 forms images based on the series of image data da 1 . (St 009 ) At that time, the control CPU 75 determines whether to “fold the sheet.” (St 010 ). When the sheet is not folded, the system shifts to the sheet stacking step, described below. The control CPU 75 sets the folding position using the folding position calculating means when the control CPU 75 has determined that the sheet is to be folded. The folding position is set to a position where it is not trimmed when trimming by positioning the folding position within the trimming line based on the virtual trimming length (first control mode).
Then, the control CPU 75 folds the sheet using the sheet folding means 31 according to the folding position set by the first control mode. This sheet folding specification folds the sheet using the folding method specified, such as a single fold or Z fold. The system shifts to the sheet stacking step, described below, for the folded sheet.
On the other hand, the control CPU 75 forms images based on the series of image data da 1 when “trimming” is not specified at St 003 . (St 013 ) Next, the control CPU 75 determines whether to “fold the sheet.” (St 014 ). When the folding process is not being applied, the system shifts to the sheet stacking step, described below. Also, when folding the sheet, the control CPU 75 executes the folding process according to the specified sheet folding specifications (St 015 ), then the system shifts to the stacking step, described below.
Images are formed in the way described above, and the folded sheet is conveyed from the sheet conveyance path 31 to the stacker 41 (St 016 ). Next, when the job end signal is received from the image-forming unit A, the control CPU 75 conveys the sheet bundle on the stacking tray 41 by the gripping conveyance means 47 to turn the sheet bundle posture 90 degrees (St 017 ). This changes the posture of the sheet bundle collated on the stacking tray 41 from a horizontal orientation to a vertical orientation to be conveyed over the bookbinding path 33 to the downstream adhesive application position F (St 018 ).
Approximately the time the sheet bundle is fed and set at the adhesive application position F, images are formed on the cover sheet at the image-forming apparatus A (St 019 ). The control CPU 75 feeds the cover sheet to the cover sheet conveyance path 34 . This cover sheet can be fed after being formed with an image at the image-forming unit A, or fed from the inserter unit E.
The sheet fed by the sheet feed path P 3 is conveyed to the conveyance path 31 . At this time the CPU 75 positions the path switching flapper 36 in the state shown in FIG. 1 to guide the sheet to the cover sheet conveyance path 34 . A registration mechanism (not shown) is furnished in the cover sheet conveyance path 34 to correct the posture of the sheet; sheets aligned by the registration mechanism are conveyed a predetermined distance from that position to reach the cover sheet binding position G and are stopped there (St 020 ). After the conveyance and setting of the cover sheet, the control CPU 75 drives the adhesive application means 55 to apply adhesive to the sheet bundle set at the adhesive application position F (St 021 ). The adhesive container 56 equipped with the applicator roller 57 moves along the tail edge of the sheet bundle to apply adhesive coated on the roller surface onto the sheet bundle.
After finishing the adhesive application operation, the control CPU 75 conveys the sheet bundle to the downstream cover sheet binding position G using the gripping conveyance means 47 . When this happens, the cover sheet is set at that position so the cover sheet is backed up by the spine support plate 61 and joined to the sheet bundle in an upside-down T-shape. Next, the sheet bundle covered by the folding plates 62 press-forming the backside of the cover sheet.
After the covering process above, the control CPU 75 determines whether a trimming mode has been selected (St 023 ). For the trimming mode, the gripping conveyance means 47 releases from the sheet bundle and returns to its default position. A trimming blade 65 x is positioned at the trimming position H and stops the descending sheet bundle (St 024 ). In this state, the movable rotating table 64 b moves from the standby position to a sheet gripping position to nippingly hold the sheet bundle between itself and the rotating table 64 a (St 025 ). Next, after the control CPU 75 moves the trimming blade 65 x to the standby position, it revolves the rotating tables 64 a , 64 b 90° to turn the sheet bundle so that its head is at the tail side (St 026 ). There, the trimming edge pressing member 65 b pressingly holds the sheet bundle and the trimming blade 65 x cuts a predetermined amount (St 027 ).
At this time, the present invention trims the fore-edge of the sheet bundle last after trimming the head and tail portions when trimming the edges of the bound sheet bundle. Next, the control CPU 75 retracts the trimming edge pressing member 65 b to the standby position, then turns the covered sheet bundle 180 degrees so that the other side is at the tail to trim the tail portion. Next, the control CPU 75 retracts the trimming edge pressing member 65 b to the standby position, then turns the sheet bundle 90 degrees so that the other side is at the tail to cut the tail portion (St 028 ). After the sides of the sheet bundle are cut and aligned in this way, the control CPU 75 ends trimming the three directions of the sheet bundle and shifts to the discharge operation.
On the other hand, at step St 023 above, if there is no trimming mode selected, the control means 75 shift to the next discharge operation (St 029 ). When “fold-printing” is not included, the system shifts to the discharge operation (St 032 and St 033 ). On the other hand, when it is determined that the “fold-printing” is included, the sheet bundle is revolved to face the fore-end portion at the trimming position (St 030 ). Also, the trimming process is executed (St 031 ) to trim free the foldout image. Next, the control CPU 75 stores this sheet bundle in the storage stacker 67 (St 032 , St 033 ).
The following will now describe the bookbinding method according to the present invention. The system is composed of “image-forming steps” (St 006 and St 009 ) to sequentially form images on a plurality of sheets based on predetermined image data da 1 ; a “folding process step” (St 008 ) to fold sheets formed with images; a “stacking step” (St 016 ) that collates sheets formed with images and/or sheets folded in the folding process step; a “bookbinding step” (St 022 ) that binds a spine edge of a sheet bundle collated in the stacking step; and “trimming steps” (St 027 , St 031 ) that trims at least the fore-edge portion of the sheet bundle bound at the bookbinding step.
Also, at the image-forming step (St 006 ), a foldout image area is set and images are formed on at least one of a series of sheets to be formed with images; at the folding process step (St 008 ), the foldout image area is folded at the folding back position; at the trimming steps (St 027 , St 031 ), the foldout image area is trimmed at the folding position and separated to fit inside the sheet bundle.
It is to be noted that this application claims priority rights from Japanese Pat. App. No. 2007-182604, which is herein incorporated by reference.
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First document/image data is printed onto a sequence of sheets that includes sheets of a given size, and sheet(s) of a size that in at least one dimension is larger than the sheets of the given size. At the same time the first document/image data is being printed, second document/image data, i.e., foldout data, is printed onto the outer margin, i.e., a foldout portion, of the sheet(s) of the larger size. The larger-size, foldout sheet(s) is then folded so as to be creased near its overlap with the given-size sheets, and is collated into the sequence of the given-size sheets to form a bundle that is then bound. Thereafter trimming to size the non-bound edge(s) of the bundle slices away the crease in the foldout sheet, leaving the foldout cut-away as an insert tucked into the booklet.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. application Ser. No. 12/483,185, filed on Jun. 11, 2009, now U.S. Pat. No. 7,728,062, which in turn is a divisional of U.S. application Ser. No. 11/240,431, filed on Sep. 30, 2005, now U.S. Pat. No. 7,563,842, which claims priority to U.S. provisional application Ser. No. 60/621,501, filed on Oct. 22, 2004.
BACKGROUND
The use of inkjet printing systems in offices and homes has grown dramatically in recent years. The growth can be attributed to drastic reductions in cost of inkjet printers and substantial improvements in print resolution and overall print quality. While the print quality has drastically improved, research and development efforts continue toward improving the permanence of inkjet images because this property still falls short of the permanence produced by other printing and photographic techniques. A continued demand in inkjet printing has resulted in the need to produce images of high quality, high permanence, and high durability, while maintaining a reasonable cost.
In inkjet printing, the inkjet image is formed on a print medium when a precise pattern of dots is ejected from a drop-generating device known as a printhead. The typical inkjet printhead has an array of precisely formed nozzles located on a nozzle plate and attached to an inkjet printhead array. The nozzles are typically 30 to 40 micrometers in diameter. The inkjet printhead array incorporates an array of firing chambers that receive liquid ink, which includes pigment-based inks and/or dye-based inks dissolved or dispersed in a liquid vehicle, through fluid communication with one or more ink reservoirs. Each chamber has a thin-film resistor, known as a firing resistor, located opposite the nozzle so ink can collect between the firing resistor and the nozzle. Upon energizing of a particular firing resistor, a droplet of ink is expelled through the nozzle toward the print medium to produce the image. The printhead is held and protected by an outer packaging referred to as a print cartridge or an inkjet pen.
However, there is still a need for pigment-based ink having stability, low viscosity, and compatibility with multiple solvents and paper types, as well as being able to produce images of high gloss, uniform area fill, and good black/color mixing, while maintaining a reasonable cost.
SUMMARY
Briefly described, embodiments of this disclosure include ink formulations. One exemplary ink formulation, among others, includes an aqueous vehicle; a pigment dispersed throughout the aqueous vehicle, the pigment having polymeric binders attached thereto; and at least one unattached polymeric binder dispersed throughout the aqueous vehicle; wherein the polymeric binders attached to the pigment are chemically similar to the at least one unattached polymeric binder.
One exemplaryink composition, among others, includes a pigment A represented by the formula in FIG. 3 , wherein a ratio of n to m is about 1.1 to about 4:1, wherein o and p can each be about 5 to 100% of the value of m, wherein PEG is polyethylene glycol and PPG is polypropylene glycol, and wherein ● is a pigment.
Another exemplaryink composition, among others, includes a pigment B represented by the formula in FIG. 4 , wherein R1 can be selected from the following: H and methyl, wherein R2 can be selected from the following: an alkyl group, wherein the value of x, y 1 , and y 2 correspond to an acid number that is from about 3 to 500, wherein the value of x, y 1 , and y 2 correspond to a glass transition temperature of about −30 to 120° C., wherein the value of k is about 0 to 100%, wherein the value of z is about 5 to 80% of the value of y 1 , wherein PEG is polyethylene glycol and PPG is polypropylene glycol, and wherein ● is a pigment.
Another exemplaryink composition, among others, includes a pigment C represented by the formula in FIG. 5 , wherein the value of a, b, and c correspond to an acid number that is about 3 to 500, wherein the value of a, b, and c correspond to a glass transition temperature of about −30 to 120° C., wherein PEG is polyethylene glycol and PPG is polypropylene glycol, and wherein ● is a pigment.
Another exemplaryink composition, among others, includes a pigment D represented by the formula in FIG. 6 , wherein the ratio of e to f is about 1:1, wherein the value of g is about 5 to 100% of the value of f, wherein the value of h is about 1 to 10, wherein PEG is polyethylene glycol and PPG is polypropylene glycol, and wherein ● is a pigment.
Another exemplaryink composition, among others, includes a pigment E represented by the formula in FIG. 7 , wherein the value of q is about 1 to 100, wherein the value of r is about 1 to 100 monomer units per chain, wherein the value of s is about 1 to 100 monomer units per chain, wherein the value of t is about 1 to 100 monomer units per chain, and wherein ● is a pigment.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of this disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale.
FIG. 1 is a schematic view of an embodiment of the ink composition of the present disclosure.
FIG. 2 is a schematic view of an embodiment of the ink composition disposed on a substrate.
FIG. 3 illustrates an embodiment of a representative reaction mechanism to produce a modified pigment A.
FIG. 4 illustrates another embodiment of a representative reaction mechanism to produce a modified pigment B.
FIG. 5 illustrates another embodiment of a representative reaction mechanism to produce a modified pigment C.
FIG. 6 illustrates another embodiment of a representative reaction mechanism to produce a modified pigment D.
FIG. 7 illustrates another embodiment of a representative reaction mechanism to produce a modified pigment E.
FIG. 8 is an illustrative graph illustrating a comparison of a standard chemically modified yellow pigment and a representative embodiment of modified pigment A.
DETAILED DESCRIPTION
It has been fortuitously and unexpectedly discovered that novel ink compositions according to embodiments of the present disclosure advantageously exhibit desirable rheological properties. In addition, modified pigments, formulations, and methods of making modified pigments and formulations, are described. Exemplary embodiments of the disclosed modified pigments, when used in ink formulations, produce images of high gloss, uniform area fill, and/or good black/color mixing. Embodiments of the disclosed modified pigments have high stability, low viscosity, and compatibility with multiple solvent and paper types, as compared to other pigments.
Part A
As shown in FIG. 1 , embodiments of the ink composition 10 include both polymeric binders B attached to a pigment P and unattached/free polymeric binders F dispersed throughout a vehicle 16 . It is contemplated that the viscosity of the ink composition 10 may be lowered when the attached polymeric binders B and free polymeric binders F are chemically similar. Without being bound to any theory, it is believed that this reduction in viscosity may be due in part to the addition of the chemically similar free polymeric binders F, which may substantially reduce electrostatic and/or electrosteric interactions between the attached binders B and the vehicle 16 .
It is to be understood that the vehicle 16 is an aqueous vehicle in embodiments of the present disclosure. As used herein, “aqueous vehicle” refers to the vehicle 16 in which pigment/colorant P is placed to form an ink composition 10 . Ink vehicles are known in the art, and a wide variety of ink vehicles may be used with embodiments of the compositions, systems and methods of the present disclosure. Such aqueous vehicles 16 may include solvents, including but not limited to glycols, amides, pyrrolidones, and/or the like, and/or mixtures thereof in amounts ranging between about 0.01 and 20 wt %; alternately, between about 0.01 and 7 wt %; or between about 0.01 and 4 wt %. Aqueous vehicles 16 may also optionally include one or more water-soluble surfactants/amphiphiles in amounts ranging between about 0 and 5 wt %; alternately, between about 0.1 and 2 wt %. The balance of the aqueous vehicle 16 is generally water in embodiments of the present disclosure.
In embodiments of the ink composition 10 , one or more co-solvents may be added to the aqueous vehicle 16 in the formulation of the ink composition 10 . Examples of suitable classes of co-solvents include, but are not limited to, aliphatic alcohols, aromatic alcohols, diols, caprolactams, lactones, formamides, acetamides, long chain alcohols, and mixtures thereof. Examples of suitable co-solvent compounds include, but are not limited to, primary aliphatic alcohols of 30 carbons or fewer, primary aromatic alcohols of 30 carbons or fewer, secondary aliphatic alcohols of 30 carbons or fewer, secondary aromatic alcohols of 30 carbons or fewer, 1,2-alcohols of 30 carbons or fewer, 1,3-alcohols of 30 carbons or fewer, 1,5-alcohols of 30 carbons or fewer, N-alkyl caprolactams, unsubstituted caprolactams, substituted formamides, unsubstituted formamides, substituted acetamides, unsubstituted acetamides, and mixtures thereof.
Some specific suitable examples of co-solvents include, but are not limited to 1,5-pentanediol, 2-pyrrolidone, 1,2-hexanediol, 2-ethyl-2-hydroxymethyl-1,3-propanediol, diethylene glycol, 3-methoxybutanol, 1,3-dimethyl-2-imidazolidinone, and mixtures thereof. The co-solvent concentration may range between about 0.01 wt. % and 50 wt. %. In an embodiment, the co-solvent concentration ranges between about 0.1 wt. % and 20 wt. %.
In embodiments of the ink composition 10 of the present disclosure wherein water-soluble surfactants are added to the aqueous vehicle, it is to be understood that these surfactants may be added as free components to the ink composition 10 and are not otherwise associated or intended to become part of the polymeric binders B/unattached binders F described herein. Non-limitative examples of suitable surfactants include fluorosurfactants, non-ionic surfactants, amphoteric surfactants, ionic surfactants, and/or mixtures thereof.
Examples of suitable surfactants include, but are not limited to the following commercially available tradenames: ZONYLs (fluorosurfactants), available from E.I. du Pont de Nemours and Co. located in Wilmington, Delaware and TERGITOLs (alkyl polyethylene oxides), available from Union Carbide in Piscataway, N.J.
Examples of amphiphiles/surfactants that may be used in embodiments of the present disclosure include, but are not limited to iso-hexadecyl ethylene oxide 20 and amine oxides, such as N,N-dimethyl-N-dodecyl amine oxide, N,N-dimethyl-N-tetradecyl amine oxide, N,N-dimethyl-N-hexadecyl amine oxide, N,N-dimethyl-N-octadecyl amine oxide, N,N-dimethyl-N-(Z-9-octadec-enyl)-N-amine oxide, and mixtures thereof. The concentration of the amphiphiles/surfactants may range between about 0 wt. % and 5 wt. %. In an embodiment, the concentration of amphiphiles/surfactants ranges between about 0.1 wt. % and 2 wt. %.
It is to be understood that various types of additives may be employed in the ink composition 10 according to embodiments of the present disclosure to optimize the properties of the ink composition 10 for specific applications. For example, biocides may be used in an embodiment of the ink composition 10 to inhibit growth of microorganisms. One suitable non-limitative example of a biocide is commercially available under the tradename PROXEL GXL (a solution of 1,2-benzisothiazolin-3-one (BIT), sodium hydroxide, and dipropylene glycol) from Avecia Inc. located in Wilmington, Del. Sequestering agents such as EDTA may be included to substantially eliminate potential deleterious effects of heavy metal impurities (if any). Buffer solutions may be used to control the pH of the ink composition 10 , as desired and/or necessitated by a particular end use.
The ink composition 10 according to embodiments of the present disclosure includes pigment P dispersed throughout the aqueous vehicle 16 . It is to be understood that any suitable pigment P that is capable of having polymeric binders B attached thereto may be used. Some non-limitative examples of suitable pigments include those supplied by Cabot Corp. in Billerica, Mass. Non-limitative examples of some suitable polymer B attached pigments P are described in U.S. Pat. No. 6,432,194 assigned to Cabot Corporation and issued to Johnson et al. entitled “Method of attaching a group to a pigment,” which patent is incorporated herein in its entirety.
The pigment P may have any suitable polymeric binders B attached thereto. The attached polymeric binders B may be selected using a variety of parameters including, but not limited to molecular weight, acid number and/or the type of monomers within the polymeric binders B. In one embodiment, the molecular weight of the attached polymeric binders B ranges between about 4,000 and about 20,000. In another embodiment, the acid number of the attached polymeric binders B may range between about 50 and about 300. Examples of suitable monomers within the polymeric binders B include, but are not limited to styrene, acrylic acid, substituted acrylic acids, maleic anhydride, and/or substituted maleic anhydrides. In addition, the pigment P can include pigments such as those described in more detail in PART B.
Some non-limitative examples of polymeric binders B capable of attaching to the pigment P are polyurethane resins, styrene-acrylic resins/polymers/copolymers, styrene-maleic anhydride resins/polymers/copolymers, styrene-acrylic resins/polymers/copolymers having ethylene and/or propylene glycol graphed thereto, styrene-maleic anhydride resins/polymers/copolymers having ethylene and/or propylene glycol graphed thereto, and combinations thereof. Styrene-acrylic resins/polymers/copolymers having ethylene and/or propylene glycol graphed thereto and styrene-maleic anhydride resins/polymers/copolymers having ethylene and/or propylene glycol graphed thereto, are discussed in more detail in PART B (e.g., FIGS. 1 and 2 ).
Some suitable polyurethane resins are commercially available from Avecia in Manchester, England. Some suitable styrene-acrylic resins/polymers are commercially available under the tradenames JONCRYL 586 (J586), JONCRYL 671 (J671) and JONCRYL 696 (J696) from Johnson Polymer, Inc. located in Sturtevant, Wis., and SMA (Styrene Maleic Anhydride) polymers available from Sartomer located in Exton, Pa.
In an embodiment, the pigment P having polymeric binders B attached thereto is present in an amount ranging between about 1 wt. % and 10 wt. % of the ink composition and about 0.5 to 2 wt. % of the ink composition. In an alternate embodiment, the pigment P having polymeric binders B attached thereto is present in an amount ranging between about 3 wt. % and 5 wt. % of the ink composition 10 .
An embodiment of the ink composition 10 further includes at least one unattached/free polymeric binder F dispersed throughout the aqueous vehicle 16 . It is to be understood that the unattached polymeric binders F may be substantially homogeneously and/or non-homogeneously mixed throughout the aqueous vehicle 16 . In an embodiment, the unattached polymeric binders F are present in an amount ranging between about 0.1 wt. % and 6 wt. % of the ink composition. In an alternate embodiment, the unattached polymeric binders F are present in an amount ranging between about 1 wt. % and 3 wt. % of the ink composition 10 .
In an embodiment of the ink composition 10 of the present disclosure, selected unattached polymeric binders F are formed from a polymeric material that is chemically similar to the selected attached polymeric binders B. “Chemically similar” as defined herein denotes compounds that have the same or similar molecular weight, acid number and/or monomer composition. It is to be understood that “similar” in regard to molecular weights as defined herein is contemplated to encompass compounds having molecular weights ranging between about 4000 and 18000.
Similar to the attached polymeric binders B, in an embodiment of the ink composition 10 , the molecular weight of the unattached polymeric binders F ranges between about 4,000 and 20,000, and the acid number ranges between about 50 and 300. Non-limitative examples of suitable unattached polymeric binders F include the polyurethane resins and styrene-acrylic resins/polymers as previously described in reference to the attached polymeric binders B.
It is believed, without being bound to any theory, that when the unattached polymeric binders F and the attached polymeric binders B are chemically similar, the electrostatic and/or electrosteric interactions between the attached polymeric binders B and the aqueous vehicle 16 may be substantially reduced. This reduction may advantageously help to lower the viscosity of the ink composition 10 . The viscosity of the ink composition 10 of the present disclosure ranges between about 2 cps and 10 cps. In an alternate embodiment, the viscosity of the ink composition 10 of the present disclosure ranges between about 2 cps and 6 cps. The reduced viscosity of the ink composition 10 may advantageously help to improve ink reliability, ink durability, and print quality.
FIG. 2 illustrates an embodiment of the ink composition 10 deposited on a substrate 14 to form a pigmented ink system 12 . It is to be understood that the ink composition 10 may be deposited on the substrate 14 using any suitable printing technique, such as an ink jet printer. Examples of suitable substrate 14 materials include, but are not limited to cellulosic materials (e.g., paper materials), wood, textile materials, polymeric materials, metals and/or mixtures thereof.
In a method of making an embodiment of the ink composition 10 , an amount of the pigment P having polymeric binders B attached thereto is admixed in a selected aqueous vehicle 16 to form an ink fluid. Further, at least one unattached polymeric binder F may be admixed with the ink fluid to form the ink composition 10 . It is to be understood that the materials described above may be selected and that the attached polymeric binders B are substantially chemically similar to the unattached polymeric binders F.
To further illustrate the present disclosure, the following examples are given. It is to be understood that these examples are provided for illustrative purposes and are not to be construed as limiting the scope of the present disclosure.
PART A EXAMPLES
Table 1 of PART A illustrates various examples of the ink composition 10 according to embodiments of the present disclosure. The examples labeled A-J, list the ingredients used, the viscosity of the embodiment of the ink composition 10 .
TABLE 1
Examples A-J
Ingredients - all wt %
A
B
C
D
E
F
G
H
I
J
Cabot Pigment
4
4
0
0
0
0
0
0
0
0
J586 attached
Cabot Pigment
0
0
4
4
0
0
4
4
0
0
J671 attached
Cabot Pigment
0
0
0
0
4
4
0
0
4
4
J696 attached
Joncryl 586,
0
2
0
0
0
0
2.5
0
2.5
0
AN 108, Mw 4600
Joncryl 671,
0
0
0
2
0
0
0
0
0
0
AN 214, Mw 17250
Joncryl 696,
0
0
0
0
0
2
0
0
0
0
AN 220, Mw 16000
Fluorosurfactant
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
2-Pyrrolidone
7
7
7
7
7
7
7
7
7
7
1,2 Alkanediol
4
4
4
4
4
4
4
4
4
4
Proxel GXL
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
Water*
Bal
Bal
Bal
Bal
Bal
Bal
Bal
Bal
Bal
Bal
Viscosity
2.09
2.44
10.45
6.3
13.12
6.68
6.74
7.31
9.84
10.53
*Water makes up the balance (Bal) of the vehicle
Comparing ink compositions C and D illustrates how the addition of unattached binders B may reduce the viscosity of the final ink composition 10 . Example C contains CABOT PIGMENT with JONCRYL 671 attached thereto and no unattached binders in the aqueous vehicle 16 . The viscosity of ink composition C was 10.45 cps. Example D contains the same composition as Example C with the addition of 2 wt. % unattached JONCRYL 671. The viscosity of Example D was lowered to 6.3 cps, making the ink composition 10 more desirable for printing.
Without being bound to any theory, it is believed that the slight rise in viscosity between ink composition A and ink composition B may be due to the following. In this case, both the attached polymeric binder B and free polymeric binder F have low molecular weights, and the pigment P-binder B interactions are less than the vehicle 16 binder B interactions. Therefore, the ink viscosity increases slightly because of the vehicle 16 -binder B interaction. In other examples, the molecular weights of the polymers are higher; thus there is more pigment P-vehicle 16 interaction.
The ink compositions 10 according to embodiments of the present disclosure may offer many advantages, examples of which include, but are not limited to the following. The combination of the chemically similar attached polymeric binders B and unattached polymeric binders F may advantageously lower the viscosity of the ink composition 10 . The lower viscosity may result in improved pen reliability, ink durability, and/or high print quality. Still further, the addition of unattached polymeric binders F that are chemically similar to the attached polymeric binders B may advantageously reduce the electrostatic and/or electrosteric interactions between the attached polymeric binders B and the aqueous vehicle 16 .
Part B
In general, the modified pigment in FIG. 3 includes, but is not limited to, a styrene-maleic anhydride co-polymer having a polyethylene glycol (PEG) and/or polypropylene glycol (PPG) compound grafted thereon. The styrene-maleic anhydride co-polymer is attached covalently to a sulfatoethylsulfone-pigment via an amine-thio linkage (hereinafter “modified pigment A”). Typically, the PEG/PPG and the sulfatoethylsulfone-pigment are disposed on different monomers of maleic anhydride. The modified pigment A is substantially resistant to chemical attacks from acids, bases, and salts. In addition, the modified pigment A is miscible with various co-solvents due, at least in part, to the ethylene glycol and/or propylene glycol.
FIG. 3 illustrates an embodiment of a representative reaction mechanism to produce the modified pigment A. A styrene-maleic anhydride co-polymer is provided and then reacted with AET-HCl (AET=NH 2 CH 2 CH 2 SH), and an amine terminated PEG and/or PPG with a base (e.g., triethylamine), where the components are in a solvent such as, but not limited to, dimethyl sulfide (DMS). Under typical reaction conditions, the pH is basic (e.g., above 10.5). The product of the reaction is the styrene-maleic anhydride co-polymer having an amine-thio linkage on a maleic anhydride monomer and an amine terminated PEG and/or PPG on a different maleic anhydride monomer. The monomers can be randomly arranged or block arranged.
The percentage of amine terminated PEG and PPG grafted onto the styrene-maleic anhydride co-polymer backbone can range from about 0.01 to 90%, about 0.01 to 50%, or from about 5 to 20% based on the anhydride groups.
Next, the product is reacted with NaOH, a sulfatoethylsulfone-pigment, and sodium acrylate to produce modified pigment A. Under typical reaction conditions, the pH is basic (e.g., above a pH of 10.5). The amount of the styrene-maleic anhydride co-polymer covalently bonded to the surface area of the sulfatoethylsulfone-pigment can range from about 0.01 to 50%, about 0.01 to 20%, or from about 5 to 15%.
The ratio of n to m can be about 1.1, about 2:1, about 3:1, and about 4:1. The value of o and p can each be from about 5 to 100%, about 5 to 50%, or about 5 to 10% of the value of m.
The molecular weight of the styrene-maleic anhydride co-polymer having PEG and/or PPG (e.g., PEG, PPG, and combinations thereof (e.g., co-polymers thereof)) grafted thereon can range from about 1000 to 100,000, about 1000 to 30,000, or about 1000 to 10,000.
The molecular weight of PEG can range from about 300 to 10,000 MW, about 300 to 5,000 MW, about 500 to 2,000 MW. The molecular weight of PPG can range from about 300 to 5,000 MW, about 300 to 2,000 MW, or about 300 to 1,000 MW. The molecular weight of the co-polymer of polyethylene glycol and polypropylene glycol can range from between about 300 to 10,000 MW, 300 to 5,000 MW, or from 300 to 2,000 MW.
In general, the modified pigment in FIG. 4 includes, but is not limited to, a styrene-acrylate co-polymer having a PEG and/or PPG grafted thereon, attached covalently to a sulfatoethylsulfone-pigment via an amine-thio linkage (hereinafter “modified pigment B”). Typically, the PEG/PPG and the sulfatoethylsulfone-pigment are associated with different monomers of the acrylic monomer. The modified pigment B is substantially resistant to chemical attacks from acids, bases, and salts. In addition, the modified pigment B is miscible with various co-solvents due, at least in part, to the ethylene glycol and/or propylene glycol.
FIG. 4 illustrates an embodiment of a representative reaction mechanism to produce the modified pigment B. A styrene-acrylic co-polymer is provided and then reacted with NH 2 CH 2 CH 2 SH, HCl, and an amine terminated PEG and/or PPG. Under typical reaction conditions, pH is basic (e.g., above a pH of 10.5). R1 can be H or methyl. R2 can include an alkyl group. In particular, R2 can be H, methyl, ethyl, propyl, and butyl. The monomers can be randomly arranged or block arranged. The product of the reaction is the styrene-acrylic co-polymer having an amine-thio linkage on an acrylic monomer and an amine terminated PEG and/or PPG on a different acrylic monomer.
The percentage of amine terminated PEG and PPG grafted onto the styrene-acrylic co-polymer backbone can range from about 1 to 90%, about 1 to 50%, and from about 5 to 20% based on the reactive carboxylic acid groups. Next, the product is reacted with NaOH, a sulfatoethylsulfone-pigment, and sodium acrylate to produce modified pigment B. Under typical reaction conditions, pH is basic (e.g., above pH of 10.5). The amount of the styrene-acrylic co-polymer covalently bonded to the surface area of the sulfatoethylsulfone-pigment can range from about 0.01 to 50%, about 0.01 to 20%, and from about 5 to 15%.
The value of x, y 1 , and y 2 in modified pigment B correspond to an acid number that is from about 3 to 500, about 3 to 400, about 3 to 300, about 3 to 250, about 3 to 200, about 10 to 500, about 10 to 400, about 10 to 300, about 10 to 250, about 10 to 200, about 25 to 500, about 25 to 400, about 25 to 300, about 25 to 250, about 25 to 200, about 50 to 500, about 50 to 400, about 50 to 300, about 50 to 250, and about 50 to 200. In addition, the value of x, y 1 , and y 2 in modified pigment B correspond to a glass transition temperature of about −30 to 120° C., about −30 to 110° C., about −30 to 80° C., about −20 to 120° C., about −20 to 110° C., about −20 to 80° C., about −10 to 120° C., about −10 to 110° C., about −10 to 80° C., about 0 to 120° C., about 0 to 110° C., about 0 to 80° C., about 10 to 120° C., about 10 to 110° C., about 10 to 80° C., about 20 to 120° C., about 20 to 110° C., and about 20 to 80° C. The value of k in modified pigment B can be from about 0 to 100%, about 5 to 75%, about 5 to 50%, about 5 to 25%, or about 5 to 10% of the value of y 1 . The value of z in modified pigment B can be from about 5 to 80%, about 5 to 65%, about 5 to 50%, about 10 to 50%, and about 10 to 30% of the value of y 1 .
The molecular weight of the styrene-acrylic co-polymer having PEG and/or PPG grafted thereon can range from about 1000 to 100,000, about 1,000 to 20,000, about 2,000 to 15,000.
The molecular weight of PEG can range from about 300 to 10,000 MW, about 300 to 5,000 MW, about 500 to 2,000 MW. The molecular weight of PPG can range from about 300 to 5,000 MW, about 300 to 2,000 MW, about 300 to 1,000 MW. The molecular weight of the co-polymer of polyethylene glycol and polypropylene glycol can range from between about 300 to 10,000 MW, 300 to 5,000 MW, and from 300 to 2,000 MW.
In general, the modified pigment in FIG. 5 includes, but is not limited to, a styrene-acrylic co-polymer having a PEG and/or PPG grafted thereon, attached covalently to a sulfatoethylsulfone-pigment via an amine linkage (hereinafter “modified pigment C”). Typically, the PEG/PPG and the sulfatoethylsulfone-pigment are disposed on different monomers of acrylic monomer. The modified pigment C is substantially resistant to chemical attacks from acids, bases, and salts. In addition, the modified pigment C is miscible with various co-solvents due, at least in part, to the ethylene glycol and/or propylene glycol.
FIG. 5 illustrates an embodiment of a representative reaction mechanism to produce the modified pigment C. The sulfatoethylamine-pigment is provided and reacted with a polyamine (e.g., primary amine, secondary amine, and polyethyleneimine (PEI)) to produce an amine terminated sulfatoethylsulfone-pigment. The amine terminated sulfatoethylamine-pigment is reacted with a styrene-acrylic co-polymer having the PEG and/or the PPG grafted thereto to produce modified pigment C. The PEG/PPG and the sulfatoethylamine-pigment are disposed on different monomers of the acrylic monomer. The monomers can be randomly arranged or block arranged.
The styrene-acrylic co-polymer having the PEG and/or the PPG grafted thereto can be fabricated in a similar manner as described above in reference to FIGS. 3 and 4 and the accompanying text. The percentage of amine terminated PEG and PPG grafted onto the styrene-acrylic co-polymer backbone can range from about 0.01 to 90%, about 0.01 to 50%, and from about 5 to 20% based on the anhydride groups.
The amount of the styrene-acrylic co-polymer covalently bonded to the surface area of the amine terminated sulfatoethylamine-pigment can range from about 0.01 to 50%, about 0.01 to 20%, and from about 5 to 15%.
The value of a, b, and c in modified pigment C correspond to an acid number that is from about 3 to 500, about 3 to 400, about 3 to 300, about 3 to 250, about 3 to 200, about 10 to 500, about 10 to 400, about 10 to 300, about 10 to 250, about 10 to 200, about 25 to 500, about 25 to 400, about 25 to 300, about 25 to 250, about 25 to 200, about 50 to 500, about 50 to 400, about 50 to 300, about 50 to 250, and about 50 to 200. In addition, the value of a, b, and c in modified pigment C correspond to a glass transition temperature of about −30 to 120° C., about −30 to 110° C., about −30 to 80° C., about −20 to 120° C., about −20 to 110° C., about −20 to 80° C., about −10 to 120° C., about −10 to 110° C., about −10 to 80° C., about 0 to 120° C., about 0 to 110° C., about 0 to 80° C., about 10 to 120° C., about 10 to 110° C., about 10 to 80° C., about 20 to 120° C., about 20 to 110° C., and about 20 to 80° C.
The molecular weight of the styrene-acrylic co-polymer having PEG and/or PPG grafted thereon can range from about 1000 to 100,000, about 1,000 to 20,000, about 2,000 to 15,000.
The molecular weight of PEG can range from about 300 to 10,000 MW, about 300 to 5,000 MW, about 500 to 2,000 MW. The molecular weight of PPG can range from about 300 to 5,000 MW, about 300 to 2,000 MW, about 300 to 1,000 MW. The molecular weight of the co-polymer of polyethylene glycol and polypropylene glycol can range from between about 300 to 10,000 MW, 300 to 5,000 MW, and from 300 to 2,000 MW.
In general, the modified pigment in FIG. 6 includes, but is not limited to, a styrene-maleic anhydride co-polymer having a PEG and/or PPG grafted thereon, attached covalently to a sulfatoethylamine-pigment via an amine linkage (hereinafter “modified pigment D”). Typically, the PEG/PPG and the sulfatoethylamine-pigment are disposed on different monomers of maleic anhydride monomer. The modified pigment D is substantially resistant to chemical attacks from acids, bases, and salts. In addition, the modified pigment D is miscible with various co-solvents due, at least in part, to the ethylene glycol and/or propylene glycol.
FIG. 6 illustrates an embodiment of a representative reaction mechanism to produce the modified pigment D. The sulfatoethylamine-pigment is provided and reacted with polyamine (e.g., primary amine, secondary amine, and polyethyleneimine (PEI)) to produce an amine terminated sulfatoethylsulfone-pigment. The amine terminated sulfatoethylamine-pigment is reacted with a styrene-maleic anhydride co-polymer having the PEG and/or the PPG grafted thereto to produce modified pigment D. The PEG/PPG and the sulfatoethylamine-pigment are disposed on different monomers of the maleic anhydride monomer. The monomers can be randomly arranged or block arranged.
The styrene-maleic anhydride co-polymer having the PEG and/or the PPG grafted thereto can be fabricated by reacting structure P with an amine terminated PEG and/or PPG. The percentage of amine terminated PEG and PPG grafted onto the styrene-maleic anhydride co-polymer backbone can range from about 0.01 to 90%, about 0.01 to 50%, and from about 5 to 20% based on the anhydride groups.
The amount of the styrene-maleic anhydride co-polymer covalently bonded to the surface area of the amine terminated sulfatoethylamine-pigment can range from about 0.01 to 50%, about 0.01 to 20%, and from about 5 to 15%.
The ratio of e to f can be about 1:1, about 2:1, about 3:1, and about 4:1. The value of g is about 5 to 100%, about 5 to 75%, about 5 to 50%, or about 5 to 20% of the value of f. The value of h is about 1 to 10.
The molecular weight of the styrene-maleic anhydride co-polymer having PEG and/or PPG grafted thereon can range from about 1000 to 100,000, about 1000 to 30,000, about 1000 to 10,000.
The molecular weight of PEG can range from about 300 to 10,000 MW, about 300 to 5,000 MW, about 500 to 2,000 MW. The molecular weight of PPG can range from about 300 to 5,000 MW, about 300 to 2,000 MW, about 300 to 1,000 MW. The molecular weight of the co-polymer of polyethylene glycol and polypropylene glycol can range from between about 300 to 10,000 MW, 300 to 5,000 MW, and from 300 to 2,000 MW. In embodiments including both the PEG and PPG molecule, the ratio of PEG to PPG can be about 100:1, about 75:1, about 50:1, about 25:1, about 10:1, and about 1:1.
In general, the modified pigment in FIG. 7 includes, but is not limited to, a styrene co-polymer having the styrene monomer attached covalently to a pigment (hereinafter “modified pigment E”). In addition, the co-polymer includes, but is not limited to, monomer B, monomer C, and monomer D. Monomer B is a hydrophobic monomer, while monomer C is a hydrophilic monomer. The monomers can be randomly arranged or block arranged. It should be noted that prior to reaction, the styrene monomer is an amine styrene monomer, but the amine group is not present in the modified pigment E per the diazonium reaction described below.
In general, an amine-styrene co-polymer (including monomer B, monomer C, and monomer D) shown in FIG. 7 is reacted with HX (X can be Cl, nitrate, and methane-sulfonic), NaNO 2 , and water. The product of the reaction is a styrene co-polymer having a diazonium cation attached to the styrene benzene ring. Subsequently, the styrene co-polymer having a diazonium cation is reacted with a pigment through a reaction involving the diazonium cation, and the pigment is covalently bonded to the pigment through the styrene benzene ring. Diazonium chemistry and reaction parameters are discussed in U.S. Pat. Nos. 6,723,783; 5,554,739; 5,922,118; 5,900,029; 5,895,522; 5,885,335; 5,851,280; 5,837,045; and 5,922,118, and U.S. patent applications 20030217672 and 20040007152, each of which are incorporated herein by reference.
The amount of the amine-styrene co-polymer covalently bonded to the surface area of the pigment can range from about 5 to 50%, about 5 to 25%, and from about 5 to 15%.
Monomer B can include hydrophobic monomers such as, but not limited to, 2-ethylhexyl methacrylate, 2-hydroxyethyl methacrylate, acrylonitrile, vinylidene chloride, methyl methacrylate, methyl acrylate, ethyl acrylate, butyl acrylate, glycidyl, methacrylate, glycidyl acrylate, lauryl methacrylate, dodecyl methacrylate, styrene, chloromethyl styrene, benzyl methacrylate, butadiene, acrylamide, alkyl vinyl ether, silylated butadienes, divinylbenzene, trimethylsilyl methacrylate, alkoxysilane containing vinyl, p-vinylphenol, 2-vinyl quinoline, m-nitrostyrene, 4-hydroxystyrene, p-halomethyl styrene, 4-acetoxy styrene, 4-tert-butoxycarbonyloxy styrene and combination thereof.
Monomer C can include hydrophilic monomers such as, but not limited to, 2-aminoethyl methacrylate hydrochloride, acrylic acid, methacrylic acid, p-styrene sulfonate, p-methyl amino styrene, vinyl alcohol, p-dimethylamino styrene, vinyl pyridine, 2-methyl-5-vinyl pyridine, maleic anhydride, phenyl maleic anhydride, vinyl amine, vinyl acetate, ethylene-glycol methacrylate, propylene-glycol methacrylate, ethylene-glycol dimethacrylate, propylene-glycol dimethacrylate, trimethylolpropane trimethacrylate, 2-sulfo-1-dimethylethyl acrylamide, 4-styrene sulfonate, 2-sulfoethyl methacrylate, 4-styrene carboxylic acid, N-vinyl pyrrolidone, 1-vinyl imidazole, vinyl benzoic acid, and combinations thereof.
Monomer D can include monomers such as, but not limited to, acrylate, acrylic acid, maleic anhydride, macro-mers, and combinations thereof.
The value of q can be from about 1 to 100, about 1 to 75, about 1 to 50, about 1 to 25, and about 1 to 10 monomer units per chain. The value of r can be from about 1 to 100, about 1 to 75, about 1 to 50, about 1 to 25, and about 1 to 10 monomer units per chain. The value of s can be from about 1 to 100, about 1 to 75, about 1 to 50, about 1 to 25, and about 1 to 10 monomer units per chain. The value of t can be from about 1 to 100, about 1 to 75, about 1 to 50, about 1 to 25, and about 1 to 10 monomer units per chain.
For each of the modified pigments (or the precursor thereof), the monomer including styrene can, in the alternative, include a substituted styrene. Examples of a substituted styrene include, but are not limited to, p-methyl styrene, p-t-butyl styrene, p-chlorostyrene, p-bromostyrene, o-chlorostyrene, o-bromostyrene, 1,3,5-trichlorostyrene, 1,3,5-tribromostyrene, o-fluorostyrene, p-fluorostyrene, pentafluorostyrene, p-hydroxystyrene, p-pentylstyrene, and the like.
For each of the modified pigments (or the precursor thereof), maleic anhydride can be substituted for another anhydride monomer, such as, but not limited to, succinic anhydride, and itaconic anhydride, in other embodiments.
The pigment can include, but is not limited to, black pigment-based inks and colored pigment-based inks. Colored pigment-based inks can include, but are not limited to, blue, brown, cyan, green, white, violet, magenta, red, orange, yellow, as well as mixtures thereof.
The following black pigments can be used in the practice of this disclosure; however, this listing is merely illustrative and not intended to limit the disclosure. The following black pigments are available from Cabot: Monarch™ 1400, Monarch™ 1300, Monarch™ 1100, Monarch™ 1000, Monarch™ 900, Monarch™ 880, Monarch™ 800, and Monarch™ 700, Cab-O-Jet™ 200, Cab-O-Jet™ 300, Black Pearls™ 2000, Black Pearls™ 1400, Black Pearls™ 1300, Black Pearls™ 1100, Black Pearls™ 1000, Black Pearls™ 900, Black Pearls™ 880, Black Pearls™ 800, Black Pearls™ 700; the following are available from Columbian: Raven 7000, Raven 5750, Raven 5250, Raven 5000, and Raven 3500; the following are available from Degussa: Color Black FW 200, Color Black FW 2, Color Black FW 2V, Color Black FW 1, Color Black FW 18, Color Black S 160, Color Black FW S 170, Special Black 6, Special Black 5, Special Black 4A, Special Black 4, Printex U, Printex 140U, Printex V, and Printex 140V Tipure™; and R-101 is available from DuPont.
The pigment may also be chosen from a wide range of conventional colored pigments. For the purposes of clarification only, and not for limitation, some exemplary colorants suitable for this purpose are set forth below. The color of the second ink formulation can include, but is not limited to, blue, black, brown, cyan, green, white, violet, magenta, red, orange, yellow, as well as mixtures thereof.
Suitable classes of colored pigments include, for example, anthraquinones, phthalocyanine blues, phthalocyanine greens, diazos, monoazos, pyranthrones, perylenes, heterocyclic yellows, quinacridones, and (thio)indigoids. Representative examples of phthalocyanine blues include copper phthalocyanine blue and derivatives thereof (Pigment Blue 15). Representative examples of quinacridones include Pigment Orange 48, Pigment Orange 49, Pigment Red 122, Pigment Red 192, Pigment Red 202, Pigment Red 206, Pigment Red 207, Pigment Red 209, Pigment Violet 19 and Pigment Violet 42. Representative examples of anthraquinones include Pigment Red 43, Pigment Red 194 (Perinone Red), Pigment Red 216 (Brominated Pyanthrone Red) and Pigment Red 226 (Pyranthrone Red). Representative examples of perylenes include Pigment Red 123 (Vermillion), Pigment Red 149 (Scarlet), Pigment Red 179 (Maroon), Pigment Red 190 (Red), Pigment Violet 19, Pigment Red 189 (Yellow Shade Red) and Pigment Red 224. Representative examples of thioindigoids include Pigment Red 86, Pigment Red 87, Pigment Red 88, Pigment Red 181, Pigment Red 198,
Pigment Violet 36, and Pigment Violet 38. Representative examples of heterocyclic yellows include Pigment Yellow 1, Pigment Yellow 3, Pigment Yellow 12, Pigment Yellow 13, Pigment Yellow 14, Pigment Yellow 17, Pigment Yellow 65, Pigment Yellow 73, Pigment Yellow 74, Pigment Yellow 151, Pigment Yellow 117, Pigment Yellow 128, Pigment Yellow 138, and Yellow Pigment 155.
Such pigments are commercially available in either powder or press cake form from a number of sources including, BASF Corporation, Engelhard Corporation and Sun Chemical Corporation. Examples of other suitable colored pigments are described in the Colour Index, 3rd edition (The Society of Dyers and Colourists, 1982).
Other examples of pigments include Hostafinet series such as Hostafine™ Yellow GR (Pigment 13), Hostafine™ Yellow (Pigment 83), Hostafine™ Red FRLL (Pigment Red 9), Hostafine™ Rubine F6B (Pigment 184), Hostafine™ Blue 2G (Pigment Blue 15:3), Hostafine™ Black T (Pigment Black 7), and Hostafine™ Black TS (Pigment Black 7), available from Hoechst Celanese Corporation, Normandy Magenta RD-2400 (Paul Uhlich), Paliogen Violet 5100 (BASF), Paliogen™ Violet 5890 (BASF), Permanent Violet VT2645 (Paul Uhlich), Heliogen Green L8730 (BASF), Argyle Green XP-111-S (Paul Uhlich), Brilliant Green Toner GR 0991 (Paul Uhlich), Heliogen™ Blue L6900, L7020 (BASF), Heliogen™ Blue D6840, D7080(BASF), Sudan Blue OS (BASF), PV Fast Blue B2GO1 (American Hoechst), Irgalite Blue BCA (Ciba-Geigy), Paliogen™ Blue 6470 (BASF), Sudan III (Matheson, Coleman, Bell), Sudan II (Matheson, Coleman, Bell), Sudan IV (Matheson, Coleman, Bell), Sudan Orange G (Aldrich), Sudan Orange 220 (BASF), Paliogen™ Orange 3040 (BASF), Ortho Orange OR 2673 (Paul Uhlich), Paliogen™ Yellow 152, 1560 (BASF), Lithol Fast Yellow 0991K (BASF), Paliotol Yellow 1840 (BASF), Novoperm™ Yellow FG 1 (Hoechst), Permanent Yellow YE 0305 (Paul Uhlich), Lumogen Yellow D0790 (BASF), Suco-Gelb L1250 (BASF), Suco-Yellow D1355 (BASF), Hostaperm™ Pink E (American Hoechst), Fanal Pink D4830 (BASF), Cinquasia Magenta (DuPont), Lithol Scarlet D3700 (BASF), Toluidine Red (Aldrich), Scarlet for Thermoplast NSD PS PA (Ugine Kuhlmann of Canada), E. D. Toluidine Red (Aldrich), Lithol Rubine Toner (Paul Uhlich), Lithol Scarlet 4440 (BASF), Bon Red C (Dominion Color Company), Royal Brilliant Red RD-8192 (Paul Uhlich), Oracet Pink RF (Ciba-Geigy), Paliogen™ Red 3871K (BASF), Paliogen™ Red 3340 (BASF), and Lithol Fast Scarlet L4300 (BASF).
It should be noted that ratios, concentrations, amounts, and other numerical data may be expressed herein in a range format. It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a concentration range of “about 0.1% to about 5%” should be interpreted to include not only the explicitly recited concentration of about 0.1 wt % to about 5 wt %, but also include individual concentrations (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the indicated range.
PART B EXAMPLES
Table 1 of PART B lists ink formulations incorporating embodiments of various modified pigments. Tables 2 and 3 of PART B compare performances of IQ attributes on various glossy media. As shown, the ink formulation including the PEG modified pigment delivers higher gloss and better media independence.
TABLE 1
Ink Formulations Having Modified Pigments (Ink A) vs. Their
Traditional Counterparts (Ink B)
Ink ID
Ink A
Ink B
Ink A
Ink B
Light
Light
Black
Black
Gray
Gray
Polyethylene glycols
3
3
3
3
2-P
6
6
6
6
Glycerol
5
5
5
5
Aliphatic diols
4
4
4
4
Hydrocarbon surfactant
0.75
0.75
0.75
0.75
Neopentyl alcohol
0.75
0.75
0.75
0.75
Fluorosurfactant
0.2
0.2
0.2
0.2
Styrene-maleic anhydride co-
0.4
0.4
0.4
0.4
polymer binder
Black Pigment (PB1100/SMA3K-
2.00
0.50
PEG)
Black Pigment (PB1100/SMA3K)
2.00
0.50
DDI water
Balance
Balance
Balance
Balance
pH = 9.1 to 9.4 w/KOH for the vehicle and final inks.
Numbers are in % wt.
pH is about 9.1 to 9.4 with KOH for the vehicle and final inks
Numbers are in % weight
TABLE 2
Gloss of the Black Inks
20 Degree
20 Degree
60 Degree
Gloss with
Gloss with
Gloss with
Epx. Media 1)
Pictorico 2)
Luster Paper 3)
Print Density
Ink A
Ink B
Ink A
Ink B
Ink A
Ink B
(low to high)
Black
Black
Black
Black
Black
Black
Media (white)
44
44
34
34
24
24
Step 1
78
130
107
114
50
51
Step 2
84
150
114
143
59
67
Step 3
88
105
106
110
56
61
Step 4
78
87
113
91
56
56
Step 5
75
111
113
101
58
56
Step 6
77
111
110
103
57
58
Step 7
78
110
112
101
58
59
Step 8
74
113
107
96
58
59
Step 9
77
109
107
106
58
63
Step 10
55
119
106
112
58
64
Step 11
13
124
93
121
48
67
Step 12
8
102
78
136
40
68
Step 13
7
100
71
146
38
69
Step 14 (full
6
99
95
147
42
71
density)
Step 15
7
106
117
145
43
70
Average Gloss
53
107
99
113
50
60
1) Exp. Media: porous silica photo paper, HP in house media.
2) Pictorico: Pictorico Photo Gallery Glossy Paper by AGA chemicals, Inc and Olympus America, Inc.
3) Luster Paper: Epson Premium Luster photo paper.
TABLE 3
Gloss of the Light Gray Inks
20 Degree
20 Degree
60 Degree
Gloss with
Gloss with
Gloss with
Epx. Media 1)
Pictorico 2)
Luster Paper 3)
Ink A
Ink B
Ink A
Ink B
Ink A
Ink B
Print Density
Light
Light
Light
Light
Light
Light
(low to high)
Gray
Gray
Gray
Gray
Gray
Gray
Media (white)
44
44
34
34
24
24
Step 1
83
85
79
62
34
27
Step 2
167
139
135
94
53
42
Step 3
177
181
167
134
69
54
Step 4
175
181
175
166
79
65
Step 5
137
181
152
182
81
72
Step 6
96
181
136
182
81
81
Step 7
73
181
110
183
75
83
Step 8
66
176
90
175
68
82
Step 9
60
151
89
161
61
84
Step 10
34
140
82
155
51
78
Step 11
10
135
91
159
47
80
Step 12
4
64
107
147
48
80
Step 13
2
38
118
127
47
81
Step 14 (full
2
26
132
125
49
80
density)
Step 15
2
16
126
121
50
79
Average Gloss
71
120
114
138
57
68
1) Exp. Media: porous silica photo paper, HP in house media.
2) Pictorico: Pictorico Photo Gallery Glossy Paper by AGA chemicals, Inc and Olympus America, Inc.
3) Luster Paper: Epson Premium Luster photo paper.
FIG. 8 illustrates a graph comparing a yellow pigment chemically modified with traditional styrene-acrylic polymer (top curve, PY74 yellow pigment, and a yellow pigment chemically modified with SMA-Peg polymer (bottom curve) such as that illustrated in FIG. 3 .
When the pigment was de-stabilized under various triggering conditions, such as ionic strength and pH, particles started to coagulate. The rate of coagulation was measured by monitoring the time evolution of the flocculation size as determined by dynamic light scattering (DLS). A characteristic coagulation time was derived from fitting the DLS data. The impact of trigger condition and surface modification type on the coagulation time was determined and provides critical insight as to how the pigment coagulation can be controlled to yield optimal print performance.
The bottom curve (SMA-PEG treated pigment) was more stable than the yellow pigment chemically modified with traditional styrene-acrylic polymer. The stability directly translates into better photo image quality. Photo paper typically triggers the flocculation of pigment dispersion by releasing salt or causing pH changes.
Yellow Pigment and Measurement Details
Both PY74 pigment dispersions were made into 100 ppm stock solutions. From the stock solution 30 uL was injected into 3 mL of 0.01 mol HCl solution in a 1 cm disposable plastic cuvet to yield a particle concentrations of 1 ppm. After thorough mixing, the cuvet was placed into the DSL instrument and measurement started within 5 seconds. DLS measurements were performed on a BIC ZetaPlus from Brookhaven Instrument Corp. which is equipped with a 30 mW, 670 nm solid state laser. Scattered light at 90° was collected by a single mode fiber optic. Autocorrelation was performed with BI-9000AT Digital Autocorrelator with a user selectable channels up to 512. During this study 200 channels were used with BI-PSDW software.
Synthesis Example for A Representative of Modified Pigment A in FIG. 3 :
A solution was prepared by dissolving poly-styrene-co-maleic anhydride (SMA) (Available from Sartomer Company) in dry DMF. To this stirred solution, at room temperature, under a steady stream of nitrogen gas, was added amine terminated poly-ethylene oxide-co-propylene oxide (e.g., Jeffamine from Huntsman Corporation) and 2-aminoethanethiol hydrochloride as a solid in one portion and then triethylamine was added dropwise. The resultant mixture was heated at about 45° C. for about 30 minutes and then at room temperature for about 4.5 hours. The product was isolated by slowly dropping into vigorously stirred in HCl. After the addition, the mixture was stirred for another 60 minutes and then suction filtered, washed in HCl and then deionized water. The resulting product was briefly air dried to afford a free flowing white solid, which contained moisture. The moisture content could be measured by weight loss after heating at 110° C. for 1 hour.
The aminoethanethiolated-poly ethylene oxide-co-propylene oxide SMA polymer (SMA-PEG-thio) was dried at 110° C. Results from elemental combustion analysis could be used to characterize the modified polymers. Thiol was measured by titration with DTNB following a modification of Ellman's procedure (Ellman, G. L. (1958) Arch. Biochem. Biophys. 74, 443 ; Bioconjugate Techniques , Greg T. Hermanson, Academic Press, Inc., 1996, p 88).
The aqueous dispersion of Black Pearls® 1100 carbon black (available from Cabot Corporation) having attached a 2-(sulfatoethylsulfone) group was prepared according to the procedure described in PCT Publication No. WO 01/51566 to yield a pigment dispersion. This dispersion was added dropwise to the solution of the SMA-PEG-thiol polymer made above (dissolved with NaOH). An additional NaOH was added to raise pH to about 12-13. The resultant mixture was then stirred at about 40-50° C. for about 3.5 hours to give a dispersion of an embodiment of the modified pigment A.
A sodium acrylate solution was prepared by dissolving acrylic acid into DDI water containing about 11.7 of Na 2 CO 3 . This solution was added to the modified pigment dispersion to “cap” any unreacted thiol groups. Heating and stirring were continued for another 3 hours and the mixture was then allowed to cool to room temperature. The resultant dispersion was then purified by diafiltration to reach a final permeate polymer concentration of less than about 50 ppm.
Many variations and modifications may be made to the above-described embodiments. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.
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Briefly described, embodiments of this disclosure include ink formulation and modified pigments. One exemplary modified pigment, among others, includes a pigment A represented by the formula in FIG. 3.
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This invention relates generally to data processing systems and, more specifically, to a digital electro-optical system which detects the phase of incident fringe patterns.
BACKGROUND AND OBJECTS OF THE INVENTION
Important applications of current interest require that the relative phase of an incident fringe pattern vis-a-vis a fixed reference be determined. Such fringe patterns are developed, for example, by interference between split components of a coherent light beam and are used for purposes per se well known, e.g., to measure small distance displacements, surface contours or irregularities, object shapes and forms, and the like.
It is an object of the present invention to provide an improved electro-optical processing apparatus.
More specifically, it is an object of the present invention to provide an electro-optical system for measuring the phase or phase shift of a wave fringe pattern.
It is another object of the present invention to provide electro-optical fringe phase detection apparatus which averages a phase measurement over plural cycles (wavelengths).
Yet another object of the present invention is the provision of fringe pattern phase measurement structure operable on a time variable basis to obviate processing of bias or direct current signal constituents.
A still further object of the present invention is to provide electro-optical apparatus for effecting complex multiplication.
SUMMARY OF THE INVENTION
The above and other objects of the present invention are realized in specific, illustrative, electro-optical apparatus which measures the average relative phase of an incident wave fringe pattern. The subject fringe, e.g., an interferometric pattern, passes through three sections of an optical mask, one characterized by fixed transmissivity and the other two by quadrature-displaced spatial fringe patterns. The light passing through each section is separately collected and detected to average the respective incident wave/mask section interactions. The phase of the incident fringe pattern relative to the mask is then determined by arithmetically processing the detected signals.
In accordance with one aspect of the present invention, the subject fringe pattern is time modulated and the quadrature-shifted mask signals A-C coupled to obviate the requirement for the third, fixed transmissivity mask section. Pursuant to a further aspect of the instant invention, a fringe pattern may be made dependent upon the magnitude and phases of two complex numbers to permit complex multiplication.
DESCRIPTION OF THE DRAWING
The above and other features and advantages of the present invention will become more clear from consideration of a specific, illustrative embodiment thereof, presented hereinbelow in conjunction with the accompanying drawing, in which:
FIG. 1 is a block diagram of illustrative electro-optical apparatus for detecting the relative phase of an incident fringe pattern 10;
FIG. 2 is a side view characterizing the optical pattern employed on a mask 12 of FIG. 1;
FIG. 3 illustrates one particular application of the FIG. 1 apparatus as in an interferometer application; and
FIG. 4 schematically illustrates apparatus for generating a fringe pattern which depends upon, and which permits multiplication of, two complex numbers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is schematically shown apparatus for determining the phase of an incident fringe pattern 10, e.g., in the z direction impinging upon the left face of a mask 12. The fringe pattern 10 is shown as being one dimensional, i.e., as varying in the x direction only, where the FIG. 1 apparatus is utilized to determine the relative phase of the pattern 10 in that x direction. The fringe pattern 10 may be generated in any manner well known to those skilled in the art. Thus, for example, the fringe may be an interferometric pattern generated by an interference developed when the portions of a split coherent beam undergo different physical paths. The optical pattern on mask 12 is illustrated in FIG. 2 and is discussed in greater detail below. Suffice it for present purposes that the mask 12 has three sections, the upper of which 12 I represents an in-phase (i.e., 0-reference phase) component, the middle section 12 O comprising a zone of constant light transmissivity, and the lower section 12 Q of which is deemed the quadrature-displaced section.
Light from the incident fringe pattern 10 passing through the respective sections 12 I , 12 O and 12 Q of mask 12 is focused by a cylindrical averaging lens 10 onto one of three light detectors 17 I , 17 O or 17 Q respectively. The detector outputs are supplied to a signal processing circuit 22 described hereinbelow which provides an output signal to output utilization means 30. The output signal of circuit 22 characterizes the relative phase or phase displacement of the fringe pattern 10 relative to the quadrature-displaced sections 12 I and 12 Q of the mask 12.
Turning now to FIG. 2, there is shown the optical pattern for each of the zones 12 I , 12 O and 12 Q of mask 12. The pattern may be formed in any manner well known to those skilled in the art, e.g., by photodeposition. The in-phase upper section 12 I of mask 12 comprises a series of optically opaque areas 13 I having intermediate clear, light transmitting areas 14 I therebetween. The alternating areas 13 and 14 are shown of equal width (50% duty cycle) for purposes of illustration only. The relative sizes of adjacent areas 13 and 14 may be varied as desired subject only to the constraint that their combined width be equal to one wavelength of the fringe pattern, i.e., the distance between adjacent lines in the incident fringe field 10.
The lower, quadrature mask section 12 Q is of substantially the same form of the upper mask section 12 I , i.e., contains alternating opaque and transparent sections 13 Q and 14 Q with the combined widths of contiguous opaque and transparent sections being equal to one wavelength at the incident fringe pattern wave frequency. The optical pattern in the quadrature shifted section 12 Q is displaced by 90 electrical degrees with respect to the upper section 12 I . That is, for example, as illustratively shown in FIG. 2, the lower, quadrature section leads the pattern in the in-phase section 12 I by one quarter wavelength such that the leading edge of each opaque section 13 I begins in the middle of the corresponding opaque section 13 Q in the lower section 12 Q (for the assumed 50% duty cycle configuration). The purpose of the quadrature displacement is discussed hereinbelow. In FIG. 2, the right edge of the mask 12 is shown truncated. The mask 12 is made sufficiently wide to include a large number of fringe pattern wavelengths such that optical averaging occurs over a large number of wavelengths.
Finally, the central section 12 O of mask 12 includes an area of fixed transmissivity. For purposes below discussed, the transmission properties of the central section 12 0 is made to be one-half of the value between the clear and dark sections 14 and 13 of the mask sections 12 I and 12 Q . Alternatively, the mask section 12 O may be made clear, and a suitable electrical one-half correction made via an attenuator following the light detector 17 O below discussed.
With the above configuration in mind, attention will now be returned to FIG. 1. The apparatus there shown determines the relative phase or phase displacement of the incident fringe pattern 10. Let the transmittance of the mask 12 sections 12 I , 12 O and 12 Q be represented by T I , T O and T Q , where
T.sub.I =1/2 (1+cos kx) (1)
T.sub.O =1/2 (2)
T.sub.Q =1/2 (1-sin kx) (3)
The incident spatial fringe pattern 10 is described by
I(x)=A+B(x) cos(kx+φ) (4)
where A is the D-C bias intensity, B(x) is the fringe spatial modulation, if any, in the x direction; and φ is the fringe phase shift relative to the mask 12 which is to be determined.
The amount of light passing through the upper or in-phase section 12 I of mask 12 is the product of the light intensity I(x) incident and the transmissivity function T I of the mask portion 12 I :
I.sub.I =I(x)·T.sub.I =1/2(A+B(x)·cos(kx+φ)) +1/2(A cos(kx)+B(x)·cos(kx+φ)·cos kx) (5)
As earlier observed, the cylindrical lens 15 performs an integration or averaging function over the width of the mask 12 since all rays, wherever occurring, algebraically add when focused upon the light detector 17. Accordingly, all terms in the equation 5 representation of the light I I reaching detector 17 I which include a term cos kx (or any other sinusoidal function of x) go to zero, the integral of the cosine over many wavelengths being substantially zero. Accordingly, Equation 5 reduces to
I.sub.I =1/2A+1/2B(x)·cos(kx+φ)·cos kx (6)
Using the identity
cos A·cos B=1/2cos (A+B)+1/2cos (A-B), (7)
The light I I reaching detector 17 I is given by
I.sub.I =1/2A+1/4B(x)·cos(2kx+φ)+1/4B(x)·cosφ(8)
The middle term in Equation 8 being a function of cos(2kx+φ), this term goes to zero for the reason above discussed. Accordingly, the light incident detector 17 I is given by
I.sub.I =1/2A+1/4B cos φ, (9)
where B is the average of B(x) over the width of the mask. In many cases, B(x) will simply be a constant in any event even before averaging.
The light I 0 passing through the middle portion 12 0 of mask 12 and reaching the light detector 17 0 via the collecting lens 15 is given by the product of the incident light I(x) and the transmissivity T 0 of the middle portion, such that
I.sub.0 =1/2A+1/2B(x)cos(kx+φ) (10)
Since the second term in Equation 10 includes as a factor a cosine with an x-dependent argument, this term approaches zero and thus
I.sub.0 =1/2A. (11)
The light I Q reaching the light detector 17 Q via the mask lower portion 12 Q is the product of the incident light I(x) and the mask 12 quadrature section transmissivity T Q . By an analysis identically paralleling that given above for the upper mask portion 12 I in Equations 5-9,
I.sub.Q =I(x)·T.sub.Q =1/2A+1/4B sin φ. (12)
As above noted, it is the ultimate objective of the FIG. 1 system to determine a value for the displacement angle φ, i.e., the amount in which the incident fringe pattern 10 phase differs from the in-phase or reference phase mask component 12 I . To this end, it is observed that
φ=tan.sup.-1 (I.sub.Q -I.sub.O)/(I.sub.I -I.sub.O) (13)
since, by inserting the relationships for I Q (Eq. 12), I 0 (Eq. 11) and I I (Eq. 9) into Equation 13,
φ=tan.sup.-1 (B/4 cosφ)/B/4 sin φ)=tan.sup.-1 (sin φ/cos φ) (14)
For small angles where
φ≐tan φ, (15)
the approximation for 0 is
φ≐(I.sub.Q -I.sub.0)/(I.sub.I -I.sub.0). (16)
As above noted the light detector array 17 includes elements 17 I , 17 O and 17 Q for respectively providing an electrical output signal proportional to the light I I , I 0 and I Q incident thereon representing the component of the incident fringe pattern 10 which passes through the corresponding mask section 12 I , 12 0 and 12 Q via the averaging lens 15. Each detector 17 may comprise any device well known to those skilled in the art for converting a light amplitude into an electronic voltage amplitude, e.g., photomultipliers, photodiodes, or the like. Thus, the electrical output signals from the detector array 17 I , 17 0 and 17 Q provide a measure of the quantities I I , I 0 and I Q of Equations 9, 11 and 12, respectively.
In the signal processing circuit 22, an algebraic summing (here subtracting) element 26 (e.g., an operational amplifier with non-inverting and inverting inputs) generates the quantity I Q -I 0 in the arc tangent numerator of Equation 13 by subtracting 1/2A (Equation 11) from the I Q relationship of Equation 12. Similarly, an algebraic summing (arithmetically subtracting) element 23 develops the arc tangent denominator I I -I 0 of Equation 13 by subtracting 1/2A (Equation 11) from I I (Equation 9). The quotient (I Q -I 0 )/(I I -I 0 ) is then computed in a divider circuit 28 and may directly constitute a measure of the phase φ to be measured if small angle displacement is assumed (Equation 16). If larger angle displacements are permissible or contemplated in the application of the FIG. 1 system, output utilization means 30 (or signal processing circuit 22) includes apparatus for computing the arc tangent function of the argument supplied thereto by the divider 28 (Equation 13) to develop a more precise value for the phase angle φ. In either event, output utilization means is furnished with the phase angle φ for differing uses depending upon the specific application intended. Thus, for example, where distance is measured by interferometric interference, the phase angle φ represents distance and can be used in a servomechanism controller to reposition a controlled element as desired. This type of application is useful as in robotics to control the relative position of a robotic work element (e.g., welder, grasping arm or the like) vis-a-vis a work piece to be operated upon.
The signal processing circuit 22 is shown as implemented by discrete algebraical adder and divider elements 23, 26 and 28 which may be analog in nature. The signal processing circuitry 22 (and the arc tangent calculation of output utilization means 30 if desired) may of course all be implemented by a single microprocessor where the electrical representations of the light quantities I I , I 0 and I Q become microprocessor input variables entered as via a multiplexer and analog-to-digital converter.
The above arrangement has thus been shown to compute the relative phase of a one dimensional fringe pattern 10 relative to the reference phase defined by the upper section 12 I of a mask 12.
Turning now to FIG. 3, there is shown an interferometer application of the instant invention. A coherent light beam 50 is incident upon a beam splitting mirror 51. A portion of the incident beam reflected by mirror 51 follows a solid line path in FIG. 3 beginning with path portion 52 to the lower fully reflecting surface of a mirror 52. This reflected beam follows the path 54 passing through the mirror 51 and is incident upon the mask 12 via the path 55. A second portion of the light beam 50 incident the beam splitting mirror 51 follows the dotted path, passing through the mirror 51 and following the dotted path 57 to a second fully reflecting mirror 54, a mirror 54 reflected path leg 60, and a mirror 51 reflected path portion 62 to the mask 12.
The two coherent beam signals reaching the mask 12 via path legs 55 and 62 interfere and cause a fringe pattern 10 on the face of the mask 12 of the composite FIG. 1 apparatus. If any small displacement occurs for the mirror 54 relative to the mirror 52, the interference pattern will change its phase and this phase change will be detected by the FIG. 1 apparatus. Thus, the output of divider circuit 28 coacting with the utilization means 30 may be employed as an error detector in a servomechanism loop to maintain the relative distance between mirror surfaces 52 and 54 in any relationship desired to an accuracy a small fraction of the wavelength of the coherent light of beam 50. Obviously, one reflecting surface 52 or 54 may be fixed, and the other disposed on any mechanical element whose position is to be monitored or controlled.
The interferometer application above discussed and shown in FIG. 3 is for purposes of illustration only. For example, the fringe pattern 10 may vary in two directions (x and y shown in FIG. 1). A beam splitting mirror (comparable to the mirror 51 in FIG. 3) may be disposed to the left of the mask 12 in FIG. 1. The FIG. 1 apparatus will then operate in the manner fully set forth above to detect the phase displacement φ in the x direction. The FIG. 1 apparatus is also replicated in a vertical orientation (but rotated 90°) to detect the phase variation in the y direction of the incident two dimensional fringe pattern furnished by the beam splitting mirror.
Moreover, the instant invention is not limited to Cartesian fringe fields. Coherent light applications (e.g., lasers with end mirrors) generate an etalon fringe formed of concentric circles. The in-phase and quadrature mask components for such a fringe field formed of concentric circles would themselves thus be concentric circles spatially radially displaced by 90°. Similarly, any incident fringe field of whatever shape may be phase detected by having in-phase and quadrature masks or mask sections, again offset by 90 degrees (one-quarter of the inter-line spacing).
It is observed that the central mask section 12 0 was required to generate the quantity 1/2A (Equation 11) for purposes of the algebraic subtractions of Equation 13 and/or 15. In physical terms, this subtracts out a fixed, time-invariant bias term. If the quantities B/4 cos φ (Equation 9) and B/4 sin φ (Equation 12) can be made time dependent, the undesired A 1/2 bias term can be eliminated by high pass filtering. This may be effected, for example, by electronically controlling (modulating) the light passage portions 14 of mask sections 12 I and 12 Q (e.g., by making the clear portions 14 of electronically sensitive liquid crystals such that the portions are either opaque or transparent depending upon the applied potential). Once a time dependency is imparted, as above noted, the outputs of the light detectors 17 I and 17 Q are simply A-C (capacitively) coupled to the divider circuit 28 input terminals.
Turning now to FIG. 4, there is shown apparatus for generating a fringe pattern (output of Bragg cell 82) which permits complex multiplication after processing by the FIG. 1 apparatus. Applications of present importance require that two complex quantities be multiplied as in radar signal processing and radar signal jamming and noise avoidance, ultrasound signal processing to avoid spurious noise signals and so forth. In such applications a first complex number may be given by A 1 e i φ 1 and a second complex number given by A 2 e i φ 2. Such complex numbers are supplied in FIG. 4 via the sources thereof 65 and 68. A carrier source 70 is applied to two amplitude modulators 75 and 78 the outputs of which are thus A 1 cos(ωt+φ 1 ) and A 2 cos(ωt+φ 2 ). The first complex number at the ω carrier frequency is employed to modulate the amplitude of light supplied by a light source 80 which is used to strobe the Bragg cell 82. A lens may be employed intermediate light source 80 and Bragg cell 82 such that the entire width of the Bragg cell may be illuminated with a plane wave. The second signal representing a complex quantity at carrier frequency supplied by modulator 78 modulates the ultrasonic transducer in the Bragg cell.
As is per se well known, the ultrasonic transducer in a Bragg cell gives rise to alternating area of local compaction and rarification in the Bragg cell glass as the ultrasonic wave propagates therethrough, thus creating areas of increased and decreased index of refraction in the glass. Thus, when the light supplied by the source 80 passes through the Bragg cell, since it is of the same frequency as the excitation applied to the transducer (coherent signals), the output of the Bragg cell is in all material respects a fringe pattern. Since light source 80 acts as a strobe for the traveling acoustic wave through the Bragg cell glass, the areas of perceived light peaks and troughs shift spatially as the phase varies between complex numbers. Similarly, the amount of light exciting the Bragg cell is proportional to the product of the light supplied by source 80 (applied excitation) and the applied acoustic modulation (degree of index of refraction modulator).
In complex multiplication, it is desired to determine the quantity A 1 ·A 2 which is the amplitude of the multiplied complex numbers ad to obtain a measure of the sum of the complex phase angles, i.e., (φ 1 +φ 2 ). That is, the amplitude product and the phase angle sum provide the results of the complex multiplication. When the fringe pattern of FIG. 4 is applied to the FIG. 1 electro-optical system, the summed phase angle information is identically present at the output of the FIG. 1 divider circuit 28 (small angle assumption) or the arc tangent computation in output utilization means 30. Similarly, the amplitude product A 1 A 2 is available at the output of the light detector 17 0 with a scaling factor of "2" which can be supplied by an operational amplifier or otherwise in a manner well known to those skilled in the art. Accordingly, the fringe pattern developed in accordance with FIG. 4, impinging upon the FIG. 1 system, provides a fast, inexpensive way of rapidly effecting complex multiplication.
The above-described apparatus is merely illustrative of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention.
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Electro-optical apparatus measures the average relative phase of an incident wave fringe pattern. The subject fringe, e.g., an interferometric pattern, passes through three sections of an optical mask, one characterized by fixed transmissivity and the other two by quadrature-displaced spatial fringe patterns. The light passing through each section is separately collected and detected to average the respective incident wave/mask section interactions. The phase of the incident fringe pattern relative to the mask is then determined by arithmetically processing the detected signals.
In accordance with one aspect of the present invention, the subject fringe pattern is time modulated and the quadrature-shifted mask signals A-C coupled to obviate the requirement for the third, fixed transmissivity mask section.
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FIELD OF INVENTION
The invention relates to a method intended for applications in a paper machine or similar equipment, particularly for cleaning orifice slots or similar objects in the blow boxes or similar units of the press or dryer sections.
Further, the invention concerns an apparatus implementing said method according to the invention for cleaning the orifice slots of a blow box.
BACKGROUND OF THE INVENTION
Paper and board machines conventionally use blow boxes within the single-wire region for supporting the web. Such apparatuses are described in FI laid-open publication 69332 and FI laid-open publication 65460.
Air to the blow boxes is generally taken as recycle air from inside the hood of a paper machine or similar equipment. The recycle air is contaminated by, e.g., dust whose landing into the blow box clogs the orifice slots of the blow box at least partially, thereby worsening the efficiency of the box. Impairment of the box function causes web instability such as flutter, whereby the frequency of web breaks and other malfunctions increases. Obviously, such problems result in decrease of production output and profitability at the paper machine or similar equipment.
It is an object of the present invention to achieve a method capable of overcoming the problems associated with the clogging of the blow boxes. A further object is to attain apparatus implementing said method, suited for rapid and easy cleaning of the orifice slots.
SUMMARY OF THE INVENTION
The invention is based on cleaning the slots of the blow box from inside the blow box using means adapted to the inside of the box.
More specifically, the invention is characterized by what is stated in the characterizing part of claim 1.
Furthermore, the apparatus implementing the method is characterized by what is stated in the characterizing part of claim 5.
The invention offers several important benefits. The orifice slot of the blow box can be cleaned rapidly and easily. Thus, the clogging of the slots is avoided, whereby the web can be run stably and with less risk of web breaks. By arranging the cleaning means movable, a simple and effective system for cleaning the orifice slot is attained. Implementing the cleaning means by way of a cleaning jet nozzle from which the cleaning solution is ejected at elevated pressure, the cleaning efficiency can be further improved. A tilted orientation of the cleaning jet nozzle or the orifice holes of the nozzle provides an advantageous and fail-safe transfer arrangement of the nozzle head.
BRIEF DESCRIPTION OF THE DRAWING
In the following the invention is examined in greater detail by way of advantageous exemplifying embodiments with reference to the annexed drawings in which
FIG. 1 shows a side view of a blow box in which the method according to the invention is implemented for cleaning an orifice slot by means of a mechanical cleaning element,
FIG. 2 shows the blow box illustrated in FIG. 1 with the bottom plate removed,
FIG. 3 shows a detail of the blow box illustrated in FIG. 1,
FIG. 4 shows a side view of a blow box in which the method according to the invention is implemented by way of fixed cleaning jets for cleaning an orifice jet,
FIG. 5 shows the blow box illustrated in FIG. 4 with the bottom plate removed,
FIG. 6 shows an alternative embodiment of the arrangement illustrated in FIG. 4,
FIG. 7 shows a blow box in which the method according to the invention is implemented for cleaning an orifice slot by way of a moving cleaning jet,
FIG. 8 shows the blow box illustrated in FIG. 7 with the bottom plate removed, and
FIG. 9 shows a detail of the blow box illustrated in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a blow box 1 employed in the press or dryer section of a paper machine or similar equipment is shown in partially sectional side view. The blow box 1 has two orifice slots 2, 3, which are advantageously aligned perpendicular to the web machine direction extending advantageously over the entire width of the web, and a manifold for routing the blowing air into the slots. The orifice slot 2 is provided with a mechanical cleaning element 4 which is moved over the longitudinal direction of the orifice slot 2 by means of a drive machinery 5, 6, 7. The drive machinery is comprised of one or more, advantageously three, drive wheels, for instance chain sprockets 6, and a drive chain 5 or similar means routed through the drive wheel set. The cleaning element 4 is arranged movable along with the drive chain 5 or equivalent means as shown in FIG. 3. A drive actuator such as an electric motor 7 is arranged to rotate the drive wheels 6 via, e.g., a shaft. The motor can also be of a reversible type, thus permitting a reciprocating movement of the cleaning element in the orifice slot. The cleaning element 4 is advantageously a peg with a diameter of 1-5 mm for instance, advantageously 2 mm. The drive machinery can be interlocked with the automatic web break control system of the paper machine or equivalent equipment, whereby the cleaning sequence can be run automatically during a web break.
FIG. 4 shows a blow box 1 arranged to have several fixed cleaning jet nozzles 8, 9 for cleaning orifice slots 2, 3. The intermediate chamber 22 of the blow box 1 is adapted to incorporate one or more pipes 10, 11 into which a liquid and/or gaseous cleaning medium or a mixture thereof is routed. The cleaning jet nozzles 8, 9 are mounted to the pipes 10, 11 so that the orifice holes of the nozzle are advantageously aligned toward the orifice slots 2, 3 of the blow box. The pipes 10, 11 have a length advantageously extending over essentially the entire length of the blow box. The cleaning jet nozzles 8, 9 are mounted to the pipes 10, 11 at a spacing of approx. 4-10 pcs./meter. The nozzles 8, 9 are arranged into the blow box 1 in a manner permitting the cleaning medium jets exiting from the nozzles to cover essentially the entire area of the orifice slot 2, 3. In an advantageous embodiment an intermediate pipe 17 is adapted between the pipe 10 and the nozzle 8, whereby the nozzles 8 can be brought closer to the orifice slot 2. Then, the cleaning medium jet is aligned directly toward the orifice slot 2.
When necessary, the pipes 10, 11 can be connected in the interior of the blow box to the pipe 12 which is further connected via a pipe 13 to the piping network running outside the blow box 1. The inlet pipe to the cleaning system is advantageously provided with a filter element 15 for removal of impurities from the cleaning jet. The filter element 15 is advantageously a microporous filter with a pore size of 200-500 μm typical. The inlet pipe 13 is also equipped with a stop/control element 14, which with the help of a control means such as a timer controller 16 directs the cleaning medium into one blow box at a time. The stop/control element 14 is advantageously a solenoid valve. The cleaning medium is pumped with the help of a pump (not shown in the diagrams) into the plant piping network.
With reference to FIGS. 7, 8 and 9, another preferred embodiment is shown in which the intermediate chamber 22 of the blow box 1 is provided with a control element 18 such as a guide rail having a width advantageously extending essentially over the entire blow box. The blow box 1, advantageously its end, is equipped with a sealable opening through which a cleaning nozzle 23 can be mounted to the interior of the blow box 1. The cleaning nozzle 23 is adapted onto a counter piece 19 such as a sliding carriage or equivalent, compatible with the guide element 18, whereby the counter piece 19 and the guide rail 18 are designed mutually compatible in a manner that permits moving the cleaning nozzle head 23 along the guide rail over the blow box from end to end. The cleaning nozzle 23, or alternatively, one or more of the nozzle orifices of the nozzle head are aligned at an angle α, thereby causing the cleaning medium jet exiting the nozzle 23 to impart a reaction force which pushes the cleaning nozzle mounted on the control element along the guide rail 18. Thus, the orifice slot of the blow box can be entirely cleaned using only a single nozzle. The cleaning nozzle 23 is advantageously connected to a pump 21, advantageously a high-pressure cleaner or similar by way of a flexible hose 20 or equivalent means. The high-pressure cleaner 21 is advantageously operated at approx. 80-120 bar pressure. The high-pressure cleaner 21 is advantageously connected in a conventional manner to water piping. The benefit of this embodiment is therein that a single cleaning apparatus can be used in a number of blow boxes. The blow boxes only have to be designed with an opening for introducing the cleaning nozzle 23 into the blow box and the nozzle element must be provided with a control element 18.
For those versed in the art it is obvious that the invention is not limited to the exemplifying embodiments described above, but rather, can be varied within the scope of the annexed claims. Thus, the blow box can be provided with multiple cleaning elements operating in different principles.
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A method for cleaning one or more orifice slots (2, 3) of a blow box (1) or similar object particularly in the press or dryer section of a paper machine or similar equipment. The orifice slot (2, 3) is subjected to treatment from inside the blow box by means of one or more mechanical cleaning elements (4) and/or a cleaning jet (8, 9, 23). The invention also concerns an apparatus suited for implementing said method.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-in-part of U.S. patent application Ser. No. 09/577,691 entitled “Venturi Scrubber With Optimized Counterflow Spray,” filed on May 22, 2000, now U.S. Pat. No. 6,383,260.
FIELD OF THE INVENTION
This invention relates to the field of air pollution control, and is particularly directed to an improved venturi scrubbing system for removing contaminants from a gaseous effluent stream, such as the output of an incinerator.
BACKGROUND OF THE INVENTION
Over the past several decades the control of air pollution has become a priority concern of society. The United States, and other countries, have developed highly elaborate regulatory programs aimed at requiring factories, and other major sources of air pollution, to install the best available control technology (BACT) for removing contaminants from gaseous effluent streams released into the atmosphere. The standards for air pollution control are becoming increasingly stringent, so that there is a constant demand for ever more effective pollution control technologies. In addition, the operating costs of running pollution control equipment can be substantial, and so there is also a constant demand for more efficient technologies.
Concerns about pollution control are directed to more than air pollution, and removing contaminants from one medium frequently results in their introduction into another. For example, the treatment of municipal wastewater under the Clean Water Act has resulted in an enormous increase in the amount of sewage sludge that must be disposed of. Many communities lack adequate disposal sites to discard sludge that is generated by their municipal wastewater treatment plants in landfills, and are turning to incineration as an alternative method of disposal. Incineration of sludge, or other waste products, while greatly reducing the volume of material that must be disposed of on land, may result in the release of contaminants in the sludge into the atmosphere. In this regard, it is noted that the sludge generated by many municipalities is contaminated by highly toxic heavy metals and organic compounds, as well as acidic compounds such as chlorides and sulfates. The release of such compounds into the atmosphere is highly regulated, and sludge incineration systems are required to use BACT for controlling the release of contaminants into the atmosphere.
One well-known type of device for removing contaminants from a gaseous effluent stream is a venturi scrubber. Venturi scrubbers are generally recognized as having the highest fine particle collection efficiency of available scrubbing devices. As the name implies, in a venturi scrubber the effluent gas is forced or drawn through a venturi tube having a narrow “throat” portion. As the gas moves through the throat it is accelerated to a high velocity. Droplets of a scrubbing or cleansing liquid, typically water, are created in the venturi, usually in the vicinity of the throat, and enter the gas flow. The droplets used are generally many orders of magnitude larger than the contaminant particles to be collected and, as a consequence, accelerate at a different rate through the venturi. The differential acceleration causes interactions between the droplets and the contaminant particles, such that the contaminant particles are collected by the droplets. The collection mechanisms involve, primarily, collisions between the particles and the droplets and diffusion of particles to the surface of the droplets. In either case, the particles are captured by the droplets. Depending on the size of the contaminant particles, one or the other of these mechanisms may predominate, with diffusion being the predominant collection mechanism for very small particles, and collision or interception being the predominant mechanism for larger particles. A venturi scrubber can also be efficient at collecting highly soluble gaseous compounds by diffusion. A detailed description of these scrubbing mechanisms is discussed in Chapter 9 of Air Pollution Control Theory, M. Crawford, (McGraw-Hill 1976).
After the particulate contaminants are collected by the scrubbing droplets, the droplets are then removed from the effluent stream which is thereby cleansed. Removal of the droplets may be accomplished by a number of known means, which typically rely on the fact that the scrubbing liquid droplets are relatively large and, due to inertia, cannot change direction rapidly. Thus, to remove the droplets, the gas flow may be directed toward a surface such as an impingement plate. While the gas moves around the surface, the inertia of the relatively large droplets causes them to strike the surface where they are captured. Likewise, the droplets may be captured by a circular flow, as in a cyclonic separator, where the relatively large droplets collide with the wall of the separator due to centrifugal force.
Most venturi scrubbers in use today are “self-atomizing,” i.e., the droplets are formed by allowing a liquid to flow into the throat of the venturi where it is atomized by the gas flow. When operated at their design conditions, these systems are not able to produce droplets of very small mass median diameter, typically 500-2000 microns.
The primary methods heretofore utilized in improving the collection efficiency of a venturi scrubber have been to decrease the size of the throat or to increase the overall rate at which gas flows through the system. Both of these methods increase the differential velocities between the contaminant particles and liquid droplets as they pass through the throat of the venturi. This causes more interactions between particles and droplets to occur, thereby improving contaminant removal. However, increasing the collection efficiency in this manner comes at a cost of significantly higher energy input into the system, thereby resulting in higher operating costs. The extra energy is expended due either to the increased overall flow resistance attributable to the reduced throat diameter, or to the increased overall flow rate through the venturi. In either case, the pressure drop across the venturi is increased and greater pumping capacity is required. Most prior art efforts to increase the fine particle collection efficiency of a venturi scrubber have involved substantial increased energy input into the system.
Of particular concern to those in the field of air pollution control is the collection of “optically active” particles. As used herein, the term “optically active particles” should be understood to mean particles having a diameter in the range of approximately 0.1 to 1.0 microns. In an effort to control these particles, the EPA has recently set “PM2.5 standards” for the emissions of particles less of than 2.5 microns. These particles are difficult to collect in conventional venturi scrubbers due to their small size. Nonetheless, particles in this size range often comprise toxic material the release of which is not permitted. Due to the relatively large surface area of optically active particles, they absorb a disproportionate amount of heavy metal contamination. As their name implies, optically active particles interact with light. Even if they do not contain toxic components, the emission of optically active particles is highly visible and undesirable from an aesthetic point of view.
As noted above, municipal sewage sludge often contains significant amounts of toxic heavy metal and organic materials. Heretofore, scrubbers have not been efficient in removing these materials from the gaseous effluent of incinerated sludge. Municipal sewage sludge incineration typically requires the use of high temperatures (i.e., between 900°-1,600° F.). At these elevated temperatures, the organic materials are vaporized and are, thus, not susceptible to efficient scrubbing. One approach to this problem has been to use an afterburner on the effluent stream, whereby the organic vapors are combusted and, thereby, transformed into non-toxic compounds, primarily water vapor and carbon dioxide. However, incomplete combustion of the organics can result in the production of carbon monoxide, soot, and/or gaseous hydrocarbons. If soot (i.e., fine particles of carbon) is produced, other compounds, such as those containing heavy metals, can be adsorbed on the surface of the carbon particles. Any particles that are formed in this way are likely to be difficult to collect due to their small diameter. And, as noted above, very small particles are efficient collectors of volatile heavy metals.
In co-assigned U.S. Pat. No. 5,279,646, (hereafter the '646 patent) by the inventor hereof (the disclosure of which is incorporated by reference), it is taught to optimize the size of the scrubbing droplets to promote the maximum collection efficiency for optically active contaminant particles. This patent describes the fact that there is a point at which a further decrease in the size of the droplets of the scrubbing liquid begins to become detrimental. The '646 patent teaches a method and apparatus for creating optimized droplets which are introduced into the effluent gas flow upstream of the venturi throat. The '646 patent further teaches the use of a two-fluid nozzle to create droplets of a scrubbing or cleansing liquid. The inventive apparatus and method of the '646 patent have proven to be quite successful when using the preferred two-fluid nozzle.
The '646 patent notes that certain hydraulic (i.e., liquid only) nozzles are capable of producing droplets in the optimal range and could be used in practicing the invention described in the patent. However, as a practical matter, it has proven difficult to achieve all of the objectives of the '646 patent when using a hydraulic nozzle.
As noted, the trend in pollution control has been towards increased stringency, such that many existing facilities face the need to upgrade or retrofit their existing pollution control equipment to achieve better results. In addition, facility owners/operators are often interested in upgrading or retrofitting existing pollution control equipment to realize the benefit of lower operational costs from improved efficiency.
In many situations, when retrofitting or upgrading an air pollution control system it is difficult due to space or power considerations to provide the pressurized air needed to operate the two-fluid nozzles described in the '646 patent. Therefore, in such situations, it is difficult to realize the benefits described in the patent.
What is desired is an apparatus and method that permits the efficient and economical scrubbing of fine particles from a gas flow using a cleansing liquid in a venturi scrubber. Specific needs include reduced scrubbing liquid pumping requirements, lower pressure drop across the venturi, improved scrubber performance, and better control of the pressure drop across the venturi scrubber.
SUMMARY OF THE INVENTION
The present invention generally comprises an apparatus and method to create a spray of fine droplets composed of a scrubbing liquid for scrubbing particulates from a contaminated gas. The scrubber includes a venturi having an inlet for receiving a contaminated gas, a throat and an outlet.
It is one aspect of the present invention to provide a venturi scrubber having a first nozzle to introduce fine droplets of a first cleansing liquid into the gas flow, and positioned upstream of the throat; and a second nozzle to introduce fine droplets of a second cleansing liquid into the gas flow, and positioned within said throat and oriented to introduce droplets with a component of velocity which is counter to the direction of gas flow through the venturi.
It is another aspect of the present invention to provide a means for introducing fine droplets of a first cleansing liquid into said flow of gas through the venturi and upstream of the throat; and means for introducing fine droplets of a second cleansing liquid into the throat in a direction counter to the direction of gas flow through the venturi.
It is yet another aspect of the present invention to provide a venturi scrubber including a nozzle to introduce fine droplets of a cleansing liquid into said gas flow, where said droplets are introduced into said throat with a component of velocity which is counter to the direction of gas flow through said venturi, and where the flow of said cleansing liquid is selected so that the pressure drop across said venturi scrubber is approximately equal to a specified pressure drop.
It is an aspect of the present invention to provide a method of cleansing a gas flow using a venturi scrubber at a prescribed pressure drop across a venturi. The method includes the steps of injecting fine droplets of cleansing liquid counterflow to the gas flow and into the throat, and where the flow of cleansing liquid has a valve to adjust the flow; and adjusting the valve to maintain said prescribed pressure drop across the venturi.
It is yet another aspect of the present invention to provide a method of providing a retrofit for a pre-existing venturi scrubber in an air pollution control system, where the pre-existing venturi has a prescribed pressure drop. This method includes the steps of installing components within said pre-existing venturi including a nozzle to introduce fine droplets of a cleansing liquid into the throat of the venturi with a component of velocity which is counter to the direction of gas flow through the venturi; and selecting the flow rate of cleansing liquid so that the pressure drop across said venturi is approximately equal to the prescribed pressure drop.
A further understanding of the invention can be had from the detailed discussion of specific embodiments below. For purposes of clarity, this discussion refers to devices, methods, and concepts in terms of specific examples. However, the method of the present invention may operate with a wide variety of types of devices. It is therefore intended that the invention not be limited by the discussion of specific embodiments.
Additional objects, advantages, aspects and features of the present invention will become apparent from the description of preferred embodiments, set forth below, which should be taken in conjunction with the accompanying drawings, a brief description of which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional diagram of the venturi scrubber of the present invention.
FIG. 2 is a schematic cross-sectional diagram of the throat of an embodiment of the venturi scrubber of the present invention showing the spray pattern in the absence of a gas flow through the throat.
FIG. 3 is a schematic cross-sectional diagram of the throat of an embodiment of the venturi scrubber of the present invention showing the spray pattern in the presence of a gas flow through the throat.
FIG. 4 is a schematic cross-sectional diagram of the throat of an alternative embodiment of the venturi scrubber of the present invention comprising a plurality of nozzles.
FIG. 5 is cross-sectional diagram of an embodiment of the venturi scrubber of the present invention having both a counterspray nozzle and an upstream spray nozzle.
FIG. 6 is a cross-sectional diagram of a preferred embodiment of a venturi scrubber with details of the venturi scrubber inlet and counterflow spray nozzle.
FIG. 7 is a partially schematic cross-sectional view of a preferred embodiment of an air pollution control system according to the present invention.
FIG. 8 is a chart showing the change in pressure drop across a venturi of a dual spray system from changes in the pressure of liquid to a counterflow nozzle.
DETAILED DESCRIPTION
The present invention is directed to a venturi scrubber for cleansing a gas flow, such as a pollution source, which is capable of removing optically active particles from the gas flow, using a spray from a hydraulic nozzle positioned within the throat of the venturi and oriented to eject droplets of a scrubbing liquid counter to the direction of gas flow through the venturi.
Turning first to FIG. 1, a venturi scrubber 10 according to the present invention is shown. As is known, venturi scrubber 10 comprises an inlet “cone” 20 , a throat 30 and an outlet cone 40 . Preferably, venturi 10 is axially symmetrical such that, for example, throat 30 is cylindrical. However, other configurations are possible. For example, venturi 10 may, alternatively have a rectangular cross section normal to the gas flow direction depicted by arrows 50 . While inlet 20 is described for convenience as a cone, in the embodiment depicted the wall of the inlet is not truly conical. Rather, as depicted inlet 20 has a curved wall. The curved venturi inlet 20 depicted is referred to as a “bellmouth” inlet and is known to be a low static pressure loss inlet.
As is well-known, as the gas flow 50 travels through venturi 10 it is accelerated by the reduced diameter of inlet 20 and throat 30 , and then decelerates as the diameter increases in outlet cone 40 . As described above, the process of accelerating and decelerating gas flow 50 facilitates interactions between droplets of a scrubbing liquid and particles in the gas flow, such that contaminant particles are captured by the droplets and removed from the gas flow with high efficiency.
A scrubbing liquid is introduced through liquid inlet 70 to a hydraulic nozzle 60 mounted within throat 30 of venturi 10 , such that the spray 80 from nozzle 60 has a component of its velocity which is counter to gas flow 50 , i.e., in a direction along the axis of the venturi opposite to the direction of gas flow. Hereinafter, when reference is made to spraying or ejecting droplets “counter” to the direction of gas flow, it is intended only that the sprayed or ejected droplets leaving the nozzle have a component of their velocity which is counter to the gas flow. In one embodiment of the invention, the water pressure to the nozzle is in the range of about 80-320 psig, and the nozzle produces fine droplets in a hollow cone spray. Preferably water is injected at a rate of about 1-10 gallons per 1,000 actual cubic feet (ACF) of gas.
As described, nozzle 60 produces a hollow spray 80 , such that most of the scrubbing liquid is ejected in a conical pattern having an included angle α, which is preferably in the range of 90°-150°. As depicted in FIG. 2, under static conditions, the droplets in spray 80 will travel linearly until they intercept the wall of venturi throat 30 . However, as depicted in FIG. 3, in the presence of gas flow 50 , the trajectories of the droplets in spray 80 become curved as the droplets become entrained in the gas flow. The trajectory of a particular droplet will depend primarily on its size and ejection velocity. It will be appreciated that the use of a spray injected counter to the gas flow, in accordance with the present invention, maximizes the differential velocity between the gas flow and the droplets of scrubbing liquid. This enhances the particle scrubbing efficiency. At the same time, the use of a spray which has a component which is radial to the venturi axis promotes the uniform distribution of droplets in the gas flow as it transits the venturi.
Because of their relatively greater momentum (and lower relative drag) larger droplets, and droplets with a higher initial ejection velocity, will travel farther laterally (i.e., towards the wall of venturi throat 30 ), than smaller, lower velocity droplets. In accordance with the present invention, this natural sorting and distribution of the droplets according to their initial momentum ensures that spray 80 is relatively evenly distributed within throat 30 of venturi scrubber 10 , as shown in FIG. 3 . Preferably, the nozzle, the scrubbing liquid pressure and the venturi dimensions are selected so that spray droplets of appropriately small diameter are distributed throughout the entire venturi throat 30 over the range of gas flows encountered in the scrubbing system. In one aspect of the present invention, a controller is used to adjust the nozzle pressure with changes in the gas flow, to ensure even distribution of spray droplets under different flow conditions.
It is considered acceptable that very large droplets, representing only a small percentage of the volume of injected scrubbing liquid, will travel all the way to wall 30 . The loss of large droplets, which do not efficiently scrub the gas flow, is not considered consequential as long as a large volume of scrubbing liquid is not being lost.
In most applications, the preferred scrubbing liquid is water due to its near universal availability, low cost and relative ease of handling. In some applications it may be desirable to incorporate into the water one or more other chemicals selected to react with gaseous substances in the gas flow. For example, if the gas flow is highly acidic, it may be desirable to use a water-based solution or mixture which neutralizes the acid components in the gas. In specialized applications other scrubbing liquids can be employed, and the specific scrubbing liquid used is not important to the present invention, although the physical properties of the liquid, such as the viscosity, may effect the selection and placement of the nozzle insofar as the physical properties affect the formation of droplets.
As the diameter of the venturi throat is increased, it becomes more difficult to produce a spray which uniformly covers the entire throat diameter using a single nozzle. Accordingly, when a larger diameter venturi is desired, a nozzle array may be used in the venturi throat rather than a single nozzle. Such a nozzle array may comprise, for example, seven nozzles, six of which are positioned at the corners of a hexagon having its center located on the axis of the venturi with the seventh nozzle positioned on the axis. FIG. 4 is a schematic cross-sectional diagram of an embodiment of the present invention comprising seven nozzles, 60 a - 60 g ; six of the nozzles are placed at the points of a hexagon with the seventh being positioned in the center, on the axis of the venturi throat. In the preferred embodiment, the points of the hexagon are derived by fitting seven equal-sized circles, each having a diameter of one-third of the venturi throat diameter, into a circle having the throat diameter. The points of the hexagon are at the centers of the outer six circles.
Suitable hydraulic nozzles for use in the present invention may be obtained from BETE Fog Nozzle Inc., 50 Greenfield Street Greenfield, Mass. 01301; (URL—http://www.bete.com/). In one embodiment, a model TF8W nozzle was used with a ¼ inch pipe at a water pressure of approximately 200 psi. At this pressure the nozzle ejects almost six gallons of scrubbing liquid per minute. This nozzle ejects a conical spray having an included angle of approximately 120°. The preferred nozzle produces water droplets having a median diameter of 100 microns, with 80% of the volume of the droplets being in the range of 50-180 microns in diameter when operated at a pressure of 200 psig. As used herein, when referring to the diameter or median diameter of the droplets in the spray, applicant intends to refer to what is more precisely termed the volume median diameter (VMD), which is sometimes referred to as the median volume diameter (MVD). Droplets in the size range of 10 to 200 microns VMD, when used in connection with the present invention, produce excellent scrubbing efficiency as described in further detail below.
A test of the effectiveness of a counterflow spray in a venturi scrubber was conducted in connection with an existing municipal sewage sludge fluid bed incineration unit. The existing unit included a traditional, self-atomizing spray, introduced upstream of the venturi throat, where the venturi has a 40″ pressure drop, which was replaced in the test with two venturi scrubber elements having counterflow sprays, as described above. In operation, the old venturi had overall particulate emissions of about 0.004 gr/dscf, while the new system had an overall emissions of about 0.0009 gr/dscf at a 20″ pressure drop and approximately 100 psig water pressure to BETE TF6W nozzles, one in each venturi throat.
While the use of a counterflow spray alone in a venturi is thus seen to have advantages over a traditional upstream spray, additional improvements in venturi scrubber operation, described subsequently, may be achieved with a counterflow spray alone, or through a dual spray injection system wherein one or more counterflow sprays are injected into the venturi throat while one or more sprays are injected upstream of the throat.
FIG. 5 shows a cross-sectional diagram of one embodiment of the dual spray injection system of the present invention. Venturi scrubber 510 comprises an inlet cone 520 , a throat 530 and an outlet cone 540 . As described for venturi scrubber 10 , venturi 510 is preferably axially symmetrical, though other configurations are within the scope of the present invention, such the venturi having a rectangular cross section normal to the gas flow direction depicted by arrows 550 .
An upstream scrubbing liquid is introduced through nozzle 590 mounted upstream of throat 530 . Nozzle 590 produces a fine mist of droplets in spray 595 that, due to the proximity to inlet 520 , generally follow flow 550 through the nozzle. Nozzle 590 and the scrubbing liquid are selected according to the droplet size, spray distribution, droplet velocity, and scrubbing abilities of the liquid. Important spray properties include droplets of a size, velocity and distribution that promote scrubbing interactions between the spray and gas. Thus nozzle 590 should produce a spray that is preferably distributed across the flow area. In addition, the droplets should promote scrubbing by being be small enough to have a large total surface area yet large enough to maintain a velocity differential between particles in the gas and the droplets. Droplets in the size range of 10 to 200 microns VMD have been found to be particularly useful in this regard. For scrubbing particles in the gas, water is a preferable scrubbing liquid, while chemical additives may be included in the scrubbing liquid to react with the particles or reactive vapors in the gas.
Examples of acceptable nozzle types for nozzle 590 include one or more air-assisted nozzles or hydraulic bypass nozzles, as described in the '646 patent. Hydraulic nozzles as typically used do not produce droplets suitable for upstream injection and in the required size range of 10 to 200 microns VMD, as described in the '646 patent. However, the inventor has discovered that this size range of droplets can be achieved with hydraulic nozzles that are operated at liquid pressures higher than those specified for normal operation, and by selecting nozzles with spray angles of 60° or more. Suitable hydraulic nozzles include, but are not limited to, those sold by BETE Fog Nozzle Inc., such as BETE MP series nozzles of the smaller sizes (models 125, 156, 187, 218, and 250) with spay angles of 60°, 90° or 120°. Operating these nozzles at pressures much greater than those specified by the manufacturer, for example greater than about 120 psi over the specified pressure of 3-80 psi, results in a fine mist suitable for upstream injection into a venturi scrubber of the present invention.
Nozzle 590 , or alternatively more than one nozzle, preferably operates with water as the scrubbing liquid at a total liquid flow rate into the venturi of about 1-7 gallons per 1,000 ACF of gas, and generates a spray 595 of droplets in the range of 10 to 200 microns VMD.
A counterflow scrubbing liquid is introduced through liquid inlet 570 to a nozzle 560 mounted within throat 530 of venturi 510 , such that the spray 580 is a counterflow spray. Nozzle 560 is preferably a hydraulic nozzle as previously described. Spray 580 is preferably water injected at a rate of about 1-10 gallons per 1,000 ACF of gas, and the spray 580 is composed of droplets in the range of 40 to 200 microns VMD. As one example of a hydraulic nozzle that produces acceptable results for the dual spray injection system of the present invention is the BETA TF series 120° hollow cone nozzles of small size, such as a TF-8W, operated at pressures of 75-300 psig.
A preferred embodiment of a venturi 510 is shown in FIG. 6 as venturi 610 , which includes an inlet 620 , a throat 630 , and an outlet similar to outlet 540 , but not shown. A static pressure tap 615 is provided within throat 630 . Inlet 620 and throat 630 are axial symmetric about centerline CL, as are gas streamlines 650 , shown for reference. Throat 630 is cylindrical with a diameter d t , and extends from an upstream plane 632 downstream to the outlet (not shown). Inlet 620 includes an opening 626 for receiving a flow 695 , a conical section 622 having an inlet diameter d i , and a toroidal section 624 that makes a smooth transition from the conical section to the cylindrical surface of throat 630 . A counterflow spray nozzle 660 is located within throat 630 . Toroidal section 624 is a surface formed by rotating, about centerline CL, an arc having an included angle β, a radius R, and a center C positioned a distance R C from centerline CL in plane 632 . Preferred dimensions are R C =(5/6)d t ; R=d t /3; d i =2.5d t ; and β≈53°.
A venturi scrubber having a dual spray injection system has several features that improve the ability of the venturi scrubber to operate over a wider range of gas flow rates that is possible with only an upstream or a counterflow spray. Changes in operation of an incinerator, for example, will result in changes in the gas flow through a venturi scrubber. For given spray conditions (drop size, velocity and density), decreased venturi gas flow rates can have deleterious effects on scrubber efficiency, as the efficiency generally depends on the velocity differential between the spray droplets and the gas in the venturi. In addition, decreased venturi flow rates decrease the pressure drop across the venturi, which may have an impact on meeting air pollution control regulations.
The effects of decreased gas flow rate through a venturi scrubber can be countered by controlling the sprays injected into the venturi. Thus, for example, a counterflow spray injected into the throat of a venturi scrubber, with our without the injection of an upstream spray, has several effects on the flow through the venturi and on the scrubbing effectiveness of the spray. As previously noted, an increased counterflow rate produces droplets that are effective at scrubbing, since they have a high velocity relative to the oncoming venturi gas flow. In addition, an increased counterflow spray momentum may increase the flow rate of gas through the venturi, further increasing the ability of any spray droplets in the contaminated gas flow. Also, an increased counterflow rate increases the pressure drop across the venturi, and thus provides a means for manipulating the pressure drop.
FIG. 7 shows an embodiment of an air pollution control system employing a venturi scrubber which include automatic control functions to adjust the operation of the system to compensate for variations in the effluent flow. Many of the components of the system of FIG. 7 are presented in of FIG. 8 and the discussion thereof in co-owned U.S. Pat. No. 5,759,233 (“the '233 patent”), incorporated herein by reference. Specifically, the portions of the air pollution control system including the selection and treatment of scrubbing liquids, the treatment of gases before and after the venturis, and post scrubbing treatment of the scrubbing liquid, including alternative embodiments thereof, are those described in the '233 patent. The main difference in the embodiment shown in FIG. 7 of the present application and the embodiment referred to in the '233 patent is the incorporation and control of inventive dual spray injection system of the present invention. A brief discussion of the overall air-pollution control system is thus presented, followed by a more detailed discussion of those features that are unique to the present invention.
A contaminated flow of particle-laden effluent gas enters enclosed chamber 730 through inlet 727 . As described in the '233 patent, the effluent gas may be from a multiple-hearth furnace used to incinerate sludge from a municipal wastewater treatment works. Such a source of effluent gas will vary both in the volume of flow and in the characteristics of the flow. Upon entering chamber 730 , the effluent flow first travels through a subcooling region, including three impingement plates 795 . As described in the '233 patent, three stages of impingement plates 795 both serve to aid in the cooling of the gas flow and to remove larger particulates from the gas flow. A spray of cooling liquid is introduced into the gas flow upstream of impingement plates 795 by nozzle 725 that is controlled by valve 723 . Liquid is also injected into the system above impingement plates 795 by liquid feed 791 controlled by valve 792 .
After passing through impingement plates 795 , the cooled effluent travels through venturi scrubbers 750 , which are fed by upstream spray nozzles 780 and counterflow spray nozzles 770 . Thereafter, the spray droplets are captured by demister 790 that serves to reconsolidate the scrubbing liquid. Demister 790 is, preferably, of the type that has a high efficiency in removing very fine droplets, such as one employing a mesh. After the scrubbing droplets have been removed, the cleansed effluent gas, which is propelled through the system by induced draft fan 705 , may be expelled into the atmosphere through stack 710 or further processed.
Chilled liquid may also be used for subcooling the effluent flow prior to its passage through the venturi stage. Automatic control according to the present invention may also be used for this purpose. In one embodiment, the temperature of the effluent flow in the system is monitored at a point between the final impingement plate and the entrance to the venturi stage. A temperature sensor 793 is shown in FIG. 7 . Temperature sensor 793 is read by control means 794 , and if the temperature rises the volume of liquid introduced by valve 792 is increased. Although more complex, those skilled in the art will appreciate that the temperature of the liquid introduced may also be adjusted.
Contaminated droplets of the scrubbing liquid are consolidated by demister 790 and flow under the influence of gravity down to tray 755 which separates the inlet ends of venturis 750 from the outlet ends. Tray 755 prevents any further downward flow of the contaminated spray liquid. Drain line 757 provides a flow path for the liquid which collects upon tray 755 , carrying it to enclosed container 758 , where it may be further treated as explained in the '233 patent.
In one embodiment of the present invention, each venturi 750 is adapted for scrubbing a gas, as in venturi 510 . Hydraulic nozzles are preferred for nozzles 770 and 780 , though air-assisted nozzles or hydraulic bypass nozzles, as discussed in the '233 patent, could be substituted for nozzle 780 . The flow of scrubbing liquid to nozzles 770 and 780 is controlled by a counterflow spray flow valve 776 and an upstream spray flow valve 786 , respectively. Preferably the same liquid is supplied to each of nozzles 770 and 780 , though alternatively each set of nozzles could have different liquids supplied thereto.
The control of the embodiment of an air pollution control system shown in FIG. 7 employs an automatic control to adjust the operation of the system to compensate for or to produce a specified pressure drop or pressure differential across the venturi. The differential pressure is measured as the difference between the output of a pressure gauge located upstream of the venturi, as measured by an upstream pressure gauge 711 , and a pressure gauge located downstream pressure gauge, as measured by a downstream pressure gauge 716 . The pressure differential between the pressure taps 711 and 716 is measured by valve control module 717 which, in turn, automatically adjusts valve 776 to change the amount of water flowing to nozzles 770 and thus the total volume of counterflow spray into venturis 750 .
Control of the pressure drop may be accomplished as follows. When the flow through the venturi decreases, the acceleration of gases passing through the venturi likewise decreases. This adversely affects scrubbing efficiency that is related to the differential acceleration of the gases and the liquid droplets as they pass through the venturi. As noted above, the addition of counterflow spray increases the pressure drop across the venturi. Thus, in accordance with one embodiment of the present invention, when the system detects a reduced effluent gas flow (measured, for example, by a drop in pressure across the venturi, or by other measurements indicative of or directly measuring the gas velocity), control module 717 responds by adjusting valve 776 to increase the volume of counterflow spray liquid which is introduced into the throat of each venturi 750 .
In an alternative embodiment, control module 717 is adapted to operate such that the pressure drop it at a specified value or within specified limits. In this case, control module 717 increases the flow through valve 776 in response to a decrease in pressure drop below a preset limit, and decrease the flow in response to an increase in the pressure drop.
In an alternative embodiment, the differential pressure can be measured as the difference between the static pressure at the throat, as measured though a pressure tap such as static pressure tap 615 , and either an upstream or downstream pressure gauge. Since the differential pressure as measured using this method is related to the pressure drop across the venturi, a control system, for example, could use it as an indication of the pressure drop across the venturi.
The embodiment of FIG. 7 was tested in an incinerator burning municipal sewage sludge. The air pollution control system that was in place prior to the test used only an upstream water spray formed from air-assisted nozzles and had an outlet emissions level of ˜9 mg/m 3 (˜0.004 gr/acf) measured optically and by particulate sampling, and the venturi had a pressure drop of 30″ of water as measured across the venturi (between the inlet and outlet). The test included replacing the air-assisted upstream nozzles with hydraulic BETE MP 125W nozzles at a pressure 140 psig, resulting in droplets of ˜155 micron VMD, and hydraulic BETE TF 10W counterflow nozzles supplied with water at 80 to 120 psig. The resulting system had outlet emissions of 3-5 mg/m 3 (˜0.002 gr/acf) measured optically operating at a venturi pressure drop of 22-25″ of water.
The system was further tested by reducing the pressure to the counterflow spray nozzles to 10 psig while maintaining a constant pressure and flow rate to the upstream spray nozzles (˜140 psig and ˜40 gpm, respectively) and constant gas flow rate. The resulting pressure drop across the venturi stage was reduced to ˜12 in H 2 O, and the output emissions increased to ˜7 mg/m 3 (˜0.003 gr/acf) measured optically. It is clear that an increase in the amount of counterflow liquid can be used to increase the capture of particulates. In practice, decreased particulate capture from decreased gas flow rates can be countered by increasing the amount of counterflow liquid injected into the venturi. This can be done with increasing the amount of upstream flow, as in the '233 patent, or providing extra compressed air to atomized the additional flow through an air-assisted nozzle.
A venturi scrubber having upstream and downstream counterflow sprays also provides greater flexibility to control the pressure across the venturi. FIG. 8 shows the increase in the pressure drop across the venturi with the supply pressure to the counterflow nozzles (which in turn is proportional to the mass flow rate through the counterflow nozzles). The change in the counterflow spray did not noticeably affect the pollution reduction, and thus provides an independent control of the pressure through the venturi. In some circumstances it is desirable to operate the venturi at approximately constant pressure drop over a range of gas flow rates, an increased counterflow can be used to restore the pressure drop across the venturi resulting from a lower flow rate. Thus, for example, if a high “turn down” capability is required, the flow in the counterflow spray can be increased and some or all of the pressure drop can be recovered.
The control of the pressure drop across the venturi may be important when retrofitting existing air pollution control systems with new venturis. Continued operation of air pollution control system depends on maintaining permitted pressure drops across wet scrubbing devices (see for example, Environmental Protection Agency 40 C.F.R. §60.153(b)(1) for operation of multiple hearth, fluidized bed, or electric sludge incinerators with wet scrubbers). Upgrading a venturi scrubber to reduce pollution may not meet the regulations for continued operation unless the pressure drop across the wet scrubber is essentially unchanged. Thus replacing a downstream spray nozzle with a counterflow spray nozzle can reduce pollution (as described above), but also reduces the pressure drop across the venturi. As a result, the upgraded venturi would require a new permit. By installing a dual spray system of the present invention, lower pollution levels can be maintained while keeping the pressure drop across the venturi at the permitted level for operation without repermitting.
While the present invention has described in connection with preferred embodiments thereof, it will be apparent to those skilled in the art that there are many variations and equivalents of that which has been described. Accordingly, it is intended that the invention should be limited only by the following claims.
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The present invention provides improved systems and methods for scrubbing gas with a venturi scrubber. A dual spray venturi scrubber, in which a scrubbing liquid is injected upstream and counter to the flow through the venturi, provides for improved scrubbing performance, including efficient and economical scrubbing of fine particles. Specifically, the present invention reduces the scrubbing liquid pumping requirements, improves the scrubber performance, and provides better control of the pressure drop across the venturi scrubber. The control of pressure drop across the venturi can be obtained with no internal mechanisms or upstream spray.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to panel lifters and more particularly pertains to a new adjustable panel installation assembly for lifting a panel to be installed in a convenient manner without excessive labor.
2. Description of the Prior Art
The use of panel lifters is known in the prior art. More specifically, panel lifters heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
Known prior art panel lifters include U.S. Pat. No. 3,910,421; U.S. Pat. No. 4,449,879; U.S. Pat. No. 5,163,799; U.S. Pat. No. 5,303,899; U.S. Pat. No. 4,150,755; and U.S. Patent Des. 307,814.
In these respects, the adjustable panel installation assembly according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of lifting a panel to be installed in a convenient manner without excessive labor.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of panel lifters now present in the prior art, the present invention provides a new adjustable panel installation assembly construction wherein the same can be utilized for lifting a panel to be installed in a convenient manner without excessive labor.
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new adjustable panel installation assembly apparatus and method which has many of the advantages of the panel lifters mentioned heretofore and many novel features that result in a new adjustable panel installation assembly which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art panel lifters, either alone or in any combination thereof.
To attain this, the present invention generally comprises a ladder with a pair of planar rectangular side members. A plurality of rungs are coupled between the side members such that the same remain in parallel relationship. As shown in FIG. 3, a pair of planar rectangular leg extenders are each coupled to a bottom end of one of the side members of the ladder and extend downwardly therefrom in collinear relationship therewith. Also included is a pair of hinges including a pivot pin coupled between top ends of the side members of the ladder. Ends of the pivot pin extend past the side members with flanges formed thereon. As shown in FIG. 3, each hinge includes a planar rectangular tab having an inboard end with a closed loop for being hingably coupled to the pivot pin. Such coupling is preferably effected between the associated side member and flange of the pivot pin. By this structure, each tab is rotatable about the pivot pin. Each tab of the hinges further has an outboard end with a pair of bores formed therein along a central axis of the tab. In use, the bores are adapted for allowing the attachment thereof with one of a plurality of joists. Next provided is a pair of panel supports each with a generally planar rectangular configuration. The panel supports each have a periphery defined by a pair of elongated side edges and a pair of short end edges. As best shown in FIG. 5, a first one of the side edges of each panel support has an extension protruding outwardly therefrom adjacent to a first one of the end edges. The first end edge further includes a semicircular cut out formed therein. A second one of the end edges includes a square cut out formed therein and remains in communication with the second one of the side edges. During operation, the semicircular cut out is received by one of the rungs of the ladder while the square cut out is received by another adjacent rung of the ladder. As such, the extension extends past the side members of the ladder to define a ledge for supporting a panel of dry wall on the side members of the ladder. As shown in the various Figures, an adjustable support pole includes a solid upper extent having an upper end pivotally coupled to a central extent of a bottommost one of the rungs. Such pivotal coupling is effected about an axis of the bottommost rung. The support pole further includes a hollow lower extent having an open upper end for slidably receiving the upper extent. A lower end of the lower extent of the support pole is equipped with a rubber foot formed thereon. In operation, the ladder may be pivoted upwardly with the panel thereon until the panel abuts the joists. Thereafter, the support pole is pivoted into a vertical orientation for maintaining the ladder elevated and horizontally oriented. As such, the panels may be attached to the joists in a convenient manner without excessive man power.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new adjustable panel installation assembly apparatus and method which has many of the advantages of the panel lifters mentioned heretofore and many novel features that result in a new adjustable panel installation assembly which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art panel lifters, either alone or in any combination thereof.
It is another object of the present invention to provide a new adjustable panel installation assembly which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new adjustable panel installation assembly which is of a durable and reliable construction.
An even further object of the present invention is to provide a new adjustable panel installation assembly which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such adjustable panel installation assembly economically available to the buying public.
Still yet another object of the present invention is to provide a new adjustable panel installation assembly which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new adjustable panel installation assembly for lifting a panel to be installed in a convenient manner without excessive labor.
Even still another object of the present invention is to provide a new adjustable panel installation assembly that includes a pair of side members hingably coupled with respect to a joist. Also included is at least one panel support coupled with respect to the side members along the length thereof, wherein the support defines a ledge for supporting a panel of dry wall on the side members such that the same may be lifted into a horizontal orientation.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a side view of a new adjustable panel installation assembly according to the present invention.
FIG. 2 is a close-up view of the panel supports of the present invention.
FIG. 3 is a top view of the present invention.
FIG. 4 is a side view of the present invention during use.
FIG. 4A is a side view of the panel supports of the present invention connected to the ladder.
FIG. 5 is a side view of the present invention with the panel supports removed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 through 5 thereof, a new adjustable panel installation assembly embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
The present invention, designated as numeral 10, includes a ladder 12 with a pair of planar rectangular side members 14. A plurality of equally spaced rungs 16 are coupled between the side members such that the same remain in parallel relationship. As shown in FIG. 3, a pair of planar rectangular leg extenders 18 are each coupled to a bottom end of one of the side members of the ladder and extend downwardly therefrom in collinear relationship therewith. As an option, a length of the leg extenders may be adjusted by any means including, but not limited to removable bolts and linearly aligned apertures formed therein. Ideally, each leg extender extends from a bottommost one of the rungs a length about 1/8 that of the ladder.
Also included is a pair of hinges 20 including a pivot pin 22 coupled between top ends of the side members of the ladder via a pair of connectors 24. Ends of the pivot pin extend past the side members with flanges 26 formed thereon. As shown in FIG. 3, each hinge includes a planar rectangular tab 28 having an inboard end with a closed loop for being hingably coupled to the pivot pin. Such coupling is preferably effected between the associated side member and flange of the pivot pin. By this structure, each tab is rotatable about the pivot pin. Each tab of the hinges further has an outboard end with a pair of bores 30 formed therein along a central axis of the tab. In use, the bores are adapted for allowing the attachment of the corresponding hinge with one of a plurality of joists. The leg extenders may be adjusted to accommodate a height of the joists.
Next provided is a pair of panel supports 32 each with a generally planar rectangular configuration. The panel supports each have a periphery defined by a pair of elongated side edges and a pair of short end edges. As best shown in FIG. 5, a first one of the side edges of each panel support has an extension 34 protruding outwardly therefrom adjacent to a first one of the end edges. A length of the extension is preferably about 1/6 a length of the supports. The first end edge further includes a semicircular cut out 38 formed therein. A second one of the end edges includes a square cut out 40 formed therein and remains in communication with the second one of the side edges. During operation, the semicircular cut out is received by one of the rungs of the ladder while the square cut out is received by another adjacent rung of the ladder. As such, the extension extends past the side members of the ladder to define a ledge for supporting a panel of dry wall on the side members of the ladder. It should be noted that the panel support members may be spaced with respect to each other any selected distance.
As shown in the various Figures, an adjustable support pole 42 includes a solid upper extent having an upper end pivotally coupled to a central extent of a bottommost one of the rungs. Such pivotal coupling is effected about an axis of the bottommost rung. The support pole further includes a hollow lower extent with a length similar to that of the upper extent. The lower extent has an open upper end for slidably receiving the upper extent. Length adjustability is afforded by way of a set pin which may be removably inserted within a bore of the lower extent and one of a plurality of linearly aligned bores formed in the upper extent. A lower end of the lower extent of the support pole is equipped with a rubber foot, as shown in FIG. 4.
In operation, the ladder may be pivoted upwardly with the panel thereon until the panel abuts the joists. Thereafter, the support pole is pivoted into a vertical orientation for maintaining the ladder elevated and horizontally oriented. As such, the panels may be attached to the joists in a convenient manner without excessive labor.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A panel installation system is provided including a pair of side members hingably coupled with respect to a joist. Also included is at least one panel support coupled with respect to the side members along the length thereof, wherein the support defines a ledge for supporting a panel of dry wall on the side members such that the same may be lifted into a horizontal orientation.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 10/908,784 filed May 26, 2005 now U.S. Pat. No. 7,118,954.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the fabrication of semiconductor integrated circuits and, more particularly, to an improved process for fabricating high-voltage devices. According to the present invention, the salicide process is integrated with the high-voltage process, thereby reducing the resistance of high-voltage metal-oxide-semiconductor transistor devices.
2. Description of the Prior Art
Integrated circuits (ICs) containing both high-voltage and low-voltage devices such as high/low voltage MOS transistor devices are known in the art. For example, the low-voltage device may be used in the control circuits as the high-voltage device may be used in electrically programmable read only memory (EPROM) or the driving circuits of the liquid crystal display devices.
It is also known that self-aligned silicide (also referred to as “salicide”) process is typically utilized to form metal silicide layer such as cobalt silicide or titanium silicide on the gates, source or drain regions in order to reduce sheet resistances. However, the salicide process is merely performed on the low-voltage devices. Considering hot carrier effects, the conventional high-voltage process cannot integrate with the salicide process. As a result, the sheet resistance of the high-voltage devices is high.
In light of the above, there is a need to provide an improved method for reducing the sheet resistance of the high-voltage devices.
SUMMARY OF THE INVENTION
It is the primary object of the present invention to provide an improved high-voltage process for fabricating high-voltage metal-oxide-semiconductor (MOS) devices, thereby reducing the sheet resistance thereof.
According to the claimed invention, a method for fabricating metal-oxide-semiconductor (MOS) devices is disclosed. A gate dielectric layer having a first thickness is formed or grown on a semiconductor substrate. A polysilicon layer is deposited on the gate dielectric layer. A resist mask is formed on the polysilicon layer. The polysilicon layer not masked by the resist mask is etched away, thereby forming a gate electrode. The gate dielectric layer not covered by the gate electrode is then etched such that remaining gate dielectric layer not covered by the gate electrode has a second thickness that is smaller than the first thickness. The resist mask is stripped. A spacer is formed on the sidewalls of the gate electrode and on remaining gate dielectric layer. A salicide block resist mask is formed to cover the gate electrode, the spacer and a portions of remaining the gate dielectric layer laterally protruding an offset “d” from bottom of the gate electrode. The remaining gate dielectric layer not covered by the salicide block resist mask is completely removed, thereby exposing the semiconductor substrate and forming a salicide block lug portions on two opposite sides of the gate electrode with the offset “d” from sidewalls of the gate electrode. The spacer has a maximum thickness that is smaller than the offset “d” such that the salicide block lug portions laterally protruding from bottom of the spacer and forms a step thereto.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 to FIG. 9 are schematic cross-sectional diagrams showing major intermediate stages in the process of fabricating high- and low-voltage MOS transistor devices in accordance with one preferred embodiment of the present invention.
FIG. 10 to FIG. 18 are schematic cross-sectional diagrams showing major intermediate stages in the process of fabricating high- and low-voltage MOS transistor devices in accordance with another preferred embodiment of the present invention.
DETAILED DESCRIPTION
Please refer to FIG. 1 to FIG. 9 . FIG. 1 to FIG. 9 are schematic cross-sectional diagrams showing major intermediate stages in the process of fabricating high- and low-voltage MOS transistor devices in accordance with one preferred embodiment of the present invention. As shown in FIG. 1 , a semiconductor substrate 10 is prepared. The semiconductor substrate 10 comprises a low-voltage device area 102 and a high-voltage device area 104 . Within the low-voltage device area 102 , low-voltage devices such as low-voltage (5V, 3.3V or lower) MOS transistors are fabricated. Within the high-voltage device area 104 , high-voltage devices such as high-voltage (12V or even higher) MOS transistors are fabricated. Initially, isolation structures 12 such as shallow trench isolation (STI) and active areas are defined on the semiconductor substrate 10 both in the low-voltage device area 102 and high-voltage device area 104 .
As shown in FIG. 2 , a low-voltage gate dielectric 22 and a high-voltage gate dielectric 24 are formed on the surface of the semiconductor substrate 10 within the low-voltage device area 102 and high-voltage device area 104 , respectively. Techniques of forming gate dielectrics with two different thicknesses are known in the art, and are not discussed further. According to the preferred embodiment, the low-voltage gate dielectric 22 has a thickness that is less than 200 angstroms, preferably less than or equal to 100 angstroms, while the high-voltage gate dielectric 24 has a thickness that is thicker than 300 angstroms, preferably thicker than 600 angstroms.
As shown in FIG. 3 , a polysilicon layer 30 is deposited on the low-voltage gate dielectric 22 and on the high-voltage gate dielectric 24 . A photoresist mask 42 and photoresist mask 44 are defined on the polysilicon layer 30 , wherein the photoresist mask 42 defines the gate pattern of a low-voltage MOS transistor device within the low-voltage device area 102 , while the photoresist mask 44 defines the gate pattern of a high-voltage MOS transistor device within the high-voltage device area 104 .
Subsequently, as shown in FIG. 4 , using the photoresist masks 42 and 44 as an etching hard mask, a plasma dry etching is carried out to etched away the polysilicon layer 30 that is not covered by the photoresist masks 42 and 44 , thereby forming a gate electrode 32 of the low-voltage MOS transistor device and gate electrode 34 of the high-voltage MOS transistor device. The low-voltage dielectric 22 outside the gate electrode 32 is etched away to expose the semiconductor substrate 10 . The aforesaid plasma dry etching is not terminated until a predetermined thickness of the thicker high-voltage dielectric 24 is removed. At this phase, the remaining high-voltage dielectric 24 still covers the high-voltage device area 104 .
As shown in FIG. 5 , a layer of photoresist (not explicitly shown) is coated over the semiconductor substrate 10 , and is then exposed and developed using conventional lithography to form photoresist mask 52 and photoresist mask 54 . The photoresist mask 52 covers the entire low-voltage device area 102 , while the photoresist mask 54 merely masks the gate electrode 34 and a portions of the remaining high-voltage dielectric 24 laterally protruding an offset “d” from the bottom of the gate electrode 34 . The offset “d” is substantially equal to the distance between the gate electrode 34 and the source/drain salicide formed in the subsequent processes.
As shown in FIG. 6 , using the photoresist mask 52 and photoresist mask 54 as a hard mask, a plasma dry etching is carried out to etch away the remaining high-voltage dielectric 24 that is not covered by the photoresist mask 54 . Thereafter, the photoresist mask 52 and photoresist mask 54 are stripped off. The remaining high-voltage dielectric 24 that is not directly under the gate electrode 34 is hereinafter referred to as lug portions 24 a that are formed on two opposite sides of the gate electrode 34 with an offset “d” from the gate sidewalls. According to the preferred embodiment, the lug portions 24 a have a thickness of about 100˜600 angstroms, and the offset “d” is in a range of about 0.4˜2.0 micrometers.
As shown in FIG. 7 , a spacer dielectric layer 60 such as silicon nitride is deposited over the semiconductor substrate 10 . Next, as shown in FIG. 8 , an isotropic dry etching is carried out to etch the spacer dielectric layer 60 , thereby forming spacers 62 and 64 on sidewalls of respective gate electrodes 32 and 34 . Conventional ion implantation process is then performed to form source/drain regions 72 within the low-voltage device area 102 and source/drain regions 74 within the low-voltage device area 104 . After the implantation of source/drain regions, a typical salicide process is carried out. A metal layer 80 such as cobalt or titanium is deposited over the semiconductor substrate 10 . The metal layer 80 covers both the low-voltage device area 102 and high-voltage device area 104 . It is one feature of the present invention that the lug portions 24 a function as a salicide block that keeps the metal layer 80 from contacting the substrate within the offset area directly under the lug portions 24 a.
Finally, as shown in FIG. 9 , a thermal process is performed. The source/drain regions 72 and 74 that are in contact with the metal layer 80 react with the overlying metal layer 80 to form metal salicide layers 82 a and 84 a . Simultaneously, metal salicide layers 82 b and 84 b are formed on the exposed gate electrodes 32 and 34 .
FIG. 10 to FIG. 18 are schematic cross-sectional diagrams showing major intermediate stages in the process of fabricating high- and low-voltage MOS transistor devices in accordance with another preferred embodiment of the present invention. As shown in FIG. 10 , likewise, the semiconductor substrate 10 comprises a low-voltage device area 102 and a high-voltage device area 104 . Within the low-voltage device area 102 , low-voltage devices such as low-voltage (5V, 3.3V or lower) MOS transistors are fabricated. Within the high-voltage device area 104 , high-voltage devices such as high-voltage (12V or even higher) MOS transistors are fabricated. Initially, isolation structures 12 such as shallow trench isolation (STI) and active areas are defined on the semiconductor substrate 10 both in the low-voltage device area 102 and high-voltage device area 104 .
As shown in FIG. 11 , a low-voltage gate dielectric 22 and a high-voltage gate dielectric 24 are formed on the surface of the semiconductor substrate 10 within the low-voltage device area 102 and high-voltage device area 104 , respectively. According to the preferred embodiment, the low-voltage gate dielectric 22 has a thickness that is less than 200 angstroms, preferably less than or equal to 100 angstroms, while the high-voltage gate dielectric 24 has a thickness that is thicker than 300 angstroms, preferably thicker than 600 angstroms.
As shown in FIG. 12 , a polysilicon layer 30 is deposited on the low-voltage gate dielectric 22 and on the high-voltage gate dielectric 24 . A photoresist mask 42 and photoresist mask 44 are defined on the polysilicon layer 30 , wherein the photoresist mask 42 defines the gate pattern of a low-voltage MOS transistor device within the low-voltage device area 102 , while the photoresist mask 44 defines the gate pattern of a high-voltage MOS transistor device within the high-voltage device area 104 .
Subsequently, as shown in FIG. 13 , using the photoresist masks 42 and 44 as an etching hard mask, a plasma dry etching is carried out to etched away the polysilicon layer 30 that is not covered by the photoresist masks 42 and 44 , thereby forming a gate electrode 32 of the low-voltage MOS transistor device and gate electrode 34 of the high-voltage MOS transistor device. The low-voltage dielectric 22 outside the gate electrode 32 is etched away to expose the semiconductor substrate 10 . The aforesaid plasma dry etching is not terminated until a predetermined thickness of the thicker high-voltage dielectric 24 is removed. At this phase, the remaining high-voltage dielectric 24 still covers the high-voltage device area 104 .
As shown in FIG. 14 , spacer 62 and spacer 64 are formed on sidewalls of gate electrodes 32 and 34 , respectively. One difference between this embodiment and previous embodiment is that in this embodiment the spacers 62 and 64 are formed prior to the formation of the lug portions 24 a.
As shown in FIG. 15 , a layer of photoresist (not explicitly shown) is coated over the semiconductor substrate 10 , and is then exposed and developed using conventional lithography to form photoresist mask 52 and salicide block photoresist mask 54 . The photoresist mask 52 covers the entire low-voltage device area 102 , while the salicide block photoresist mask 54 merely masks the gate electrode 34 , spacer 64 and a portions of the remaining high-voltage dielectric 24 laterally protruding an offset “d” from the bottom of the gate electrode 34 . The offset “d” is substantially equal to the distance between the gate electrode 34 and the source/drain salicide to be formed in the subsequent processes.
As shown in FIG. 16 , using the photoresist mask 52 and salicide block photoresist mask 54 as a hard mask, a plasma dry etching is carried out to etch away the remaining high-voltage dielectric 24 that is not covered by the salicide block photoresist mask 54 , thereby forming lug portions 24 a . The spacer 64 has a maximum thickness that is smaller than the offset “d” such that the salicide block lug portions 24 a laterally protruding from bottom of the spacer 64 and forms a step thereto.
Thereafter, the photoresist mask 52 and photoresist mask 54 are stripped off. The lug portions 24 a are formed on two opposite sides of the gate electrode 34 and protruding with an offset “d” from bottom of the gate sidewalls. According to the preferred embodiment, the lug portions 24 a have a thickness of about 100˜600 angstroms, and the offset “d” is in a range of about 0.4˜2.0 micrometers.
As shown in FIG. 17 , ion implantation processes are performed to form source/drain regions 72 within the low-voltage device area 102 and source/drain regions 74 within the low-voltage device area 104 . After the implantation of source/drain regions, likewise, a typical salicide process is carried out. A metal layer 80 such as cobalt or titanium is deposited over the semiconductor substrate 10 . The metal layer 80 covers both the low-voltage device area 102 and high-voltage device area 104 . The lug portions 24 a function as a salicide block that keeps the metal layer 80 from contacting the substrate within the offset area directly under the lug portions 24 a.
Finally, as shown in FIG. 18 , a thermal process is performed. The source/drain regions 72 and 74 that are in contact with the metal layer 80 react with the overlying metal layer 80 to form metal salicide layers 82 a and 84 a . Simultaneously, metal salicide layers 82 b and 84 b are formed on the exposed gate electrodes 32 and 34 .
Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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A method for fabricating metal-oxide-semiconductor devices is provided. The method includes forming a gate dielectric layer on a substrate; depositing a polysilicon layer on the gate dielectric layer; forming a resist mask on the polysilicon layer; etching the polysilicon layer not masked by the resist mask, thereby forming a gate electrode; etching a thickness of the gate dielectric layer not covered by the gate electrode; stripping the resist mask; forming a salicide block resist mask covering the gate electrode and a portions of the remaining gate dielectric layer; etching away the remaining gate dielectric layer not covered by the salicide block resist mask, thereby exposing the substrate and forming a salicide block lug portions on two opposite sides of the gate electrode; and making a metal layer react with the substrate, thereby forming a salicide layer that is kept a distance “d” away from the gate electrode.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present invention is a continuation in part of Provisional U.S. Patent Application No. 61/220,191, entitled “SOFTWARE DEVELOPMENT, DEPLOYMENT AND EVOLUTION SYSTEM, METHOD AND PROGRAM PRODUCT” to Peri L. Tan et al., filed Jun. 24, 2009 assigned to the assignee of the present invention and incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to evolving software to meet changing needs and distributing the evolved software; and more particularly, to monitoring active software and creating up to date versions of evolved software to meet changing needs for the software and distributing the evolved software in a “data-centric” manner.
BACKGROUND DESCRIPTION
[0003] Typically, software developers write applications, software systems, and services in one or more particular programming languages, using programming models geared for a fixed set of target contexts and usages. The software is then compiled, distributed and deployed as a full blown application. Whenever a particular application proves useful, its use may extend well beyond its planed life, e.g., the life of the particular language and model. Moreover, users may find uses in a variety of contexts that extend well beyond what the software developer(s) intended and anticipated. So, successful software may well outlive its original programming language(s), models and paradigm(s); some or all of the original software stack; and even, the original operating system(s), middleware and hardware on which it was based and for which was developed. Consequently, evolving—or even maintaining—such software has become increasingly expensive and problematic.
[0004] There have been a small number of techniques available to developers for making software more adaptable in somewhat limited ways. Developers may offer software in what are known as Software Product Lines (SPLs) that are designed with variation points in particular parts of the software to anticipate expected needs. As a simple example, a SPL may have an open point for adding new printers based on the assumption that all printers support Portable Document Format (PDF). The developers would be unable to extend that particular SPL to print to a Postscript printer.
[0005] Alternately, developers have used what is known as dynamic loading and dynamic weaving to provide applications capable of what is known as dynamic adaptation. Dynamic adaptation is a different technique for enabling software to work in contexts other than what it is originally developed for. More particularly, dynamic adaptation involves loading one piece of software (replacement) that replaces a functionally equivalent or similar part of an existing piece of software.
[0006] Dynamic loading involves removing a part of a running software system (a library, a component, a class, or other unit of functionality) from memory, loading a replacement, and redirecting subsequent usage from the replaced software to the replacement. Dynamic weaving involves modifying parts of running software to add or remove functionality, without need for recompilation or restarting the running software. Both dynamic loading and dynamic weaving are limited, invasive and involve potentially hazardous actions. Both techniques, for example, very easily introduce errors into running software. Failing to provide fully compatible replacement components, can cause software to produce erroneous results, go into infinite loops (cause a computer to slow down or crash), hang, or otherwise crash entirely.
[0007] Equally problematic is the cost of providing “life support” and experienced support personnel and resources, which increases with the age of the application being supported. As time passes, the size of the pool of people with skills required to maintain older software and its requisite infrastructure declines. Experienced developers are expensive, charging more for the experience. Neophyte (cheaper) developers normally train for the state of the art, ignoring outdated languages and technologies that may be necessary for maintaining the software in its required environment, i.e., providing life support.
[0008] Previously, the only alternative to continuing expensive life support was rewriting software using newer technologies. This has required extensive knowledge of new technologies, of existing software and older technologies on which the software depends, as well as knowledge of how the particular application is deployed and post-deployment operating conditions. Also, most real state of the art software is very large and complex and does extremely significant, complex things. New development is time consuming, and requires major resource expenditures, i.e., people, money, software and hardware. Consequently, previously it took at least as many people and the same level of resources to rewrite new versions of software and to ensure that new versions functioned correctly. Moreover, typical redevelopment is very likely to introduce new bugs that, potentially, cause tremendous impact on both the software users and software owners. Unfortunately, both maintaining life support and rewriting software are extremely expensive and risky alternatives.
[0009] How successful software is determines the eventual range of contexts of its use. Successful software, especially software that solves an important, ubiquitous problem, may be used and reused in a wide range of unforeseeable contexts. Consequently, planning for its reuse is very likely inadequate. Planning for variations of particular software adds to design, implementation, maintenance, evolution, test and qualification time. This all increases development and maintenance costs. When developers can predict variants with a high degree of accuracy, this cost increase may be acceptable and preferable. However, when the predictions are wrong—as they very often are—the normal result is more complex software that is unnecessarily more difficult to maintain, evolve, and adapt than it would have been otherwise, i.e., if unused variation points had not been included.
[0010] Moreover, deploying a rewrite or new version of successful software, further extends the life of the software and is likely to continue the need for further rewrites. So after deploying rewritten software, if it works well and addresses a more ubiquitous need, it may be necessary to continue evolving the software as new contexts arise. This increases the likelihood that others will take and deploy newer versions into other contexts that the developers and/or redevelopers did not originally anticipate. consequently, adapting and modifying software for each new context has been a time-consuming and error-prone task; long-term maintenance and subsequent software evolution tends to be a nightmare. This is especially true since the above previous solutions usually required invasive modification, adapting software statically for new contexts, either manually or by using technology, e.g., aspect-oriented programming.
[0011] Thus, there is a need for simplifying extending the life of existing software and for simply and seamlessly recreating and redeploying software that addresses evolving needs that extend beyond original design goals.
SUMMARY OF THE INVENTION
[0012] It is a purpose of the invention to reduce maintenance costs of useful software;
[0013] It is another purpose of the invention to reduce costs of evolving useful software;
[0014] It is yet another purpose of the invention to reduce the development costs of new versions or iterations of existing software;
[0015] It is yet another purpose of the invention to make software malleable and adaptable;
[0016] It is yet another purpose of the invention to produce software that is more readily adapted/evolved to new and evolving contexts throughout the lifetime of the software;
[0017] It is yet another purpose of the invention to make software that more readily is adapted to new and evolving contexts while reducing or removing sources of otherwise ever-increasing maintenance and evolution costs;
[0018] It is yet another purpose of the invention to produce malleable, adaptable software that is easier to evolve for unanticipated uses and in different and unforeseeable contexts while minimizing maintenance costs;
[0019] It is yet another purpose of the invention to allow software developers to reuse software in multiple programming languages, and adapted for contexts that extend well beyond the original contexts for which it was originally created.
[0020] The present invention relates to a method of software evolution, software evolution system and program product therefor. A context specification handler stores and manages context specifications, this management including the creation and addition of the context specification, the modification of existing context specifications, the deletion of existing context specification, as well as the listing and retrieval of existing context specifications. The context specifications describe software environment requirements and constraints and provide instructions for assembling the software from a set of Software Part Semantics Specifications (SPSSs). An SPSS handler stores and managers all software part semantics specifications, this management including creation, modification, deletion and retrieval of software part semantics specifications. Software Implementations (SIs) describe how a given software part can be implemented. An SI handler stores SIs. A Behavior History handler stores a history of results of software behavior analysis of previous versions of active context-adapted software. A software rendering handler takes as input a set of SPSSs from a SPSS handler, a context specification from context specification handler describing the intended context in which the resulting context-adapted software version will run, and behavioral history of the software from any previous versions. Then, the software rendering handler assembles and may distribute resulting context-adapted software. An inspection handler continuously monitors the active (new) version and analyzes behavior and execution characteristics, e.g., performance, scalability, failure rate, availability, etc. If the inspection handler discovers that the active context-adapted software is not addressing the requirements specified in its context specification, the inspection handler refers the context-adapted software back to the software rendering handler. The software rendering handler reassembles a new version of context-adapted software, better adapted for the context in which it is used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The foregoing and other objects, aspects and advantages will be better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawings, in which:
[0022] FIG. 1 shows a block diagram of an example of a context-adaptive software evolution system according to one embodiment of the present invention;
[0023] FIG. 2 shows an example of the flow control of a context-adaptive software evolution system according to one embodiment of the present invention;
[0024] FIG. 3 shows an example of the flow control of a rendering handler according to one embodiment of the present invention;
[0025] FIGS. 4A-B show a comparison between an example of a previous approach to creating and deploying software with an example of creating, evolving and deploying software according to one embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] Turning now to the drawings and, more particularly, FIG. 1 shows an example of a context-adaptive software evolution system 1000 according to a preferred embodiment of the present invention. Preferably, context-adapted software is created, evolved and deployed in a “data-centric” manner. In particular, developers write data-centric software such that semantics are separated from function analogous to using Cascading Style Sheets (CSS) to separate document content from document presentation in creating Hypertext Markup Language (HTML) based web pages. Thus, developers write semantics-oriented Software Part Semantics Specifications (SPSSs) that describe intended semantics of the software parts without specifying any details about how those semantics are realized. The SPSSs may describe the semantics of pieces of software of any size (small, medium, or large) that are intended, not as a final product, but as components of context-adapted software product or products. Preferably, the SPSSs are free from context or programming language-specific details.
[0027] Software Implementations (SIs) supply implementations for the SPSSs. A given SI indicates how to accomplish the task described by a given SPSS. In particular, the SIs provide behavioral semantics, analogous to visual presentation semantics that CSS provides. For example, some SIs may effectively provide the semantics of modern-day programming languages (e.g., Java CSS-type semantics or a C# CSS-type semantics); others may provide library-like services, such as mathematical capabilities and messaging services. Thus, advantageously, the present invention simplifies retargeting existing software to a more modern programming language, non-invasively by replacing the particular SI.
[0028] So, for example, a phrase intended emphatically may be represented in HTML as <em>I really mean business!</em>. How the text is rendered depends on the context in which the text will appear. One CSS realization of <em> might produce an italicized version, I really mean business! Another realization might produce a version of the text in flashing red letters or bold. This separation between HTML (where the intended text semantics are described by markup) and CSS (which specifies the realization of that markup) allows multiple different renderings of the same text without having to modify the HTML. Thus, there are multiple SIs can fulfill the requirements of a given SPSS.
[0029] As shown in the example of FIG. 1 , the system 1000 may include any suitable computing node that is able to load and execute programmatic code, including, but not limited to: products sold by IBM such as ThinkPad® or PowerPC®, running the operating system and server application suite sold by Microsoft, e.g., Windows® XP, or a Linux operating system. The system logic 1050 is preferably embodied as computer executable code that is stored and loaded from a remote source (e.g., from a network file system), local permanent optical (CD-ROM), magnetic storage (such as disk), or storage 1020 into memory 1040 for execution by CPU 1010 . The system 1000 may also include a data network interface 1030 , through which the system 1000 can communicate. Such an interface 1030 may include, but is not limited to a hardwired one, e.g., Ethernet over coax cable, wireless IP, and telephone to IP (VoIP), such as that provided by the DVG-1402S Broadband Phone Service VoIP Router from D-Link®. Preferably, as will be discussed in greater detail below, the memory 1040 includes computer readable instructions, data structures, program modules and application interfaces forming the following components: a rendering handler 1060 , a software parts semantics specification (SPSS) Handler 1070 , a software implementation specification (SI) handler 1080 , a context specification handler 1090 , an inspection handler 1100 , an evolving context information handler 1110 , a behavior history handler 1120 , and a system database 1130 .
[0030] Handlers 1070 - 1120 are described in detail with reference to FIG. 2 , with the rendering handler 1060 being described in detail with reference to FIG. 3 . The system database 1130 , in one embodiment, provides for creation, deletion and modification of persistent data, and is used by all of the handlers 1060 - 1120 . An example of a product providing such function includes IBM DB/2 database system. It should be noted that the system database 1130 may be local or on another network accessible node. Further, one or more handlers 1060 - 1120 may include a dedicated independent database. Thus, a single shared database is not required.
[0031] FIG. 2 shows an example of control flow of through logic 1050 of the context-adapted evolution system 1000 in an embodiment of the current invention. FIG. 2 also provides an overview example of context-adapted software evolution according to a preferred embodiment of the present invention. In step 2000 , a software developer(s) selects(select) all of the relevant Software Part Semantics Specifications (SPSSs) from the SPSS handler 1070 , adding in any new required SPSSs first. As described above, the SPSSs describe what the software parts are to do without specifying any details about how the result is realized. The selected SPSSs are then passed to the rendering handler 1060 .
[0032] So, in step 2010 , all of the context specifications for context-adapted software are selected from the context specification handler 1100 , any new needed specifications being added first. These context specifications describe the specific context requirements on the context-adapted software, such as performance requirements, network configuration and expected load. The context specifications also describe the context in which the assembled software must operate or run and drive software assembly. Multiple possible realizations are allowed for any particular application (e.g., PC, Mac®, Unix®, Linux) through the definition of different CSS-like context specifications. Preferably, all context specifications are stored in a context specification handler 1090 . The handler 1090 allows for the creation, modification and retrieval of context specifications. New specifications can be added by developers. Further, users and developers may change software requirements over time. So, the inspection handler 1100 may change and update context specifications, when the inspection handler 1100 identifies changes and updates. In step 2010 , context specification handler 1090 returns all selected context specifications to the rendering handler 1060 . Next in step 2020 , the rendering handler 1060 , attempts to create context-adapted software providing the semantics indicated by the selected SPSSs, and fulfilling the returned context specification. This is described in more detail hereinbelow with reference to FIG. 4 .
[0033] As shown in FIG. 3 , in step 3010 , the rendering handler 1060 , guided by the selected context specifications, attempts to select statically or dynamically, the software implementations (SIs) that accomplish the specified SPSSs. Since one or more of the needed SIs might not be available from the SI handler 1080 ; in step 3020 , the rendering handler 1060 checks whether all of the necessary SIs have been retrieved. For example, although there may be SIs in Java1.1 and Java1.3 which provide a particular mathematical calculation, one might not be implemented in Java 2. Thus, if Java 2 were the specified programming language in the context specification, no SI for the given mathematical calculation would be available.
[0034] Whenever all SIs are found, in step 3030 the rendering handler 1060 assembles the retrieved SIs into context-adapted software (e.g., a stand alone application or a component). The context-adapted software may be fixed in any suitable physical medium for distribution, for example, in magnetic storage, Compact Disks (CDs), Digital Versatile Disks (DVDs), flash storage, or transferred over a network (not shown) to/from client local storage. Next in step 3040 , the rendering handler 1060 returns this new software element. Alternatively, if any required SIs are not found, then in step 3050 an indication is provided of which SPSS cannot be matched and why. So, for the example above, the indication indicates that an implementation for the given mathematical calculation implemented in Java 2 cannot be found.
[0035] After indicating missing SPSSs, in step 3060 the context specification is checked to determine whether to modify the context specification to resolve the problem. If modification is selected, then in step 3070 , the developer(s) can modify the current context specification, e.g., relaxing the requirement for Java 2, to Java 1.3. If in step 3060 , however, modifying the context specification is not selected, then in step 3080 a check is made whether the missing/required SI(s) will be provided. Such SIs can be provided either manually by a developer or automatically, e.g., from a search for SIs, for example, from public 3 rd -party SIs repositories. If the missing/required SI(s) can be provided, then in step 3090 , the required SIs are added to the SI handler 1080 . After resolving the problem either by modifying 3070 the context specification or by providing 3090 the missing/required SI(s); returning to step 3010 , the rendering handler again tries to find SIs that provide the semantics specified by the given SPSSs and that fulfill the context specification. If adding the required SIs is denied in step 3080 , then in step 3100 the rendering handler 1010 signals failure. Thus advantageously, software function (SPSSs) is disentangled from the particular software implementation (SIs) describing the particular programming language in which each implementation is expressed and from the particular context in which the implementations may run.
[0036] Advantageously, the rendering handler 1060 can also check whether all of the necessary SPSSs are available from the SPSS handler 1070 . For example, one SPSS specified in step 2000 may be or include an invocation by an object A of method P. If in this example, the SPSS handler 1070 has no definition of method P for object A, a preferred embodiment makes this determination and posts an alert.
[0037] Returning to FIG. 2 , in step 2030 the rendering handler 1060 checks whether it was successful in creating the context-adapted software. If not, in step 2040 failure is signaled and assembly ends. Otherwise, when context-adapted software is created successfully, the rendering handler 1060 checks in step 2050 whether the context-adapted software can be run on its own, e.g., as a full application. If not, as with a single library function, in step 2050 , the rendering handler 1060 passes the context-adapted software to the SI handler 1080 to be stored as a new component SI for use as a subcomponent in future software projects. Otherwise, in step 2070 , the context-adapted software may be deployed (active) on any appropriate single device (e.g., a personal computer (PC), a server, a phone), a collection of devices (e.g., a distributed network), or as a service in what is well known as “the Cloud.”
[0038] Once deployed 2070 , the inspection handler (e.g., 1100 in FIG. 1 ) monitors 2080 the performance and behavior of the context-adapted software. The inspection handler 1100 may be a human inspector or, preferably, a suitable computer application. The inspection handler 1100 updates the behavior history of the context-adapted software, saving the data using the behavior history handler 1120 . The inspection handler 1100 also updates the evolving context specifications, saving the relevant data using the evolving context specification information handler 1110 .
[0039] For example, the specified context specification may indicate that the context-adapted software has to support only 1,000 concurrent users. If the inspection handler 1100 finds that 100,000 concurrent user are frequently active, it would store this fact using the evolving context information handler 1110 . Any and all other such context specification discrepancies would also be stored using the evolving context information handler 1110 . It should be noted that once updated, and for any subsequent reassemblies, the rendering handler 1060 can also use the information held by the behavior history handler 1120 . The evolving context information handler 1110 guides selection of SIs for reassembly into a new version. Each new version is better adapted for the context in which the previous/current version is used. Use of latest behavior data and context information insures that the new version of the context-adapted software satisfies the current context specifications.
[0040] So in step 2090 , the inspection handler 1100 checks whether the context-adapted software's performance satisfies the requirements described by the specified context specification. If so, the context-adapted software is passed to the SI handler 1080 and saved in step 2110 as a new implementation—an application SI—if the current implementation has not already been saved. Then, returning to step 2080 , the inspection handler 1100 monitors the context-adapted software's behavior and performance.
[0041] Alternatively, if the inspection handler 1100 finds that the context-adapted software fails to meet the context specifications in step 2090 , the inspection handler 1100 first updates the context specification in step 2100 using the context specification handler 1090 . The context specification updates provided in step 2100 include any new specification information stored in the evolving context information handler 1110 (e.g., that the context-adapted software must support 100,000 concurrent users, rather than just 1,000). Then, returning to and proceeding from step 2010 the rendering handler 1060 retrieves up-to-date context specifications from the context specification handler 1090 .
[0042] It should be noted that through the updates to the context specification in step 2100 , the inspection handler 1100 communicates new and/or updated context requirements to the rendering handler 1060 for a new version of the context-adapted software. For example, if the inspection handler 1100 finds at step 2080 that the context-adapted software frequency crashes from lack of memory; the inspection handler 1100 can update the context specification to require a greater amount of available memory. The inspection handler 1100 also may determine (via an error messages) when the context-adapted software is using a now-obsolete version of a given protocol or language (e.g., Java 1.3 rather than Java 2.0). In response, the inspection handler 1100 can update or change the context specification to include the requirement for a newer version. Further, the inspection handler 1100 can invoke the rendering handler 1060 to assemble a new version of the context-adapted software, a version more likely to address the context specification requirements, returning the process 1050 to step 3020 .
[0043] It should also be noted that while the context-adapted software's performance checks in step 2090 may succeed for a time, the checks may eventually fail due to changes over time in the deployment environment. For example, suppose that although the context-adapted software runs without interruption for several weeks, but then, due to increased usage load begins to crash and requires restarts several times a day. Since eventually this degradation would not meet the requirement for 24×7 availability, the inspection handler's 1100 check would fail at step 2090 and the context specification would be updated in step 2100 .
[0044] Again, the rendering handler 1060 is invoked to create a new version back up in step 2020 . The changes in the specification and deployment environment are available as updates to the rendering handler 1060 from the context specification handler 1090 , the behavior handler 1120 and evolving context information handler 1110 that were updated by the inspection handler 1100 . Further, since none of the context-specific requirements are built into the SPSSs, the SPSSs can be considered “pure.” So, the rendering handler 1060 can choose different SIs, based on the actual behavioral information the inspection handler 1100 provides for the current version. Then, using the same or some variation of the same SPSSs, the rendering handler 1060 assembles a new version. The new version, and any subsequent versions are thus directed to the actual contextual requirements, e.g., reflected in feed back from the inspection handler 1100 in the context specification and behavior history.
[0045] FIGS. 4A-B show a comparison between an example of a previous approach 120 to creating and distributing software with an example of creating, evolving and distributing software 112 according to a preferred embodiment of the present invention. Previously, as shown in the control-centric example of FIG. 4A , the software developer produced software 120 that produces a single application, e.g., printing “Hello World” (the data) with a given format. Changing or varying how the software operates on the data to give a different result (i.e., printing “Hello World” in a different format) requires changing the software 120 .
[0046] By contrast, as noted hereinabove, the rendering handler ( 1060 in FIG. 1 ) may assemble context-adapted software 112 developed according to a preferred embodiment of the present invention, much more flexibly. The present invention employs a technique similar to web page design where developers use markup to describe the semantics of annotated (marked-up) text. Analogous to HTML, where, one may use CSS to separately describe the markup semantics; the SIs provide alternate SPSS implementations that the rendering handler 1060 uses in creating context-adapted software 112 .
[0047] In the example of FIG. 4B , the rendering handler 1060 may assemble the same single set of SPSSs 108 into a Java™ realization 1120 , a Ruby programming language realization 1122 , a simple realization 1124 or a fancy realization 1126 . So, in this example, printing 122 the data “Hello World” provides different results, e.g., 124 and 126 , depending upon the SIs 1124 and 1126 chosen. Further, the rendering handler 1060 assembles these variants without modifying the SPSSs, simply by choosing different appropriate SIs 1120 , 1122 , 1124 and 1126 from SI handler 1080 .
[0048] Over time, new SIs—reflecting new languages, libraries, features—are written and stored in SI handler 1080 . Moreover, these new SIs may be distributed “virally,” propagating across a network of service hubs in a network or networks, e.g., across the world-wide web. These new SIs may be opportunistically used in assembling context-adapted software, based on semi-automated evaluation by the inspection handler 1100 . The inspection handler 1100 may consider the relative risks and value associated with replacing an existing SI implementation with a new one.
[0049] It should be noted that in addition to producing an instance of context-adapted software, the rendering handler 1060 could also produce a summary of the context specification upon which the context-adapted software is based. This summary can include both the full current context specification, but also an indication of the actual usage levels, this information drawn from the evolving context information handler 1110 . For example, a given context specification might indicate that the context-adapted software must be able to support of graphic files of up to 1 GB. In contrast, the evolving context information handler 1110 might show that no file greater that 10 MB was ever processed. Therefore, the context specification summary produced by the rendering handler 1060 would include both the required value of 1 GB and the actual value of 10 MB. Also, since the context specification for each version of context-adapted software changes with each evolutionary cycle's updates from the inspection handler 1100 , the relevant context specification may differ greater from that specified for the first version. Thus advantageously, one may obtain the actual summary context specification for a later version of context-adapted software. Information such as that included in such a context specification summary facilitates resource planning related to the use of the context-adapted software.
[0050] Advantageously, the present invention simplifies retargeting existing software to a more modern programming language(s), libraries, components, operating systems, or other underlying functionality. Further, after retargeting new DCCs non-invasively replacing the previously created DCCs. Thus, the useful life of existing applications is extended beyond the life of the original programming language, libraries, components, operating systems, or other underlying functionality in which the application happened to be implemented. Life support costs are dramatically reduced because older applications can be regenerated using newer languages that do not require support by personnel experienced in otherwise obsolete technology. Moreover, the present invention provides up to date software tailored to current needs by continually monitoring, adapting and distributing software in response to changes in the context as they occur and are encountered. Thus, development costs associated with modifying existing applications to meet context changes are avoided by simply reassembling the application based on updated contexts and redistributing the updated version.
[0051] While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims. It is intended that all such variations and modifications fall within the scope of the appended claims.
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A method of software evolution, software evolution system and program product therefor. A context specification handler stores context specifications describing requirements on context-adapted software. A Software Part Semantics Specification (SPSS) handler stores software part semantics specifications. A Software Implementation (SI) handler stores SIs. Behavior History handler stores a history of active software behavior analysis results of monitoring previous versions. A software rendering handler combines software behavior history with context specification, software part semantics specifications and SIs and distributes (and optionally deploys) context-adapted software. A software inspector continuously monitors context behavior of deployed versions and selectively identifies active context-adapted software failing to satisfy context specification for reassembly of a new version(s).
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/EP01/14127, filed Dec. 3, 2001, which designated the United States and was not published in English.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to an apparatus for smoothing articles of clothing, particularly shirts and blouses, by an inflatable body, i.e., an ironing dummy.
[0003] A variety of devices for ironing articles of clothing by an ironing dummy are known from the prior art. European Patent Application EP 0 193 483 A1 (subsequent application of FR 8500673) describes a method and an ironing dummy for ironing an article of clothing. The article of clothing is placed on an inflatable bag of the ironing dummy for ironing. An airflow in the interior of the inflatable bag blows through the bag and the article of clothing, drying and smoothing the article of clothing. Because the inflatable bag also extends into the sleeves of the clothing, these are also dried. In a development of that invention, the inflatable bag extends beyond the cuffs (potentially beyond the collar as well) of the clothing. Flexible flaps are attached at these extensions on the exterior. They are, preferably, made of the same material as the inflatable bag. When the article of clothing is positioned on the ironing dummy, and the airflow is activated, then the inflatable bag and the flaps are penetrated by the air jointly and simultaneously. The airflow inflates the inflatable bag and the flaps. The inflatable bag, then, contacts the clothing from inside. The flaps, however, contact the cuffs of the clothing from the outside. Because the flaps are also penetrated by the drying air, the cuffs are dried from inside by the inflatable bag and from outside by the flaps.
[0004] When the clothing is to be removed from the ironing dummy after the drying process, the flaps must first be moved in the other direction by hand before the clothing can be taken down off the ironing dummy. Such a procedure is complicated and time-consuming. Furthermore, it is cumbersome for the sleeves of the clothing, particularly, the cuffs, to remain hanging at the flaps each time the clothing is put on or taken off, which would, undesireably, crease the freshly ironed cuffs.
[0005] Another disadvantage to the cited prior art lies in the fact that cuffs of clothing are usually buttonable and contain a placket above the cuff (in the direction of the shoulder).
[0006] Because the inflatable bag inflates during the drying process, the bag presses the placket and opens it. The disadvantage is that an open placket is dried in that shape—a shape that is undesirable for aesthetic reasons.
SUMMARY OF THE INVENTION
[0007] It is accordingly an object of the invention to provide an apparatus for smoothing shirts that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and that provides a way in which and a device (in the form of an ironing dummy) with which the ironing result can be improved and the device, as a whole, can be made easier to handle with little expenditure.
[0008] With the foregoing and other objects in view, there is provided, in accordance with the invention, a device for smoothing articles of clothing having a cuff, including a shirt-shaped inflatable body having a flexible covering and at least one arm portion with an end and at least one stiffening connected to the flexible covering at the end, the stiffening disposed inside the cuff when the cuff is being smoothed.
[0009] With the objects of the invention in view, there is also provided a device for pressing articles of clothing having and arm portion and a cuff, including a shirt-shaped inflatable body having a flexible covering for receiving a shirt-shaped piece of clothing thereon and at least one arm portion with an end for receiving the arm portion and cuff, and at least one stiffening connected to the flexible covering adjacent the end, the stiffening disposed inside the cuff when at least one of the arm portion and the cuff is being smoothed.
[0010] It has been discovered that smoothing the cuffs is also possible by directly or indirectly stiffening the inflatable bag in the region of the ends of the sleeves. That is, the stiffening is provided only on the inside of the clothing, and, therefore, makes unnecessary the disruptive flaps beneath the cuffs (which are present in the prior art). Direct stiffening means that the inflatable bag, itself, is stiffened. In contrast, indirect stiffening means stiffening by an additional part on the inflatable bag, again, only in the sleeve region of the clothing. The advantage of these stiffenings is that they are easy to realize.
[0011] According to the invention, the stiffening can be provided either only in the region of the cuff or only between the cuff and the shoulder region of the clothing (above the cuff) or in both regions.
[0012] Such stiffening can be provided in the material of the inflatable bag. For instance, stiff materials can be incorporated in the inflatable bag. Another possibility is to soak the bag, at least at certain points, with liquids that, upon hardening, lend the bag the required stability.
[0013] When the ironing dummy functions such that an air flow from its interior dries the article of clothing, it is advantageous when the stiffening is air-permeable. That way, the drying air can also flow through the clothing in the region of the stiffening and dry it. If small holes of sufficiently small diameter are incorporated in the stiffening, the stiffening is sufficiently stable, while air is able to flow through it, but the inflatable bag cannot press through the holes and deform the clothing.
[0014] A specific type of stiffening is achieved by attaching a stiffening part on the inflatable bag. This stiffening part will be referred to hereinafter as a slotted spoon. As indicated by its name, the slotted spoon serves for stiffening the inflatable bag in the region of the placket in the clothing above the cuff and has the shape of a spoon or, more precisely, a shoehorn. A widening of the placket by the inflatable bag is no longer possible. It is also true of the slotted spoon that, given operating of the ironing dummy by a drying airflow from its interior, the slotted spoon should also be air-permeable, for instance, it should be constructed with holes. The slotted spoon, in particular, as well as the stiffening, in general, can also be realized in an air-impermeable form.
[0015] For this slotted spoon to maintain its hold on the inflatable bag, at least one of its ends can engage a strap, which can be sewn onto the inflatable bag, for example. This strap can better compensate relative movements between the slotted spoon and the inflatable bag because the slotted spoon can slide in the strap.
[0016] But, it is also possible for the slotted spoon to be attached directly to the inflatable bag at least with one end, for instance, with glue. of course, both fastening options can be combined because such a slotted spoon has two ends. The slotted spoon can be fastened, i.e., glued, to the inflatable bag on the inside or on the outside.
[0017] In accordance with another feature of the invention, the clothing has a placket adjacent the cuff and the stiffening has a portion covering the placket when the article of clothing is being smoothed.
[0018] In accordance with a further feature of the invention, the clothing has a placket adjacent the cuff and the placket has an interior and the stiffening has a portion covering the interior of the placket when the article of clothing is being smoothed.
[0019] It can be advantageous when the cuff of the clothing is held during ironing. The cuff, thereby, gains better seating and is more reliably smoothed. It is particularly practical when a clamp is formed at the slotted spoon, in either a releasable or fixed fashion. Regardless of whether the drying airflow comes from outside or inside, because the clamp grips the cuff on the outside, it is advantageous when the clamp also is air-permeable so that the drying is not impeded by parts situated on the outside. The air permeability can be accomplished by holes.
[0020] In accordance with an added feature of the invention, the stiffening has holding devices for fastening the article of clothing thereon.
[0021] In accordance with an additional feature of the invention, the stiffening has means for fastening the article of clothing thereon.
[0022] In accordance with yet another feature of the invention, the air-permeability is purposely impeded. Because the face side of the bottom end of the inflatable bag part that is located in the sleeve of the clothing plays no role in the drying process, it is expedient if none of the valuable drying air escapes from the face side while the ironing dummy is being operated with an air flow from its interior.
[0023] Frequently, the pressing force of the inflatable bag is insufficient for smoothing the cuff of the clothing to a satisfactory degree. To achieve a satisfactory result despite this, a tension mechanism can be disposed in the inflatable bag in the region of the cuff. This tension mechanism expediently has two chuck jaws that brace against one another under spring tension. Preferably, the stiffening is an internal tension mechanism and the two chuck jaws are connected to one another.
[0024] In accordance with yet a further feature of the invention, the stiffening has offset surfaces or angled surfaces for exerting traction on the article of clothing.
[0025] In accordance with a concomitant feature of the invention, the stiffening has means for exerting traction adjacent the cuff.
[0026] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0027] Although the invention is illustrated and described herein as embodied in an apparatus for smoothing shirts, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0028] The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 is a fragmentary, elevational and partially hidden view of part of an ironing dummy according to the invention with a corresponding portion of an article of clothing and with a stiffening in the region of a cuff;
[0030] [0030]FIG. 2 is a fragmentary, elevational and partially hidden view of the dummy of FIG. 1 with an additional stiffening in the form of a slotted spoon in the region above the cuff;
[0031] [0031]FIG. 3 a fragmentary, elevational and partially hidden view of the dummy of FIG. 2 with a clamp formed on the slotted spoon; and
[0032] [0032]FIG. 4 is a cross-sectional view of the dummy of FIG. 1 through a region of a cuff, the dummy having a tension mechanism for the cuff.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a stiffening of the inflatable bag 7 in the region of a buttonable cuff 3 of an article of clothing 2 . This stiffening represents the function of a cuff smoother 1 . The stiffening of the cuff smoother 1 has rendered it air-impermeable. For that reason, the cuff smoother 1 is provided with air holes 9 so that the airflow can also dry the cuff 3 . The bottom end of the inflatable bag (corresponding to the left side of the FIG. 1) includes an air-impermeable region 14 so that valuable drying air cannot penetrate outside unused. After the clothing 2 is placed on the ironing dummy, and the cuff 3 is buttoned, the airflow for the inflatable bag 7 can be switched on. Because the cuff smoother 1 is provided with airholes, the drying air penetrates these holes to the outside and dries and smoothes the cuff 3 . The stiffening is defined with respect to the remaining region of the inflatable bag 7 and the clothing 2 by a boundary line 13 . This region of the sleeve 15 is characterized by a placket in the material. The overlapping material in the region of the placket is also referred to in the industry as the overlap 21 . The underlying material is called the underlap 22 . The narrow, tapering (to the right of FIG. 1) strip of material on the exterior is referred to as trimming 20 . In the region 12 , at least one double layer of material emerges. Given operating of the ironing dummy, the air in the inflatable bag 7 presses the region 12 apart. The overlap 21 and the underlap 22 experience movement in an expansion direction 19 . When the material of the clothing 2 is not stiff enough in relation to the pressure in the inflatable bag 7 , an unintentional deformation of the clothing 2 can occur in the region 12 .
[0034] [0034]FIG. 2 represents a remedy for the deformation in the region of the overlap 21 and underlap 22 . A stiffening in the form of a slotted spoon 11 is utilized in addition to the cuff smoother 1 . This slotted spoon 11 is held by a strap 10 at one end (to the right of FIG. 2). This strap 10 is fastened to the inflatable bag 7 with seams 8 . In this exemplifying embodiment, the other end of the slotted spoon 11 is fastened to the inflatable bag 7 in the vicinity of the cuff 3 .
[0035] Pressure is exerted on the overlap 21 and underlap 22 by the stiffening with the aid of the slotted spoon 11 ; however, there is no notable widening of the placket because the slotted spoon 11 presses flush and, due to its rigidity, allows hardly any arching.
[0036] [0036]FIG. 3 represents another development of the invention. The slotted spoon 11 is provided with air holes 9 so that it does not impede the drying of the clothing 2 given a drying airflow from inside the inflatable bag 7 . In addition, the slotted spoon 11 is provided with a clamp 6 . This clamp 6 is formed on the slotted spoon in a fixed manner. Because the slotted spoon 11 is disposed between the inflatable bag 7 and the clothing 2 , and because the clamp 6 surrounds the cuff 3 , the cuff 3 is held and shaped by the clamp 6 . The clamp 6 is also provided with air holes 9 for better air permeability.
[0037] In the exemplifying embodiment of FIG. 3, the cuff smoother 1 is no longer characterized by an additional stiffening in the region of the cuff 3 . But it is still possible to speak of a cuff smoother 1 , because the inflated bag 7 still exerts a stressing effect and, thus, a smoothing effect. In this example, the inflatable bag 7 is wholly air-permeable in the region of the clothing 2 . For this reason, for purposes of illustration, the air-impermeable region 14 at the face side of the inflatable bag 7 has been highlighted by hatching, in contrast to FIGS. 1 and 2.
[0038] The cross-section represented in FIG. 4 illustrates one possible tension mechanism 16 for the cuff 3 of an article of clothing 2 . For purposes of clarity, the ellipsoidal lines in FIG. 4 have been set apart clearly so that they do not overlap. In reality, they are situated immediately adjacent one another. The cuff 3 is closed with the aid of a button 4 . Further in is the inflatable bag 7 . Two chuck jaws 17 press the inflatable bag 7 from inside. This pressing force comes from a spring 18 , which presses the guided chuck jaws 17 apart. The chuck jaws 17 do not fill the entire volume of the cuff 3 , but complete filling of the volume is not necessary for a satisfactory smoothing result. Namely, when the chuck jaws 17 tense the ellipse longitudinally in the indicated manner, the airflow in the inflatable bag 7 can, nevertheless, produce a slight arcing of the cuff 3 , which generates a notable tangential tensioning effect.
[0039] The chuck jaws 17 can be constructed with non-illustrated air holes 9 so that they do not block access by a drying airflow to the cuff 3 (in case the airflow comes from inside the inflatable bag).
[0040] For easier changing of the article of clothing 2 in the region of the cuff 3 , the tension mechanism 16 need only be compressed using the fingers of one hand.
[0041] The chuck jaws 17 are connected only to the inflatable bag and are, therefore, optimally lightweight. With the inflation of the bag 7 , the arm portions of the bag 7 are also stressed longitudinally so that the chuck jaws 17 are pressed outward, and the sleeve 15 of the clothing 2 , which is attached to the chuck jaws, is drawn outward. The sleeve of the clothing 2 that is to be smoothed can, thus, be drawn out by the air pressure in the inflatable bag 7 , thereby improving the smoothing result in this region with little expenditure. The configuration is advantageous because expensive pulling devices, which take up additional space and interfere with handling, are rendered unnecessary.
[0042] To increase the traction effect of the chuck jaws 17 on the sleeve of the clothing, the exterior surface of the chuck jaws 17 can be provided with offsets or inclined surfaces so that the cross-section of the body formed by the chuck jaws 17 decreases in the outward direction. Because the cross-section of a sleeve 15 usually decreases in the outward direction, the chuck jaws 17 can, thus, exert a stronger longitudinal pull on the sleeve; that is, the tensile force with which the chuck jaws 17 are pushed apart can be lower. The stress on the button when the cuffs 3 are stressed from inside while in the buttoned condition can, thus, be reduced. This cross-sectional enlargement can engage particularly well at points where seams run transverse to the intended pulling direction, as is the case at the sleeve end, where the cuff 3 is sewn on.
[0043] An elastic body such as a foam or foam rubber body can also be utilized for pushing the two chuck jaws 17 apart.
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A device for ironing items of clothing having sleeves, especially, shirts and blouses, by an ironing dummy includes an inflatable bag placed inside the item of clothing when ironing and reaching into the cuffs of the clothing item. To be better able to smooth out the sleeves when ironing, the end of the inflatable bag in the region of the cuffs is provided with a reinforcement that fixes the end of the sleeve and exercises a longitudinal pull on the sleeve during inflation of the inflatable bag. An inner clamping mechanism is disposed inside the cuff for the fixing process.
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RELATED APPLICATION
This application is a continuation-in-part application Ser. No. 08/667,085, filed on Jun. 20, 1996, which is incorporated herein by reference now abandon.
BACKGROUND
The present invention relates to valve handles, and more particularly to wrenches for operating gate valves and the like as are commonly found in utility gas lines.
In emergencies such as earthquakes and fires it is often desired to quickly shut off utility gas service to structures that are or may be affected by the emergency. Normally, a shut-off valve is connected in a service line upstream of a meter that is accessible outside of the structure. Typically, the shut-off valve is a gate valve wherein a rotary gate member moves from an open position wherein a projecting blade portion of the gate member is aligned with the service line, and a closed position wherein the blade portion is cross-wise with the service line. This type of gate valve is generally inoperative without the assistance of a wrench or other suitable tool. Such tools may or may not be readily available to service customers under normal conditions, but typically the tools are "safely" stored within the structure if they are on hand at all.
Thus it has been advocated to keep a suitable wrench stored proximate each gas service valve for emergency use. However, shut-off valves and gas meters are not generally adapted for conveniently storing suitable wrenches. More importantly, a further hazard is presented in many cases when the service valve is closed and subsequently reopened in that gas may leak from unlighted pilots or undiscovered breaks in the line. Consequently, many gas utility providers are reluctant to recommend that emergency wrenches be provided at service valves, citing the safety hazard of unauthorized turning on of the gate valve, preferring that the valves be turned on by authorized personnel only.
Thus there is a need for an emergency valve shut-off wrench that overcomes the disadvantages of the prior art, that can be stored at the meter, and that can not be used to open the fluid gate valve.
SUMMARY
The present invention meets this need by providing an emergency shut-off wrench for a fluid gate-valve that is rigidly connected in a fluid line and having a gate member that is rotatable approximately 90 degrees between respective open and closed positions. The wrench includes a handle member having a shank portion and a head portion; a plug member for engaging the head portion of the handle member, the plug member having an engagement surface for coupling rotational movement to the gate member of the valve; means for transmitting torque between the handle member and the plug member in a magnitude sufficient for rotation of the gate member in one direction only; and a stop member rigidly fixable in projecting relation to the plug member for preventing further rotation of the gate member beyond a predetermined position thereof when the plug member is engaging the gate member and transmitting the torque.
In one aspect of the invention, the plug member is rotatably mounted to the handle member, the means for transmitting including a dog member being circumferentially fixable on one of the plug member and the handle member for engaging a stop surface that is fixed relative to the other of the plug member and the handle member at a predetermined angular orientation of the plug member relative to the handle member. The dog member can include a threaded fastener having a projecting head portion. The fastener can be selectively located in one of a plurality of threaded openings being formed in the one of the plug member and the handle member for producing the abutting contact at a selectable angular orientation of the plug member relative to the handle member. Alternatively, the dog member can include a radially oriented spring plunger.
In another aspect of the invention, the means for transmitting includes the plug member being threadingly engagable with the head portion, the plug member making abutting engagement with the head portion at a predetermined angular orientation relative to the handle member. Preferably the abutting engagement is with circumferentially facing contact between respective dog members that are fixably located on the plug and handle members in eccentric relation to the plug member for preventing binding between the plug and handle members. The plug member can have a threaded stem portion of diameter C, the abutting engagement being preferably outside the diameter C for limiting loading of the dog members.
The engagement surface of the plug member can have an effective length in a direction normal to a rotational axis of the plug member, the plug member having threaded contact with the handle member within a diameter being less than the length for limiting the transmission of torque from the handle member to the plug member in a direction opposite the one direction. Preferably the plug member has a threaded stem portion for engaging the handle member, the stem portion having an outside diameter C being less than the length . The wrench can further include a projection projecting concentrically with the stem portion for making axially abutting contact between the plug member and the handle member within a diameter d, the diameter d being less than the diameter C.
The stop member can include a stem member that is eccentrically mounted to the handle member for contacting the fluid line, and means for fixably holding the stem member relative to the handle member, for adjusting an angular orientation of the gate member when the stop member contracts the fluid line. The wrench can further include a spring clip fastened to the handle member for gripping the fluid line.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:
FIG. 1 is a partially exploded perspective view of an emergency valve shut-off wrench according to the present invention;
FIG. 2 is a fragmentary sectional view of the wrench of FIG. 1; and
FIG. 3 is an elevational view showing the wrench of FIG. 1 in use in connection with a gate valve.
FIG. 5 is a third embodiment with a plunger stop element.
FIG. 6 is a top view of FIG. 5.
FIG. 7 is a fourth embodiment with a threaded member stop element.
DESCRIPTION
The present invention is directed to an emergency wrench that is particularly effective for one-way operation of a fluid valve such as a utility gas shut-off valve. With reference to FIGS. 1-3 of the drawings, a wrench 10 includes a handle member 12 having a shank portion 14 and a head portion 16, a threaded cavity 18 being formed therein, a plug member 20 threadingly engagable with the cavity 18 and having a slot 22 formed therein, and a stop member 24 projecting from an intermediate location along the shank portion 14. The slot 22 is adapted for engagement with a gate member 26 of a fluid valve 28 that is rigidly connected in a fluid line 30. Typically, the fluid line 30 is a utility gas pipe that is connected to the inlet of a utility gas meter (not shown). A projecting blade 32 of the gate member 26 is normally aligned with the line 30 in an open position of the valve 28, being rotated approximately 90 degrees from such alignment in a closed position of the valve 28.
A principal feature of the present invention is that sufficient torque for rotating the gate member 26 of the valve 28 can be transmitted in one direction only from the handle member 12 to the plug member 20, in combination with the stop member 24 limiting rotation of the handle member 12 when the plug member 20 is engaging the gate member 26. Particularly, the stop member 24 projects to one side of the fluid line 30 as shown in FIG. 2 when the blade 32 of the gate member 26 is seated within the slot 22 of the plug member 20. In the following description, right-handed threaded engagement of the plug member 20 with the cavity 18 is assumed, it being understood that left-handed engagement is also possible within the scope of the present invention.
FIG. 3 shows the wrench 10 in a starting position engaging the blade 32 in the open position of the valve 28 as indicated by solid lines, the handle member 12 projecting approximately at right angles to the fluid line 30. The valve 28 and the line 30 are shown by dashed lines as transparent, being in front of the wrench 10. Movement of the shank portion 14 in a counterclockwise direction as viewed in FIG. 3 produces a corresponding rotation of the gate member 26, the valve 28 becoming fully closed when the handle member 12 is approximately aligned with the fluid line 30 as indicated by dashed lines in FIG. 3. The plug member 20 is maintained rigidly coupled to the handle member 12 by the clockwise threaded engagement with the cavity 18, the plug member 20 becoming more tightly coupled to the head portion 16 during such tightening. Further counterclockwise movement of the shank portion 14 is prevented by the stop member 24 coming against the fluid line 30. In case a user of the wrench 10 attempts to reverse the rotation of the gate member 26, the plug member 20 proceeds to disengage from the handle member 12 by unscrewing from the cavity 18. This disengagement is promoted by a center projection 34 of the plug member 20 engaging a wall portion 36 of the head portion 16 at a diameter d that is sufficiently large for sustaining compressive loads produced by operation of the wrench 10 but smaller than an outside diameter C of a threaded stem portion 38 of the plug member 20, the diameter C also being less than an effective length of engagement . The threaded engagement is preferably somewhat coarse (in terms of lead per revolution) for limiting the compressive loading when torque is applied to the threaded engagement. Also, the threaded engagement between the plug member 20 and the handle 12 is preferably slightly loose-fitting for promoting unthreading rotation of the plug member whenever reverse torque is applied. The slot 22 can be formed in a desired angular orientation relative to the threaded engagement using any of several conventional means, such as by assembling the plug member 20 with the handle member 12 prior to formation of the slot 22. More efficient means include forming the threaded portion of the cavity 18 in a repeatable orientation relative to the handle member 12, in combination with assembly of the plug member 18 into a threaded fixture cavity having like orientation prior to formation of the slot 22. Also, the threaded configuration of the stem portion 38 can be completed in a repeatable orientation using tooling that engages the (previously formed) slot 22.
As further shown in FIGS. 1-3, the stop member 24 is adjustably fixable relative to the handle member 12 for accommodating variously sized fluid lines 30 and for canceling variations in the orientation of the slot 22 relative to the handle 12 in the assembled condition of the wrench 10. An exemplary configuration of the stop member 24 includes a Z-shaped rod 40 having threaded engagement with the shank portion 14, a lock-nut 42 and washer 44 being provided for securing the rod 40 in a desired rotational orientation relative to the handle member 12. It is contemplated that the stop member 24 would be adjusted for indexing the gate member 26 approximately centered in its fully closed position when the rod 40 comes into contact with the fluid line 30.
As described above, the stem portion 38 of the plug member 20 is threaded right-handed, it being understood, of course, that the stem portion 38 can be threaded oppositely (left-handed), the direction of rotation of the handle member 12 in operation of the wrench 10 being correspondingly reversed without substantially altering the utility of the wrench 10. This is because gate valves of the type described above are operable in either direction and the side of the fluid line 30 against which stop member 24 rests upon closure of the valve 28 is not normally critical.
Preferably the wrench 10 is supported prior to use in convenient proximity to the valve 28. In the exemplary configuration shown in the drawings, a spring clip 46 is affixed to the handle member 12 for releasably gripping the fluid line 30 as indicated at 30' in FIG. 2. As shown in FIG. 2, a counterpart of the lock-nut 42 holds the spring clip 46 against the shank portion 14 of the handle member 12 on the rod 40 opposite the plug member 20. The handle 12 is also formed having an opening 48 therethrough for hanging the wrench 38 on any suitable hook (not shown).
With further reference to FIG. 4, a preferred alternative configuration of the wrench 10 has the means for unidirectional torque transmission implemented by the plug member engaging a rotational stop dog 50 that is rigidly located on the head portion 16 of the handle 12 for avoiding axial loading between the plug member 20 and the handle 12. Thus the stem portion 38 does not make bottoming engagement with the threaded cavity 18. Particularly, the stop dog 50 is located outside of the cavity 18, a head dog 52 rigidly projecting from the plug member toward the stop dog 50 for producing circumferentially facing contact between the dogs 50 and 52 at a predetermined amount of the threaded advancement of the stem portion 38 into the cavity 18. Preferably, the head dog 52 axially overlaps the stop dog 50 by only slightly less than a lead λ of the threaded engagement for enhanced overlap of the dogs 50 and 52 in the abutting condition as shown by solid lines in FIG. 4. As in the previously described implementation of FIGS. 1-3, rotation of the handle 12 in a direction opposite that producing rotation of the gate member 26 causes unscrewing of the plug member 20 from the cavity 18, the dogs 50 and 52 passing in close proximity at one revolution from the engaged condition as shown by broken lines in FIG. 4.
As further shown in FIG. 4, a counterpart of the stop member, designated 54, rigidly projects from the plug member 20 in a predetermined radially spaced relation with the slot 22, the spring clip 46 being attached to the handle 12 by any suitable fastener such as a headed screw (not shown). It will be understood that a stop member having the offset configuration of FIGS. 1-3 can extend from the plug member 20, provided that a suitably strong mounting thereof is effected. Such mounting can lockably secure the stop member in a selected one of a plurality of discrete angular orientations.
With further reference to FIGS. 5 and 6, another alternative configuration of the wrench, designated 10', has a plug member 60 that is rotationally supported in a counterpart of the handle member, designated 62. A shank portion 64 of the plug member 60 is formed for receiving a retaining ring 65, a head portion 66 of the handle member 62 being retained by the ring 65 between a large washer 68 and a small washer 69. A spring plunger 70 is threadingly retained transversely in the shank portion 64, projecting radially outwardly for engaging an inside ramp surface 72 of the head portion 66, the rotational torque being transmitted from the handle 62 to the valve 28 when the plunger 70 engages a stop portion 73 of the ramp surface 72. In the configuration of FIGS. 5 and 6, the spring plunger 70 corresponds to the head dog 52, the stop portion 73 of the ramp surface 72 corresponding to the stop dog 50 (FIG. 4). It will be understood that the ramp surface 72 can be formed on the plug member, the spring plunger 70 being inwardly oriented in the handle member 12. Advantageously, reversal of the assembly of the plug member 60 with the handle 62 is possible upon removal of the retaining ring 65, yet the removal typically requires a special snap-ring tool that is not generally carried by those that might wish to open the valve 28 after it has been closed by the wrench 10'.
With further reference to FIG. 7, an alternative configuration of the wrench 10' incorporates counterparts of the stop dog 50 and the head dog 52 in the form of respective stop fasteners 74 and 76. The stop fasteners 74 and 76 are socket head cap screws, the heads of which make the abutting contact in substantially circumferentially facing relation. The stop fastener 76 extends transversely into the shank portion 64, being axially located for retaining the plug member 60 rotatably engaged with the handle member 12. Thus the stop fastener 76 replaces the retaining ring 65 of FIGS. 5 and 6. Also, the washers 68 and 69, being optional, are not included in the configuration of FIG. 7.
As further shown in FIG. 7, a threaded opening 78 is formed in the handle head portion 66 for providing a selectable alternative location for the stop fastener 74, the fastener 74 threadingly engaging a counterpart of the opening 78 (not shown). Thus the angular orientation of the slot 22 relative to the handle member 12 is selectively adjustable by means of locating the stop fastener 74 in one or the other of the threaded openings 78. In the configuration of FIG. 7, reversal of movement of the gate member is prevented by suitably locating the stop member 54 and the stop fasteners 74 and 76 relative to the slot 22, whereby the stop member 54 engages the valve 28 or the lone 30 prior to abutting engagement between the fasteners 74 and 76 when the handle member 12 is moved in the direction opposite that in which the valve 28 is closed.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, when the stop member 54 projects from the head portion 16 of the handle 12, the shank portion 14 of the handle can be threadingly connected to the head portion. Also, the wrench 10 can be stored with the plug member pressed onto the blade portion of the gate member. Further, when the stop member 54 extends from the plug member 20, the handle 12 can be coupled to that combination by a one-way ratchet mechanism. Therefore, the spirit and scope of the appended claims should not necessarily be limited to the description of the preferred versions contained herein.
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An emergency shut-off wrench for a fluid gate-valve includes a handle having shank and head portions; a plug for engaging the head portion of the handle, the plug having an engagement surface for coupling rotational movement to a gate of the valve, the gate being rotatable approximately 90° between open and closed positions; and a stop rigidly fixable in projecting relation to the plug for preventing further rotation of the gate beyond a predetermined position thereof when the plug is engaging the gate. The plug is rotatably connected to the head portion and respective dogs make abutting engagement between the plug and the head portion at a predetermined angular orientation with the handle for transmitting torque between the handle and the plug in a magnitude sufficient for rotation of the gate in one direction only. The plug can be threadingly engagable with the head portion. The stop can include a stem member that is eccentrically mounted to the handle and fixably held relative to the handle for adjusting an angular orientation of the gate when the stop contacts the fluid line.
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FIELD OF THE INVENTION
The present invention relates to a method for determining the presence of roll of ink in a pressureless ink fountain of a rotary printing press, as well as to several associated devices.
DESCRIPTION OF THE PRIOR ART
A device for inking a screen roller is known from EP 0 663 293 A1, wherein ink rotates around a longitudinal axis parallel with the screen roller in a filled ink chamber of circular cross section.
A negatively pitched working doctor blade and a positively pitched finishing doctor blade are provided.
U.S. Pat. No. 2,399,688 describes a device for maintaining the filling level in an ink fountain constant.
GB 2 299 546 shows a device for placing ink into an ink fountain, which can displaced in the longitudinal direction on a carriage. Sensors for monitoring the fill level of the ink in the ink fountain are fastened on the carriages.
SUMMARY OF THE INVENTION
The object of the present invention is based on providing a method as well as a device, by means of which it can be determined whether build-up of ink forming a roll of ink is formed in an ink fountain in the course of the running of the press.
In accordance with the invention, this object is attained by measuring ink thickness values, the thickness of a rotating built-up roll of ink or the partial hydrostatic pressure exerted on a side wall of an ink fountain. The measured values are evaluated and are used to determine the presence of a built-up roll of ink and its size.
The advantages which can be achieved by means of the invention consist, in particular, in that the thickness of the built-up roll of ink being formed in the course of the running of the press is determined continuously or at intervals, and that an electrical, optical and/or acoustic signal is issued in case of a deviation from a nominal value. In accordance with the value and the direction of the deviation, either a signal for controlling the ink delivery device or a warning signal for the operator is issued.
BRIEF DESCRIPTION OF THE DRAWINGS
Several preferred embodiments of the invention are represented in the drawings and will be described in greater detail in what follows. Shown are in:
FIG. 1, a schematic representation of a cross section through an ink fountain placed on a roller, which has a device in accordance with a first preferred embodiment;
FIGS. 2 to 9 , further embodiment variations of devices for executing the method; and
FIGS. 10, 11 , and 12 schematic representations of an ink fountain placed on a roller with further embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An ink fountain 1 , which is typically a pressureless ink fountain, open at the top, has a left and a right lateral wall 2 , 3 , as well as two sealing front or end walls 6 , 7 , which are matched to the periphery of a driven roller 4 . The ink fountain 1 extends over the entire length of the roller 4 which, for example, can be embodied as a screen roller or as a rotogravure cylinder. A working doctor blade 8 as well as a finishing doctor blade 9 are exchangeably attached at the bottom of the lateral walls 2 , 3 .
In place of the doctor blades 8 , 9 it is also possible to employ ink metering blades arranged next to each other over the length of the roller 4 .
Preferably highly viscous ink 11 having a viscosity greater than 60 poise is placed into the ink fountain 1 , which in the course of the operation of the press forms a build-up of ink forming a roll of ink 12 that rotates or rolls in accordance with the direction of rotation of the roller 4 , for example in a counterclockwise direction A and, which is in contact with the left inside 17 of the lateral wall 2 as well as the free width b as well as the length of the doctor blade 8 . The doctor blade edge of the doctor blade 8 removes ink from the surface 5 of the roller 4 .
At a defined position of its length, the rotating built-up roll of ink 12 has a nominal thickness d 1 , which is proportional to the used-up and replenished ink from the ink fountain 1 . Measurements are performed continuously or at intervals by means of a device 28 , which is directly or indirectly oriented toward the built-up roll of ink 12 and fixed in place on the lateral frame or on the ink reservoir, and the result of the measurements is evaluated.
The measurement of the distance takes place selectively by means of optical or acoustic means, for example laser beams or ultrasonics, which are emitted by the device 28 and impinge directly and contact-free on the surface 21 of the built-up roll of ink 12 . The thickness d 1 of the built-up roll of ink 12 is then determined on the basis of the known distance between the surface 5 of the roller 4 and the device 28 .
Because of the delivery of ink 11 from the ink fountain 1 to the ink roller 4 during the operation of the press, a built-up roll of ink 32 of a reduced thickness d 2 is formed—represented in dashed lines -. Thereupon the device 28 issues a signal which starts an ink pump, not represented, which supplies the ink fountain 1 with fresh ink via the ink delivery device 27 .
In case of a large negative deviation d 3 or a large positive deviation d 4 of the thickness of the built-up roll of ink 33 , 34 —represented in dashed lines -, an optical or acoustic warning signal is emitted, which draws the attention of the operator to an error in the inking unit.
The device 28 is connected by means of an electrical or optical conductor 29 with the control post of the press. The time interval to be measured, as well as the fixed distance value, can be set by means of preselector switches 30 , 31 .
As represented by dashed lines in the drawings, the device 28 can be arranged projecting past the upper edge 38 of the ink fountain 1 . It is also possible to provide measurements by means of a device operating on a capacitive basis.
Moreover, the device 28 can also be arranged over the length of the ink fountain 1 on a guide rail, which is fastened parallel with the roller, and can be displaced manually or by means of a motor.
In accordance with another preferred embodiment of the present invention, as depicted in FIG. 10, a built-up roll of ink sensing lever 23 is hinged on a bearing 18 fastened on the inside 17 of the left lateral wall 2 , whose underside 36 rests tangentially on the periphery 21 of the built-up roll of ink 12 . In this way, a distance between the top 37 of the sensing lever 23 and the device 28 is measured indirectly and by contact, so that it is possible by taking into consideration the thickness of the material of the sensing lever 23 , to determine the various thicknesses d 1 to d 4 of the built-up roll of ink 12 , 32 , 33 , 34 .
In accordance with a third preferred embodiment, as seen in FIG. 11, the sensing lever 23 can be part of a double-armed sensing lever assembly 16 , whose second arm 22 points in the direction toward the opening of the ink fountain 1 and which joins the first arm 23 in the bearing 18 at an angle ∝, for example of 130° to 140°. A device 39 , that is the same as device 28 , is arranged on the upper edge 38 of the right lateral wall 3 and measures a horizontal distance between the device 39 and the second arm 22 , again in an indirect and contacting manner, while the underside 36 of the first arm 23 rests against the periphery 21 of the built-up roll of ink 12 .
The position of the two-armed sensing lever assembly 16 changes as a function of the thickness d 1 to d 4 ofthe built-up roll of ink 12 , 32 , 33 , 34 , so that the device 39 , 16 determines the thickness of the built-up roll of ink. The device 39 can be designed in the same way as the device 28 .
In accordance with a fourth preferred embodiment, depicted in FIG. 12, the two-armed sensing lever assembly 16 has a vane 24 at the end of its second arm 22 , which is in contactless connection with an inductive device 13 , for example. The vane 24 can be made of sheet metal. The underside 36 of the first arm 23 of the two-armed sensing lever 16 rests tangentially against the built-up roll of ink 12 of a thickness d 1 , so that the sensing lever 16 is in a first, solid line position. The amount of ink is reduced in the course of the operation of the press, so that a resultant built-up roll of ink 32 now has a reduced thickness d 2 . In this case, the sensing lever 16 is in second position—represented by dashed lines -. A signal for the control of the ink delivery device 27 is emitted by the device 13 , so that the built-up roll of ink again attains the nominal thickness d 1 .
The device 13 is arranged fixed in place on the lateral frame or on the ink fountain and is connected via an electrical conductor 26 with the control post of the press.
Of course, the device can also be set in such a way that a short turn-on of the ink delivery device 27 can immediately take place with even a lesser reduction of the nominal thickness d 1 . The thickness of the built-up roll of ink is preferably scanned continuously or at preselectable time intervals.
The number of intervals d 1 , d 2 , d 1 occurring in the course of a correct printing operation—taking into consideration the ink surface portion of the material to be printed as well as the number of revolutions of the press—is advantageously determined during a preselected length of time, for example of five minutes, by means of a known evaluation circuit. For example, five intervals are created within a preselected length of time of five minutes.
If the preselected number of intervals falls below this, this is a sign for the wrong formation of the built-up roll of ink and therefore a sign for an erroneous delivery of the amount of ink. In this case an additional alarm signal is emitted.
The principle of the methods of the present invention lies in that the ink fountain 1 is filled with ink, for example highly viscous ink, in such a way that during the operating stage a part of the lower ink fountain 1 is free of ink, while a built-up roll of ink 12 is formed in the other lower part of the ink fountain 1 . This status is determined by means of further exemplary embodiments and is evaluated.
In accordance with a fifth preferred embodiment, as seen in FIG. 2, a measuring device 39 , for example an ultrasonic sensor or a running time sensor, is arranged above the ink fountain 1 , which measuring device 39 can be pivoted over an angle βof approximately 20° in the circumferential direction of the roller 4 , for the contactless measurement of the thickness d 1 of the, built-up roll of ink 12 in a continuous manner or at intervals. This measuring device 39 measures the distance from the planes C and E. Based on a preselected nominal difference between both planes C, E, it is possible to determine whether sufficient ink 11 is present, or respectively whether a built-up roll of ink 12 has been formed at all.
In accordance with a sixth preferred embodiment, as seen in FIG. 3, a measuring device 39 is arranged above the ink fountain 1 , and which device 39 can be displaced in the circumferential direction of the roller 4 by an amount f, for example corresponding to half the width of the ink fountain 1 . The measuring device 39 operates as described in connection with the fifth preferred embodiment, and can be moved back and forth on a rail fixed in place on the lateral frame by means of a linear drive which is not represented.
In accordance with a seventh preferred embodiment, as seen in FIG. 4, spaced measuring devices 39 are arranged fixed in place above the ink fountain 1 , and which are spaced from each other by an amount f. The left measuring device 39 determines the distance from the plane C, and the right measuring device 39 determines the distance from the plane E. The measuring method operates as described in connection with the fifth preferred embodiment.
In accordance with an eighth preferred embodiment, as seen in FIG. 5, a CCD camera 41 is arranged above the ink fountain 1 , by means of which the actual formation of the built-up roll of ink 12 is detected, which is compared with a nominal formation of the built-up roll of ink stored in a computer. In case of deviations outside of the tolerance range, appropriate signals are emitted, the same as in connection with the previous exemplary embodiments.
In accordance with a ninth preferred embodiment, as seen in FIG. 6, a measuring device 39 is arranged on a plane G located above the ink fountain 1 , and which works together with a pivotable mirror 42 located above the ink fountain 1 . The mirror 42 can be pivoted around an angle β, of approximately 20°, for example by means of an electromagnet which is not represented, which can be returned into the initial position by a spring force. The mirror 42 selectively directs the measuring beam on the surface 21 of the built-up roll of ink 12 (plane C) or on the plane E.
In accordance with a tenth preferred embodiment, as seen in FIG. 7, a measurement at intervals of the thickness d 1 of the built-up roll of ink 12 in a plane C takes place by means of an angled lever 43 , which is fixed in place on the ink fountain and touches the surface 21 of the built-up roll of ink 12 in a radial direction. The angled lever 43 is designed in an L-shape, for example. A first leg 46 of the angled lever 43 is fastened on the surface of the lateral wall 2 and has a wire strain gauge 44 . The second leg 47 extends vertically and parallel with the lateral wall 2 . The plane C is at an approximate distance from the surface of the roller 4 which corresponds to the diameter d 1 of a built-up roll of ink 12 , as seen in FIG. 7 . It is furthermore possible to also arrange the wire strain gauge 44 on the second leg 47 of the angled lever 43 .
In accordance with an eleventh preferred embodiment, as seen in FIG. 8, the lateral walls 2 and/or 3 are set back in the direction toward the interior of the ink fountain 1 . The depression created by this is covered by a flexible piece of sheet metal 48 . It is fastened, at an upper portion, to the lateral wall 2 , or respectively 3 , and with its lower end either cooperates with the inside of the doctor blades 8 and 9 to form a very narrow gap, or rests on them. At least one wire strain gauge 49 has been applied on the inside of the flexible piece of sheet metal 48 , which projects into the depression. A bending moment is generated by the contact of the rotating built-up roll of ink 12 with the flexible piece of sheet metal 48 , which bending is detected by the wire strain gauge 49 , which emits a corresponding signal, which is evaluated. It is also possible to detect oscillations by means of the wire strain gauge, which are evaluated and are used as an indicator of a rotating movement of the ink roll 12 .
The distance h can be up to several millimeters.
However, it is also possible to arrange an elastic material, for example silicon caoutchouc, between the support 48 and the lateral wall 2 .
In accordance with another embodiment which is not specifically represented, at least one of the lateral walls has a pressure-measuring pickup. A signal is emitted when the ink roll 12 comes into contact with the pressure-measuring pickup.
With the preferred embodiment in accordance with FIG. 9, the device operates the same as with the subject of FIG. 8 . In place of a flexible piece of sheet metal 48 with a lower free end, a flexible piece of sheet metal 51 is now used, which is fastened on the top and bottom on the lateral wall 2 and/or 3 and in this way covers a depression or opening 52 in them—sealed against the entry of ink.
The “flexible piece of sheet metal” can, as shown in FIG. 9, also be created by the removal of material from the lateral wall 2 and/or 3 from the outside. Because of this, the lateral wall 2 , 3 can be stressed by bending because of the hydrodynamic forces generated by the rotating built-up roll of ink 12 . These generated bending stresses can be detected by means of wire strain gauges 49 and evaluated. They are a measurement for determining whether the built-up roll of ink 12 rotates. This can also be determined in another way by means of the wire strain gauges 49 . It is possible to electronically evaluate the oscillations, by means of which the rotating built-up roll of ink 12 excites the flexible piece of sheet metal 51 , from the signals of the wire strain gauges.
While preferred embodiments of an ink fountain in accordance with the present invention have been set forth and completely hereinabove, it will be apparent to one of the skill in the art that a number of changes in, for example the specific printing press, the ink supply device and the like could be made without departing for the true spirit and scope of the present invention which is accordingly to be limited only by the following claims.
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The density or size of an ink roll, which is formed in an ink fountain of a rotary printing press, is determined either directly or indirectly at several spaced locations. The measured values are then evaluated. A signal is generated to an ink feed device, or a warning signal can be transmitted in accordance with the size or density of the ink roll and its deviation from reference values.
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FIELD OF INVENTION
This invention relates generally to fluid dispensing devices for controlling the flow of fluid therefrom and components therefor.
BACKGROUND OF INVENTION
One particular application of the present invention is in the automotive industry where oil is stored in a bulk tank and supplied to a work area through for example a pipe system and hose reel. The fluid dispensing device permits the amount of oil being dispensed to be controlled. It will be readily apparent to those persons skilled in the art that the dispensing device of the present invention could be used in a variety of applications and as such reference to the aforementioned particular application is not to be taken as a limitation on the scope of the present invention.
Fluid dispensing devices for controlling the discharge of fluid are known. Generally such devices include a control valve and meter through which fluid to be dispensed is passed and a display providing a reading of the quantity of fluid dispensed and/or required to be dispensed. In some currently known dispensing devices the required amount of fluid to be dispensed can be indicated on the display. The device can thereafter be activated so that fluid can be discharged from the device until the selected amount of fluid has been discharged. Once this has been achieved the device is adapted so as to stop the flow of fluid being discharged.
Known devices include electronic systems by which the quantity of fluid required to be dispensed can be set and subsequently stopped. A problem with electronic systems is that they can be relatively expensive and prone to damage particularly where the environment of use leads to rough handling of equipment. Mechanical systems have also been proposed but these are usually in the form of a settable rotary dial which have a limited accuracy.
It is an object of the present invention to provide an improved dispensing device which alleviates one or more of the aforementioned disadvantages.
SUMMARY
The present invention is concerned with a fluid dispensing device of the type, including a shut off valve means for controlling fluid flow through the device and an actuating trigger operable to cause the shut off valve to adopt an open position in which fluid can be dispensed from the device and a closed position, a control meter which enables the volume of fluid being disposed to be measured, a latching mechanism operable to hold the shut off valve in the open position and cause the shut off valve to adopt the closed position when the predetermined volume of fluid has been dispensed, and a setting mechanism being operatively connected to the control meter for indicating a predetermined volume of fluid required to be dispensed and indicating when that predetermined volume has been dispensed.
According to one aspect of the present invention there is provided a setting mechanism suitable for use in a fluid dispensing device of the type described above the setting mechanism including a plurality of display wheels which can indicate the predetermined quantity of fluid to be dispensed. The display wheels are operatively connected to the control meter so that the flow of fluid through the control meter can be displayed on the display wheels. The arrangement is such that when the shut off valve is in the closed position the display wheels can be adjusted to indicate the predetermined quantity of fluid to be dispensed and when the shut off valve is opened the display wheels can indicate when the predetermined volume has been dispensed. The setting mechanism includes a plurality of setting wheels each setting wheel being associated with a respective one of the display wheels, each setting wheel being operatively connectible with the display wheel with which it is associated via a gear train, each setting wheel being mounted for movement between an engaged position and a disengaged position.
In the engaged position each setting wheel is operatively connected to the display wheel with which it is associated via the gear train so that rotation of the setting wheel causes rotation of the display wheel with which it is associated. In the disengaged position the setting wheel is disconnected from the display wheel with which it is associated and may be freely rotatable.
The setting mechanism may include a support frame to which the setting wheels and display wheels are operatively mounted.
Each setting wheel may be operatively mounted to a pivot member which is pivotally connected to the support frame, so that pivotal movement of the pivot member causes movement of the setting wheel between the engaged and disengaged positions.
There may further be provided spring means for urging each setting wheel into the disengaged position. The spring means may be in the form of a generally resilient leg on the pivot member.
According to another aspect of the invention there is provided a latching mechanism suitable for use in a fluid dispensing device of the type described above either in its broadest form or more specific forms the latching mechanism including a latch setting assembly for setting the actuating trigger of the device so that the shut off valve is in the open position, a trip assembly which is actuatable at a preselected display on the display wheels of the setting mechanism, a first catch assembly operable so as to adopt an engaged position or a disengaged position and arranged such that actuation of the trip assembly causes the first catch assembly to adopt the disengaged position, and a second catch assembly which can adopt an engaged position when the actuator trigger of the device is in an actuating position in which the shut off valve is open, the first catch assembly adopting the engaged position when the actuator trigger is moved to the actuating position.
The latch setting assembly may include a setting button mounted on the actuator trigger, and a connector arm operatively connected to the button.
The first catch assembly may include a control member which is pivotally mounted to a part of the body portion of the trigger. The control member may include a catch and push element adapted to cooperate with a latch member. The latch member may be in the form of a latching plate pivotally mounted to the housing at a pivot mounting. The catch assembly may include first and second latching sections defined by shoulders formed as edges of apertures in the latching plate.
The second catch assembly may include a catch member having a catch thereon which is operatively connected to a trip assembly. A spring may act on the catch member.
The trip assembly may include a trip pin actuatable by a boss on one of the display wheel. A coupling member is caused to be moved by the trip pin whereupon it is engaged by an activating projection on another display wheel.
The latching mechanism is operable so as to be able to adopt a latched position in which position the valve of the dispensing device is open and a release position in which the valve can return to a closed position. Preferably the trigger can be activated to cause the valve to open whether or not the latch mechanism is in the latched position.
To set the latching mechanism the trigger is depressed. This causes rotation of the shaft and cam surface which acts on the valve follower to cause the valve to open. The rotational movement of the trigger body moves the control member into engagement with the latch plate. The latch plate is pivotal about its pivot mounting causing the catch to engage with first latching section on latch plate. At this stage the catch is not engaged with latching section and the trigger can return to its first position under the influence of a spring.
To set the trigger it is moved to its second position causing a pivotal movement of the control member and depression of the button causes arm to engage the end of the control member so that the catch engages latching section thereby holding the trigger in the second position.
The setting mechanism enables a volume to be set correlating to three display wheels. For example, the device can be set to read tenth increments, unit increments and decade increments. The selected volume is set by pressing and rotating to the selected reading each of the thumb wheels each of which is associated with a respective display wheel. When moved the thumb wheels disengage from the other wheels so that they can be separately set without interference from the other wheels. All wheels can be rotation in both directions.
When the trigger is moved to the second position and the latch mechanism set fluid can flow through the meter and the display wheels will rotate counting down towards zero. When the meter reaches zero the valve latch is released and the flow stops.
In accordance with other aspects of the present invention there is provided a fluid dispensing device of the type described above.
BRIEF DESCRIPTION OF DRAWINGS
Preferred embodiments of the invention will hereinafter be described with reference to the accompanying drawings, and in those drawings:
FIG. 1 is a perspective view of a fluid dispensing device according to the present invention;
FIG. 2 is an exploded view of the device shown in FIG. 1 ;
FIGS. 2( a ) and 2 ( b ) are views from different positions of a connection between part of a setting mechanism and a calibrating gear box which form part of the fluid dispensing device shown in FIGS. 1 and 2 ;
FIGS. 3( a ) and 3 ( b ) are exploded perspective views of a setting mechanism which forms part of the device shown in FIGS. 1 and 2 ;
FIG. 4 is a detail of part of the setting mechanism shown in FIG. 3 ;
FIG. 5 is a detail of another part of the setting mechanism shown in FIG. 3 ;
FIG. 6 is a different view of that part of the setting mechanism shown in FIG. 5 ;
FIGS. 7 and 8 illustrate a detail of part of the setting mechanism shown in FIG. 3 ;
FIGS. 9 to 13 illustrate another part of the setting mechanism shown in FIG. 3 ;
FIG. 14 is a perspective view of a latching mechanism forming part of the device shown in FIGS. 1 and 2 ;
FIGS. 15 to 18 illustrate how the latching mechanism is triggered; and
FIGS. 19 to 23 illustrate the operation of the latching and triggering mechanisms.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 there is shown a fluid dispensing device 10 which includes a main body 12 having a handle 14 , an inlet 15 which is connectible to a hose (not shown) from which fluid is delivered to the device and an outlet 16 to which a nozzle (not shown) can be attached for discharging fluid from the device 10 . The device further includes a trigger 17 operable so that it can adopt first and second positions which causes a valve 18 ( FIG. 19 to 23 ) to open or close. With reference to FIGS. 19 to 23 the trigger includes a body portion 26 to which a pivot shaft 27 is mounted. The pivot shaft 27 includes cam section 28 in the form of a flat side face on the pivot shaft 27 which acts against an extension or follower 19 of the valve 18 . A spring 29 urges the valve 18 into its closed position. The trigger is pivotally movable from the first position ( FIG. 19 ) in which the valve 18 is closed to the second position ( FIG. 20 ) in which the valve 18 is open. To open the valve 18 the cam section 28 acts on the free end of the valve extension 19 when the trigger 17 moves into the second position (see FIG. 20 ). A spring (not shown) urges the trigger 17 into the first position. In use when the trigger 17 is in the second position fluid can flow through the device 10 from the inlet 15 to the outlet 16 . The device further includes a constant volume control meter 20 which measures the flow of fluid therethrough, a calibrating gear box 22 operatively connected to the control meter 20 and a setting mechanism 50 which can be set a predetermined volume so that the valve 18 will be closed upon actuation of a latching mechanism which is triggered when the predetermined volume of fluid has passed through the device. The setting mechanism is housed within a casing 24 and a protective rubber boot (not shown) surrounds the main body of the device.
The present invention is concerned in particular with the improved setting mechanism and/or the associated latching mechanism. There are several new and distinct aspects of these mechanisms which may constitute separate and distinct inventions in their own right.
The Setting Mechanism
Referring to FIGS. 3( a ) and 3 ( b ) of the drawings there is shown a setting mechanism 50 for setting and displaying a selected volume of fluid to be dispensed through the meter 20 . The setting mechanism 50 comprises first, second and third setting wheels 52 , 54 and 56 . Each setting wheel is mounted for movement between an engaged position and a disengaged position. In the engaged position each setting wheel is operatively connected to a respective one of the display wheels 53 , 55 and 57 with which it is associated via individual gear trains. In the particular application described the first display wheel 53 displays tenths, the second display wheel 55 displays units, and the third display wheel 57 displays decades, in relation to volume units of fluid dispensed through the control meter 20 . The various components of the mechanism are operatively connected directly or indirectly to a support frame which includes first and second mounting plate sections 58 and 59 . As best seen in FIGS. 5 to 7 mounting plate section 59 comprises two parts. The mechanism includes an input transmission assembly 70 which includes an input shaft 71 and a bevel gear 72 which is operatively connected to the control meter 20 through calibrating gear box 22 . The interconnection between the control meter 20 and input assembly 70 is best seen in FIGS. 2( a ) and 2 ( b ). The control meter 20 is connected to the calibrating gear box 22 having an output shaft 32 to which a bevel gear 34 is mounted. Bevel gear 34 is in engagement with bevel gear 72 of the input transmission assembly 70 . The input transmission assembly 70 further includes an input gear 73 which is operatively connected to a first gear train. The display wheels 53 , 55 , 57 are carried on a support shaft 74 which extends between mounting plate sections 58 and 59 .
The first setting wheel 52 is operatively connected to display wheel 53 via the first gear train which will be described in more detail below. In the disengaged position it is disconnected from the gear train. To this end the setting wheel 52 is mounted to a spring biased pivot member 60 and arranged such that depression of the wheel 52 causes pivotal movement of the pivot member 60 so that the setting wheel will adopt the engaged position wherein it is in operative connection with the display wheel 53 via the first gear train. This is best seen in FIGS. 3( b ), 5 and 7 . The pivot member 60 includes a mounting leg 61 to which the first setting wheel is rotatably mounted and a spring leg 62 which in the assembled position abuts against a stop 63 . ( FIG. 3( b )). Manual depression of the first setting wheel 52 causes partial rotation of pivot member 60 against the action of spring leg 62 so that the wheel 52 engages the first gear train.
The first gear train includes a thumb gear 84 which is operatively connected to the setting wheel 52 for rotation therewith and is connectable with an idler drive gear 85 operable to drive an idler gear 86 which in turn engages a gear section 79 of a display wheel 53 . The drive gear 85 and idler gear 86 are mounted on an idler gear shaft 87 . The idler gear shaft 87 is mounted at a pivot mounting 88 on plate 58 for limited pivotal movement for reasons which will become hereinafter apparent. The other end of the shaft 87 is received within slots 51 , 76 and 77 in frame 59 and pivot member 60 .
The idler drive gear section 89 is in meshing engagement with input gear 73 . When setting wheel 52 is depressed, thumb gear 84 moves into meshing engagement with idler drive gear 85 and depression into its extreme position causes disengagement of input gear 73 from idler drive gear section 89 . When depressed, rotation of setting wheel 52 will cause rotation of display wheel 53 so that it can be set at a selected unit of volume.
The second setting wheel 54 is operatively connected to display wheel 55 via a second gear train. The second setting wheel 54 is mounted to a pivot member 160 which is mounted to mounting plate 59 and operates in a similar fashion to the pivot member 60 so that the setting wheel can be disengaged from the second gear train.
The second gear train includes a thumb gear 184 which is directly connected to the setting wheel 54 . The gear train further includes an idler drive gear and idler gear which engages a gear section 179 on display wheel 55 . The structure of the second gear train is substantially the same as that of the first gear train. The second setting wheel 54 and its associated gear train do not engage directly with the input transmission assembly 70 at any time.
The arrangement of the third setting wheel 56 is similar to those described above and is best seen in FIG. 4 . Again there is an operative connection between the third setting wheel 56 and third display wheel 57 via a third gear train. The third setting wheel 56 is mounted to a pivot member 260 mounted to plate 58 .
The structure and operation of pivot member 260 is the same as the pivot members 60 and 160 described earlier. The third gear train includes a thumb gear 284 which is directly connected to the setting wheel 57 . The third gear train further includes an idler drive gear 285 and an idler gear 286 . The display wheel has a gear section 297 wheel is in meshing engagement with idler gear 286 . The third gear train does not directly engage with the input transmission assembly 70 at any stage.
A first indexing arrangement is provided between the first and second display wheels 53 and 55 and a second indexing arrangement is provided between the second and third display wheels 55 and 57 in order to provide for correct timing between the two associated display wheels. The first indexing arrangement includes an indexing element 90 in the form of two gear teeth 91 adapted to be engaged by the drive gear 185 of the second gear train. The second indexing arrangement includes an indexing element comprising two gear teeth on the second display wheel. Each arrangement further incudes a locating device comprising a detent cam 93 and 97 which cooperate with a follower 94 and 98 on spring arm 92 and 99 ensure that the display wheels are correctly indexed with respect to one another.
The setting mechanism enables a preselected volume of fluid required to be dispensed to be displayed on the display wheels. When the trigger 17 of the device is activated to open valve 18 the volume of fluid passing through the device drives the valve control meter which in turn drives the calibrating gear which in turn drives the input transmission assembly 70 causing the display wheels to rotate in volume display descending fashion. The display wheel 52 is directly connected to transmission assembly 70 . Each revolution of the display wheel 52 will cause engagement between that wheel and wheel 54 through the indexing mechanism associated therewith causing rotation thereof each time the indexing mechanism engages. The wheel 54 and wheel 56 will operate in a similar manner to that of wheel 52 and 54 until a reading is reached whereby the latching mechanism is triggered.
The Latch Mechanism
The latch mechanism includes a latch setting assembly 300 associated with trigger 17 of the dispensing device which is operable to set the latch mechanism when the trigger 17 is depressed and in the second position. The latch setting assembly 300 includes a setting button 302 mounted on the trigger 17 , and a connector arm 303 operatively connected to the button 302 .
The latch mechanism further includes a first catch assembly comprising a control member 305 which is pivotally mounted to a part of the body portion 26 of the trigger 17 . The control member 305 includes a catch 315 and push element 316 adapted to cooperate with a latch member 307 . A spring (not shown) urges the control member 305 into the position shown in FIG. 19 . The latch member 307 is in the form of a latch plate pivotally mounted to the housing at pivot mounting 319 . The latch member 307 includes first and second latching sections 317 and 318 defined by shoulders formed as edges of apertures in the latch plate.
The latch mechanism may further include a second catch assembly comprising a catch member 308 having a catch 314 thereon is operatively connected to a trip assembly 312 . A spring 319 acts on catch member 308 as shown.
The trip assembly 312 includes a trip pin 322 actuatable by a boss 324 on the display wheel 57 . A coupling member 326 is caused to be moved by the trip pin 322 whereupon it is engaged by activating projection 330 on display wheel 55 .
The latching mechanism is operable so as to be able to adopt a latched position in which position the valve 18 of the dispensing device is open and a release position in which the valve 18 can return to a closed position. Preferably the trigger 17 can be activated to cause the valve to open whether or not the latch mechanism is in the latched position.
To set the latching mechanism the trigger 17 is depressed. This causes rotation of the shaft 27 and cam surface 28 which acts on the valve follower 19 to cause the valve 18 to open. The rotational movement of the trigger body 27 moves the control member 305 into engagement with the latch plate 307 . The latch plate 307 is pivotal about its pivot mounting 319 causing the catch 314 to engage with first latching section 317 on latch plate 307 . At this stage the catch 315 is not engaged with latching section 318 and the trigger 17 can return to its first position under the influence of the spring (not shown) described earlier.
To set the trigger 17 it is moved to its second position causing a pivotal movement of the control member 308 and depression of the button 302 causes arm 303 to engage the end of the control member 308 so that the catch 315 engages latching section 318 thereby holding the trigger in the second position.
In the embodiment shown, the setting mechanism enables a volume to be set correlating to three display wheels. For example, the device can be set to read tenth increments, unit increments and decade increments. The selected volume is set by pressing and rotating to the selected reading each of the thumb wheels each of which is associated with a respective display wheel. When moved the thumb wheels disengage from the other wheels so that they can be separately set without interference from the other wheels. All wheels can be rotation in both directions.
When the trigger is moved to the second position and the latch mechanism set fluid can flow through the meter and the display wheels will rotate counting down towards zero. When the meter reaches zero the valve latch is released and the flow stops.
Finally, it is to be understood that various alterations, modifications and/or additions may be incorporated into the various constructions and arrangements of parts without departing from the spirit or ambit of the invention.
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A fluid dispensing device of the type, including a shut off valve means for controlling fluid flow through the device and an actuating trigger operable to cause the shut off valve to adopt an open position in which fluid can be dispensed from the device and a closed position, a control meter which enables the volume of fluid being disposed to be measured, a latching mechanism operable to hold the shut off valve in the open position and cause the shut off valve to adopt the closed position when the predetermined volume of fluid has been dispensed, and a setting mechanism being operatively connected to the control meter for indicating a predetermined volume of fluid required to be dispensed and indicating when that predetermined volume has been dispensed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of data processing systems. In particular, this relates to the detection of computer data containing compressed video data as banned computer data, such as, for example, computer files or streamed computer data containing a copyright infringing movie.
[0003] 2. Description of the Prior Art
[0004] It is known to provide malware scanners, which may for example be web access scanners, email scanners, on demand file scanners, on access file scanners and the like, that serve to detect malware within data being stored, received, manipulated or used in some other way. The threat posed by computer viruses is well known. It is also important in other circumstances, particularly to many businesses, that their computer systems should not be used in connection with improper, inappropriate or otherwise undesirable computer data. As an example, email scanners may be used to scan email traffic for the presence of words or phrase indicative of email messages which are abusive in some way or otherwise undesirable.
[0005] One type of undesirable computer data which it may be wished to exclude from a computer system is copyright infringing or otherwise unauthorised video data. It is well known that the Internet is a source for copyright infringing music files, such as MP3 files, which can be downloaded from many different sources. There has also arisen a problem with unauthorised and/or copyright infringing video data being distributed via the Internet and other mechanisms. There is often considerable interest in a new released movie and it is known for compressed versions of the video data of such movies to be made available for download via the Internet. These compressed versions are often pirate, copyright-infringing versions.
[0006] An individual or organisation may wish to prevent such pirated, copyright-infringing video data from being present on their computer system. It can be embarrassing, damaging and potentially actionable should such material circulate within a corporate network environment. In addition to this, the use of such a corporate network to manipulate this kind of material is an inappropriate use of the computing resources of the organisation and likely in contravention to company policy.
SUMMARY OF THE INVENTION
[0007] Viewed from one aspect the present invention provides a computer program product having a computer program for controlling a computer to detect computer data containing compressed video data as being banned computer data, said computer program product comprising:
[0008] identifier reading code operable to read from said computer data an identifier of a decoder operable to decompress said compressed video data;
[0009] identifier comparing code operable to compare said identifier with one or more predetermined characteristics indicative of whether said identifier is associated with banned computer data; and
[0010] triggering code operable if said identifier is associated with banned computer data, to trigger a banned computer data action.
[0011] The invention recognises that a large proportion of banned computer data containing compressed video data uses distinctive decoders that are identified within the computer data and are different from the decoders that are typically used by legitimate computer data containing compressed video data. The banned versions typically tend to use higher degrees of compression than the legitimate versions of the material, so as to ease download or storage on conventional CDs. These higher degrees of compression rely upon their own non-standard decoders. Accordingly, identifying the decoder to be used with some compressed video data and comparing this with predetermined characteristics indicative of whether or not the decoder is associated with banned material is an efficient and effective way of identifying such material. The technique does not seek to characterise the decompressed video data itself, but rather takes the approach of characterising the decoder associated with that compressed video data. This is surprisingly effective and may be relatively readily implemented. Alternatives relying upon the decompression and examination of the compressed video data itself are much less efficient and prone to significant inaccuracies.
[0012] It will be appreciated that the computer data which is being examined for the presence of inappropriate or illicit material could take a variety of different forms. Some particular forms to which the present technique may be applied are when the computer data forms a computer file or a stream of transmitted data, such as is streamed to an Internet browser during live playback.
[0013] Whilst the identifier of the decoder could take a variety of forms, preferred embodiments of the invention are ones in which the identifier is a decoder identifying field embedded within the compressed video file. This is a relatively commonly used way of identifying the decoder and is particularly well suited to the present technique since the identification can be extracted from a known point with relatively little processing and overhead. Furthermore, this may be done upon receipt of only the first portion of the computer data concerned.
[0014] In the context of systems which tend to operate on a modular basis for improved flexibility, the decoder identifying field may be the key used by an operating system to associate the computer data concerned with a decoder registered to the operating system. Such a decoder can be used for various different purposes and accessed by any process in possession of the appropriate key identifying the decoder to be used.
[0015] The compressed video data can take a variety of forms, but the technique is well suited to systems in which the compressed video data is a video stream typically interleaved with other forms of data, such as audio and possibly text data.
[0016] The computer data may be in a variety of different formats such as an AVI file, an MPEG file, a MOV file, a Quicktime file, or a streamed data file format of some other form.
[0017] The predetermined characteristics may be identifiers, such as names or embedded code values and the like relating to decoders known to be associated with banned computer data. In such embodiments banned computer data actions may be triggered when such identifiers are detected.
[0018] As an alternative approach, possibly giving a higher degree of security at the cost of more false alarms, other embodiments can use identifiers of decoders associated with allowed computer data, e.g. known legitimate decoders, and trigger banned computer data actions if a match with a known allowed decoder is not found.
[0019] The computer data to be examined could take a variety of different forms. As an example, the computer data could be a computer file stored on a CD which it is desired to scan before use. However, the invention is particularly well suited to systems to which computer data is downloaded with an Internet link. The primary source of banned computer data of the type of addressed by the present technique is Internet downloaded computer data.
[0020] The present technique can be employed in a variety of different ways to detect banned computer data within a computer system. Particularly appropriate uses are within an Internet content scanner, an email scanner for scanning attached files, a stand only file scanner and applications such as on demand or on access scanners.
[0021] The banned computer data actions can take a variety of forms, which may be configured according to the requirements of the particular system, but typically include one or more of blocking access to the banned computer data, deleting the banned computer data, quarantining the banned computer data, generating an alert message to a user or Administrator, and replacing the banned computer data with computer data operable to generate a video message informing the user of the presence of the banned computer data.
[0022] It will be appreciated that the decoder is the element needed to decompress the decompressed video data. However, such decoders are commonly part of a codec computer program which both compresses and decompresses video data and the identifier concerned may be an identifier of the codec rather than specifically of the decoder.
[0023] Viewed from another aspect of the present invention provides a method of detecting computer data containing compressed video data as being banned computer data, said method comprising the steps of:
[0024] reading from said computer data an identifier of a decoder operable to decompress said compressed video data;
[0025] comparing said identifier with one or more predetermined characteristics indicative of whether said identifier is associated with banned computer data; and
[0026] if said identifier is associated with banned computer data, then triggering a banned computer data action.
[0027] Viewed from a further aspect the present invention provides apparatus for detecting computer data containing compressed video data as being banned computer data, said apparatus comprising:
[0028] an identifier reader operable to read from said computer data an identifier of a decoder operable to decompress said compressed video data;
[0029] an identifier comparitor operable to compare said identifier with one or more predetermined characteristics indicative of whether said identifier is associated with banned computer data; and
[0030] triggering logic operable if said identifier is associated with banned computer data, to trigger a banned computer data action.
[0031] The above and other objects, features and advantages of this invention will be apparent from the following detailed description of illustrative embodiments which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] [0032]FIG. 1 schematically illustrates a computer system attached to the Internet and various sources of banned computer data:
[0033] [0033]FIG. 2 schematically illustrates a computer file containing compressed video data;
[0034] [0034]FIG. 3 is a flow diagram schematically illustrating the process of normal playback of a compressed video file;
[0035] [0035]FIG. 4 is a flow diagram schematically illustrating the detection of banned computer data in accordance with the present technique; and
[0036] [0036]FIG. 5 is a diagram schematically illustrating the architecture of a general purpose computer for implementing the above described techniques.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] [0037]FIG. 1 illustrates a computer network 2 , such as a corporate computer network, comprising a gateway server 4 , a file server 6 and a plurality of client computers 8 , 10 , 12 . The network 2 is connected via the Internet to provide a plurality of sources of data. Some of these sources of data may be sources of legitimate data, such as an FTP server 14 containing a legal copy of a video file that can be downloaded and used by appropriately authorised persons connected by the Internet. Conversely, another FTP server 16 may store a copy which is a pirate, copyright-infringing version of the video concerned and which it is desired to prevent from being manipulated within the network 2 . An email server 18 may serve as a source for the banned material, such as email messages containing the banned material as an email attachment. There are also known number of file sharing schemes whereby banned computer files, such as pirate, copyright-infringing versions of computer files are stored on a distributed collection of file sharing source computers 20 , 22 which may be accessed by a file sharing client program 24 executing on a client computer. These file sharing schemes are difficult to combat since the source computers can rapidly appear and disappear and may themselves only store a portion of the banned computer file concerned. Furthermore, the central computer agency which co-ordinates the actively and allows users to identify where banned computer files are stored does not itself store those computer files.
[0038] The gateway server 4 of the network 2 typically includes an Internet content scanner for scanning Internet traffic going in and out of the network 2 for banned material. The gateway server 4 may also provide an email scanner for scanning inbound and outbound emails and their attachments. The file server 6 may incorporate an on-demand or on-access malware scanner checking for computer viruses, Trojans, worms and the like. The present technique can be used by one or more of the Internet content scanner, the email scanner, the on-access scanner or the on-demand scanner. The role of the present technique is to use a decoder identifier within computer data associated with compressed video data to determine whether or not the computer data is banned computer data.
[0039] [0039]FIG. 2 schematically illustrates a first portion of a computer file 26 . This computer file 26 includes a header portion 28 which amongst other parameters specifies a key identifying a video codec to be used with the video data 30 , 32 , 34 within the computer file 26 . An identifier for an audio codec may also be included. The structure of the computer file 26 can vary considerably depending upon the particular implementation. One known type of implementation is for AVI files. Details of this type of file may be found in the publicly available documentation, such as those guides produced for programmers wishing to develop software to interact with this file format. Other file formats with which the present technique may be used include MPEG files, MOV files, Quicktime files and other streamed data format files. It will be appreciated that the computer data upon which the present technique is used need not comprise a discrete computer file. As an example, it is known to stream compressed video data via a network link, such as an Internet link, to a video player. The video data may be a realtime video stream and this would not conventionally be considered to be a computer file, although it will at least normally be temporarily stored in the form of temporary computer files and the like.
[0040] [0040]FIG. 3 is a flow diagram schematically illustrating the normal way in which an AVI file which contains compressed video data may be read and played within the Windows operating system environment. At step 36 the system waits for an AVI file to be received. Other files may be received which are not AVI files and will not trigger processing in accordance with the techniques illustrated FIG. 3, but will instead by processed in accordance with there own different techniques. When an AVI file has been received for processing, step 38 reads the codec identifier from the AVI file header. Step 40 then uses this codec identifier, which may be a four character key value, to reference the operating system registry and thereby identify the codec executable file to be used to decompress the compressed video data within the AVI file. At step 42 the compressed video data is decompressed with the identified codec executable. At step 44 the decompressed video data is rendered with a player, such as by drawing to an appropriate portion of computer display. It will be appreciated that steps 42 and 44 may not be sequential and what will typically happen is that a portion of the compressed video data will be decompressed and then rendered in parallel with the next portion of the video data being decompressed such that a continuous decompressed stream of video data becomes available for rendering by the player and uninterrupted playback achieved without having to first decompress and store the entire video data concerned.
[0041] [0041]FIG. 3 describes a Windows AVI playback system. It will be appreciated that a wide variety of different playback systems are known and maybe utilised with the present technique. As an example, a particular video player may contain its own video codec and not need to reference this via a lookup to an operating system concerned registry. However, the computer data concerned would still include an identifier to indicate that the video data had been compressed this video codec. Compressed video data typically cannot be decompressed other than by the decompressor specifically intended for use with that compressed video data and using the decompression parameters associated with the codec and the data itself.
[0042] [0042]FIG. 4 is a flow diagram schematically illustrating the present technique for detecting banned computer data containing, for example, copyright infringing compressed video data. At step 46 the system waits for a file to be downloaded. This particular example is related to an Internet content scanner, but modifications will be apparent to those in the field to adapt this technique to an email attachment scanner, an on-access scanner or an on-demand scanner as well as other possible uses.
[0043] When a file for download has been identified, step 48 determines whether this is a file containing compressed video data which needs to be checked in accordance with the present technique. If the file is not one containing compressed video data, then the thread illustrated in FIG. 4 need not be used and processing returns to step 46 to await the next file.
[0044] If the file being downloaded does contain compressed video data, then step 50 serves to download at least the header portion of that computer file. The complete computer file need not necessary be downloaded in order that it be scanned. This is useful since such computer files can be large and the resource wasted on downloading an entire computer file which was then to be banned would be disadvantageous. When at least the header has been downloaded, step 52 picks out the video handler identifier from the header.
[0045] At step 54 , the read video handler identifier is compared with one or more predetermined characteristics. These predetermined characteristics can be hardcoded into the algorithm concerned or possibly read from a configuration file or data file 56 which may be set up by a user of the system or downloaded from a supplier of the system who keeps an up-to-date list of suspicious video handler identifiers. The predetermined characteristics may be characteristics of known suspicious video handler identifiers and a match with any of these will produce a fail result at step 58 . Alternatively, the predetermined characteristics may be identifiers of known allowed video handlers and a lack of a match with one of these will trigger a fail result at step 58 .
[0046] Step 58 performs the match test discussed above and generates either a pass or fail result. If the computer file containing compressed video data fails the test, then processing proceeds to step 60 at which the banned computer data actions are triggered, such as blocking access to that computer data, deleting that computer data, quarantining that computer data, generating an alert message, either to a user or an Administrator, or replacing the banned computer data with some other video data or generating a video message indicating that banned computer video data has been detected. After the banned file actions have been triggered, processing returns to step 46 .
[0047] If the determination at step 58 was that the computer data was not banned, then processing proceeds to step 62 at which the full computer file is downloaded and released for playing in the normal way, such as in accordance with FIG. 3. Processing then returns to step 46 .
[0048] As previously mentioned there are a number of video codecs that are known to be associated with banned computer data. Examples of these are the Divx codec and the Angel potion codec. Conversely, known legitimate codecs include the Indeo codec, 1263 codec, MPEG codec and the like. Detection of banned computer data may be made by detecting the use of one of the known suspicious video codecs or by detecting the lack of use of one of the known legitimate codecs.
[0049] [0049]FIG. 5 schematically illustrates a general purpose computer 200 of the type that may be used to implement the above described techniques. The general purpose computer 200 includes a central processing unit 202 , a random access memory 204 , a read only memory 206 , a network interface card 208 , a hard disk drive 210 , a display driver 212 and monitor 214 and a user input/output circuit 216 with a keyboard 218 and mouse 220 all connected via a common bus 222 . In operation the central processing unit 202 will execute computer program instructions that may be stored in one or more of the random access memory 204 , the read only memory 206 and the hard disk drive 210 or dynamically downloaded via the network interface card 208 . The results of the processing performed may be displayed to a user via the display driver 212 and the monitor 214 . User inputs for controlling the operation of the general purpose computer 200 may be received via the user input output circuit 216 from the keyboard 218 or the mouse 220 . It will be appreciated that the computer program could be written in a variety of different computer languages. The computer program may be stored and distributed on a recording medium or dynamically downloaded to the general purpose computer 200 . When operating under control of an appropriate computer program, the general purpose computer 200 can perform the above described techniques and can be considered to form an apparatus for performing the above described technique. The architecture of the general purpose computer 200 could vary considerably and FIG. 5 is only one example.
[0050] Although illustrative embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope and spirit of the invention as defined by the appended claims.
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Computer data containing compressed video data is examined to see if it is banned computer data, for example containing pirate or copyright-infringing video material, by examining the identifier of the video codec associated with the compressed video data. Certain video codec identifiers are highly correlated with the computer data concerned being banned computer data. Thus, an examination of the header file of the computer data may be used as an efficient and sensitive tool for identifying the computer data as banned computer data.
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PRIORITY CLAIM
The present application is a non-provisional application claiming the benefit of U.S. Provisional Application No. 61/786,770, filed on Mar. 15, 2013 by Horn Bon Lin et al., entitled “ELECTROSPRAYER FOR ARTHROPOD TAGGING,” the entire contents of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to insect and arthropod tagging and, more specifically, to tagging using an electrosprayer.
Description of the Prior Art
A reliable method for tagging insects (and other potential appropriate arthropods, such as scorpions, spiders, etc., hereinafter simply referred to as “insects”) is a key component in studies of their biology, ethology, and demography. Reliable and effective methods depend on a device that can consistently deliver the tagging material onto the target insects efficiently. Devices are needed to tag insects with marking agents that include: fluorescent dyes, quantum dots, molecular beacons or aptamers and proteins, and magnetic particles. Moreover, the devices need to tag insects in a short period of time, i.e., within a few seconds to a minute to avoid over-stressing the organism.
Current insect tagging devices utilize nebulization to create and apply liquid droplets for coating. This method is relatively ineffective because the bodies of insects are typically covered with hairs or bristles (setae) that are dense enough to prevent droplets larger than about 50 microns from reaching the exoskeleton below. In this fashion, the bristles on the insect's body act as a hydrophobic barrier for protection, shielding the subject from foreign materials such as rain, mist, and small debris. Nebulization methods of droplet creation typically produce droplets too large to penetrate this protective barrier. When using these methods, excessive wetting of the insects usually results from efforts to compensate for the lack of penetration of the droplets. This is not only wasteful of potentially expensive reagent solutions, but can leave such high amounts of fluid on the insects so as to incapacitate and/or harm them, while still failing to provide a satisfactory coating.
BRIEF SUMMARY OF THE INVENTION
The aforementioned problems are overcome in the present invention which provides an electrosprayer for insect and arthropod tagging having a nozzle cartridge comprising a liquid reservoir, a high voltage connector, and at least one nozzle; a spray chamber where each nozzle is directed into the spray chamber; and a high voltage power supply, where the power supply applies voltage through the high voltage connector. Also disclosed is the related method for tagging insects and arthropods.
The present invention pertains generally to the use of an electrospray, chamber device used for the labeling of arthropods (insects) with specific tagging agents including fluorescence dyes, quantum dots, magnetic metallic particles, molecular proteins, and biological binding materials. The invention relates to an apparatus that is capable of generating charged droplets that are sub-micrometer or even nanometer in size for efficient topical coating (tagging) of insects. The ability to spray-coat (tag) insects in a consistent manner using these materials is useful over a broad spectrum of sciences. Behavior monitoring and forensic studies are two examples of areas that benefit from the tagging of insects.
The electrospray device of the present invention produces droplets that can range in size from nanometers up to a few micrometers. This size range of droplets more easily penetrates between the body bristles to the exoskeleton underneath. Additionally, the electrospray process places a substantial amount of static charge onto the surface of the droplets. This charge is beneficial since it attracts the droplets to the insect body for better adhesion. Additionally, once the droplets are placed onto the subjects' body beneath the bristles, they are protected from washing or being bumped off; thus creating a more permanent method of tagging. Electrosprays operate at low mass flow rates that will not be mechanically violent to smaller subjects such as gnats, mosquitoes, etc. Flow rates typically are less than 5 μl/min (compared to about 1 ml/min [200 times greater] for typical nebulizers). This has the additional advantage that a quantity of about 5 ml of tagging solution could be continuously sprayed for more than 16 hours. Due to the higher efficiency of the smaller droplets from an electrospray, both the amount of material needed and the exposure time (less than 5 seconds in typical cases) can be considerably reduced.
These and other features and advantages of the invention, as well as the invention itself, will become better understood by reference to the following detailed description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of an electrospray nozzle cartridge assembly.
FIGS. 2A and 2B are black-and-white photos showing a side view of the basic component of an electrospray cartridge ( FIG. 2A ), and a single nozzle cartridge seen from below ( FIG. 2B ).
FIG. 3 is a schematic of an insect electrospraying device.
FIG. 4 is a black-and-white microscope photo of an area on a fly wing after being electrosprayed with rhodamine 6 G dye (left and lower). The image shows individual dye droplets much smaller than the setae and spaces between the setae (individual seta are approx. 100 microns in length).
DETAILED DESCRIPTION OF THE INVENTION
In view of the foregoing, it is therefore an object of the present invention to provide an effective sprayer device particularly useful for efficiently and effectively tagging insect subjects. It is a further object of the invention to provide a spraying apparatus that is capable of generating a charged solution into the chamber to coat insects with low concentrations and quantities of aerosol droplets. The solution comprises tagging agents or a mixture of tagging agents, such as fluorescent dyes, quantum dots, molecular beacons, aptamers, proteins, and aqueously suspended metallic particles. These and other objects of the invention are achieved via a liquid spraying device. The device components include: an electrospray nozzle cartridge, a high voltage power supply, a spraying, chamber, and a laser for visually monitoring the electrospray operation.
Electrospray Nozzle Cartridge Assembly
The nozzle cartridge 100 is shown in FIG. 1 . In a preferred embodiment, it comprises a 1-inch diameter cylinder made of polypropylene plastic that forms a central liquid reservoir 110 . This central liquid reservoir 110 supplies the (liquid) tagging solution to the electrospray nozzle(s) 120 located at the bottom of the nozzle cartridge. The cartridge holds the electrospray nozzle(s) 120 in place and accommodates an electric connector wire 130 to be attached to the high voltage source for the electrospraying operation. The volume for the reservoir is typically 1-5 ml. The number of electrospray nozzles 120 mounted at the bottom of each cartridge 100 provides control over the rate of application of tagging material. The design shown in FIG. 1 has been kept simple to reduce fabrication cost. Cartridges with varying number of nozzles and array configurations can be constructed while maintaining the overall dimensions of the piece. This establishes an interchangeable standardized part, permitting easy replacement in case of clogging or desired nozzle re-configurations (e.g., for application rate changes). FIGS. 2A and 2B are two photos showing ( FIG. 2A ) a vertical view and ( FIG. 2B ) a bottom-end orientation showing a single electrospray nozzle.
In a preferred embodiment, the electrospray nozzles 120 are created from a ¾″ length section of silica capillary tubing. The outside diameter (O.D.) of this tubing is 360 micrometers, and can have various inside diameters (I.D.) ranging from 25 to 150 micrometers. To mount an electrospray nozzle 120 , a hole matching the O.D. is bored into the bottom of a cartridge 100 . An electrospray nozzle 120 is inserted into the hole, so that the capillary tubing protrudes slightly above the inside bottom of the reservoir, and is fixed with adhesive applied to the outside surface. The central section of the cartridge 102 will have been counter-bored, or inset, so that the nozzles 120 do not protrude below the end of the cartridge body. This serves to protect the nozzle tips while allowing the cartridge 100 to be placed upright on a flat surface.
A common syringe connector 140 (e.g. Luer Lock) can be built into the top end of the cartridge 100 so that a syringe can be used to inject liquid solution into the reservoir 110 and to provide a pressure to prime the nozzle(s) at the beginning of operation, just prior to the application of the high voltage (HV) to begin the electrospray. A direct current (DC) HV (typically in the range of 2.5-10 kilovolts) is applied through the embedded HV connector 130 that is tapped into the side-wall of the cartridge 100 . A very fine spray of submicron droplets will result from the nozzle(s) 120 at the bottom of the cartridge 100 when these conditions are met.
These standardized interchangeable cartridges 100 can be easily inserted into the top section of the Head Assembly as described in the following paragraphs.
Head Assembly
The head assembly 10 comprises a top section 200 and the nozzle cartridge assembly 100 (described above) as shown in FIG. 3 . In a preferred embodiment, a standardized, commercially available high voltage connector 230 is built into the top section 200 . When the nozzle cartridge 100 is inserted into the top section 200 , the high voltage connector 230 built into the top section 200 makes electrical contact with the customized high voltage connector 130 on the nozzle cartridge 100 to complete the circuit for electrospray operation.
Spray Chamber
The spray chamber 20 provides a confinement space for tagging the insect subjects. A bottom portion 210 of the head assembly fits into a top portion 310 of the spray chamber. The floor 400 of the spray chamber 20 is an electrically grounded conducting plate 410 required for electrospray operation. In a preferred embodiment, the spray chamber 20 is cylindrical in shape and made of transparent plastic such as Lucite with optical windows built into the sides. Two of these windows 302 and 304 should be diametrically opposed to permit the laser beam to propagate through the center of the chamber 20 and illuminate the electrospray plume when in operation. A third window (not shown) can be used for viewing the laser light scattered by the spray droplets.
Chamber Body
FIG. 3 shows the chamber body 300 as a transparent, cylindrical tube of Lucite. While FIG. 3 is not to scale, typical dimensions are 2 inches (diameter)×⅛ inches (thickness) ×2 inches (height). There are three openings cut to accommodate three optical windows. The diatmetrically opposed pair of windows 302 and 304 is centered top to bottom and is about 1 inch long. A third, viewing window may be placed at an arbitrary angle.
Bottom Plate
The bottom plate 400 comprises a Lucite plate imbedded with a metal grounding plate 410 . The circular metal (aluminum or copper) grounding plate 410 is ¼-inch thick, and serves as an electrical ground for the electrospray. The grounding plate 410 diameter matches the chamber body 300 inside diameter 312 . The upper part of the Lucite bottom plate 400 is bored out to match the metal ground plate 410 diameter. Its function is to isolate the grounding plate 410 from any contact with the surroundings for safety reasons. The grounding plate 410 is accessed for connection to the ground connector 430 through a hole 420 drilled through the side of the Lucite plate. This permits a metal rod (not shown) to connect the grounding plate 410 to an outside high voltage connector 430 . A standardized commercial high voltage connector 430 of the opposite polarity to the top section 200 is then connected to this metal rod and attached to the bottom plate 400 .
High Voltage DC Power Supply
A commercial power supply capable of providing up to 10 kilovolts of DC voltage is required (not shown). During operation, the current from a typical electrospray has been found to be less than 100 nanoamperes, so a low current power supply is adequate, and recommended for safety considerations.
TYPICAL OPERATION
Electrospray
For operating the electrospray, there are several steps to follow. With a filled cartridge 100 in place, connect the high voltage source to the HV connector 130 on the top section. Using the laser to illuminate the area just below the nozzle cartridge 100 , gradually dial the voltage up until the spray action is observed. If the voltage has reached the maximum voltage that the power supply can provide and no spray action is observed, turn the voltage down to zero and wait for a minute to allow discharge of any residual voltages. Then place an air filled syringe onto the syringe adapter 140 on the top of cartridge 100 and push the syringe to squeeze some liquid out of the nozzle tip(s) 110 to ensure a capillary is not clogged. Turn on the voltage and repeat again until the spraying occurs.
Insect Spraying
With the high voltage source turned off and disconnected from the device, pull out the head assembly 10 from the sprayer chamber 20 and drop the insect(s) for tagging through the opening from the top into the chamber. Replace the assembly top 10 . After connecting the HV wire gradually increase the HV power source and watch the spray action through the viewing window until the spray is going steadily as described above. Typical spraying times are a few seconds, but may need to be adjusted depending on the type and number of insects being tagged. After spraying, turn the voltage and the laser off, and wait for at least one minute to allow an residual static charges to dissipate. Pull off the head assembly 10 to retrieve the sprayed insect(s).
As an illustration of the technique, FIG. 4 is a microscopic image of a blow fly wing in which the left lower diagonal area has been electrosprayed with a dye. This area shows a nearly uniform coating, compared to the normal uncoated wing area in the upper right. In this particular case, the dye used was an aqueous solution of rhodamine 6 G.
In the description of this invention specific dimensions have been listed. These specific dimensions are not required to produce the desired effect of properly tagging insects. Constraints on the volume of the chamber 100 are only such that the insects are not further than approximately 2 inches from the spray nozzles 110 . The one inch diameter of the spray cartridges 100 has been used in the development due to convenience, since various off-the-shelf supports use this dimension. The specific material the apparatus is created from is not needed to be the same as listed here, but does need to be electrically nonconductive.
The above descriptions are those of the preferred embodiments of the invention. Various modifications and variations are possible in light of the above teachings without departing from the spirit and broader aspects of the invention. It is therefore to be understood that the claimed invention may be practiced otherwise than as specifically described. Any references to claim elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular.
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Disclosed is an apparatus and associated method for tagging insects and arthropods. According to an exemplary embodiment of this disclosure, an electrosprayer is provided including a nozzle cartridge, a spray chamber removably attached to the nozzle cartridge and a power supply operatively connected to the nozzle cartridge and a grounding plate within the spray chamber to electrically charge droplets expelled from the nozzle which coat one or more insects contained in the spray chamber.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Ser. No. 60/773,790, filed Feb. 14, 2006, and which is incorporated herein in its entirety.
BACKGROUND
[0002] This invention relates to a game, and in particular to a game in which playing pieces formed in the shape of stylized acrobats.
SUMMARY OF THE INVENTION
[0003] This invention includes a game wherein a number of the stylized acrobats launched toward a target. Each acrobat has extended extremities, and on each extremity is mounted a magnet. The magnets are mounted on the extremities of each acrobat so all north poles or all south poles of magnets mounted on a particular playing piece face outward. Each game includes at least one of each “north” and “south” magnetic pole acrobats. Each game also includes a launcher. The launcher includes a base on which a lever is mounted. The lever has a first end, a fulcrum and a second end. The second end preferably includes an angled surface so that when an acrobat playing piece is placed on the second end the acrobat is tilted slightly away from the fulcrum and toward the target. A metallic strip is mounted on the base beneath the second lever end, and serves to stabilize the playing piece on the second end prior to the playing piece being launched. The game also includes a target that is placed a distance away from the launcher, and is preferably marked with different scoring areas.
[0004] The game is played by successively launching acrobat playing pieces toward the target. “North” pole and “south” pole acrobats are launched in alternating order. The goal of the game is to score the greatest number of points by landing an acrobat playing piece on the highest scoring area of the target, and by then landing successive acrobat playing pieces atop the earlier-launched acrobat playing pieces. Different scoring multiples are assigned for acrobat playing pieces that are landed atop and “stick” to earlier launched acrobats. These and other features of the invention will be described by reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a front elevational view of an acrobat playing piece according to a preferred embodiment of the invention.
[0006] FIG. 2 is a side elevational view of an acrobat playing piece according to a preferred embodiment of the invention.
[0007] FIG. 3 is a top view of an acrobat playing piece according to a preferred embodiment of the invention.
[0008] FIG. 4 is a side perspective view of a preferred embodiment of the invention, including a launcher, an acrobat playing piece shown in position for launch, after launch (in phantom), and the target toward which the acrobat playing pieces are launched.
[0009] FIG. 5 is a side elevational view of the embodiment illustrated in FIG. 4 , and showing three acrobat playing pieces on the target, and a fourth in place for launch.
[0010] FIG. 6 is a perspective view of the embodiment illustrated in FIG. 5 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0011] Referring now to FIGS. 1-3 , each acrobat playing piece 10 includes a body, four extended extremities 11 - 14 , and a head 15 . Head 15 is preferably resilient member lodged between extremities 11 and 12 , and having portions 16 and 17 extending beyond the front and rear surfaces of the acrobat playing piece body (see FIG. 2 ). The operation of head 15 will be explained in greater detail below. A magnet 18 is mounted on each extremity.
[0012] In the preferred embodiments, playing pieces 10 are constructed in two different configurations. In a first configuration, each magnet 18 is oriented with its north magnetic pole facing outwardly from the body center 19 . In a second configuration each magnet 18 is oriented with its south magnetic pole facing outwardly from the body center 19 . The operation of the playing pieces will be explained in greater detail below.
[0013] Referring now to FIGS. 4-6 , a launcher is shown at 20 , and includes a base 22 and a lever 24 mounted on a pivoting fulcrum 26 . Lever 24 includes an angled end portion 28 . A magnetically susceptible metallic strip 30 is mounted under the angled end 28 of lever 24 . At the opposite end of base 20 a support 21 can be optionally provide to limit the travel of lever 24 , thereby ensuring that playing piece 10 is launched outwardly as well as upwardly. A target 30 is positioned near the launcher 20 . Target 30 includes a magnetically susceptible metallic upper surface 32 . In certain embodiments (not shown) the target 30 can define different areas that score different point values.
[0014] The playing of the game will now be described. The game is played by players taking turns launching the acrobat playing pieces toward the target, first a “north” piece, then a “south” piece in alternating order until all the pieces have been launched, ending that player's turn. One object of the game is to land successive playing pieces atop earlier launched pieces, thereby stacking the playing pieces. The player's score is totaled, and the next player then takes their turn in the same manner.
[0015] Referring to FIGS. 4-6 , the acrobat playing pieces launched by each player are scored according to where they land on the target and/or whether they land and stay on top of an earlier launched playing piece. It is for this reason that the playing pieces are launched in alternating “north” and “south” order, so that the opposite magnetic poles presented by each playing piece are presented to the previously launched playing piece, causing the pieces to stick together if the successive piece is accurately launched. One possible arrangement of playing pieces is shown in FIGS. 5 and 6 for illustrative purposes.
[0016] In FIGS. 5 and 6 , the player has launched three playing pieces, and the fourth is in position to be launched. Playing piece 10 a was successfully landed on the target, and is scored an assigned point value. Playing piece 10 b was successfully landed atop playing piece 10 a, and according to a preferred embodiment, is awarded twice the points awarded to playing piece 10 a. Playing piece 10 c was successfully landed atop playing piece 10 b, and being the “third” level of stacking, is awarded three times the point value of playing piece 10 a. If playing piece 10 is then launched and successfully landed atop playing piece 10 c, it would be awarded 4 times the point value assigned to playing piece 10 a. Referring to FIG. 6 , it can be seen that playing pieces 10 b and 10 a are stacked with only one extremity connected. It would also be possible for the pieces to be stacked with two extremities connected. In the preferred embodiment each would score as described above. However, in the illustrated configuration, it would be possible for playing piece 10 to be launched and to land and stack on any of playing pieces 10 a, 10 b, or 10 c, by engaging one exposed extremity of either playing piece, both extremities of playing piece 10 c, or to land on the target 30 . Playing piece 10 would be scored according to which “level” it landed whether on target 30 or any of the three stacked playing pieces. The invention is not limited to any specific scoring system, and in fact can be played without a cumulative scoring system at all.
[0017] Referring again to FIGS. 1-3 , mention was made of head 15 and portions 16 and 17 that extend beyond the front and rear of the playing piece body. Head 15 is preferably a resilient polymeric material, and is provided to ensure that if a playing piece lands on its side, the resilient head “bounces” and urges the playing piece into an upright position.
[0018] In other aspects of the invention, the playing pieces can be formed of any suitable material, including but not limited to wood or polymeric materials.
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A game in which game pieces in the form of acrobats are launched toward a target. The game pieces include magnets at the distal end of the extremities of the stylized acrobat game pieces.
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FIELD OF THE INVENTION
The present invention relates to a double layer capacitor, a method for the preparation thereof and the use thereof in a combined application with batteries.
BACKGROUND OF THE INVENTION
The development of capacitor technology based on the principle of energy storage in the electrochemical double layer formed at the interface between an ion-conducting phase, i.e. the electrolyte, and an electron-conducting phase, i.e, the electrode, has provided capacitors of extremely high capacitance. Such capacitors are usually referred to as double layer capacitors, supercapacitors, electrochemical capacitor or ultracapacitors.
The energy storage in such capacitors may involve electrochemical processes like in batteries, i.e. energy is stored chemically in the capacitor electrodes and the electrode reactions involve redox processes. One such system is the rubidium silver iodide low voltage electrochemical Hypercap capacitor from Technautics. Alternatively, the capacitor may be based entirely on the double layer energy storage principle. Such capacitors will below be referred to as double layer capacitors.
One important application of double layer capacitors is in hybrid combinations with batteries. Traditionally, double layer capacitors provide high power capabilities compared to batteries, e.g. during pulse applications a higher power is obtainable from the double layer capacitor than from the battery. Accordingly, the power capability of hybrid combinations is higher than for the battery alone, and further the stress on the battery is reduced due to more uniform load. A number of patents describes the use of such battery-capacitor hybrid systems, among those U.S. Pat. No. 5,587,250 and U.S. Pat. No. 5,670,266 to Motorola.
High capacitance and low impedance are the two main technical features providing the high power capabilities of double layer capacitors. The capacitance provides the energy for the load, whereas the low impedance allows good power accessibility in that the energy is available without too high internal losses.
In particular, as most pulsed loadings operate in the Hz-range from 1Hz to 1kHz, the capacitor impedance in this should be low, i.e. the main part of the energy stored in the capacitor should be available in this frequency range. A number of patents and patent applications describe approaches to double layer capacitors of low internal resistance.
European patent application EP 763,836 to Nisshinbo Industries discloses a polarisable electrode for use in a electric double layer capacitor, having a low internal resistance and a high capacitance, the carbon mixture of the electrode characterised by comprising fibrillated carbon. A conductive agent may be added to the carbon mixture to improve electrical conductivity. Such electrode has long life and can be charged and discharged at large electric currents.
European patent application EP 660,345 to Nisshinbo Industries discloses a polarisable electrode comprising a solid active carbon, characterised in that the electrode on the surface and/or inside has discontinuous portions free from said solid active carbon. A conductive agent such as graphite or carbon black may be added to the carbon mixture to improve electrical conductivity.
U.S. Pat. No. 5,682,288 to Japan Gore-Tex, Inc. discloses a planar layered electrode comprising acicular electrically conductive particles to provide low electrical resistance and which has high electric storage capacity.
U.S. Pat. No. 5,077,634 to Isuzu describes electrodes for double layer capacitors, which are compressed for reduction of internal resistance.
Low impedance double layer capacitors should display low intra-component impedance as well as low inter-component impedance. Whereas the above prior art has been focussed on low intra-component impedance in the electrode structures, the impedance of the interface to the current collectors is just as important. Electrodes of high resistance at the current collector-electrode interphase, e.g. due to poor adhesion and poor electrical contact, will suffer from poor power capability due to internal losses.
A number of patents describes double layer capacitors of elaborated electrode-current collector interface.
JP-06,084,700 to Matsushita discloses a conductor layer made of carbonaceous material such as graphite provided between the electrode and the collector, the binder being an acrylic acid-styrene copolymer and providing increased adhesion for the electrodes. JP-61,102,025 to Matsushita discloses an electric double layer capacitor of polarising electrodes from activated carbon fiber felt, the electrode having a conductive layer on one side. The conductive layer may be aluminium, titanium, nickel or tantalum, stainless steel or a conductive paint containing carbon particles. The electrolyte of said capacitor is a solution of (NEt 4 ) ClO 4 in propylene carbonate. Upon repeated charging and discharging, the capacitor has stable capacitance.
JP-60,050,914 to NEC discloses a double layer capacitor having a reduced internal resistance, the capacitor having electrodes covered by conductive layers consisting of a polymer such as polypropylene and a conductor such as carbon black or carbon fibers.
U.S. Pat. No. 5,150,283 to Matsushita describes electrodes for a double layer capacitor composed of electrically conductive substrates, coated with a mixture of activated carbon with a water-soluble material-based binding agent. Such capacitor has low internal resistance, withstanding high voltages.
U.S. Pat. No. 5,115,378 to Isuzu describes an electrode for a double layer capacitor formed from a porous sintered body of joined active carbon particles, conductivity being provided during sintering. Such capacitor has reduced internal resistance as low contact resistance between electrode body and current collector is obtained.
U.S. Pat. No. 5,099,398 to Isuzu describes an electrode for a double layer capacitor applied on an electrically conductive film, the surface of which is dissolved in a solvent and the dissolved portions of said current collector being present in the pores of the electrode bodies. Such capacitor has low internal resistance due to intimate contact at the molecular level.
Accordingly, several approaches to low internal resistance capacitors exist, including introducting of conductive coatings at the interface between the electrode and the current collector. Still, however, the is a need for a conductive coating which is stable under the severe conductions existing at this interface. This conductive coating should provide good adhesion to the current collector and to the electrode, and it should maintain its mechanical integrity upon handling such as folding and winding. Further, the coating should be stable at highly oxidative potentials at the positive electrode, and at highly reductive potentials at the negative electrode as well as being stable against corrosive electrolytes.
OBJECT OF THE INVENTION
Therefore, it is the objective of the present invention to provide a double layer capacitor with a conductive coating, which is mechanically, chemically, and eletrochemically stable during manufacture and operation. Such coating comprises a conductive agent, a binder and optionally auxiliary materials. Auxiliary materials may be materials used entirely during the processing of the conductive coating and which are removed from the final coating, or they be materials which facilitate the processing and which remain in the final coating.
BRIEF DESCRIPTION OF THE INVENTION
From a comprehensive study of a high number of conductive coatings it has now been found, that those coatings based on binders of the melamine resin type fulfil the above objectives.
Surprisingly it was found, that the melamine resin binders provide long term reduction stability at potentials as low as +1.OV vs. Li/Li + . Whereas the considerable stability of melamine resins against oxidation is well known from their long term stability under ambient conditions, their high stability against reduction is surprising considering their chemical composition. Traditionally only fluorinated compound display stability under such reductive conditions.
From the study it was also found, that despite the fact that melamine resins are hard and often brittle, the coating based on melamine resin binders showed good mechanical integrity and flexibility during processing of double layer capacitors.
Thus, according to the present invention a double layer capacitor is provided, which comprises a conductive coating comprising a melamine resin binder at the interfaces between current collectors and electrodes. In particular, the present invention provides a double layer capacitor comprising metal foil current collectors, carbon electrode structures with a polymer binder, conductive coatings comprising a melamine resin binder at the interfaces between current collectors and electrodes, and a non-aqueous electrolyte. Such double layer capacitors display long term low impedance at the electrode-current collector interface and high power capabilities.
DETAILED DESCRIPTION OF THE INVENTION
In a preferred embodiment of the invention, the melamine resin is a alkylated melamine formaldehyde resin, preferably a methylated melamine formaldehyde resin. As reaction partner for the polymerisation process alkyd resins are preferred.
Further, the excellent performance has been found to be mostly pronounced for those double layer capacitors, which have conductive coatings of a thickness of 1-10 μm.
The conductive coating comprising a melamine resin binder preferably has a composition prior to coating of:
5-50% by weight, preferably 10-40% by weight, more preferably 20-35% by weight of carbon blacks;
5-20% by weight, preferably 5-15% by weight, more preferably 10-15% by weight of graphite;
5-40%, by weight, preferably 10-30% by weight, more preferably 15-25% by weight of melamine resin binder and polymerisation reaction partner;
25-85% by weight, preferably 30-74% by weight, more preferably 35-53% by weight of solvent; and
0-10% by weight, preferably 1-5% by weight, more preferably 2-5% by weight of auxiliary materials, preferably selected from the group consisting of dispersing agents, defoaming agents and rheological control agents.
The carbon blacks should display high structure and are advantageously selected from the group consisting of furnace blacks, acetylene blacks and lampblacks. The graphites should display low particle size, advantageously in the range of 0.5-20 μm, preferably 0.5-10 μm.
The solvents are preferably alcohols R 1 —OH, wherein R 1 represents C 1 -C 4 alkyl, and glycols and glycol ethers R 2 —(OCHR 3 CH 2 ) n —OH, n=1-3, wherein R 2 represents hydrogen or C 1 -C 4 alkyl and wherein R 3 represents hydrogen or methyl.
The dispersing agent may be non-ionic, anionic, cationic, as well as amphoteric. Preferably an anionic dispersing agent, such as Disperbyk 170 from BYK Chemie is used.
The defoaming agent may be a mineral oil or silicone oil defoaming agent, preferably a silicone oil defoaming agent, such as BYK-080 from BYK Chemie.
The rheological control agent may be an organo clay, silica and castor oil derivative, preferably an organo clays, such as Viscogel B7 from Chimica Mineraria SpA.
The conductive coating may be commercially available products with a melamine resin binder, such as the XZ302 screen printing dye from Wiederhold Siebdruckfarben of Germany. This dye is based on carbon black and graphite and a thermosetting resin of the melamine resin type, the solvent mixture comprising 2-(2-butoxyethoxy) ethanol, 2-butoxyethanol, butan-1-ol and 1-methoxypropan-2-ol. The retarder UV4 from Wiederhold Siebdruckfarben may be used for optimisation of viscosity and drying time.
In a preferred embodiment of the invention the melamine resin-based conductive coating is used in double layer capacitors of electrolytes based on tetraalkyl-ammonium salts. Thus, it has been found, that those double layer capacitors based on tetraalkylammonium salts have a high capacitance and a higher power capability than double layer capacitors using electrolyte compositions of other salts like lithium and sodium salts. Although not fully understood, the formation of any interface layer appears highly dependent on the ionic species of the electrolyte, as well as on the surface structure and chemical composition of the electrode carbon. The excellent performance of double layer capacitors based on tetraalkylammonium salts is ascribed to little, thin, stable and dense interface layers being formed at the electrode-electrolyte interfaces of such capacitors, allowing a narrow charge separation and a high capacitance. In contrast, in the case of lithium salts, thicker, unstable and less dense interface layers are formed, which provide less capacitance. Accordingly, the concept of conductive coatings based of melamine resin binder is particularly advantageous in those cases, where the electrolyte salt is a tetraalkylammonium salt. Thus, the higher capacitance of capacitors of such salts is most effectively applied when combined when the low impedance and low internal loss of the conductive coatings of the present invention.
Although a high number of tetraalkylammonium salt may be used, the above advantage is especially pronounced for tetramethylammonium tetrafluoroborate, tetraethylammonium tetrafluoroborate, tetrabutylammonium tetrafluoroborate, tetramethylammoniumhexafluorophosphate, tetraethylammonium hexafluorophosphate and tetrabutylammonium hexafluorophosphate, in particular tetraethylammonium tetrafluoroborate. The electrolyte solvent may be any non-aqeuous solvent selected from the groups of carbonates, lactones and nitriles. Preferably the electrolyte solvent is selected from the group of ethylene carbonate, propylene carbonate, dimethyl carbonate, diethyl carbonate, ethyl methyl carbonate, γ-butyrolactone, γ-valerolactone and acetonitrile and mixtures thereof. More preferably the electrolyte solvent is γ-butyrolactone.
In a preferred embodiment of the invention the electrolyte is confined in a separator, consisting of a porous structure made from a polymer, preferably polyethylene or polypropylene.
In a preferred embodiment of the invention the current collector is a metal current collector, preferably of nickel, copper or aluminium, more preferably of aluminium.
The electrode structures of the double layer capacitors of the present invention comprises carbon, binder, solvent and optionally graphites and any auxiliary compounds
In a preferred embodiment of the invention the carbons of the electrode structure are high surface active carbons.
In a preferred embodiment of the invention the binder of the electrode structure is selected from the group consisting of melamine resins, polyvinyl butyrals and fluorocontaining polymers, preferably PVdF and PVdF-copolymers, including PVdF-hexafluoro propylene copolymers. For the processing of such binders, solvents therefor are preferably selected from the group consisting of glycol ethers and glycol ether esters, dimethyl formamid, dimethyl acetamid and N-methyl-pyrrolidone.
The invention further relates to a simple, low-cost method of preparing double layer capacitors.
According to the invention the conductive coating is prepared from a paste comprising carbon black, graphite, melamine resin binder, solvent and optionally any auxiliary compounds. Carbon blacks and graphites materials are added along with any dispersing agents and defoaming agent and a polymerisation reaction partner are mixed in alcohols, glycols or glycol ethers. The melamine resin is added along with any rheological control agent to produce a uniform paste, which is coated or printed onto the current collector and heated to 100-150° C. for 10-30 min.
Electrode pastes are prepared similar to the above conductive paste from active carbon, binder, solvent and optionally graphite and any auxiliary compounds, and coated or printed onto the conductive coating.
The coating or printing technique applied is preferably a screen printing, gravure printing or a slot die coating technique.
Double layer capacitors are formed by sandwiching between two of the above conductive coating-electrode laminates a porous separator. The capacitor laminate is subsequently confined in a polymer coated metal pouch and impregnated with the electrolyte solution. Eventually, the pouch is sealed.
A final aspect of the invention relates to the use of double layer capacitors according to the present invention in a hybrid combination with batteries, in which combination the double layer capacitor provides peak current, whereas the battery provides the base load currents. In such applications the battery capacity utilisation is improved, as the stress on the battery is reduced.
The invention is illustrated by the following non-limiting examples.
EXAMPLES
CONDUCTIVE COATING PASTE PREPARATION:
EXAMPLE 1
A mill base was prepared from 100 g of carbon black (Shawinigan Black 100% compressed from Chevron), 50 g of graphite (Lonza KS15 from TIMCAL) and 2 g of dispersing agent (Disperbyk 170 from BYK Chemie), which was added to 100 g of butoxy-ethanol and 100 g of 1-methoxy-propan-2-ol and milled in a pearlmill for 30 min. 70 g of alkyd resin reaction partner (Alftalat AC317 from Hoechst) was added and the mill base was mixed for further 30 min.
Under stirring, 30 g of methylated melamine formaldehyde (Marprenal MF 927 from Hoechst) and 3 g of theological control agent (Viscogel B7 from Chimica Mineraria SpA) were added to the mill base to form the final conductive coating paste.
EXAMPLE 2
500 g of XZ302 screen printing dye from Wiederhold Siebdruckfarben of Germany is mixed with 150 g of UV4 from Wiederhold Siebdruckfarben of Germany.
CONDUCTIVE COATING PREPARATION
EXAMPLE 3
The conductive coating paste of example 1 was coated onto a 20 μm aluminium current collector by screen printing. Subsequently, the coating was cured at 110° C. for 30 min. The coated layer had a thickness of 5 μm.
EXAMPLE 4
The conductive coating paste of example 2 was coated onto a 20 μm aluminium current collector by screen printing. Subsequently, the coating was cured at 120° C. for 30 min. The coated layer had a thickness of 5 μm.
ELECTRODE PASTE PREPARATION
EXAMPLE 5
192 g of polyvinyl butyral from Hoechst was dissolved in 3653 g of Dowanol PMA (propylene glycol methyl ether acetate) from Dow Chemicals in a high speed mixer. 1170 g of active carbon CECA 4S from CECA of France is added to the solution to form a pre-mixed paste. The pre-mixed paste was milled in a pearlmill for 60 min. to form the final paste.
ELECTRODE COATING
EXAMPLE 6
The electrode paste of example 5 was applied onto the conductive layer coated current collector of example 3 by screen printing. The electrode layer had a thickness of 15 μm.
EXAMPLE 7
The electrode paste of example 5 was applied onto the conductive layer coated current collector of example 4 by screen printing. The electrode layer had a thickness of 15 μm.
DOUBLE LAYER CAPACITOR PREPARATION
EXAMPLE 8
The conductive coating-electrode laminates of example 6 were used for the preparation of a double layer capacitor with an active area of 46 mm×111 mm. The double layer capacitor laminate was produced by sandwiching between two of the above conductive coating-electrode laminates a 20 μm porous polyethylene separator. The capacitor laminate was confined in a polymer coated aluminum pouch. The double layer capacitor laminate was impregnated with 1 ml of an electrolyte solution prepared by dissolving 50 g of tetraethylammonium tetrafluoroborate in 200 ml of γ-butyrolactone, and the pouch was sealed.
The double layer capacitor was charged at a constant potential of 2.5 V for 72 hours at room temperature. The impedance was measured in the range 20 kHz-1Hz using a Solartron 1250 Frequency Response Analyser and a Solartron 1286 Electrochemical Interface. The impedance and capacitance were determined from the real and imaginary impedances at 200 Hz. The impedance was 38 mΩ and the capacitance was 188 mF, respectively. Following 1680 hours of operation at elevated temperature, 70° C., the capacitance was unchanged, however, the impedance was increased by a factor of 4.2 to 160 mΩ. Assuming an activation energy of 50-60 kJ/mole for any degradation process occuring, the 1680 hours operation at 70° C. corresponds to several years of ambient temperature lifetime, indicating the long tem stability.
EXAMPLE 9
A double layer capacitor of an active area of 46 mm×111 mm was prepared and tested similar to example 8, however, using the conductive coating-electrode laminate of example 7.
The impedance was 30 mΩ and the capacitance was 199 mF, respectively. Following 1680 hours of operation at 70° C., the impedance was increased by a factor of 3.8 to 114 mΩ. The capacitance was unchanged.
COMPARATIVE EXAMPLE
A double layer capacitor essentially similar to the double layer capacitor described in the above example 8 was prepared, however, substituting a conductive coating prepared from a mixture of 4,000 gr. Shawiningan Black 100% compressed from Chevron, 5,72 g of polyacrylic acid from Aldrich and 12,28 g of water for the melamine resin binder of example 1.
The impedance was 300 mΩ and the capacitance was 100 mF, respectively. Following 200 hours of operation at 70° C., the impedance was increased by a factor of 4 to 1.2 Ω, rendering the capacitor impedance unacceptably high for high power applications.
EXAMPLE 10
A 5 V double layer capacitor was produced from a series connection of two capacitors of example 8.
Upon pulsed discharge (0.6 ms @ 1.5 A+4.4 ms @ 0.3 A, continuously repeated) of a 400 mAh (1C) lithium-ion battery (graphite/lithium manganese oxide spinel) to a cutoff voltage of 2.5 V, a battery capacity utilisation of 224 mAh was obtained.
Applying the same discharge profile to the same battery, however, parallelly combined with the 5 V double layer capacitor, an extended capacity utilisation of 315 mAh was reached.
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A double layer capacitor and a method for producing the same wherein the double layer capacitor comprises a conductive coating based on binders of the melamine resin type such that the conductive coating is present at the interfaces between the current collectors and the electrodes. The double layer capacitor thus produced has good mechanical and chemical integrity and flexibility and is suitable for use in combination with batteries.
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RELATED APPLICATIONS
[0001] The present invention relates to a system that applies tension to a patient's spine to treat the spine related diseases. More specifically, the present invention relates to a positioning correction system that applies tension to a patient's spinal lesion area through a range of angles, and that can adjust the angle dynamically under tension without changing the intended tension, for the purpose of fine tuning treatment angle for each patient.
BACKGROUND OF THE INVENTION
[0002] Therapists utilize spinal decompression therapy non-operative in vitro to treat various spinal ailments including herniated discs, degenerative disc disease, sciatica, posterior facet syndrome, and post surgical pain. Decompression therapy is a derivative of traditional traction-based therapy, whereby the spine is pulled by an outside force (such as by a therapist manually or by an automated process). The spine is typically held in a continuous state of tension during traditional traction-based therapy. Decompression therapy differs from traditional traction therapy in that tension is applied to the spine at a specific angle. Also, during decompression therapy, various tensile forces are applied or cycled throughout the treatment period such that paraspinal muscles are relaxed and fatigued, allowing for interdiscal separation. These functions provide for a smooth transition between different levels of tension. In either traditional traction or decompression therapy, spinal tension is typically maintained for periods of 30 minutes or longer.
[0003] As the spine is placed into a state of tension, the spinal vertebrae will occur morphology change, this requires the control system must have the dynamic positioning correction function. Meanwhile, the dynamic automatic positioning correction processing also allows the lesioned intervertebral disc time to heal in the non-loaded state. Additionally, herniated discs (nucleus pulposa) is produced in back to normal position via negative pressure created by the separation of the vertebrae, realized the intervertebral disc disease to accept reset. Meanwhile, This dynamic positioning correction function can also be aided to implement para-spinal muscles maximum relax according to the patient weight set nonlinear logarithmic minus pressure control system. Since the conscious human (patient) may voluntarily and/or subconsciously flex the spinal muscles in reaction to tensile forces. Either or both patient reactions degrade the effectiveness of spinal traction or spinal decompression therapy.
[0004] A common spinal decompression therapy utilizes a non-feedback-providing tension producing actuator (any type of electro-mechanical, pneumatic, magnetic, hydraulic, or chemical actuator) connected to a patient via a patient interface device. The patient lay supine upon a treatment bed, head distal to the applied tension source. An upper body patient harness secures the upper patient body to the distal end of the bed (that end of the bed furthest from the source of tensile force generation). A lower body harness secures about the waist, and serves as the point at which the tension strap is connected. Tension-producing actuator output is increased or decreased to produce resultant tension changes at the point where the strap is attached to the patient. A linear actuator (any type of electro-mechanical, pneumatic, magnetic, hydraulic, or chemical actuator) is utilized to pull the patient's whole spine. And spinal decompression treatment system is based on the weighing data system by weighing the patients, for patients to be automatic setting decompression treatment, through the imaging data combining with a narrative, healthcare provider will complete lesions of the initial position, the positioner raise and lower the point at which the tension strap pulls from (treatment positioner), relative to the place of attachment to the patient, thus adjusting the angle of applied tension. The system also includes a tension measuring device (e.g., a loadcell) that is connected inline with the tension-producing actuator and patient to communicate tension metrics to a tension-producing actuator controlling device (e.g. computer). Thus, the system operates as a controlled-feedback loop whereby a planned tension profile can be applied to the patient and the actual applied forces can be verified by the computer.
[0005] In the above example, the point at which the tension strap pulls from relative to the place of attachment to the patient is typically fixed during application of tension. As the direction of pull is neither parallel nor perpendicular to the patient's spine, and as the patient lay supine (in this example) with their head distal to the applied tension source, the applied tension can be modeled as two force vectors, one inline with the patient's spine and away from the head, and one perpendicular to the patient's spine. In the event that the patient lay prone, the direction of the horizontal component of the applied tension resultant would remain the same, however the direction of the vertical component of the applied tension resultant would be reversed.
[0006] One defining characteristic of spinal decompression is that tension is applied at an angle, and that specific angles (which are specific to each device's design) affect a specific positioning ability to allow healthcare providers to treat location specific injuries, such as herniated spinal discs. In effect, locating the site(s) of spinal elongation maximizes the therapeutic benefit per therapy session. Traction, whereby forces are applied mostly inline with the spine, does not attempt to maximize spinal discs at specific interdiscal locations and spinal elongation position column by the adjustment on the angle of tension in spinal.
[0007] Devices of the type described above provide general guidelines as to the relative interdiscal space(s) affected by various angles of applied tension. These angles are calculated in many ways; no standards exist for their calculation. Spinal decompression manufacturers calculate which interdiscal space(s) is affected by relating applied tension force vectors (specific to their device) to commonly available radiographical charts. These radiographical charts typically show the ‘average spine’ (based on studies of measurements taken over many patients) or the ‘ideal spine’ (based on best-fit mathematical modeling of the spine). Variations in patient's spines can mean that a treatment angle designed to align the L4 and L5 vertebra actually is insufficient to align said vertebra or overly much, brining inferior vertebra in-line with unintended superior vertebra.
[0008] The shape of the human spine varies from human to human. Lordosis, or an inward curve (towards the front of the patient body), and kyphosis, or an outward curve (towards the back of the patient body), exist throughout the spine, and serve to balance the spine and body. Generally, the spine exhibits a lordotic curve between the Thoracic (middle spine) and Lumbar (lower spine) regions, and a kyphotic curve between the Thoracic and Cervical (upper spine or neck) region. The points and degree of inflection and deflection vary across patient populations.
[0009] At present, Magnetic Resonance Imaging (MRI) is routinely indicated prior to spinal decompression therapy, whereby affected disc levels are identified. Once the MRI-described interdiscal space(s) is established, healthcare providers follow spinal decompression device manufacturer's recommendations as to appropriate applied tension treatment angles. The healthcare provider is able to judge, by physical examination of the patient, advanced patient imaging (MRI, CT, X-ray, etc.), spinal decompression device manufacturer's treatment angle design, and experience using spinal decompression devices the ‘most likely’ proper treatment angle for a particular patient. Once the patient is actually on the spinal decompression device, strapped in, the final level of scrutiny by the healthcare provider with regards to treatment angle occurs. The healthcare provider will visually observe the patient's posture, feel the patient's spine and or other related bodies, and/or query the patient to make a final determination as to the correct treatment angle for that particular patient.
[0010] At present, The spinal pressure relief devices are employed angle positioning technology, healthcare providers must do one of two things when adjusting treatment angle after initiating treatment. The first option, pausing treatment, adjust treatment angle, and restart treatment, but since the provider can't dynamic continuous real-time observation of the spine in the minus pressure condition of the patients with feedback in this case, thus even if to adjust, can not ensure the accurate angle, which makes it difficult to realize patients and the provider interactive communication, scanning, and ultimately positioning lesions in the purpose of the position. The second option, in the treatment process and under the action of tension, while the provider observes and adjusts the angle. But this practice, since human operation, will inevitably change dynamic system in the system, which leads to exceed expected tension setting range change. This adjustment, for the present not tension compensation of the closed loop feedback system (with tension compensation feedback closed-loop system can make the expected tension in a time constant), due to the sudden change of angle, will make the expected tension suddenly changes that lead to spinal side muscle strong contraction, thus affecting the treatment effect.
[0011] The present invention seeks to demonstrate a unique method for fine tuning treatment angle for each patient. The present invention proposes a system designed to allow the healthcare provider to adjust treatment angle without changing intended tension levels. The system proposed would be able to account for mechanical dynamics and mechanical advantages of the system, and be calibrated to anticipate the increases and decreases in resultant tension that would otherwise occur while changing treatment angle under tension.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention relates to a tension producing actuator feedback and correction system. The system is fast enough to allow treatment angle change under tension without changing intended tension , the advantages of this design are numerous. While the patient is under an initial intended tension and treatment angle, the healthcare provider can observe via sight and touch, and additionally querying the patient, the interdiscal sites affected by the initial treatment angle at which the resultant tension is applied to the patient. Keeping the patient at the initial intended tension while changing treatment angle (without changing intended tension level) allows the healthcare provider to observe, via at least the same pathways, the transition in patient posture, without inciting paraspinal muscle contraction due to unintended tension level changes. Dynamically adjusting treatment angle under tension allows the healthcare provider to adjust, up or down, the treatment angle to accommodate increases and decreases in lordosis, as observed under tension. Dynamically adjusting treatment angle under tension also allows the healthcare provider to query the patient for comfort and or increases or decreases in perceived pain, incorporating a measure of biofeedback into the therapy.
[0013] In general, the patient is positioned supine on the treatment bed, their lower spine over a lordotic support. The lordotic support is used to locate the apex of lordosis, which is utilized as a universal metric for calculating treatment angle across average or ideal patient morphologies. Regardless of the design of treatment angles for a specific spinal decompression or traction device, the device does include treatment angle designations designed to affect specific interdiscal locations. While the inclusion of designer treatment angle designations for a spinal decompression or fraction device is not required, it is likely present per the current technology.
[0014] Average or ideal radiographical spinal models typically include a mean segmental angle and at least the first or second standard deviation measurements. The segmental angle would be an angle of lordosis, in the case of the lumbar spine, between one or more vertebra. The segmental angles utilized would be those between the fifth lumbar vertebra and the first sacral vertebra or L5-S1, the fourth and the fifth lumbar vertebra or L4-L5, the third and the fourth lumbar vertebra or L3-L4, the second and the third lumbar vertebra or L2-L3, and the first and second lumbar vertebra or L1-L2.
[0015] The design of the spinal decompression device provides treatment angles which would align vertebra (spinal disc) and elongate their intervertebral spaces for an average or ideal spine. As described above, differences in the degree of lordosis between vertebral segments will range slightly above or below the average or ideal models.
[0016] If the spinal decompression device is designed to allow treatment angle change without changing intended tension, and that treatment angle change is bounded by one standard deviation of measured or calculated (depending on the data used in the design of the device), then the device is capable of accommodating the average or ideal spine and all those patients within one standard deviation of the average or ideal model, formed according to an embodiment of the present invention. The device's dynamic angle adjustment bounds may be extended to two or even three standard deviations of the average or ideal model, to accommodate even more patients. The device's dynamic angle adjustment bounds may incorporate the entire angle adjustment range of the device, allowing the healthcare provider to move up and down the entire lower spine.
[0017] By first utilizing angles described by spinal decompression device manufacturers as treating specific interdiscal locations and by then applying tension at that angle, the healthcare provider is able to initiate therapy in the general location of the interdiscal space(s) to be treated. If the healthcare provider is then capable of further adjusting the angle of applied tension during the application of said tension, and if the tension feedback and correction mechanism of the spinal decompression device is fast and accurate enough such that no noticeable increase or decrease in intended tension is incurred (thus minimizing conscious and subconscious paraspinal muscle contraction), the healthcare provider is then capable of fine tuning the treatment angle. The healthcare provider can observe real-time changes in the patient and the alignment of their spine, under tension. Paraspinal muscles may contract in response to stretching, and definitely will contract in an involuntary guarding response if sudden changes in tension occur. If the spinal decompression device's tension control feedback and correction loop is fast and accurate enough to allow for angle change and compensate for inevitable changes in mechanical advantage such that the paraspinal muscles are not incited to guard and contract, then the healthcare provider can in effect ‘scan’ the patient's spine in the vicinity of the interdiscal space(s) of interest. This process may be limited to an initial period of treatment. This process may also be limited to a range of angle adjustment, whereby the healthcare provider selects an initial treatment angle based on diagnostic evidence and device manufacturer design, and then fine tunes only to less than, only to greater than, or above and below the initial treatment angle by a certain amount (e.g., 0.5 degrees).
[0018] In summary, the present invention describes the device of which as being capable of adjusting the angle of applied tension without changing (significantly) the amount of intended tension, such that the healthcare provider can adjust the angle of tension during the application of tension without inciting conscious or subconscious paraspinal muscle contraction.
[0019] Additionally, the present invention may be utilized in conjunction with patient feedback to help locate the treatment angle that best addresses the patient's pain. Just as therapeutic massage addresses muscular tensions, whereupon the recipient of the massage knows instantly when the therapist addresses the correct site or source of pain, so may the patient undergoing spinal decompression therapy recognize when a spinal decompression device addresses the correct interdiscal site or source of pain. If the healthcare provider is then capable of further adjusting the angle of applied tension during the application of said tension, and if the tension feedback and correction mechanism of the spinal decompression device is fast and accurate enough such that no noticeable increase or decrease in intended tension is incurred, the healthcare provider is then capable of querying the patient real-time as to whether increasing or decreasing the angle of applied tension feels more or less appropriate.
[0020] By scanning the spine and querying the patient as to what feels more appropriate, the healthcare provider has an additional input as to the correct location for spinal decompression to be maximized.
[0021] According to one respect of the present invention, providing a tensioning device, comprising: a patient-positioning means configured to high precisionly, repeatedly align a target region of a patient spine; a tension-producing actuator configured to place a patient spine in tension; a positioning device operationally configured to position tension producing actuator relative to target region of patient spine; a patient interface device operationally configured to interface tension producing actuator with patient spine; a control system with feedback on resultant tension vector applied to patient spine operationally configured to allow for adjustment of either tension producing actuator position, patient position, or both while applying tension to the patient spine during non-therapeutic tension levels; and a display operationally configured to provide data regarding resultant tension vector to the user or healthcare provider; wherein the control system automatically adjusts tension producing actuator work levels such that resultant tension vector magnitude remains ideally constant during adjustment of resultant tension vector angle, reducing risk of eliciting paraspinal muscle contraction due to changes in resultant tension vector magnitude.
[0022] The patient positioning means includes a patient bed, wherein a region of the patient bed is identified as the alignment-region over which a target region of the patient spine should be positioned. The patient bed includes physically removable portions of the bed body and a series of physical device related to the treatment attached thereof.
[0023] The tension producing actuator includes an electro-mechanical device which generates torque through rotation. The tension producing actuator includes a means of increasing or decreasing torque generated.
[0024] The positioning device includes a removable positioning means by which increases and decreases in the height of the tension producing actuator relative to the target region of the patient spine are accomplished.
[0025] The patient interface includes a strap connected to a patient harness, one end of the strap includes a connection to the rotation of the tension producing actuator, and a connection to a patient harness at its opposite end, the patient harness cradling a portion of the patient pelvis and the spine. The patient interface is operationally configured to translate the decompression tension generated by the torque generated by the tension producing actuator to the patient spine.
[0026] The control system allows for user or healthcare provider input and includes a means to set, generate, and keep ideally constant resultant tension vector magnitude during which either resultant tension vector angle or patient spine target region position relative on the device is adjusted by user or healthcare provider. The control system allows for user or healthcare provider to modify resultant tension vector angle while tension is applied to patient spine, the resultant tension vector magnitude kept ideally constant, while patient spine target region position relative to a location on the device is unchanged.
[0027] The control system allows for user or healthcare provider to modify patient spine target region position relative to a location on the device while tension is applied to patient spine, the resultant tension vector magnitude kept ideally constant, while tension producing actuator position relative to a location on the device is unchanged.
[0028] The control system allows for user or healthcare provider to set resultant tension vector angle and to modify patient spine target region position relative to a location on the device while tension is applied to patient spine, the resultant tension vector magnitude kept ideally constant, the control system automatically adjusting tension producing actuator position relative to a location on the device to maintain user set resultant tension vector angle.
[0029] The control system includes a display or means for communicating resultant tension vector angle and magnitude to the user or healthcare provider.
[0030] The control system allows for a user or healthcare provider to visually assess, physical palpitate, or verbally or otherwise receive feedback from the patient to modify patient position and to achieve concentration of resultant tension vector magnitude near a vertebral area of interest during applied ideally constant resultant tension vector magnitude.
[0031] The control system indicates the region of the spine where resultant tension is concentrated based on empirical calculation of said location relative to a spinal model and mathematical and medical assumptions.
[0032] The control system calculates region of the spine where resultant tension is concentrated based on ideal spine models arrived at through clinically cited spinal morphology studies.
[0033] The user or healthcare provider is able to visually assess, palpitate, and/or query patient to determine optimum pre-treatment treatment angle or resultant tension vector angle while reducing risk associated with eliciting a paraspinal muscle contraction due to changes in resultant tension vector magnitude.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 illustrates a side view of a spinal therapy system formed according to an embodiment of the present invention.
[0035] FIG. 2 illustrates the coccyx, sacrum, and lumbar spine, the lumbar spine being modeled about an ellipse, showing angles between adjacent vertebra.
[0036] FIG. 3 illustrates a side view of a spinal therapy system utilizing a lordotic support, specific patient positioning, and treatment angle structure based on FIG. 2 , formed according to an embodiment of the present invention.
[0037] FIG. 4 illustrates two side views of a coccyx, sacrum, and lumbar spine before and after the application of tension at a specific angle designed to align the sacrum and lowest lumbar vertebra (S1 and L5 respectively) and to elongate that interdiscal space (L5-S1), formed according to an embodiment of the present invention.
[0038] FIG. 5 illustrates two side views of a coccyx, sacrum, and lumbar spine. The upper view illustrates the lower spine after the application of tension at an angle designed to align the sacrum and lowest lumbar vertebra (S1 and L5 respectively) and to elongate that interdiscal space (L5-S1). The lower view illustrates the upper view after the application of tension at an additional specific angle designed to align the lowest lumbar vertebra with the fourth distal lumbar vertebra (L5 and L4 respectively), and to elongate the interdiscal spaces (L5-S1 and L4-L5), formed according to an embodiment of the present invention.
[0039] FIG. 6 illustrates three views of the coccyx, sacrum, and lumbar spine. The upper view represents the lower spine relaxed, before the application of tension at a specific angle. The second (middle) view represents the lower spine after the application of tension at an angle designed(θ T ) (using average or ideal spine radiographical models) to align the first sacral and fifth lumbar vertebra. The second view illustrates the first sacral vertebra rotated overly much upwards beyond alignment with the fifth lumbar vertebra by an angle (θ diff ). The second view shows how the fifth lumbar vertebra L5 is rotating towards an unintended alignment with the fourth lumbar vertebra L4. The third (lowest) view shows the first sacral vertebra rotated downward by a subtractional angle (θ diff ), adjusted during tension by the healthcare provider, sufficient to bring the first sacral vertebra into proper alignment with the fifth lumbar vertebra for that patient segmental angle (θ 1 -θ 0 ), formed according to an embodiment of the present invention.
[0040] FIG. 7 illustrates three views of the coccyx, sacrum, and lumbar spine. The upper view represents the lower spine relaxed, before the application of tension at a specific angle. The second (middle) view represents the lower spine after the application of tension at an angle designed (using average or ideal spine radiographical models) to align the first sacral and fifth lumbar vertebra. The second view illustrates the first sacral vertebra rotated insufficiently upwards towards alignment with the fifth lumbar vertebra by an angle (θ T ) designed to align the vertebra. The third (lowest) view shows the first sacral vertebra rotated upward by an additional angle (θ diff ), adjusted during tension by the healthcare provider, sufficient to bring the first sacral vertebra in proper alignment with the fifth lumbar vertebra, formed according to an embodiment of the present invention.
[0041] FIG. 8 illustrates a flowchart demonstrating an algorithm for adjusting treatment angle by a predetermined amount while not changing intended tension, formed according to an embodiment of the present invention.
[0042] FIG. 9 illustrates a spinal decompression treatment graph, showing intended tension, treatment angle, measured tension, and tension correction versus time, formed according to an embodiment of the present invention.
[0043] The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentalities shown in the attached drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0044] FIG. 1 illustrates a spinal therapy system 10 used to treat a patient 110 formed according to an embodiment of the present invention. The system 10 includes a microprocessor, control system, or computing device 190 having firmware and/or software that operates to utilize and control an actuator 170 . The computing device 190 is configured to interface with a user, such as by use of a monitor and keyboard setup. By way of example only, the actuator 170 may be electronically, hydraulically, pneumatically, or mechanically operated. The actuator 170 is connected to a patient 110 via a patient interface device 120 . By way of example, the actuator 170 may be operated through a system of gears or pulleys such that the tensile forces applied to the patient 110 by the patient interface device 120 are carefully controlled. This system 10 is used to perform decompression therapy on the patient 110 by applying cycles of tensile forces from the actuator 170 on the spine 108 of the patient 110 through the interface device 120 . Alternatively, the system 10 may be used to perform fraction therapy without use of cycles of tensile forces.
[0045] The patient 110 is positioned supine on a mechanical apparatus 100 that may be a flat surface such as a bed or table. The bed 100 includes a head end 104 where the patient 110 lay his or her head and a base end 106 where the patient 110 lay his or her legs and feet. The bed 100 is positioned such that the patient 110 may be easily placed into alignment for treatment with the system 10 . Additionally, the bed 100 may employ arm supports or rails to position the patient 110 . The patient 110 wears a lower-body harness 118 that is connectable to the patient interface device 120 . This lower-body harness allows for connection to the patient interface device 120 at or near the base of the sacrum, or is designed to locate the origin of the resultant tension vector at or near the base of the sacrum. Alternatively, the patient may wear any other appropriate device that is configured to connect the patient 110 to the interface device 120 , provided the device position the origin or locate the origin of the resultant tension vector at or near the base of the sacrum. The patient 110 wears an upper-body harness 119 that is connectable to the head end 104 of the bed 100 . The upper-body harness 119 secures the upper body of the patient 110 to the bed 100 , and keeps the upper body of the patient 110 from moving towards or away from the tower 130 which houses the actuator 170 and interface positioning device 140 .
[0046] The healthcare provider positions the patient's 110 lumbar spine 108 over an adjustable lordotic support 112 . The adjustable lordotic support 112 is pneumatically inflated and deflated to accommodate various degrees of lumbar lordosis between patients 110 . The lordotic support 112 may be adjustable or fixed in shape, and may be adjustable by several methods, including pneumatic, electro-mechanical, hydraulic, chemical, etc. Specifically, the healthcare provider positions the apex of lordosis, the third lumbar vertebra (L3), over the center-top of the lordotic support 112 . Positioning the apex of lordosis over the center-top of the lordotic support 112 and anchoring the patient's 110 upper body to the head end 104 of the bed 100 forms a reliable and consistent endpoint for the horizontal line (opposite side) of the triangle which is used to calculate treatment angle.
[0047] The healthcare provider places a knee bolster 117 under the patient's 110 knees, reducing pressure on the patient's 110 lower spine 108 . The patient's 110 position on the bed 100 , supine with a bolster 117 under the knees, forms the basis for selection of radiographical measurements which take into account this position for use in designating treatment angles.
[0048] The lower-body harness 118 is connected to the actuator 170 by the patient interface device 120 . The harness 118 may be connected to the patient interface device 120 through a clip or buckle that may alternately be secured and removed. The interface device 120 is configured to deliver and align tensile forces generated by the actuator 170 through the harness 118 along the spine 108 of the patient 110 .
[0049] The interface device 120 may be a strap, belt, or cable that is positioned relative to the patient 110 via a patient interface positioning device 140 . The patient interface positioning device 140 may itself be moved to preferred positions by an vertical actuator 148 , which may be a linear actuator, or any other type of electro-mechanical, pneumatic, hydraulic, or chemical actuator. The vertical actuator 148 may contain a relative or absolute encoder, potentiometer, or optical distance sensor, for use in communicating the position of the patient interface positioning device 140 to an electronic communication hub 155 by way of arrow F. The patient interface device 120 , as it travels up and down via the patient interface positioning device 140 and vertical actuator 148 , may pass thru a slot 145 in the front of the tower 130 , which may utilize some form of flexible material to move with the patient interface device 120 and shield the inside of the tower 130 from outside interference.
[0050] The head end 104 and base end 106 bed 100 mattresses may be moved together horizontally towards and away from the tower 130 via a horizontal actuator 114 and clevis 116 , which may be a linear actuator or any of electro-mechanical, pneumatic, hydraulic, or chemical type. This would generally be done to accommodate patients 110 of various heights, such that those patient's 110 feet would not be uncomfortably near to or beyond the base end 106 of the bed 100 . The horizontal actuator 114 may contain a relative or absolute encoder, potentiometer, or optical distance sensor, for use in communicating the position of the lordotic support 112 and head end 104 mattress to either or both the computing device 190 and electronic communication hub 155 .
[0051] The base end 106 mattress of the bed 100 is designed to be locked into place with and travel horizontally with the head end 104 mattress of the bed 100 . It is also capable of unlocking from the head end 104 mattress of the bed 100 , and traveling a fixed distance away from the head end 104 mattress of the bed 100 along linear guides. This function serves to allow the spine 108 to elongate more easily under tension, as opposed to slipping and sliding down the base end 106 mattress of the bed 100 were it fixed to the head end 104 mattress. The base end 106 mattress and head end 104 mattress were joined entirety, this case would be less favorable for the spine free elongation with the decompression tension.
[0052] The system 10 further includes a tensile force feedback system 160 which engages the interface device 120 between the actuator 170 and the lower-body harness 118 . The feedback system 160 may include a loadcell or dynamometer 150 that is positioned inline with the actuator 170 and is configured for electronically providing feedback to the electronic communication hub 155 as indicated by arrow E.
[0053] The electronic communications hub 155 is designed to collect and relay various system 10 metrics to the computing device 190 as indicated by arrow A. This device may synchronize various system 10 measurement device information into a single data stream A designed to be best utilized by the computing device 190 .
[0054] The actuator 170 electronically communicates with, and is controlled directly by, an actuator controller 192 as shown by arrow B. By way of example only the actuator controller 192 is a servo-amplifier 192 . The actuator 170 may also be attached to, or connected inline with, an encoder 180 that is capable of communicating motor shaft position and other motor metrics with the servo-amplifier 192 . The servo-amplifier 192 may be capable of calculating any number of motor metrics, including work, position, distance, torque, and rate and electronically communicating those metrics to, and receiving them from, the computing device 190 as indicated by arrow C to the computing device 190 .
[0055] The computing device 190 may be configured to communicate with the servo-amplifier 192 , and the actuator 170 , to monitor and to correct as needed the resultant tensile force and motor metrics applied by the actuator 170 from the servo-amplifier 192 . The computing device 190 may also be configured for use with a user interface system (e.g., keyboard and monitor) which communicates and deciphers the user's commands to the computer 190 . This interface allows the user to structure treatment parameters. By way of example, all tension-producing and delivery apparatus are contained within a tower 130 located in a position relative to the patient 110 .
[0056] In operation, spinal treatment begins by positioning the patient 110 correctly onto the bed 100 . The patient's head is positioned at the head end 104 of the bed 100 , and the patient's feet are positioned at the base end 106 of the bed 100 . The patient 110 is outfitted with the lower body harness 118 such that the patient 110 is connected to the patient interface device 120 , and the lower body harness 118 is configured to apply tensile forces to the spine 108 of the patient 110 , the origin of the resultant tension vector located at or near the base of the sacrum. The patient is outfitted with an upper body harness 119 which is fixed into position at the head end 104 of the bed 100 . The healthcare provider positions the patient's 110 apex of lordosis over the center-top of the lordotic support 112 , adjusts the height of the support to match the curvature of the patient's lordosis there, and adjusts the upper-body harness 119 connection to the head end 104 of the bed 100 to make certain the upper body of the patient 110 is fixed into position on the head end 104 mattress. A bolster 117 is placed under the patient's 110 knees.
[0057] The operator of the decompression system 10 may use the patient interface system of the computer 190 to select the proper treatment parameters for the therapy. The operator may then select a tension treatment program for the patient 110 and instruct the computing device 190 to execute the selected treatment profile. The computing device 190 activates the servo-amplifier 192 and/or actuator 170 such that the actuator 170 rotates, for example in the direction of arrow D, to tighten the patient interface device 120 and thus apply tension to the patient's spine 108 through the lower body harness 118 . The computing device 190 adjusts the tensile output to follow the cycles of tensile forces defined in the treatment program entered by the user. The program may include low and high tension plateaus above, by way of example only, 125 pounds, and may also include any number of decompression therapy variations cyclically applying tension to the patient's spine 108 .
[0058] FIG. 2 illustrates the Lumbar Lordosis Elliptical Model 205 formed of radiographic measurements over many patients. Janik et all developed an idealized average subject anthropometric model of the lumbar lordosis from inferior of T12 to superior S1. The elliptical model 205 represents the idealized path of the posterior longitudinal ligament along the posterior aspect of the vertebral bodies2. This model 205 represents one method by which spinal decompression device designers may designate treatment angles formed according to an embodiment of the present invention. The ellipse 205 about which the spine 200 is modeled has minor axis B 210 passing through the inferior endplate 212 of T12 275 and a major axis A 215 perpendicular to the minor axis 210 . Janik et all found the b/a ratio of 0.32 to be the best fit for the data presented.
[0059] The lower spine 200 pictured in FIG. 2 is composed of the first sacral vertebra 230 (S1), the fifth lumbar vertebra 225 (L5), the fourth lumbar vertebra 240 (L4), the third lumbar vertebra 250 (L3), the second lumbar vertebra 260 (L2), the first lumbar vertebra 270 (L1), and the twelfth thoracic vertebra 275 (T12).
[0060] The tangent lines in FIG. 2 are drawn according to the Harrison Posterior Tangent (HPT) method. The HPT lines drawn along the posterior bodies of the bony vertebra are shown, the angle between adjacent tangent lines defining the segmental angle between vertebra per the elliptical model 205 .
[0061] The segmental angle between L5 225 and S1 230 , or L5-S1, is determined by the angle between the tangent lines θ 1 235 and θ 0 220 .
[0062] The segmental angle between L4 240 and L5 225 , or L4-L5, is determined by the angle between the tangent lines θ 2 245 and θ 1 235 .
[0063] The segmental angle between L3 250 and L4 240 , or L3-L4, is determined by the angle between the tangent lines θ 3 255 and θ 2 245 .
[0064] The segmental angle between L2 260 and L3 250 , or L2-L3, is determined by the angle between the tangent lines θ 4 265 and θ 3 255 .
[0065] The segmental angle between L1 270 and L2 260 , or L1-S2, is determined by the angle between the tangent lines θ 5 280 and θ 4 265 .
[0066] The segmental angles discussed above are utilized according to an embodiment of the present invention to determine angles specific to the device of FIG. 1 for treating various portions of the lumbar spine 200 . Different radiographical methods and data may be more or less appropriate for a specific spinal decompression device design. It is important to choose measurement data that befits the patient's 110 position on the device, in the system of 10 that being supine and with a bolster under the knees.
[0067] FIG. 3 illustrates a side view of the system 10 formed by an embodiment of the present invention, detailing the designation of treatment angles. The patient 110 is positioned supine on the bed 100 , head on the head end 104 of the bed. The patient's 110 spine 108 is shown over the lordotic support 112 , the apex of lordosis L3 250 over the center-top of the lordotic support 112 . Although not shown, the lower body harness 118 is present, as indicated by the vertical and horizontal components 304 and 306 , ‘x’ and ‘y’ respectively, of the resultant tension vector with origin 302 at the base of the sacrum 230 . Also not shown, the upper body harness 119 is affixed to the head end 104 of the bed 100 . The bolster 117 is not shown; however the patient's 110 legs are angled as if over the bolster 117 .
[0068] As the patient interface device 120 is retracted by the actuator 170 , S1 230 , by way of the lower body harness 118 , is rotated upward. The apex of lordosis, L3 250 acts as the fulcrum 310 for this rotation, as S1 230 , L5 225 , and L4 240 all reside below L3 250 . L3 250 acts to oppose the movement of S1 230 in the vertical direction ‘y’ 304 as L3 250 upon the lordotic support 112 . This opposition continues until the treatment angle is sufficient to act upon the L3 250 vertebral body. As L3 250 is acted upon and lifted, so the fulcrum 310 shifts superior to L2 260 . As L2 260 is acted upon by a sufficient treatment angle, so the fulcrum 310 shifts superior once again to L1 270. In all cases the fulcrum 310 is formed by the opposition to an increase in treatment angle and more specifically to the vertical component of the resultant tension ‘y’ 304 against the lordotic support 112 .
[0069] The hypotenuse 328 is formed of the patient interface device 120 at the point where it exits the tower 130 through slot 145 and the point 310 . The treatment angle 338 is equivalent to the angle formed by the HPT lines 235 and 220 formed of the posterior sides of S1 230 and L5 225 , (θ 1 -θ 0 ) 338 or L5-S1
[0070] The hypotenuse 326 is formed of the patient interface device 120 at the point where it exits the tower 130 through slot 145 and the point 310 . The treatment angle 336 is equivalent to the angle formed by the HPT lines 245 and 235 formed of the posterior sides of L5 225 and L4 240 , (θ 2 -θ 1 ) 336 or L4-L5. The entire treatment angle however would consist of (θ 2 -θ 1 ) 336 +(θ 1 -θ 0 ) 338 .
[0071] The hypotenuse 324 is formed of the patient interface device 120 at the point where it exits the tower 130 through slot 145 and the point 310 . The treatment angle 334 is equivalent to the angle formed by the HPT lines 255 and 245 formed of the posterior sides of L4 240 and L3 250 , (θ 3 -θ 2 ) 334 or L3-L4. The entire treatment angle however would consist of (θ 3 -θ 2 ) 334 +(θ 2 -θ 1 ) 336 +(θ 1 -θ 0 ) 338 .
[0072] The hypotenuse 322 is formed of the patient interface device 120 at the point where it exits the tower 130 through slot 145 and the point 310 . The treatment angle 332 is equivalent to the angle formed by the HPT lines 265 and 255 formed of the posterior sides of L3 250 and L2 260 , (θ 4 -θ 3 ) 332 or L2-L3. The entire treatment angle however would consist of (θ 4 -θ 3 ) 332 +(θ 3 -θ 2 ) 334 +(θ 2 -θ 1 ) 336 +(θ 1 -θ 0 ) 338 .
[0073] The hypotenuse 320 is formed of the patient interface device 120 at the point where it exits the tower 130 through slot 145 and the point 310 . The treatment angle 330 is equivalent to the angle formed by the HPT lines 280 and 265 formed of the posterior sides of L2 260 and L1 270 , (θ 5 -θ 4 ) 330 or L1-L2. The entire treatment angle however would consist of (θ 5 -θ 4 ) 330 +(θ 4 -θ 3 ) 332 +(θ 3 -θ 2 ) 334 +(θ 2 -θ 1 ) 336 +(θ 1 -θ 0 ) 338 .
[0074] The patient interface device 120 and interface positioning device 140 is raised and lowered by the vertical actuator 148 to accommodate the various designated treatment angles 320 . 322 , 324 , 326 , and 328 . The system 10 utilizes passive or absolute encoder, potentiometer, optical distance sensor, or other distance metering feedback to determine vertical position of the patient interface device 120 . The bed 100 , composed of the base end 106 mattress and head end 104 mattress, is moved together horizontally towards and away from the tower 130 via the horizontal actuator 114 . The position of the horizontal actuator 114 is known to the system 10 via passive or absolute encoder, potentiometer, optical distance sensor or other distance metering feedback. Together, the vertical position of the patient interface device 120 at the interface positioning device and the horizontal position of the center-top 310 of the lordotic support 112 via the horizontal actuator 114 are known to the system and are used to calculate treatment angle.
[0075] FIG. 4 contains two views of the lower spine, 400 and 401 . The upper view, 400 , illustrates the spine before the additional application of resultant tension vector F 402 at treatment angle 490 . The lower view, 401 , illustrates the spine after application of said resultant F 402 .
[0076] The HPT tangent lines 420 , 430 , 440 , 450 , 460 , and 470 are drawn posterior to the vertebral bodies S1 410 , L5 411 , L4 412 , L3 413 , L2 414 , and L1 415 .
[0077] The resultant F 402 is applied to the patient 110 via the patient interface device 120 via the lower body harness 118 . The lower patient harness 118 is designed to originate the resultant tension vector F 402 at the base of the sacrum 410 , underneath the supine patient 110 in this embodiment of the present invention. The resultant F 402 , when broken down into a vertical Fy and horizontal Fx component 404 and 403 , acts in two ways on the lower spine 400 / 401 . First, the vertical component Fy 404 can be thought of as lifting, from the sacrum 410 , countered by the third vertebra L3 413 , the apex of lordosis, upon the center-top 310 of the lordotic support 112 . The horizontal component Fx 403 can be thought of as pulling through the aligned spinal segments to elongate the spine.
[0078] In 400 , none of the spinal segments 410 , 411 , 412 , 413 , 414 , 415 , and 416 have a segmental angle of zero (aligned) as there are no external forces acting on the spine and it is assumed some amount of lordosis is naturally present in between all segments of the lower spine in the patient. Were there no natural lordosis whatsoever in the lower spine 400 , and simultaneously no natural kyphosis, then there would be no need to utilize any treatment angle other than zero degrees.
[0079] The lower spine in 401 is acted upon by the resultant 402 . The vertebral segment S1 410 is acted upon via the resultant 402 via the lower body harness 118 via the patient interface device 120 . The magnitude of the resultant tension 402 is set as a general guideline to ½ patient body weight as is customary in the art; however the healthcare provider is responsible for tuning this magnitude sufficient to lift the lower and rotate the lower patient body, sacrum/pelvis/hips, into position. The vertebral segment S1 410 is caused to lift and rotate relative to the inferior endplate of L5 411 per the vertical component Fy 404 of resultant tension 402 . The angle of application 490 of resultant tension 402 is θ 1 -θ 0 , 430 - 420 , which is sufficient to bring the posterior sides of the vertebral bodies S1 410 and L5 411 parallel to each other, and so into ‘alignment’. Once the vertebral bodies S1 410 and L5 411 are aligned, the intervertebral discs are decompressed uniformly 480 , anterior and posterior. Through the cycling of resultant tension 402 , between maximal and minimal levels, the vertebral bodies S1 410 and L5 411 are brought into and out of alignment.
[0080] The bringing of into and out of alignment of the vertebral bodies S1 410 and L5 411 results in a confusion and relaxation of paraspinal muscles, especially when resultant tension 402 is cycled smoothly. Additionally, the bringing of into and out of alignment of the vertebral bodies S1 410 and L5 411 results in increased imbibition by the intervertebral discs at the end plates of the vertebral bodies, as the process by which imbibition occurs is a mechanical movement of vertebral bodies relative to each other, as described by the bringing into and out of alignment of said bodies. Further, the elongation 480 of aligned vertebral bodies S1 410 and L5 411 results in a drop in interdiscal pressure at the location of elongation, which acts to move nucleosus pulposus through the spine.
[0081] FIG. 5 contains two views of the lower spine, 500 and 501 . The upper view, 500 , illustrates the spine before the additional application of resultant tension vector F 502 at treatment angle 591 . The upper view of 500 is analogous to the lower view 401 of FIG. 4 , rotated by 490 and elongated 480 . The lower view, 501 , illustrates the spine after application of said resultant F 502 .
[0082] The HPT tangent lines 530 , 540 , 550 , 560 , and 570 are drawn posterior to the vertebral bodies L5 511 , L4 512 , L3 513 , L2 514 , and L1 515 . The resultant F 502 is applied to the patient 110 via the patient interface device 120 via the lower body harness 118 . The lower patient harness 118 is designed to originate the resultant tension vector F 502 at the base of the sacrum 510 , underneath the supine patient 110 in this embodiment of the present invention. The resultant F 502 , when broken down into a vertical Fy and horizontal Fx component 504 and 503 , acts in two ways on the lower spine 500 / 501 . First, the vertical component Fy 504 can be thought of as lifting, from the sacrum 510 , countered by the third vertebra L3 513 , the apex of lordosis, upon the center-top 310 of the lordotic support 112 . The horizontal component Fx 503 can be thought of as pulling through the aligned spinal segments to elongate the spine.
[0083] In 500 , only S1 510 and L5 511 are aligned, as described in 401 of FIG. 4 . None of the other spinal segments 511 , 512 , 513 , 514 , 515 , and 516 have a segmental angle of zero (aligned) as the resultant 402 acting on the spine is at a treatment angle sufficient only to align 510 and 511 . Additionally, it is assumed some amount of lordosis is naturally present in between all segments of the lower spine in the patient 110 . Were there no natural lordosis whatsoever in the lower spine 500 , and simultaneously no natural kyphosis, then there would be no need to utilize any treatment angle other than zero degrees.
[0084] The lower spine in 501 is acted upon by the resultant 502 . The vertebral segments L5 511 , and by way of the initial resultant 402 S1 510 , are acted upon via the resultant 502 via the lower body harness 118 via the patient interface device 120 .
[0085] The magnitude of the resultant tension 502 is set as a general guideline to ½ patient body weight as is customary in the art; however the healthcare provider is responsible for tuning this magnitude sufficient to lift the lower and rotate the lower patient body, sacrum/pelvis/hips, into position. The vertebral segments L5 511 , and by way of 402 S1 510 , are caused to lift and rotate relative to the inferior endplate of L4 512 per the vertical component Fy 504 of resultant tension 502 . The angle of application 591 of resultant tension 502 is θ 2 -θ 1 , 540 - 530 , plus that of 590 , is sufficient to bring the posterior sides of the vertebral bodies L5 511 and L4 512 parallel to each other, and so into ‘alignment’. Once the vertebral bodies L5 511 and L4 512 , and by way of 402 S1 510 and L5 511 , are aligned, the intervertebral discs are decompressed uniformly 581 and 580 , anterior and posterior. Through the cycling of resultant tension 502 , between maximal and minimal levels, the vertebral bodies L5 511 and L4 512 , and S1 510 and L5 511 , are brought into and out of alignment.
[0086] The benefits of decompressing, 580 and 581 , and bringing into and out of alignment the vertebral bodies have been described in FIG. 4 . It should be noted that according to this embodiment formed of the present invention, to align two vertebral bodies for the purpose of decompressing, increasing imbibition, and creating an interdiscal local nucleous pulposus pressure drop, it is required to first bring into alignment all distal vertebral segments, starting with S1 510 and L5 511 .
[0087] FIG. 6 illustrates three views of the coccyx( 600 , 695 , 696 ). The upper view 600 represents the lower spine relaxed, before the application of resultant tension vector 602 at treatment angle (θ T ) 608 . The second (middle) view 695 represents the lower spine after the application of resultant tension vector 602 at treatment angle (θ T ) 608 designed (using average or ideal spine radiographical models) to align the first sacral vertebra S1 610 and fifth lumbar vertebra L5 611 . The third (lower) view 696 represents the lower spine after the application of resultant tension vector 607 at the treatment angle dynamically adjusted during tension to a reduced (θ T ) 608 −(θ diff ) 609 .
[0088] The HPT tangent lines 620 , 630 , 640 , 650 , 660 , and 670 are drawn posterior to the vertebral bodies S1 610 , L5 611 , L4 612 , L3 613 , L2 614 , and L1 615 . The resultant F 602 is applied to the patient 110 via the patient interface device 120 via the lower body harness 118 in the second view 695 . The lower patient harness 118 is designed to originate the resultant tension vector F 602 at the base of the sacrum 610 , underneath the supine patient 110 in this embodiment of the present invention. The resultant F 602 , when broken down into a vertical Fy and horizontal Fx component 604 and 603 , acts in two ways on the lower spine 600 / 695 / 696 . First, the vertical component Fy 604 can be thought of as lifting, from the sacrum 610 , countered by the third vertebra L3 613 , the apex of lordosis, upon the center-top 310 of the lordotic support 112 . The horizontal component Fx 603 can be thought of as pulling through the aligned spinal segments to elongate the spine.
[0089] In 600 , none of the spinal segments 610 , 611 , 612 , 613 , 614 , 615 , and 616 have a segmental angle of zero (aligned) as there are no external forces acting on the spine and it is assumed some amount of lordosis is naturally present in between all segments of the lower spine in the patient. Were there no natural lordosis whatsoever in the lower spine 600 , and simultaneously no natural kyphosis, then there would be no need to utilize any treatment angle other than zero degrees.
[0090] The lower spine in 695 is acted upon by the resultant 602 . The vertebral segment S1 610 is acted upon via the resultant 602 via the lower body harness 118 via the patient interface device 120 . The magnitude of the resultant tension 602 is set as a general guideline to ½ patient body weight as is customary in the art; however the healthcare provider is responsible for tuning this magnitude sufficient to lift the lower and rotate the lower patient body, sacrum/pelvis/hips, into position. The vertebral segment S1 610 is caused to lift and rotate relative to the inferior endplate of L5 611 per the vertical component Fy 604 of resultant tension 602 .
[0091] The second view 695 illustrates the first sacral vertebra S1 610 rotated overly much upwards beyond alignment with the fifth lumbar vertebra L5 611 by treatment angle (θ T ) 608 . While treatment angle (θ T ) 608 was designed for system 10 to bring only the first sacral vertebra S1 610 into alignment with the fifth lumbar vertebra L5 611 , in this particular patient the treatment angle (θ T ) 608 exceeds the patient's natural segmental angle L5-S1, (θ 1 -θ 0 ) 338 , by a difference of angle (θ diff ) 609 . The second view 695 shows how the fifth lumbar vertebra L5 611 is rotating towards an unintended alignment with the fourth lumbar vertebra L4 612 . At the treatment angle (θ T ) 608 , resultant tension vector 602 is causing intentionally the first sacral vertebra S1 610 and the fifth lumbar vertebra L5 611 to align and elongate 618 , and unintentionally the fifth lumbar vertebra L5 611 and fourth lumbar vertebra L4 612 to align and elongate 619 .
[0092] The initial treatment angle (θ T ) 608 of the resultant tension vector 602 produces the changes described above, at which point the healthcare provider may observe visually and by touch, and additionally by diagnostic equipment and/or patient feedback that L5 611 and L4 612 are unintentionally partially or wholly aligned and elongated 619 . The healthcare provider may decide to dynamically adjust treatment angle (θ T ) 608 under tension. As the treatment angle is adjusted dynamically, the healthcare provider can more accurately judge the proper segmental angle L5-S1, (θ 1 -θ 0 ) 338 , for that patient.
[0093] The third (lowest) view 696 shows the first sacral vertebra S1 610 rotated downward by angle (θ diff ) 609 , adjusted dynamically during tension by the healthcare provider, sufficient to bring the first sacral vertebra S1 610 into proper alignment with the fifth lumbar vertebra L5 611 for that patient's segmental angle (θ 1 -θ 0 ) 338 , formed according to an embodiment of the present invention. The new resultant tension vector 607 has the same magnitude as the initial resultant tension vector 602 , but is applied to the patient 110 at a new treatment angle (θ T ) 608 minus (θ diff ) 609 , equivalent to (θ 1 -θ 0 ) 338 .
[0094] By reducing the treatment angle (θ T ) 608 by (θ diff ) 609 , the fifth lumbar vertebra L5 611 is no longer in alignment with the fourth lumbar vertebra L4 612 . As L5 611 and L4 612 are not aligned, elongation 619 between L5 611 and L4 612 is minimized. The new treatment angle (θ T ) 608 minus (θ diff ) 609 maximizes elongation only at L5-S1, 618 .
[0095] FIG. 7 illustrates three views of the coccyx( 600 , 695 , 696 ). The upper view 700 represents the lower spine relaxed, before the application of resultant tension vector 702 at treatment angle (θ T ) 708 . The second (middle) view 795 represents the lower spine after the application of resultant tension vector 702 at treatment angle (θ T ) 708 designed (using average or ideal spine radiographical models) to align the first sacral vertebra S1 710 and fifth lumbar vertebra L5 711 . The third (lower) view 796 represents the lower spine after the application of resultant tension vector 707 at the treatment angle dynamically adjusted during tension to an increased (θ T ) 708 +(θ diff ) 709 .
[0096] The HPT tangent lines 720 , 730 , 740 , 750 , 760 , and 770 are drawn posterior to the vertebral bodies S1 710 , L5 711 , L4 712 , L3 713 , L2 714 , and L1 715 .
[0097] The resultant F 702 is applied to the patient 110 via the patient interface device 120 via the lower body harness 118 in the second view 795 . The lower patient harness 118 is designed to originate the resultant tension vector F 702 at the base of the sacrum 710 , underneath the supine patient 110 in this embodiment of the present invention. The resultant F 702 , when broken down into a vertical Fy and horizontal Fx component 704 and 703 , acts in two ways on the lower spine 700 / 795 / 796 . First, the vertical component Fy 704 can be thought of as lifting, from the sacrum 710 , countered by the third vertebra L3 713 , the apex of lordosis, upon the center-top 310 of the lordotic support 112 . The horizontal component Fx 703 can be thought of as pulling through the aligned spinal segments to elongate the spine.
[0098] In 700 , none of the spinal segments 710 , 711 , 712 , 713 , 714 , 715 , and 716 have a segmental angle of zero (aligned) as there are no external forces acting on the spine and it is assumed some amount of lordosis is naturally present in between all segments of the lower spine in the patient. Were there no natural lordosis whatsoever in the lower spine 700 , and simultaneously no natural kyphosis, then there would be no need to utilize any treatment angle other than zero degrees.
[0099] The lower spine in 795 is acted upon by the resultant 702 . The vertebral segment S1 710 is acted upon via the resultant 702 via the lower body harness 118 via the patient interface device 120 . The magnitude of the resultant tension 702 is set as a general guideline to ½ patient body weight as is customary in the art, however the healthcare provider is responsible for tuning this magnitude sufficient to lift the lower and rotate the lower patient body, sacrum/pelvis/hips, into position. The vertebral segment S1 710 is caused to lift and rotate relative to the inferior endplate of L5 711 per the vertical component Fy 704 of resultant tension 702 .
[0100] The second view 795 illustrates the first sacral vertebra S1 710 rotated insufficiently upwards toward alignment with the fifth lumbar vertebra L5 711 by treatment angle (θ T ) 708 . While treatment angle (θ T ) 708 was designed for system 10 to bring the first sacral vertebra S1 710 into alignment with the fifth lumbar vertebra L5 711 , in this particular patient the treatment angle (θ T ) 708 is less than the patient's natural segmental angle L5-S1, (θ 1 -θ 0 ) 338 , by a difference of angle (θ diff ) 709 . At the treatment angle (θ T ) 708 , resultant tension vector 702 is insufficient to cause the first sacral vertebra S1 710 and the fifth lumbar vertebra L5 711 to align and elongate.
[0101] The initial treatment angle (θ T ) 708 of the resultant tension vector 702 produces the changes described above, at which point the healthcare provider may observe visually and by touch, and additionally by diagnostic equipment and/or patient feedback that S1 710 and L5 711 are not fully aligned and elongated. The healthcare provider may decide to dynamically adjust treatment angle (θ T ) 708 under tension. As the treatment angle is adjusted dynamically, the healthcare provider can more accurately judge the proper segmental angle L5-S1, (θ 1 -θ 0 ) 338 , for that patient.
[0102] The third (lowest) view 796 shows the first sacral vertebra S1 710 rotated upward by angle (θ diff ) 709 , adjusted dynamically during tension by the healthcare provider, sufficient to bring the first sacral vertebra S1 710 into proper alignment with the fifth lumbar vertebra L5 711 for that patient's segmental angle (θ 1 -θ 0 ) 338 , formed according to an embodiment of the present invention. The new resultant tension vector 707 has the same magnitude as the initial resultant tension vector 702 , but is applied to the patient 110 at a new treatment angle (θ T ) 708 plus (θ diff ) 709 , equivalent to (θ 1 -θ 0 ) 338 .
[0103] By increasing the treatment angle (θ T ) 708 by (θ diff ) 709 , the first sacral vertebra S1 710 and the fifth lumbar vertebra L5 711 are brought into alignment, maximizing elongation 719 between at L5-S1, 718 .
[0104] FIG. 8 illustrates a flowchart demonstrating an algorithm for adjusting treatment angle by a predetermined amount while not changing intended tension, formed according to an embodiment of the present invention
[0105] The algorithm proceeds from initial powering-on of the spinal decompression device 800 . As part of the system 10 initialization routine 802 , the vertical linear actuator 148 is reset to the lowest position. Any passive or active encoder data, or potentiometer data, relayed by an internally or externally mounted distance metering device relative to vertical linear actuator 148 , will be measured against this initial zero point. Also as part of the system 10 initialization routine, the horizontal actuator 114 is reset to the position nearest the tension producing actuator 170 . Any passive or active encoder data, or potentiometer data, relayed by an internally or externally mounted distance metering device relative to horizontal linear actuator 114 , will be measured against this initial zero point 802 . At this point the device calculates the initial treatment angle 804 . Optionally, the device may employ absolute distance metering devices, which do not require the device to initialize vertical and horizontal actuators as in 802 . Optionally, the device may commit to non-volatile memory the last known location of the vertical and horizontal linear actuators, and so not require initialization 802 . The system of 10 then displays the treatment angle 806 .
[0106] The healthcare provider may enter 808 into the treatment computer 190 the intended maximum and minimum tension for spinal decompression therapy. They may also enter the initial treatment angle and treatment time, among other parameters. This may be done before physical patient setup 810 as shown, or afterwards.
[0107] The healthcare provider then physically configures 810 the patient 110 upon the bed 100 . The upper body harness 119 is secured to the head end of the bed 104 . A knee bolster 117 is placed under the patient's knees. The bed 100 is adjusted horizontally and/or the patient 110 is adjusted on the bed 100 to locate the apex of lordosis, L3 250 , over the center-top 310 of the lordotic support 112 . The lower body harness 118 is connected to the patient interface device 120 . The healthcare provider may then initiate treatment 812 .
[0108] As treatment is initiated 812 , the treatment computer 190 relays C treatment profile data, tension profile, to the servo-amplifier 192 , which in-turn communicates B with the servo-motor 170 , in this embodiment of the present invention. The tension producing actuator 170 rotates D, increasing tension on the patient interface device 120 . The loadcell 150 registers tension, and relays E that metric to electronics 155 . The electronics 155 relay A that information to the treatment computer 190 . The treatment computer 190 sends updated tension profile information C to the servo-amplifier 192 , completing a closed-loop feedback profile 814 .
[0109] The healthcare provider may decide they want to increase or decrease treatment angle dynamically, under tension, after initiation of treatment 812 . The healthcare provider would either want to increase treatment angle by pressing a button corresponding to vertical linear actuator 148 movement upwards 816 , or want to decrease treatment angle by pressing a button corresponding to vertical linear actuator 148 movement downwards 832 .
[0110] In the case of 816 , treatment angle increase is indicated, and the treatment computer 190 decides if, based on software presets, dynamic angle adjustment is allowed 818 . If dynamic angle adjustment is allowed 818 , then the treatment computer 190 communicates A with electronics 155 to very slowly start and very slowly maintain vertical linear actuator 148 movement while the upwards-indicating vertical linear actuator button is pressed 820 . In this embodiment of the present invention, no immediate or step transition in vertical linear actuator 148 movement is allowed. Once the upwards-indicating button is pressed 816 , and for as long as it is pressed 826 , the vertical linear actuator will continue to move slowly upwards 820 . If the upwards-indicating button is no longer pressed, then the treatment computer 190 and electronics 155 will initiate a very slow stop of vertical linear actuator 148 movement 828 . During that time 828 , both the upward or downward indicating vertical linear actuator buttons are disabled 828 . Once the vertical linear actuator 148 movement is stopped, as verified by distance metering devices, both the upward and downward indicating vertical linear actuator buttons are enabled 830 .
[0111] While vertical linear actuator 148 movement is increasing treatment angle 820 , the treatment computer 190 and electronics 155 continuously monitor the loadcell 155 information, and any other system 10 metrics, such that the magnitude of the resultant tension vector applied to the patient remains on its intended tension profile, while treatment angle is adjusted 822 . As treatment angle is adjusted 820 , the treatment computer 190 and electronics 155 monitor distance metering devices relative to the vertical linear actuator 148 and recalculate and display treatment angle 824 .
[0112] It should be noted that treatment angle may be allowed to increase or decrease only by a small amount, based on perhaps one or more standard deviations away from average or ideal segmental angles for a particular treatment angle. Regardless of the bounds of dynamic angle adjustment amongst the full range of vertical linear actuator movement, as the vertical linear actuator approaches these bounds, it automatically slow-stops to avoid immediate change in treatment angle.
[0113] Once the actions 818 , 820 , 822 , 824 , 826 , 828 , and 830 , as initiated by the healthcare provider 816 , are completed, the device returns to monitoring the tension profile under assumed static vertical linear actuator 148 position 814 .
[0114] In the case of 832 , treatment angle decrease is indicated, and the treatment computer 190 decides if, based on software presets, dynamic angle adjustment is allowed 834 . If dynamic angle adjustment is allowed 834 , then the treatment computer 190 communicates A with electronics 155 to very slowly start and very slowly maintain vertical linear actuator 148 movement while the downwards-indicating vertical linear actuator button is pressed 836 . In this embodiment of the present invention, no immediate or step transition in vertical linear actuator 148 movement is allowed. Once the downwards-indicating button is pressed 832 , and for as long as it is pressed 842 , the vertical linear actuator will continue to move slowly downwards 836 . If the downwards-indicating button is no longer pressed, then the treatment computer 190 and electronics 155 will initiate a very slow stop of vertical linear actuator 148 movement 844 . During that time 844 , both the upward or downward indicating vertical linear actuator buttons are disabled 844 . Once the vertical linear actuator 148 movement is stopped, as verified by distance metering devices, both the upward and downward indicating vertical linear actuator buttons are enabled 846 .
[0115] While vertical linear actuator 148 movement is decreasing treatment angle 836 , the treatment computer 190 and electronics 155 continuously monitor the loadcell 155 information, and any other system 10 metrics, such that the magnitude of the resultant tension vector applied to the patient remains on its intended tension profile, while treatment angle is adjusted 838 . As treatment angle is adjusted 836 , the treatment computer 190 and electronics 155 monitor distance metering devices relative to the vertical linear actuator 148 and recalculate and display treatment angle 840 .
[0116] Once the actions 834 , 836 , 838 , 840 , 842 , 842 , 846 , and 830 , as initiated by the healthcare provider 832 , are completed, the device returns to monitoring the tension profile under assumed static vertical linear actuator 148 position 814 .
[0117] FIG. 9 represents a treatment screen 900 as may be displayed on the spinal decompression device of system 10 and/or printed. In 900 , four graphs 901 , 902 , 903 , and 904 are shown, vertically aligned, all plotted against the same horizontal scale (time).
[0118] In 901 , the intended tension profile is shown. In this embodiment of the present invention, the intended tension profile is a series of maximum and minimum tension level plateaus, connected by logarithmic increases and decreases in tension 911 . The y-axis 910 for 901 is tension, plotted in pounds, shown from zero to 160 lbs. From the plot 901 , the maximum tension plateaus are 140 lbs., and the minimum tension plateaus are 30 lbs.
[0119] In 902 , the treatment angle is plotted versus time. The y-axis 920 is treatment angle, plotted in degrees. The y-axis 920 is centered about the initial treatment angle 923 , 12°, which is shown enlarged and bounded for clarity. In this embodiment of the present invention, 12° is the setting for the L5-S1 intervertebral space, and the first standard deviation of segmental angles for L5-S1 are plus and minus 1.5°. In this embodiment of the present invention, the bounds for dynamic angle adjustment are one standard deviation away from the spinal decompression device's designed treatment angles.
[0120] In 902 , as treatment is initiated, the healthcare provider is able to dynamically adjust tension for a period including up to the end of the first maximum tension plateau 921 . Beyond 921 , the ability to dynamically adjust treatment angle is disabled 922 , as set in software, in this embodiment of the present invention. As treatment is initiated, the healthcare provider dynamically adjust treatment angle downward 0.5° 924 . The healthcare provider then adjusts treatment angle 2° upwards to 13.0° 925 . The healthcare provider then adjusts treatment angle downwards to 12.5° 926 , where it is maintained for the rest of the treatment.
[0121] The current treatment angle 927 is displayed in a box to the right of 902 . This display 927 changes and is updated as treatment angle is changed.
[0122] In 903 , the measured tension 931 is displayed, as relayed by the loadcell 155 in this embodiment of the present invention but that may be relayed by any load or torque sensing device. The measured tension 931 is plotted against y-axis 930 in lbs. which is the same as scale 910 . It should be noted that, according to this embodiment of the present invention, measured tension 931 is the same as intended tension profile 911 , even during dynamic angle adjustment period 921 .
[0123] In 904 , tension correction 944 is displayed. Tension correction 944 is plotted against y-axis 940 in lbs. In the system 10 formed of one embodiment of the present invention, as treatment angle is adjusted downwards 924 , tension must be increased momentarily 941 to counteract changes in system dynamics and system mechanical advantages, keeping measured tension 931 the same as intended tension 911 . In the system 10 formed of one embodiment of the present invention, as treatment angle is adjusted upwards 925 , tension must be decreased momentarily 942 to counteract changes in system dynamics and system mechanical advantages, keeping measured tension 931 the same as intended tension 911 . In the system 10 formed of one embodiment of the present invention, as treatment angle is adjusted downwards 926 , tension must be increased momentarily 943 to counteract changes in system dynamics and system mechanical advantages, keeping measured tension 931 the same as intended tension 911 . Variations in the design of spinal decompression devices may change the way the system's 10 tension producing actuator 170 reacts to changes in treatment angle, as reflected in that particular system's 10 tension correction profile for a treatment period 904 .
[0124] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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A system for dynamically adjusting treatment angle under tension to accommodate variations in spinal morphology during spinal decompression therapy is provided. It provides a tensioning device including a patient-positioning means, a tension-producing actuator, a positioning device, a patient interface device, a control system and a display. The control system with feedback on the resultant tension vector applied to patient spine operationally configured to allow for adjustment of either tension producing actuator position, patient position, or both while applying tension to the patient spine during non-therapeutic tension levels. The control system automatically adjusts tension producing actuator work levels such that the resultant tension vector magnitude remains ideally constant during adjustment of resultant tension vector angle, reducing the risk of eliciting paraspinal muscle contraction due to changes in resultant tension vector magnitude.
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CLAIM OF PRIORITY
This application claims the benefit of priority from and is a divisional application of U.S. patent application Ser. No. 12/409,404, entitled “Multi-Carrier Communication Systems Employing Variable Symbol Rates and Number of Carriers” and filed Mar. 23, 2009 (now U.S. Pat. No. 8,923,431 issued on Dec. 30, 2014), which claims the benefit of priority from and is a divisional application of U.S. patent application Ser. No. 09/839,565, entitled “Multi-Carrier Communication Systems Employing Variable Symbol Rates and Number of Carriers” and filed Apr. 20, 2001 (now U.S. Pat. No. 7,397,859 issued on Jul. 8, 2008), which claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 60/199,049, entitled “Multi-Carrier Communication Systems Employing Variable Symbol Rates and Number of Carriers” and filed Apr. 22, 2000, all of which are fully incorporated herein by reference for all purposes and to the extent not inconsistent with this application.
BACKGROUND
1. Field of the Invention
The present invention is generally directed to communication systems and networks and is particularly directed to such systems and networks which use multi-carrier protocols such as orthogonal frequency division multiplexing and discrete multi-tone protocols, and to techniques for communicating there over.
2. Background of Related Art
Orthogonal frequency division multiplexing (OFDM) and discrete multi-tone (DMT) are two closely related formats which have become popular as communication protocols. Systems of this type take a relatively wide bandwidth communication channel and break it into many smaller frequency sub-channels. The narrower sub-channels are then used simultaneously to transmit data at a high rate. These techniques have advantages when the communication channel has multi-path or narrow band interference.
The following discussion of the prior art and the invention will address OFDM systems; however, it will be understood that the invention is equally applicable to DMT systems (as well as other types of communication systems) with only minor modifications that will be readily apparent to those skilled in the art.
A functional block diagram of a typical OFDM transmitter is shown in FIG. 1 . Here, an incoming stream 10 of N symbols d 0 , d 1 . . . d N-1 is mapped by a serial-to-parallel converter 20 over N parallel lines 30 , each line corresponding to a particular subcarrier within the overall OFDM channel. An Inverse Fast Fourier Transform (iFFT) processor 40 accepts these as frequency domain components and generates a set 50 of time domain subcarriers corresponding thereto. Each set of time domain subcarriers is considered a symbol. The rate at which these symbols are created determines the rate at which transitions are made on each of the individual carriers (one transmission per symbol time). The time domain subcarriers are converted by a parallel-to-serial converter 60 . Due to the characteristics of the inverse Fourier transform, although the frequency spectra of the subcarrier channels overlap, each subcarrier is orthogonal to the others. Thus, the frequency at which each subcarrier in the received signal is evaluated is one at which the contribution from all other signals is zero.
A functional block diagram of the corresponding OFDM receiver is shown in FIG. 2 . Here, an OFDM signal is received and converted into multiple time domain signals 210 by a serial-to-parallel converter 220 . These signals are processed by a Fast Fourier Transform (FFT) processor 230 before being multiplexed by parallel-to-serial converter 240 to recover the original data stream 250 .
FIG. 3 shows a plot of the transmitted frequency spectrum from an OFDM system. The number of carriers within the signal is determined by the size of the iFFT processor in the transmitter and corresponding size of the FFT processor in the receiver. The spacing of the individual carriers within the signal is dependent on the rate at which the iFFT symbols are generated (the symbol rate). This is generally proportional to the rate at which the iFFT and FFT processors are being clocked. Finally, the overall bandwidth occupied by the signal is roughly equivalent to the number of carriers multiplied by the carrier spacing.
The symbol rate is generally chosen to limit the effect of multi-path interference in the channel. When the rate of iFFT/FFT symbol generation is low, the rate of the symbols going over the channel is slow, and the carrier spacing is close. These slow symbols are long in time, much longer than the longest echoes within the multi-path delays of the channel. Therefore, it is possible to avoid or minimize the multi-path echoes, since they are much shorter than the data symbols themselves.
In some multi-carrier systems, the amount of power allocated to each carrier is varied according to the quality of the channel over which the signal will be sent. In addition, the complexity of the modulation constellation is also varied according to the channel on a per carrier basis. For example, some carriers may use 4-QAM modulation, while others use 16-QAM, 64-QAM or even more complex modulation. The more complex modulations allow more data to be transmitted in a single symbol or period of time. However, they require a much better signal to noise ratio in order to operate correctly. In other systems, it may be difficult to determine details about the channel, or the channel may change rapidly in time, such that this adaptation of the multi-carrier transmission is not practical. Rapidly changing channel conditions are common in radio communications.
Although some existing multi-carrier systems adapt the power allocation and modulation complexity as described above, existing multi-carrier systems maintain a constant number of carriers (constant size of the iFFT and FFT processors) and a constant carrier spacing (constant rate of iFFT/FFT symbol generation), and therefore a constant overall occupied bandwidth. The constant carrier spacing is chosen to insure that multi-path echoes are a small portion of the data symbol time in all possible channels that the communication system might encounter.
It is advantageous to minimize the number of carriers in use. The number of carriers is directly related to the size of the iFFT processor in the transmitter and corresponding FFT processor in the receiver. The complexity and power consumption of an iFFT or FFT processor increases as N*log(N), where N is the size of the processor, and therefore the number of carriers present in the signal. To limit complexity and particularly power consumption, it is therefore desirable to minimize the number of carriers in use. Additionally, it is desirable to generate the iFFT/FFT symbols at the highest rate possible. This increases the symbol rate, and thereby increases the data rate within the channel. Taken together, the goal of low complexity, low power, and high data rate pushes toward a system with few carriers and a high iFFT/FFT symbol generation rate. However, there is a limitation. As the symbol rate becomes higher, the symbols become shorter in time. For a given channel, the multi-path echoes will become a larger fraction of the symbol time, and will increasingly corrupt the communication. In addition, since the total bandwidth occupied is roughly equal to the number of carriers times the carrier spacing (proportional to the symbol rate), the overall occupied bandwidth may also increase as the symbol rate is increased.
Existing multi-carrier systems, which maintain a fixed number of carriers, a fixed symbol rate, and a fixed overall bandwidth, do not operate under optimal conditions. Because these fixed parameters must be chosen to accommodate the worst possible channel conditions, they are often far too conservative and not optimal for the channel currently available.
SUMMARY OF THE INVENTION
In view of the above problems of the prior art, an object of the present invention is to provide a multi-carrier system in which the number of carriers, the symbol rate, and thereby the overall occupied bandwidth can be varied. This can provide a more optimal combination of data rate, power consumption, and circuit complexity for a given channel.
It is another object of the present invention to provide a control system that regulates the operational mode of a multi-carrier system with regard to the number of carriers, symbol rate, and occupied bandwidth. This control system may operate based on a priori knowledge of the channel conditions (in response to a sounding of the channel), or in a trial and error fashion.
It is a further object of the present invention to provide a method for dynamically changing the number of carriers, symbol rate, and occupied bandwidth in a multi-carrier communication system on a packet-to-packet basis.
The above objects are achieved according to one aspect of the present invention by changing the size and clocking rate of iFFT and FFT processors used in a multi-carrier communication system as well as their surrounding circuits. Control signals for these changes in operation can be derived from a controlling circuit that has user inputs; results from channel sounding, a history of trial and error results, or information in the beginning of a received data packet.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features, and advantages of the present invention are better understood by reading the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of an OFDM transmitter according to the prior art;
FIG. 2 is a functional block diagram of an OFDM receiver according to the prior art;
FIG. 3 is a diagram of the spectrum of a transmitted OFDM waveform;
FIG. 4 is a diagram of the spectrum of the transmitted waveform when the symbol rate is doubled;
FIG. 5 is a diagram of the spectrum of the transmitted waveform when the size of the iFFT processor is doubled;
FIG. 6 shows a preferred embodiment of the present invention which changes the symbol rate with a frequency synthesizer;
FIG. 7 shows an embodiment which changes the symbol rate with a divider;
FIG. 8 shows an embodiment which changes the number of carriers with a single fixed iFFT processor;
FIG. 9 shows an embodiment which changes the number of carriers with a variable size iFFT processor block; and
FIG. 10 shows a controller unit that has a variety of control inputs for determining the symbol rate and number of carriers that is optimal for a given situation.
DETAILED DESCRIPTION
FIG. 4 shows the transmitted spectrum of an OFDM signal in which the symbol rate has been doubled in comparison to the one shown in FIG. 3 . The carrier spacing has doubled, as has the overall occupied bandwidth. Such a signal would be able to transmit at twice the data rate compared to the system in FIG. 3 . However, since the symbol rate has doubled and therefore the symbol duration halved, it would be more susceptible to multi-path echoes.
FIG. 5 shows the transmitted spectrum of an OFDM signal in which the number of carriers is doubled, but the symbol time remains constant. This approach also doubles the occupied bandwidth and the data rate relative to FIG. 3 . However, since the symbol rate is unchanged, it remains resistant to long multi-path echoes. Unfortunately, this approach requires more complex IFFT and FFT processors which consume more power and are more expensive to build.
For a given channel, there is an optimal occupied bandwidth, symbol rate, and thereby number of separate carriers. It is therefore beneficial to be able to vary both the symbol rate and the size of the iFFT processor according to the quality of the current channel.
Variable Symbol Rate
Many methods known in the art for changing a clock frequency can be used to change the symbol rate of the multi-carrier system. The following discussion describes several preferred embodiments for varying the symbol rate. As can be seen from the similarity of the transmitting circuit and receiving circuits in FIGS. 1 and 2 , almost any approach for changing the symbol rate at the transmitter can be used in a similar fashion at the receiver.
FIG. 6 shows a circuit for changing the OFDM symbol rate. In this circuit, a frequency synthesizer (or variable phase locked loop) is able to generate nearly any arbitrary frequency with which to clock the IFFT processor and its surrounding serial-to-parallel and parallel-to-serial converters. The advantage to this approach is the symbol rate can be finely adjusted to ideally optimize for a given channel. A disadvantage to this approach is that it takes a significant time for the synthesizer to change its frequency. Therefore, it would not be practical to have the synthesizer change frequency on a packet-by-packet basis in a fast communication system (situations in which changing the symbol rate on a packet-by-packet basis would be desired are presented later).
FIG. 7 shows a circuit for changing the symbol rate using dividers and multipliers. A multiplexer can be used in order to choose which of the circuits is used at a given time. In the drawing, the dividers have variable divide and multiplication amounts. In practice it might be desirable to use circuits that can only divide by fixed amounts, and select among several of them using a multiplexer as shown. The advantage to this approach is that the changing of clocking frequencies can be done very quickly and in a very well controlled way. This would allow the dynamic changing of symbol rate between packets, or even within packets in a communication system. The disadvantage to this approach is that the symbol rate cannot be as finely adjusted as in the case of a frequency synthesizer.
Variable Number of Carriers
There are a number of ways to change the number of carriers in active use. The following discussion illustrates several preferred embodiments for changing the number of carriers in active use. As before, almost any approach for changing the number of carriers at the transmitter can be used in a similar fashion at the receiver.
FIG. 8 shows an approach in which a single iFFT processor can be used without modification to generate a different number of carriers. The iFFT is designed to be sufficiently large enough to handle the maximum number of carriers that might ever be required. In any given situation, a subset of the carriers can be used by simply inputting zero magnitude signals on the carriers that are not to be used. This has the advantage of requiring little change to the overall circuitry and no change at all to the iFFT processor. The disadvantage is that the power savings from using a smaller number of carriers will be minimal.
Another approach is to implement a block of multiple complete iFFT processors of various sizes. For a given transmission, only one of these would be operated. This has the advantage that since only the appropriately-sized processor is in use, the power consumption will be minimized. Unfortunately, fabricating several different sizes of iFFT and FFT processors increases the complexity and thus the cost of the circuit.
FIG. 9 shows a circuit in which the iFFT processor itself has been designed to disable portions of its internal circuitry depending on how many carriers are active. Similarly, the serial-to-parallel and parallel-to-serial converters also alter their operation, so they act only on carriers that will actually be used at a given time. This allows the construction of one block of circuitry which operates in a power-efficient manner in all modes of operation.
In general, iFFT and FFT processor sizes come in powers of two. There are structures that can produce an arbitrary number of carriers, but these are less efficient. The number of carriers used can therefore be restricted to be a power of two, or the iFFT and FFT processors can be operated at the power of two size equal to or just larger than the number of carriers desired. The technique shown in FIG. 8 can then be used to trim this nearest power of two down to the actual desired size.
It is also possible to change the symbol rate and the number of carriers simultaneously. For example, if the channel could allow both a doubling of the symbol rate (due to low time delay in the multi-path echoes), and a quadrupling of the occupied bandwidth (due to an exceptionally broad channel or few other users to share with), it would make sense to simultaneously double the number of carriers and the symbol rate. These changes taken together would allow a quadrupling of the data rate in the channel.
Control of Symbol Rate and Number of Carriers
FIG. 10 shows a controller unit which accepts several inputs. Based on these inputs, the controller decides the appropriate symbol rate and number of carriers according to the techniques set forth below. Each of the inputs represents a factor that is important in the decision of what symbol rate and number of carriers is appropriate to use. For example, a timer input may be used to indicate to the controller that it should operate in a predetermined mode, such as legacy mode, for a period of time, while another input allows a user or higher protocol layer to arbitrarily force the controller to operate in a particular mode. Any number of inputs could be used, but the shown preferred approach combines the factors listed below. For convenience, in the following section the combination of symbol rate and number of carriers will be called the operating “mode.”
Setting the Operating Mode Based on Prior Knowledge
The desired operating mode may be based upon prior knowledge of the quality of the channel a node will encounter. For example, if a controller knows it has a very short (in terms of distance) communication channel with weak and short multi-path echoes, it can force the nodes on the network to operate with a high symbol rate. Similarly, if it knows there is a lot of spectrum available because the channel is wide and the channel bandwidth does not need to be shared with other systems, it can force the nodes in the network to operate with a high symbol rate (if there is little multi-path echo) or with many carriers (if there is significant multi-path echo).
It may be advantageous to set all nodes communicating in a given network to the same operating mode. This enables all nodes to understand all messages, and prevents them from having to quickly change from one operating mode to another. On the other hand, the channel between a given pair of nodes may be different than the channel between other pairs in the network. If this is known, and maximum efficiency is desired, it may be best to assign the operating mode on a pair-by-pair basis. Therefore, a given node may transmit in a different mode depending on which node it is transmitting to. This will require nodes to change modes, potentially on a packet-by-packet basis, depending on who is sending or receiving the current packet.
Setting the Operating Mode Based on Measurement
The best operating mode could be based on a trial “sounding” of the communications channel. The transmitter would send out a special signal (e.g., a reference signal having constant and known phase/magnitude characteristics that can be easily observed) or packet of information. The receiver would analyze this signal to determine the quality of the channel. Factors would include the multi-path delay as well as the total available bandwidth. These observations would be sent back to the original transmitter, presumably using a very robust mode of transmission, or at least a mode of transmission that is receivable for the channel in question. At this point, both nodes will be aware of the channel conditions. The channel sounding signal ideally would span the maximum bandwidth that the nodes would consider using. However, it may be possible to infer many things about the channel (such as multi-path echoes) using a narrower bandwidth signal. In addition, it may be possible to determine some channel degradations, such as if another node is using a portion of the channel, simply by listening to the channel.
It may be preferred not to send a unique channel sounding message for efficiency reasons. Instead, the nodes could transmit at a base mode, i.e., a mode which all nodes can understand, even in a worst-case scenario. Assuming that is successful, the nodes could move to more and more complex, and higher data rate, modes. Eventually when communication fails, they would have learned the highest rate at which communication can be achieved. The same process could be followed in reverse, starting from the highest mode and backing down to the lowest mode until transmission is successful.
Once the best mode for communication has been established between a particular pair of devices, this mode can be stored and used in the future without repeating the initial learning process. However, the channel may change over time, particularly if it is a radio channel. In that case, periodic relearning, or period experimenting to see which modes work or do not work, might be required.
Changing the Operating Mode on a Packet-by-packet Basis
There are several reasons to change the mode of communication on a packet-by-packet basis. At the receiver, a packet from one transmitting node may be followed by a packet from a different transmitting node. The channel may be different for the two transmitting nodes, and therefore they may have decided to use different modes for their transmission. In addition, the different transmitting nodes may have different capabilities, forcing them to employ different modes of transmission. In either case, the receiving node needs to quickly change its mode based on the arriving packet.
A preferred approach might be to have a short header on the packet that would be in a base mode that all nodes could receive and would always expect at the beginning of the packet. Within that header would be an indication of which mode the remainder of the packet will be in. The receiver would then quickly switch modes to receive the remainder of the packet.
Similarly, when transmitting, the mode may need to be adjusted on a packet-by-packet basis to accommodate different destinations. Different destinations may be through different channels with different bandwidths, multi-path echo, or interference from other users. In addition, a given destination might support only a subset of the available modes of the transmitter. In particular, previous generation devices may not support as many different modes as newer devices. In all cases, the transmitting node will need to be able to change modes for each packet destination. Preferably, it should signal the mode a particular packet is going to use in the header of the packet as described above.
Another way to support “legacy” nodes that do not operate in the newer modes is to have a period of time during which all nodes act in a legacy mode. This period of time can be fixed, or it can be determined by listening for legacy nodes to request service. For example, in a radio network, an access point or a base station could periodically send a message in a legacy mode asking if any nodes that can only operate in that mode require service. If it gets a response, the base station could then schedule a period of time of operation in the legacy mode so those nodes could accomplish their tasks.
Respecting Constraints
While a node has a tremendous number of possible modes to choose from, the controller unit should be sure to stay within certain constraints. One constraint would be the total consumed bandwidth. In radio systems, the FCC regulates the usage of the spectrum. The controlling circuit must insure that whatever mode is chosen will not violate FCC rules. Similarly, the FCC limits the spurious emissions that may emanate from wired communication systems. These limitations are dependent in part on the frequency of the spurious emissions. Once again it is important to limit the total bandwidth of the transmitted signal.
Another constraint described above is that all nodes may not support all modes. Broadcast messages, or any other messages that need to be received by multiple nodes, must be transmitted in a mode that all nodes to which they are directed are able to receive.
Communicating the Mode of Operation
One method for communicating the mode of operation, as disclosed above, is to signal it in the header of the packet. If nodes are not able to change modes very quickly (within the middle of a packet) it might be preferred to send a first short exchange establishing the mode at which the data communication will take place. This first short exchange would be done with a base mode of operation that all nodes support.
If the mode of operation will not be changed on a packet-by-packet basis, a user might manually configure all nodes in a network with a single operating mode, or with a table that describes the operating mode for each possible connection. On the other hand, the user might program only one node in such a manner and have other nodes learn of the desired node setting through communication with other nodes. For example, when a new node enters a network, it could learn of the operating mode by listening to the other nodes in the network, either seeing which operating mode they are in, or receiving a packet header or special packet. The special packet might indicate what mode they are in or might contain the complete table of which nodes employ which modes of operation. The packet header or special packet could be transmitted in some base mode that all nodes are guaranteed to support.
The present invention has been described above in connection with preferred embodiments thereof however, this has been done for purposes of illustration only, and the invention is not so limited. Indeed, variations of the invention will be readily apparent to those skilled in the art and also fall within the scope of the invention. For example, although preferred embodiments of the present invention are implemented using a wireless communication medium, it will be readily apparent to those skilled in the art that it may be applied to a number of other communication media with similar benefits. Such variations also fall within the scope of the claims appended hereto.
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A multi-carrier communication system such as an OFDM or DMT system has nodes which are allowed to dynamically change their receive and transmit symbol rates, and the number of carriers within their signals. Changing of the symbol rate is done by changing the clocking frequency of the nodes' iFFT and FFT processors, as well as their serializers and deserializers. The nodes have several ways of dynamically changing the number of earners used. The selection of symbol rate and number of earners can be optimized for a given channel based on explicit channel measurements, a priori knowledge of the channel, or past experience. Provision is made for accommodating legacy nodes that may have constraints in symbol rate or the number of carriers they can support. The receiver can determine the correct symbol rate and number of earners through a priori knowledge, a first exchange of packets in a base mode that all nodes can understand, or an indication in the header of the data packet which is transmitted in a base mode of operation that all nodes can understand.
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FIELD OF THE INVENTION
[0001] The present invention relates to a space partitioning member, and more particularly to a convenient and portable space partitioning member.
BACKGROUND OF THE INVENTION
[0002] A space partitioning member is a popular device that is used for partitioning a space of a specific area such as an office or a family house to create a privacy for an office worker. A space partitioning member can also be used for implementing a flexibility of space if an element of the space partitioning member can be assembled with other elements of the space partitioning member. However, the assembly of the space partitioning member is tended to be difficult because of its weight and its complexity of elements.
[0003] Therefore, there are drawbacks of heavy weight and complexity for building a conventional space partitioning member.
SUMMARY OF THE INVENTION
[0004] Therefore, an object of the present invention is to provide a light weight, easy storage and easy installation of a convenient and portable space partitioning device. A partitioning frame, having an upper frame member, a lower frame member, and two side frame members joined between the upper frame member and the lower frame member, and a hallow space being provided between the upper frame member and the lower frame member. A partitioning cover body, covering an outer surface of the partitioning frame member, the partitioning cover body having a zipper on both edges of the partitioning frame member, the zipper having a sliding fastener on at least one edge of the partitioning frame member, and the partitioning cover body being bonded to another one of the adjacent partitioning cover body by the zipper and the sliding fastener.
[0005] According to the present invention, wherein both ends of the upper frame member are welded with the two side frame members.
[0006] According to the present invention, wherein the side frame member includes a first side frame element and a second side frame element, and the first side frame element has a first engaging portion which is joined with a second engaging portion of the second side frame element.
[0007] According to the present invention, wherein the first side frame element and the second side frame element are joined by a side frame extension element provided therebetween.
[0008] According to the present invention, wherein the partitioning cover body is a cloth body.
[0009] According to the present invention, wherein the upper frame member, the lower frame member and the two side frame members are a hollow tubular body.
[0010] According to the present invention, wherein the space of the partitioning frame member is provided with a soundproofing member.
[0011] According to the present invention, wherein the space of the partitioning frame member is provided with a magnetic boards.
[0012] According to the present invention, wherein one edge of the partitioning cover body has a plurality of the zippers, and there is provided between the partitioning cover body and the adjacent partitioning cover body with the sliding fastener which correspond to the plurality of the zippers.
[0013] According to the present invention, wherein the partitioning frame member has a foot, the foot is pivotally connected to the bottom of side frame member.
[0014] According to the present invention, wherein the partitioning frame has a hallow space so as the characteristic of the partitioning frame is light weight. Further, the partitioning cover body is easily removed from the partitioning frame member and folded, so the storage of the partitioning cover body is smoothly. In the preferred embodiment, the partitioning frame can be removed, so the storage of the partitioning frame more convenient. Moreover, the partitioning cover body is bonded to another the adjacent partitioning cover body by the zipper. Multiple convenient and portable space partitioning devices are assembled easily to achieve the effect of simple separated space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The structure and the technical means applied by the present invention for achieving the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings.
[0016] FIG. 1 is a schematic stereogram illustrating an embodiment of convenient and portable space partitioning device according to the present invention.
[0017] FIG. 2 is a schematic exploded view illustrating an embodiment of convenient and portable space partitioning device according to the present invention.
[0018] FIG. 3 is an enlarged view illustrating a schematic part of zipper in an embodiment of convenient and portable space partitioning member which is enlarged from part A of FIG. 2 , in the present invention.
[0019] FIG. 4 a is a schematic exploded stereogram illustrating another embodiment of partitioning frame member of convenient and portable space partitioning device according to the present invention.
[0020] FIG. 4 b is a schematic exploded stereogram illustrating another embodiment of partitioning frame member of convenient and portable space partitioning device according to the present invention.
[0021] FIG. 4 c is a schematic stereogram illustrating another embodiment of partitioning frame member of convenient and portable space partitioning device according to the present invention.
[0022] FIG. 4 d is a schematic stereogram illustrating another embodiment of partitioning frame member of convenient and portable space partitioning device according to the present invention.
[0023] FIG. 5 a is a schematic stereogram illustrating another embodiment of partitioning frame member of convenient and portable space partitioning device according to the present invention.
[0024] FIG. 5 b is a schematic stereogram illustrating another embodiment of convenient and portable space partitioning device according to the present invention.
[0025] FIG. 6 a to FIG. 6 f is schematic top views illustrating another embodiment of convenient and portable space partitioning device according to the present invention.
[0026] FIG. 7 a is a schematic stereogram illustrating another embodiment of convenient and portable space partitioning device according to the present invention.
[0027] FIG. 7 b is a schematic stereogram illustrating another embodiment of convenient and portable space partitioning device according to the present invention.
[0028] FIG. 7 c is a schematic stereogram illustrating another embodiment of convenient and portable space partitioning device according to the present invention.
[0029] FIG. 8 a is a schematic stereogram illustrating another embodiment of convenient and portable space partitioning device according to the present invention.
[0030] FIG. 8 b is a schematic stereogram illustrating another embodiment of convenient and portable space partitioning device according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The detailed description of the invention which follows is made with reference to the drawings and in terms of a preferred embodiment of the invention. The detailed description is not intended to limit the scope of the present invention, and the only limitations intended are those embodied in the claims hereto.
[0032] Please refer to FIG. 1 FIG. 2 and FIG. 3 . FIG. 1 is a schematic stereogram illustrating an embodiment of convenient and portable space partitioning device according to the present invention. FIG. 2 is a schematic exploded view illustrating an embodiment of convenient and portable space partitioning device according to the present invention. FIG. 3 is an enlarged view illustrating a schematic part of zipper in an embodiment of convenient and portable space partitioning member which is enlarged from part A of FIG. 2 , in the present invention. A convenient and portable space partitioning device 100 according to the present invention includes a partitioning frame member 1 and a partitioning cover body 2 . The partitioning cover body 2 covers an outer surface of the partitioning frame 1 . The material of the partitioning cover body 2 may be made of a cotton cloth, a wool cloth body, or a plastic cloth body.
[0033] The partitioning frame member 1 has an upper frame member 11 , a lower frame member 12 , a side frame member 13 a joined between one side of the upper frame member 11 and the lower frame member 12 , and another side frame member 13 b joined between the other side of the upper frame member 11 and the lower frame member 12 . At the bottom of the side frame member 13 a and a bottom of the side frame member 13 b, there are provided a foot portion 14 respectively. The side frame member 13 a includes a first side frame element 131 a and a second side frame element 132 a, and the side frame member 13 b includes a first side frame element 131 b and a second side frame element 132 b.
[0034] The two ends of the upper frame member 11 are welded to join with the first side frame element 131 a and the first side frame element 131 b, and the two ends of the lower frame member 12 are welded to join with the second side frame element 132 a and the second side frame element 132 b. The first side frame element 131 a is provided with a first engaging portion 133 a to join with a second engaging portion 134 a of the second side frame element 132 a. The first side frame element 131 b is provided with a first engaging portion 133 b to join with a second engaging portion 134 b of the second side frame element 132 b. Moreover, a hallow space S is allocated within the upper frame member 11 , the lower frame member 12 , the side frame member 13 a , and the side frame member 13 b. The upper frame member 11 , the lower frame member 12 , the side frame member 13 a , and the side frame member 13 b are elements such as hallow tubes, so the weight of the convenient and portable space partitioning device 100 is lighter.
[0035] As an embodiment of the present invention, in FIG. 2 , the partitioning cover body 2 is a cloth body which is a rectangular hollow cover. In FIG. 3 , one edge of the partitioning cover body 2 is provided with two zippers 21 . The zipper 21 in one edge of the partitioning cover body 2 is provided with a sliding fastener 22 . Alternatively, there are two zippers 21 each with one sliding fastener 22 in both edges of the partitioning cover body 2 . The zipper 21 is provided in an extension element 23 which extends from the partitioning cover body 2 . The inner of the partitioning cover body 2 forms a containing space to cover the partitioning frame member 1 . At lateral edge of the partitioning cover body is provided an opening facing toward the lower frame member 12 . The opening is for covering the containing space of the partitioning cover body 2 .
[0036] In another embodiment of the present invention, there is provided with one zipper or more than two zippers in an edge of the partitioning cover body. There is a sliding fastener provided between one partitioning cover body and the adjacent partitioning cover body. One sliding fastener corresponds to one zipper or more zippers, which is not shown. The two adjacent partitioning cover bodies bond together with the sliding fastener which corresponds to one zipper or more zippers.
[0037] Please refer to FIG. 4 a , which is a schematic exploded stereogram illustrating another embodiment of the present invention. As shown in the embodiment, the partitioning frame 1 a of the convenient and portable space partitioning member 100 a has a upper frame member 11 , a lower frame member 12 , a side frame member 13 c joined between one side of the upper frame member 11 and the lower frame member 12 , and a side frame member 13 d joined between another side of the upper frame member 11 and the lower frame member 12 . The side frame member 13 c includes a first side frame element 131 c, a second side frame element 132 c, and a side frame extension element 135 a. The side frame member 13 d includes a first side frame element 131 d, a second side frame element 132 d, and a side frame extension element 135 b. The two ends of the upper frame member 11 are welded to join the first side frame element 131 c and the first side frame element 131 d . The two ends of the lower frame member 12 are welded to join between the second side frame element 132 c and the second side frame element 132 d. The first side frame element 131 c is provided with a first engaging portion 133 c, which joins with a third engaging portion 137 a of the side frame extension element 135 a. The second side frame element 132 c provided with a second engaging portion 134 c, which joins with a forth engaging portion 138 a of the side frame extension element 135 a. Moreover, the first side frame element 131 d is provided with a first engaging portion 133 d, which joins with a third engaging portion 137 b of the side frame extension element 135 b . The second side frame element 132 d provided with a second engaging portion 134 d, which joins with a forth engaging portion 138 b of the side frame extension element 135 b. The convenient and portable space partitioning member 100 a can be adjusted by applying above method to provide different height and/or width.
[0038] Moreover, please refer to FIG. 4 b , which is a schematic exploded stereogram illustrating another embodiment of the present invention. The partitioning frame lb of the convenient and portable space partitioning member 100 b has an upper frame member 11 , a lower frame member 12 , a side frame member 13 e joined between one side of the upper frame member 11 and the lower frame member 12 . A side frame member 13 f is joined between another side of the upper frame member 11 and the lower frame member 12 . The side frame member 13 e includes a first side frame element 131 e and a second side frame element 132 e. The side frame member 13 f includes a first side frame element 131 f and a second side frame element 132 f. A transverse accessory 136 is welded between the first side frame element 131 e and the first side frame element 131 f. Therefore, the transverse accessory 136 strengthens the whole structure of the convenient and portable space partitioning member 100 b.
[0039] Please refer to FIG. 4 c , which is a schematic exploded stereogram illustrating another embodiment of the present invention. As shown in the embodiment, the partitioning frame 1 c of the convenient and portable space partitioning member 100 c has an upper frame member 11 , a lower frame member 12 , a side frame member 13 g, a side frame member 13 h, and a transverse accessory 136 welded between the side frame member 13 g and the side frame member 13 h. A soundproofing member 3 is provided with the lower frame member 12 , the side frame member 13 g, the side frame member 13 h, and the transverse accessory 136 . Another soundproofing member 3 a is provided with the upper frame member 11 , the side frame member 13 g, the side frame member 13 h, and the transverse accessory 136 . The material of the soundproofing member is foam material.
[0040] Please refer to FIG. 4 d , which is a schematic exploded stereogram illustrating another embodiment of the present invention. As shown in the embodiment, the partitioning frame 1 c of the convenient and portable space partitioning member 100 d has an upper frame member 11 , a lower frame member 12 , a side frame member 13 i, a side frame member 13 j, and a transverse accessory 136 welded between the side frame member 13 i and the side frame member 13 j . A magnetic board 4 is provided with the lower frame member 12 , the side frame member 13 i, the side frame member 13 j, and the transverse accessory 136 . A magnetic board 4 a is provided with the upper frame member 11 , the side frame member 13 i, the side frame member 13 j, and the transverse accessory 136 . The magnetic board is a hard magnetic material or a soft magnetic material. Preferably, the thickness of the magnetic board is less than 0.3 centimeter. The best thickness of the magnetic board is 0.1 centimeter. A magnetic substance is applied to attach one object on the magnetic board.
[0041] Please refer to FIG. 5 a , which are schematic exploded stereogram explosion views illustrating another embodiment of the present invention. As shown in the embodiment, the space partitioning member of the present invention having a plurality of the adjacent partitioning cover bodies is extended by bonding a plurality of the zippers and the slide fastener slider with each other to form a spread state. Moreover, please refer to FIG. 5 b , which are schematic exploded stereogram views illustrating another embodiment of the present invention. As shown in the embodiment, the adjacent partitioning cover bodies with different heights, such as the partitioning cover body 2 b and the partitioning cover body 2 c , are bonded with each other by applying a plurality of the zippers and the sliding fastener.
[0042] Please refer to FIG. 6 a to FIG. 6 f , which are schematic top views illustrating another embodiment of the present invention. As shown in the embodiment, the adjacent partitioning cover bodies are formed with diverse modes by applying a plurality of the zippers 21 and the sliding fastener bonded with each other. The diverse mode includes as the bonding of two adjacent partitioning cover bodies, three adjacent partitioning cover bodies, four adjacent partitioning cover bodies, and five adjacent partitioning cover bodies. Further, please refer to FIG. 6 b and FIG. 6 c , the adjacent partitioning cover bodies can be implemented by adjusting angle (0-360°) between each other. The convenient and portable space partitioning device can be grounded on the floor as a plurality of the adjacent partitioning cover bodies 2 are bonded by the zippers and the sliding fastener.
[0043] Please refer to FIG. 7 a to FIG. 7 c , which are schematic views illustrating another embodiment of the present invention. The single convenient and portable space partitioning device or the bonded convenient and portable space partitioning devices can be grounded on the floor with a foot 15 . The foot 15 has a perpendicular portion 151 . A foot wed 152 is pivotally connected to the bottom of side frame member 13 k. The plastic film is covered in the inner wall of the perpendicular portion 151 to avoid scraping the side frame member 13 k. The connecting angle between the foot 15 and the side frame member 131 can be adjusted according to any specific space. Preferably, the angle of the foot 15 is fixed by screws. In another embodiment, the foot wed 152 a is provided with two rollers 153 and 153 a. In the other embodiment, the foot base 16 is pivotally to the foot base roller 161 .
[0044] Please refer to FIG. 8 a , which are schematic views illustrating another embodiment of the present invention. The convenient and portable space partitioning device 100 j further includes a corner retaining member 5 . The adjacent convenient and portable space partitioning devices are formed perpendicular to each other by the corner retaining member 5 having a corner fixing member 51 and a corner fixing member 52 . Moreover, as shown FIG. 8 b , a message board 6 is provided on the partitioning cover body 2 h for human to record messages.
[0045] The above description should be considered as only the discussion of the preferred embodiments of the present invention. However, a person skilled in the art may make various modifications to the present invention. Those modifications still fall within the spirit and scope defined by the appended claims.
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A convenient and portable space partitioning device comprises a partitioning frame, having an upper frame member, a lower frame member, and two side frame members joined between the upper frame member and the lower frame member, and a hallow space being provided between the upper frame member and the lower frame member. A partitioning cover body, covering an outer surface of the partitioning frame member, is easily removed from the partitioning frame member, while the partitioning cover body and the partitioning frame member are stored conveniently. Moreover, the partitioning cover body has a zipper on both edges of the partitioning frame member, the zipper having a sliding fastener on at least one edge of the partitioning frame member, and the partitioning cover body being bonded to another one of the adjacent partitioning cover body by the zipper and the sliding fastener.
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The present application claims the priority benefit of U.S. provisional application Nos. 61/658,616, filed Jun. 12, 2012, and 61/661,641, filed Jun. 19, 2012, each of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to transgenic fish, particularly green transgenic fish.
2. Description of Related Art
Transgenic technology involves the transfer of a foreign gene into a host organism enabling the host to acquire a new and inheritable trait. Transgenic technology has many potential applications. For example, it can be used to introduce a transgene into a fish in order to create new varieties of fish. There are many ways of introducing a foreign gene into fish, including: microinjection (e.g., Zhu et al., 1985; Du et al., 1992), electroporation (Powers et al., 1992), sperm-mediated gene transfer (Khoo et al., 1992; Sin et al., 1993), gene bombardment or gene gun (Zelenin et al., 1991), liposome-mediated gene transfer (Szelei et al., 1994), and the direct injection of DNA into muscle tissue (Xu et al., 1999). The first transgenic fish report was published by Zhu et al., (1985) using a chimeric gene construct consisting of a mouse metallothionein gene promoter and a human growth hormone gene. Most of the early transgenic fish studies have concentrated on growth hormone gene transfer with an aim of generating fast growing fish. While a majority of early attempts used heterologous growth hormone genes and promoters and failed to produce these fish (e.g. Chourrout et al., 1986; Penman et al., 1990; Brem et al., 1988; Gross et al., 1992), enhanced growth of transgenic fish has been demonstrated in several fish species including Atlantic salmon, several species of Pacific salmons, and loach (e.g. Du et al., 1992; Delvin et al., 1994, 1995; Tsai et al., 1995).
The black skirt tetra ( Gymnocorymbus ternetzi ) has been commercially cultured in the United States at least as early as 1950 (Innes, 1950). However, for the ornamental fish industry the dark striped pigmentation of the adult black skirt tetra does not aid in the efficient display of the various colors. The albino black skirt tetra, or “white tetra” is a variant that arose during domestication and shows decreased pigmentation. The availability of such fish having modified pigmentation for transgenesis with fluorescent proteins would result in better products for the ornamental fish industry due to better visualization of the various colors.
Many fluorescent proteins are known in the art and have been used to investigate various cellular processes, including fluorescent proteins exhibiting various green, red, yellow, blue, or purple colors. Although transgenic experiments involving fluorescent proteins have provided new markers and reporters for transgenesis, progress in the field of developing and producing ornamental fish that express such proteins has been limited.
SUMMARY OF THE INVENTION
In certain embodiments, the present invention concerns making transgenic fluorescent fish and providing such fish to the ornamental fish industry.
In some embodiments, transgenic fish or methods of making transgenic fish are provided. In certain aspects, the transgenic fish are fertile, transgenic, fluorescent fish. In a particular embodiment, the fish for use with the disclosed constructs and methods is the white tetra. Tetra skin color is determined by pigment cells in their skin, which contain pigment granules called melanosomes (black or brown color), xanthosomes (yellow color), erythrosomes (orange or red color), or iridosomes (iridescent colors, including white color). The number, size, and density of the pigment granules per pigment cell influence the color of the fish skin. White tetra have diminished number, size, and density of melanosomes and hence have lighter skin when compared to the wild type black skirt tetra.
In certain specific embodiments there are provided transgenic tetra or progeny thereof comprising specific transgenic integration events, referred to herein as transformation events. These fish are of particular interest because, for example, they embody an aesthetically pleasing green color. Transgenic fish comprising these specific transgenic events may be homozygous or heterozygous (including, for example, hemizygous) for the transformation event. Homozygous fish bred with fish lacking a transformation event will in nearly all cases produce 100% heterozygous offspring. Eggs, sperm, and embryos comprising these specific transgenic events are also included as part of the invention.
In one such embodiment regarding a specific transgenic integration event, a green transgenic tetra or progeny thereof is provided comprising chromosomally integrated transgenes, wherein the tetra comprises the “Green tetra 1 transformation event,” sperm comprising the Green tetra 1 transformation event having been deposited as ECACC accession no. 12061301. The chromosomally integrated transgenes may be present on one integrated expression cassette or two or more integrated expression cassettes. In certain aspects, such a transgenic tetra is a fertile, transgenic tetra. In more specific aspects, such a tetra is a transgenic White tetra. Such a transgenic tetra may be homozygous or heterozygous (including, for example, hemizygous) for the transgenes or integrated expression cassette(s).
Also disclosed are methods of providing a transgenic tetra comprising the Green tetra 1 transformation event to the ornamental fish market. In some embodiments, the method comprises obtaining a transgenic tetra or progeny thereof comprising chromosomally integrated transgenes, wherein the tetra comprises the “Green tetra 1 transformation event,” sperm comprising the Green tetra 1 transformation event having been deposited as ECACC accession no. 12061301, and distributing the fish to the ornamental fish market. Such fish may be distributed by a grower to a commercial distributor, or such fish may be distributed by a grower or a commercial distributor to a retailer such as, for example, a multi-product retailer having an ornamental fish department.
In some aspects, methods of producing a transgenic tetra are provided comprising: (a) obtaining a tetra that exhibits fluorescence and comprises one or more chromosomally integrated transgenes or expression cassettes, wherein the tetra comprises the “Green tetra 1 transformation event,” sperm comprising the Green tetra 1 transformation event having been deposited as ECACC accession no. 12061301; and (b) breeding the obtained tetra with a second tetra to provide a transgenic tetra comprising the Green tetra 1 transformation event. The second tetra may be a transgenic or non-transgenic tetra.
In further embodiments, also provided are methods of producing a transgenic organism, the method comprising using sperm comprising the Green tetra 1 transformation, such sperm having been deposited as ECACC accession no. 12061301, to produce transgenic offspring. Such offspring may be, for example, a tetra, a species of the Gymnocorymbus genus, a fish species or genus related to tetra, or another fish species or genus. In some aspects, the fish may be produced using in vitro fertilization techniques known in the art or described herein.
As used in this specification, “a” or “an” may mean one or more. As used herein in the claim(s), when used in conjunction with the word “comprising,” the words “a” or “an” may mean one or more than one.
The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” As used herein “another” may mean at least a second or more.
Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.
Any embodiment of any of the present methods, kits, and compositions may consist of or consist essentially of—rather than comprise/include/contain/have—the described features and/or steps. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” may be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb.
Other objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
DETAILED DESCRIPTION OF THE INVENTION
Transgenic Fish
In some aspects, the invention regards transgenic fish. Methods of making transgenic fish are described in, for example, U.S. Pat. Nos. 7,135,613; 7,700,825; 7,834,239, each of which is incorporated by reference in its entirety.
It is preferred that fish belonging to species and varieties of fish of commercial value, particularly commercial value within the ornamental fish industry, be used. Such fish include but are not limited to catfish, zebrafish and other danios, medaka, carp, tilapia, goldfish, tetras, barbs, sharks (family Cyprinidae ), angelfish, loach, koi, glassfish, catfish, discus, eel, tetra, goby, gourami, guppy, Xiphophorus, hatchet fish, Molly fish, or pangasius. A particular fish for use in the context of the invention is a tetra, Gymnocorymbus ternetzi . Tetra are increasingly popular ornamental animals and would be of added commercial value in various colors. Tetra embryos are easily accessible and nearly transparent. A fish that is of particular use with the disclosed constructs and methods is the White Tetra. Tetra skin color is determined by pigment cells in the skin, which contain pigment granules called melanosomes. The number, size, and density of the melanosomes per pigment cell influence the color of the fish skin. White Tetra have diminished number, size, and density of melanosomes and hence have lighter skin when compared to the wild type tetra.
Fertilization from Frozen Sperm
Fish sperm freezing methods are well-known in the art; see, e.g., Walker and Streisinger (1983) and Draper and Moens (2007), both of which are incorporated herein by reference in their entireties. To obtain the transgenic fish disclosed herein, frozen tetra sperm may be used to fertilize eggs.
Briefly, one or two breeding pairs of tetra should be placed in a shoebox with an artificial spawning mat. The water level in the shoebox should be ˜2-3 inches and kept at 75-85° F. Low salinity (conductivity 100-200 uS/cm) and slight acidity (˜pH 6.9) promote spawning. The fish may be exposed to a natural or artificial light cycle; the photoperiod starts at 8 am and ends at 10 pm. The following morning, remove and discard the eggs. Tetra may be anesthetized by immersion in tricaine solution at 16 mg/100 mL water. After gill movement has slowed, remove one female, rinse it in water, and gently blot the belly damp-dry with a paper towel. The eggs should not be exposed to water as this will prevent fertilization. Gently squeeze out the eggs onto a slightly concave surface by applying light pressure to the sides of the abdomen with a thumb and index finger and sliding the fingers to the genital pore. Ready to spawn females will release the eggs extremely easily, and care should be taken not to squeeze the eggs out while blotting the fish. Good eggs are yellowish and translucent; eggs that have remained in the female too long appear white and opaque. The females will release the eggs only for an hour or so. Eggs from several females may be pooled; the eggs can be kept unfertilized for several minutes. The sperm is thawed at 33° C. in a water bath for 18-20 seconds. 70 μl room temperature Hanks solution is added to the vial and mixed. The sperm is then immediately added to the eggs and gently mixed. The sperm and eggs are activated by adding 750 μl of fish water and mixing. The mixture is incubated for 5 minutes at room temperature. The dish is then filled with fish water and incubated at 28° C. After 2-3 hours, fertile embryos are transferred to small dishes where they are further cultured.
Parichy and Johnson, 2001, which is incorporated by reference in its entirety, provides additional examples regarding in vitro fertilization.
The invention further encompasses progeny of a transgenic fish containing the Green tetra 1 transformation event, as well as such transgenic fish derived from a transgenic fish egg, sperm cell, embryo, or other cell containing a genomically integrated transgenic construct. “Progeny,” as the term is used herein, can result from breeding two transgenic fish of the invention, or from breeding a first transgenic fish of the invention to a second fish that is not a transgenic fish of the invention. In the latter case, the second fish can, for example, be a wild-type fish, a specialized strain of fish, a mutant fish, or another transgenic fish. The hybrid progeny of these matings have the benefits of the transgene for fluorescence combined with the benefits derived from these other lineages.
The simplest way to identify fish containing the Green tetra 1 transformation event is by visual inspection, as the fish in question would be green colored and immediately distinguishable from non-transgenic fish.
EXAMPLES
Certain embodiments of the invention are further described with reference to the following examples. These examples are intended to be merely illustrative of the invention and are not intended to limit or restrict the scope of the present invention in any way and should not be construed as providing conditions, parameters, reagents, or starting materials that must be utilized exclusively in order to practice the art of the present invention.
Example 1
Green Transgenic Tetra
Transgenic fish exhibiting a green color are provided. The specific transgenic events embodied in these fish are designated Green tetra 1. Sperm from these fish may be used to fertilize tetra eggs and thereby breed transgenic tetra that comprise these specific transgenic integration events. Sperm from this line is being deposited at the European Collection of Cell Cultures (ECACC), Porton Down, Salisbury, SP4 OJG, United Kingdom, under the provisions of the Budapest Treaty as “Green tetra 1” (accession no. 12061301).
The fluorescent transgenic fish have use as ornamental fish in the market. Stably expressing transgenic lines can be developed by breeding a transgenic individual with a wild-type fish, mutant fish, or another transgenic fish. The desired transgenic fish can be distinguished from non-transgenic fish by observing the fish in white light, sunlight, ultraviolet light, blue light, or any other useful lighting condition that allows visualization of the green color of the transgenic fish.
The fluorescent transgenic fish should also be valuable in the market for scientific research tools because they can be used for embryonic studies such as tracing cell lineage and cell migration. Additionally, these fish can be used to mark cells in genetic mosaic experiments and in fish cancer models.
***
All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit and scope of the invention. More specifically, it will be apparent that certain agents that are both chemically and physiologically related may be substituted for the agents described herein while the same or similar results would be achieved. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the invention as defined by the appended claims.
References
The following references, to the extent that they provide exemplary procedural or other details supplementary to those set forth herein, are specifically incorporated herein by reference.
U.S. Pat. No. 7,135,613 U.S. Pat. No. 7,700,825 U.S. Pat. No. 7,834,239 Brem et al., Aquaculture, 68:209-219, 1988. Chourrout et al., Aquaculture, 51:143-150, 1986. Delvin et al., Nature, 371:209-210, 1994. Draper and Moens, In: The Zebrafish Book, 5 th Ed.; Eugene, University of Oregon Press, 2007. Du et al., Bio/Technology, 10:176-181, 1992. Innes, W. T., Exotic Aquarium Fishes: A work of general reference, Innes Publishing Company, Philadelphia, 1950. Gross et al., Aquaculture, 103:253-273, 1992. Khoo et al., Aquaculture, 107:1-19, 1992. Lamason et al., Science, 310 (5755):1782-1786, 2005. Penman et al., Aquaculture, 85:35-50, 1990. Powers et al., Mol. Marine Biol. Biotechnol., 1:301-308, 1992. Sin et al., Aquaculture, 117:57-69, 1993. Szelei et al., Transgenic Res., 3:116-119, 1994. Tsai et al., Can. J. Fish Aquat. Sci., 52:776-787, 1995. Walker and Streisinger, Genetics 103: 125-136, 1983. Xu et al., DNA Cell Biol., 18, 85-95, 1999. Zelenin et al., FEBS Lett., 287 (1-2):118-120, 1991. Zhu et al., Z. Angew. Ichthyol., 1:31-34, 1985.
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The present invention relates to transgenic green ornamental fish, as well as methods of making such fish by in vitro fertilization techniques. Also disclosed are methods of establishing a population of such transgenic fish and methods of providing them to the ornamental fish industry for the purpose of marketing.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a locking device, and more particularly to locking device for securing an inner tube in an outer tube of a telescopic tube assembly.
[0003] 2. Description of Related Art
[0004] With reference to FIG. 6 , a conventional locking device ( 30 ) for a telescopic tube assembly having an outer tube ( 40 ) and an inner tube ( 41 ) slidably received in the outer tube ( 40 ) includes a knob ( 31 ) rotatably mounted on a side of the locking device ( 30 ).
[0005] When the relative position of the inner tube ( 41 ) is to be readjusted in relation to the outer tube ( 40 ), the operator has to hold the inner tube ( 41 ) to prevent the inner tube ( 41 ) from slipping too far into the outer tube ( 40 ). Then the operator is able to unscrew the knob ( 51 ) and change the relative position of the inner tube ( 41 ) to the outer tube ( 40 ). However, when a distal end of the inner tube ( 41 ) is provided with a heavy load, e.g., an illuminating device, it is impossible for the operator to hold the weight of the illuminating device. Therefore, assistance from the others becomes essential. That is, it is almost impossible for a lone operator to finish the adjustment of the telescopic tube assembly especially when a weighty object is mounted on the top of the telescopic tube assembly.
[0006] With reference to FIG. 7 , a second conventional locking device for a telescopic tube assembly having an outer tube ( 50 ) and an inner tube ( 51 ) slidably received in the outer tube ( 50 ) includes a sleeve ( 60 ) screwingly connected to the outer tube ( 50 ), a stopping sleeve ( 61 ) formed on a distal end of the inner tube ( 51 ) and a C clip ( 62 ) provided between the outer tube ( 50 ) and the inner tube ( 51 ).
[0007] When this conventional locking device is in application, the stopping sleeve ( 61 ) engages with an inner face of the outer tube ( 50 ) to stop relative movement between the inner tube and the outer tube ( 50 , 51 ). Furthermore, the deformation of the C clip ( 62 ) by the rotation of the sleeve ( 60 ) enhances the immovability of the inner tube ( 51 ) relative to the outer tube ( 50 ). Therefore, unscrewing the sleeve ( 60 ) enables the operator to adjust the relative position of the inner tube ( 51 ) to the outer tube ( 50 ).
[0008] With reference to FIG. 8 , another conventional locking device for a telescopic tube assembly having an outer tube ( 70 ) and an inner tube ( 71 ) slidably received in the outer tube ( 70 ) includes an engaging sleeve ( 72 ) for preventing the inner tube ( 71 ) separating from the outer tube ( 70 ), multiple resilient straps ( 73 ) mounted on the outer periphery of the inner tube ( 71 ) to engage with the inner periphery of the outer tube ( 70 ), a spring ( 74 ) mounted on the bottom of the inner tube ( 71 ) and a muffler ( 75 ) received in the outer tube ( 70 ) to-diminish the noise from the engagement between the resilient straps ( 73 ) and the inner periphery of the outer tube ( 70 ).
[0009] Despite the different structure of the three conventional locking devices, there is a common drawback that hinders the performance of the locking devices. That is, the friction force to prevent the inner tube from falling into the outer tube becomes weaker and weaker each time the relative position between the inner tube and the outer tube is adjusted.
[0010] To overcome the shortcomings, the present invention tends to provide an improved locking device to mitigate the aforementioned problems.
SUMMARY OF THE INVENTION
[0011] The primary objective of the present invention is to provide an improved locking device to enable the operator to safely finish the adjustment of the relative position of the inner tube relative to the outer tube with ease.
[0012] Another objective of the present invention is that the locking device of the present invention is able to increase the friction with the inner periphery of the outer tube so as to support the inner tube inside the outer tube.
[0013] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an exploded perspective view of the locking device applied on a stand;
[0015] FIG. 2 is schematic perspective view showing that the telescopic tube assembly is used to support a microphone and is supported by the stand.
[0016] FIGS. 3, 4 and 5 are partial cross sectional views showing the application of the locking device of the present invention inside the inner tube and the outer tube;
[0017] FIG. 6 is a side view showing a conventional locking device used to secure the inner tube inside the outer tube;
[0018] FIG. 7 is a partial cross sectional view of another conventional locking device in the telescopic tube assembly; and
[0019] FIG. 8 is a partial cross sectional view showing a further conventional locking device to secure the relative position of the inner tube to the outer tube.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] With reference to FIGS. 1 and 2 , a telescopic tube assembly includes an outer tube ( 20 ) and an inner tube ( 21 ) slidably received in the outer tube ( 20 ). The outer tube ( 20 ) has inner threading ( 200 ) formed on an inner periphery of the outer tube ( 20 ) and a guiding groove ( 201 ) defined in opposite sides of the inner periphery of the outer tube ( 20 ). The inner tube ( 21 ) has a threaded rod ( 211 ) formed on and extending out of a distal end of the inner tube ( 21 ).
[0021] A locking device in accordance with the present invention includes a guiding ring ( 22 ), a securing ring ( 23 ), a friction element ( 24 ), a spring ( 25 ), a wedge ( 26 ) and a bolt ( 27 ). A top cap ( 29 ) and a bottom cap ( 28 ) are provided to respective openings of the outer tube ( 20 ).
[0022] The guiding ring ( 22 ) has a first through hole ( 220 ) defined through the guiding ring ( 22 ) and a guide ( 221 ) formed on opposite outer peripheries of the guiding ring ( 22 ) to correspond to the guiding grooves ( 201 ). The securing ring ( 23 ) is provided with a threaded hole ( 231 ) defined to correspond to the bolt ( 27 ). The friction element ( 24 ) has a first through hole ( 241 ) to correspond to the bolt ( 27 ) and multiple legs ( 242 ) deformably formed on and extending out of the friction element ( 24 ). The wedge ( 26 ) has a second through hole ( 261 ) defined to correspond to the bolt ( 27 ).
[0023] The top cap and the bottom cap ( 29 , 28 ) both have a through hole, namely, the third through hole ( 291 ) and fourth through hole ( 281 ), and an outer threading ( 292 , 282 ) formed to correspond to the inner threading ( 200 ) of the outer tube ( 20 ).
[0024] A stand ( 10 ) with multiple extensions ( 100 ) extending out from a body ( 11 ) has a knob ( 101 ) rotatably mounted on a side of the body ( 11 ) and an insertion hole ( 102 ) defined to correspond to a distal end of the outer tube ( 20 ).
[0025] With reference to FIGS. 3, 4 and 5 , when the locking device of the present invention is assembled, it is noted that the guiding ring ( 22 ) is securely mounted on an upper portion of the inner tube ( 21 ) and the securing ring ( 23 ) is securely received in the inner tube ( 21 ) such that the securing ring ( 23 ) is immovable relative to the inner tube ( 21 ). Thereafter, the bolt ( 27 ) is extended through the second through hole ( 261 ) of the wedge ( 26 ), the spring ( 25 ), the first through hole ( 241 ) of the friction element ( 24 ) and the threaded hole ( 231 ) of the securing ring ( 23 ). Then the assembly is received in the outer tube ( 20 ), and the top cap ( 29 ) and the bottom cap ( 28 ) are respectively applied to the opening (not numbered) of the outer tube ( 20 ) to prevent the inner tube from slipping out of the outer tube ( 20 ). It is noted that to secure the engagement between the top cap ( 29 ) and the outer tube ( 20 ) and the engagement between the bottom cap ( 28 ) and the outer tube ( 20 ), both the top and bottom caps ( 29 , 28 ) are provided with the outer threading ( 292 , 282 ) formed on outer peripheries of the top and bottom caps ( 29 , 28 ) to correspond to and screwingly engage with the inner threading ( 200 ) of the outer tube ( 20 ). After the extension of the bolt ( 27 ) through the wedge ( 26 ), the spring ( 25 ), the friction element ( 24 ) and into the securing ring ( 23 ), it is noted that the friction element ( 24 ) has an upper portion securely fitted into the inner tube ( 21 ) and a shoulder ( 243 ) formed on an outer periphery of a mediate portion of the friction element ( 24 ) to abut a peripheral edge of the inner tube ( 21 ). Therefore, when the operator is using a tool (not shown), preferably a screwdriver, to rotate the bolt ( 27 ) from the fourth through hole ( 281 ) of the bottom cap ( 28 ), due to the bolt ( 27 ) being screwingly engaged with the threaded hole ( 231 ) of the securing ring ( 23 ), movement of the bolt ( 27 ) toward the securing ring ( 23 ) forces the wedge ( 26 ) to move toward the friction element ( 24 ). As a result, the legs ( 242 ) are forced to extend toward the inner periphery of the outer tube ( 20 ). With further movement of the wedge ( 26 ) towards the friction element ( 24 ), the friction between the legs ( 242 ) :and the outer tube ( 20 ) becomes larger. Therefore, the inner tube ( 21 ) becomes immovable relative to the outer tube ( 20 ).
[0026] In order to readjust relative position of the inner tube ( 21 ) to the outer tube ( 20 ), the operator gradually unscrews the bolt ( 27 ) to lessen the friction with the inner periphery of the outer tube ( 20 ) such that the inner tube ( 21 ) is movable relative to the outer tube ( 20 ). After the inner tube ( 21 ) is moved to a proper position, the operator screws the bolt ( 27 ) to force the legs ( 242 ) to extend and thus the friction between the legs ( 242 ) and the inner periphery of the outer tube ( 20 ) is able to support the weight of the inner tube ( 21 ). When readjustment of the inner tube ( 21 ) to the outer tube ( 20 ) is required, the bolt ( 27 ) is moved backward, which lessens the driving force to the wedge ( 26 ). Therefore, the force from the spring ( 25 ) expedite the movement of the wedge ( 26 ) away from the friction element ( 24 ) and therefore the friction between the legs ( 242 ) and the inner periphery of the outer tube ( 20 ) is reduced.
[0027] Referring to FIG. 2 , it is noted that when there is a load on top of the inner tube ( 21 ), the friction between the legs ( 242 ) and the inner periphery of the outer tube ( 20 ) is able to support the total weight of the inner tube ( 21 ) and the weight of an additional device, such as a microphone assembly ( 11 ).
[0028] Furthermore, while the inner tube ( 21 ) is moving inside the outer tube ( 20 ), the guide ( 221 ) is also moved along the guiding grooves ( 200 ) inside the outer tube ( 20 ) to smoothen the movement of the inner tube ( 21 ) to the outer tube ( 20 ).
[0029] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A locking device for a telescopic tube assembly having an outer tube and an inner tube slidably received in the outer tube includes a securing ring securable inside the inner tube, a friction element adapted to be securely mounted on one distal end of the inner tube and having legs deformably extending out and a wedge adapted to be selectively and movably received inside the outer tube to force the legs to extend toward an inner periphery of the outer tube so as to increase friction between the legs and the outer tube. Thus movement of the inner tube in the outer tube is selectively controlled.
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[0001] This application claims priority from U.S. Provisional Application No. 60/468,644, filed May 8, 2003, the entire content of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates, in general, to severe acute respiratory syndrome (SARS) and, in particular, to a method of generating neutralizing antibodies to the virus. The invention further relates to a method of detecting the presence of the virus and to a method of treating an infected individual.
BACKGROUND
[0003] Since the severe acute respiratory syndrome (SARS) epidemic surfaced in Asia, more than 2600 cases have been identified in 19 countries, and more than 100 deaths have been reported. SARS has recently been identified as a new clinical entity (INFECTIOUS DISEASES: Deferring Competition, Global Net Closes In on SARS. Science 300(5617):224-5 (2003); Ksiazek et al, N. Engl. J. Med. Apr 10 (2003); Drosten et al, N. Engl. J. Med. Apr 10 [epub ahead of print] (2003); Poutanen et al, N. Engl. J. Med. Apr 10 [epub ahead of print] (2003)). It has been found that a novel coronavirus is associated with this outbreak, and the evidence indicates that this virus has an etiologic role in SARS since this virus was found in samples from multiple SARS patients in several independent laboratories. The complete genome of the SARS associated coronavirus (“the SARS virus”) was derived by sequencing of gene fragments generated using consensus coronavirus primers designed to amplify SARS genes by reverse transcription-polymerase chain reaction (RT-PCR).
[0004] The SARS virus is RNA virus with the genome size of approximately 29K nucleotides. The complete SARS virus genome sequence has been reported by Jones et al and is available in the NCBI DNA database (GI: 29826277). Phylogenetic analyses and sequence comparisons showed that the SARS virus is not closely related to any of the previously characterized coronaviruses ( FIGS. 1-5 ).
SUMMARY OF THE INVENTION
[0005] The present invention relates generally to SARS. More specifically, the invention relates to a method of producing neutralizing antibodies to the virus and to a method of treating individuals infected with the virus. The invention further relates to a method of detecting the presence of the virus in a sample. The invention additionally relates to compounds and compositions suitable for use in such methods.
[0006] Objects and advantages of the present invention will be clear from the description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 . Amino acid sequence comparison of spike protein between SARS coronavirus with bovine coronavirus.
[0008] FIG. 2 . Amino acid sequence comparison of spike proteins between SARS coronavirus with human coronavirus OC43.
[0009] FIG. 3 . Phylogenetic analysis of coronavirus N protein. FIG. 4 . Phylogenetic analysis of coronavirus S protein.
[0010] FIG. 5 . Phylogenetic analysis of coronavirus M protein.
[0011] FIG. 6 . Protein structure of SARS virus spike glycoprotein.
[0012] FIG. 7 . Protein structure of SARS virus nucleocapsid (NP) protein.
[0013] FIG. 8 . SARS spike protein peptides.
[0014] FIG. 9 . SARS NP protein peptides.
[0015] FIG. 10 . Coronavirus spike protein among isolates.
[0016] FIG. 11 . Peptide design based on predicated SARS spike protein antigenic epitopes.
[0017] FIG. 12 . HR and LZ domains in coronavirus spike proteins. (HR1 (SEQ ID NO:34), HR2 (SEQ ID NO:35))
[0018] FIG. 13 . Immunization protocol of rabbits with SARS spike protein peptides.
[0019] FIG. 14 . Schematic representation of SARS expression vectors.
[0020] FIG. 15 . Western blot analysis of SARS spike protein, shown are purified SARS spike protein (lane 1), spike protein Ig fusion protein (lane 3) is and mock transfection supernatant control, produced in transformed 293 cells and purified using a lectin column—analysis was effected using Western blot and detection using immune sera of a mouse immunized with a DNA vaccine expressing SARS spike protein.
[0021] FIG. 16 . Induction of antibody reacted with recombinant SARS spike protein by immunization with plasmid DNAs that express SARS-spike protein or spike protein-Ig. Serum samples were collected 10 days after immunizations and assayed by ELISA. Shown are the end-point ELISA titers against recombinant SARS spike proteins coated on a 96-well plate (200 ng/well).
DETAILED DESCRIPTION OF THE INVENTION
[0022] In one embodiment, the present invention relates to a method of producing neutralizing antibodies to the SARS virus. In a further embodiment, the invention relates to a method of treating an individual infected with the virus. In another embodiment, the invention relates to a method of detecting the presence of the SARS virus in a sample (e.g.. a biological sample). The invention also relates to compounds and compositions suitable for use in the such methods.
[0023] The structure of the SARS virus putative spike glycoprotein (1,255 amino acids) and that of the nucleocapsid protein (NP) (422 amino acids) have been analyzed using DNAStar computer program, version 3.16 (DNAStar Inc.) (see FIGS. 6 and 7 , respectively; the notation on the right margin indicates the nature of the region such as antigenicity index, surface probability etc.).
[0024] Based on the antigenic index of these two proteins, and data in the literature relating to other coronaviruses, the panel of peptides listed in Table 1 (SEQ ID NO:1 to SEQ ID NO:33, respectively) has been designed (see also FIG. 8 and 9 ). Positions of variability that have been identified in the SARS virus spike protein are shown in FIG. 10 .
TABLE 1 Synthetic Peptides derived from SARS coronavirus spike and N proteins. Name of a.a peptide Amino acid sequence position DUHVI SA-S1 TTFDDVQAPNYTQHTSSMRGVYYPDE 20-51* IFRSDT DUHVI SA-S2 FKDGIYFAATEKSNVVRGWVFGSTMN 83-113 NKSQS DUHVI SA-S3 NSTNVVIRACNFELCDNPFFAVSKPM 119-149 GTQTH DUHVI SA-S4-A FEYISDAFSLDVSEKSGNFKHLREFV 161-188* FK DUHVI SA-S4 DVSEKSGNFKHLREFVFKNKDGFLYV 171-213 YKGYQPIDVVRDLPS DUHVI SA-S4-B KGYQPIDVVRDLPSGFNTLKPIFK 198-221* DUHVI SA-S5 FSPAQDIWGTSAAAYFVGYLKPTTFM 238-273 LKYDENGTIT DUHVI SA-S6 KYDENGTITDAVDCSQNPLAELK 265-287* DUHVI SA-S7 FSPAQDIWGTSAAAYFVGYLKPTTFM 288-320 LKYDENGTIT DUHVI SA-S8 FVVKGDDVRQIAPGQTGVIADYNYKL 386-417 PDDFM DUHVI SA-S9 NTRNIDATSGNYNYKYRYLRHGKLRP 424-457* FERDISN DUHVI SA-S10 FSPDGKPCTPPALNCYWPLNDYGFYT 460-490 TTGIG DUHVI SA-S11 PKLSTDLIKNQCVNFNFNGLTGTGVL 513-546 TPSSKRFQ DUHVI SA-S12 TPSSKRFQPFQQFGRDVSDFTDSVRD 539-569* PKTSE DUHVI SA-S13 TNASSEVAVLYQDVNCTDVSTAIHAD 588-626 QLTPAWRIYSTGN DUHVI SA-S14 EHVDTSYECDIPIGAGICASYHTVSL 640-674 LRSTSQKSI DUHVI SA-S15 EHVDTSYECDIPIGAGICASYHTVSL 753-782 LRSTSQKSI DUHVI SA-S16 LKPTKRSFIEDLLFNKVTLADAGFMK 792-831 QYGECLGDINARDL DUHVI SA-S17 NQKQIANQFNKAISQIQESLTTTSTA 901-939 LGKLQDVVNQNAQ DUHVI SA-S18 SKRVDFCGKGYHLMSFPQAAPHGVVF 1019-1057 LHVTYVPSQERNF DUHVI SA-S19 EGKAYFPREGVFVFNGTSWFITQRNF 1066-1094 FSP DUHVI SA-S20 DPLQPELDSFKEELDKYFKNHTSPDV 1121-1153* DLGDISG DUHVI SA-S21 QKEIDRLNEVAKNLNESLIDLQELGK 1162-1191 YEQY DUHVI SA-S22 LTVLPPLLTDDMIAAYTAALVSGTAT 841-882* AGWTFGAGAALQIPF DUHVI SA-S23 AMQMAYRFNGIGVTQNVLYENQKQIA 843-921* NQFNTAISQIQESL DUHVI SA-S24 ELDSFKEELDKYFKNHTSPDVDLGDI 1127-1161* SGINASVV DUHVI SA-S25 NIQKEIDRLNEVAKNLNESLIDLQEL 1162-1197* GKYEQYIKWPW DHVI SA-N1 DSTDNNQNGGRNGARPKQRRPQGLPN 23-49* N DHVI SA-N2 GSRGGSQASSRSSSRSRGNSRNSTPG 176-210* SSRGNSPAR DHVI SA-N3 KVSGKGQQQQGQTVTKKSAAEASKKP 234-267* RQKRTATK DHVI SA-N4 GRRGPEQTQGNFGDQDLIRQGTDYKH 276-301* DHVI SA-N5 HIDAYKTFPPTEPKKDKKKKTDEAQP 357-369 LPQRQKKQ DHVI SA-N6 QKKQPTVTLLPAADMDDFSRQLQNSM 387-421 SGASADSTQ
[0025] The present invention includes the peptides set forth in Table 1 (and FIGS. 8 and 9 ), corresponding peptides from other SARS virus isolates and unique and/or antigenic portions of such peptides. Unique and/or antigenic portions are preferably at least 5 amino acids in length, more preferably, at least 6, 7, 8, 9 or 10 amino acids in length. The peptides can be synthesized, for example, using standard chemical syntheses techniques, as can polymers containing multiple copies of one or more of the above peptides or portions. The peptides (portions and polymers) can also be synthesized using well-known recombinant DNA techniques. Recombinant synthesis may be preferred when the peptides are covalently linked.
[0026] In addition to the above peptides (and portions and polymers), the invention also relates to nucleic acids encoding the same. The nucleic acids (e.g., DNA) can be present in a vector (e.g., a viral vector or a plasmid), advantageously linked to a promoter.
[0027] The invention includes compositions containing one or more of the above peptides (or portions or polymers), or nucleic acids encoding same, and a carrier, e.g., a pharmaceutically acceptable carrier. The peptide-containing compositions can further include an adjuvant (such as alum). The peptides of the invention (or portions or polymers) can be present in the composition conjugated to a carrier molecule, either directly or indirectly via a spacer molecule. Carrier molecules are, advantageously, non-toxic, pharmaceutically acceptable and of a size sufficient to produce an immune response in mammals. Examples of suitable carriers include tetanus toxoid and keyhole limpet hemocyanin.
[0028] As indicated above, in one embodiment, the present invention relates to a method of producing neutralizing antibodies in a mammal (e.g., a human) to the SARS virus. The method comprises administering to a mammal in need thereof an amount of one or more of the above-described peptides, portions or polymers, sufficient to effect the production of neutralizing antibodies. (See also FIGS. 11 and 12 —the regions specifically depicted in FIG. 11 corresponding to regions reportedly associated with the induction of neutralizing antibodies in the context of other coronaviruses; FIG. 12 provides the sequences of HR1 and HR2—these are sequences demonstrated to be capable of inhibiting fusion of animal coronaviruses (see Daniel et al, J. Virol. 67:1185-1194 (1993); Routledge et al, J. Virol. 65:254-262 (1991); Talbot et al. J. Virol 62:3032-3036 (1988) and Luo and Weiss In Coronavirus and Arteriviruses, ed. by Enjuanes, pp. 17-22 (1998)).) Optimum dosing regimens, which can vary with the peptide used, the patient and the effect sought, can be readily determined by one skilled in the art.
[0029] In an alternative aspect of this embodiment, production of neutralizing antibodies to the SARS virus can be effected by administering the above-described nucleic acids under conditions such that the nucleic acid is expressed, the encoded peptide produced and the neutralizing antibodies generated. That is, nucleic acids encoding the peptides (portions and polymers) of the invention can be used as components of, for example, a DNA vaccine wherein the peptide encoding sequence(s) is/are administered as naked DNA or, for example, a minigene encoding the peptides can be present in a viral vector. The encoding sequence(s) can be present, for example, in a replicating or non-replicating adenoviral vector, an adeno-associated virus vector, an attenuated mycobacterium tuberculosis vector, a Bacillus Calmette Guerin (BCG) vector, a vaccinia or Modified Vaccinia Ankara (MVA) vector, another pox virus vector, recombinant polio and other enteric virus vector, Salmonella species bacterial vector, Shigella species bacterial vector, Venezuelean Equine Encephalitis Virus (VEE) vector, a Semliki is Forest Virus vector, or a Tobacco Mosaic Virus vector. The encoding sequence(s), can also be expressed as a DNA plasmid with, for example, an active promoter such as a CMV promoter. Other live vectors can also be used to express the sequences of the invention. Expression of the peptides of the invention can be induced in a patient's own cells, by introduction into those cells of nucleic acids that encode the peptides, preferably using codons and promoters that optimize expression in human cells. Examples of methods of making and using DNA vaccines are disclosed in U.S. Pat. Nos. 5,580,859, 5,589,466, and 5,703,055.
[0030] In another embodiment, the present invention relates to a method of treating an individual (e.g., a human) infected with the SARS virus. As above, this method can be effected by administering the above-described peptides (portions and polymers) (the use of one or more of peptides SA-20 to SA-25 from Table 1, or portions thereof or polymers comprising same, being preferred) or nucleic acids in an amount and under conditions such that the treatment is effected. Peptides comprising HR-1 and/or HR-2, or portions thereof, are particulaly preferred. The significance of the HR-1 and HR-2 (LZ (leucine zipper)) regions is that these are homologous regions to the coil coil structures of HIV gp41, and HR-2 corresponds to the HR-2 or (T-20) drug that is working so well for HIV. Thus, the SARS virus HR-1 or HR-2 peptide (or portion thereof) can be expected to inhibit fusion of infected cells and prevent virus entry.
[0031] Optimum dosing regimens can be readily determined by one skilled in the art.
[0032] Suitable routes of administration of the peptides (portions and polymers) and nucleic acid of the invention include systemic (e.g. intramuscular or subcutaneous). Alternative routes can be used when an immune response is sought in a mucosal immune system (e.g., intranasal).
[0033] In another embodiment, the invention relates to methods of detecting the SARS virus in a sample (e.g., a biological sample from a patient, such as a blood, serum, sputum or fecal sample, or an environmental sample, such as a water or sewage sample). As appropriate, the method can be effected by detecting the presence of viral proteins or nucleic acids. For example, the above-described peptides (portions or polymers) can be used to generate antibodies (polyclonal or monoclonal) using standard techniques. The antibodies (or binding fragments thereof) can then be used, for example, in standard immunoassays, to detect the presence of SARS viral protein in the sample. The peptides (portions and polymers) can also be used, for example, in accordance with standard immunoassay techniques, to detect the presence of viral antibodies in, for example, the blood of a patient. Alternatively, the nucleic acids described above, or complements thereof, can be used according to standard techniques as probes or primers to detect the presence of viral encoding sequences in a sample. It will be appreciated that any of the peptides (portions or polymers), antibodies (or fragment) or nucleic acids can bear a detectable label (e.g., a fluorescent or radiolabel).
[0034] Certain aspects of the invention can be described in greater detail in the non-limiting Examples that follows.
EXAMPLE 1
Development of Polyclonal Immune Sera by Immunization in Rabbits with Synthetic Peptides Derived from SARS Virus
[0035] Peptides listed in Table 1 are synthesized as crude peptides, purified and analyzed. Rabbits (2 for each peptides) are immunized with this panel of SARS virus peptides at a dose of 250 μg per injection per animal for a total of 5 immunizations with RIBI adjuvant. Serum samples are collected 10 days after each immunization, and assayed against the immunizing peptides. Further characterization of immune sera including the reactivity of immune sera with native SARS virus proteins is effected.
EXAMPLE 2
Development of Monoclonal Antibodies Against the SARS Virus Spike Glycoprotein and NP Using Synthetic Peptides Derived the SARS Virus as Immunogen
[0036] Based on the initial immunogenicity results of the panel of SARS virus peptides, 1-2 peptides are selected from both SARS spike glycoprotein and NP as immunogens to immunize Balb/c mice for development of monoclonal antibodies. Immune sera and initial screening of hybridoma cell culture are carried out using the immunizing peptides. Further characterization and screening of monoclonal antibodies are effected using SARS native spike glycoprotein and NP expressed in a eukaryotic cell expression system. The neutralizing activities of the monoclonal antibodies are assessed.
EXAMPLE 3
Development of Polyclonal Immune Sera by Immunization of Rabbits with Synthetic Peptides Derived from SARS Coronavirus
[0037] The protein structure of the putative spike glycoprotein (1,255 amino acids) has been analyzed using DNAStar computer program. Based on the antigenic index of these two proteins, a panel of 33 peptides derived from SARS coronavirus spike protein and NP proteins (as listed in Table 1) has been designed. Of these peptides, nine (S1, S4A, S4B, S9, S12, S20, S23. S24 and S25) have been used to immunize rabbits using a immunization protocol as shown in FIG. 13 . Other peptides will be used in the future experiments.
EXAMPLE 4
Expression of SARS Coronavirus Spike Glycoprotein and Development of Monoclonal Antibodies (Mabs) Against SARS Virus
[0038] To develop Mabs and vaccine immunogens against SARS virus, a SARS coronavirus spike protein gene has been developed with codon- and RNA structure optimized for optimal expression. To produce secreted soluble SARS spike protein, an expression vector (SARS SΔTC) was generated in which the transmembrane (TM) and cytoplasmic domain (Cyt) of SARS spike protein was deleted. To enhance the immunogenicity and stability as well as to provide for ease of purification of SARS spike protein, the extracellular domain of SARS spike protein was linked with either mouse or human IgG constant region genomic sequence ( FIG. 14 ). These 2 vectors were used for production of spike protein in vitro by transfection and also used as vaccine immunogens for development of monoclonal antibody as well as vaccine immunogens for induction of neutralizing antibodies against SARS virus.
[0039] As shown in FIG. 15 , SARS spike proteins have been expressed in 293 cells by transfection with SARS SΔTC and SARSΔTC-Ig vectors and purified using a lectin column. Purified proteins were analyzed by SDS-PAGE and Western blot ( FIG. 15 ). The extracellular domain SARS spike protein has a molecular weight of approximately 150 Kda, and SARS spike protein-Ig fusion protein has a molecular weight of approximately 170 Kda as detected by immune serum from a mouse immunized with the DNA vaccine that expresses SARS spike protein extracellular domain ( FIG. 14 ). The purified SARS spike protein has been used for evaluation of immunogenicity of SARS spike protein expression DNA vaccine (see below). To generate Mabs, mice (4 mice for each group) have been immunized with the SARS SΔTC vector that expresses SARS spike protein. Mice developed antibody responses as detected using Western blot ( FIG. 15 ) and ELISA ( FIG. 16 ). Both SARS SΔTC and SARSΔTC-Ig vectors were also used as DNA vaccine immunogens for evaluation of the immunogenicity for induction of neutralizing antibody against SARS.
[0040] All documents cited above are hereby incorporated in their entirety by reference.
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The present invention relates, in general, to severe acute respiratory syndrome and, in particular, to a method of generating neutralizing antibodies to the virus. The invention further relates to methods of detecting the presence of the virus and to methods of treating infected individuals.
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